Volvo EC240CL Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EC240CL Excavators, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo Construction EC240CL 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.
Volvo EC240CL Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,176 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
000 - Foreword....2
000 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Machine view, waste handler_{05-18-17}....5
Machine view, waste handler_{05-18-41}....7
Machine view_{06-10-39}....9
Machine view_{06-11-03}....11
Product plates....13
03 - SPECIFICATIONS....15
2-pump flow selector valve....19
Adjustable boom and cylinder, specifications....21
Adjustable boom selector valve....23
Air conditioning unit, specifications....25
Alternator, specifications ....28
Attachment quick coupler solenoid valve, specification....30
Audio remote controller, specifications_{04-08-11}....31
Audio remote controller, specifications_{04-08-25}....33
Auto_Manual pump control switch, specifications ....36
Automatic lubrication system, specifications....38
Battery, specifications ....41
Boom lifting cylinder, specifications....42
Boom, specifications....44
Bucket cylinder, specifications....45
Cab, weight....47
Center passage, tightening torques....49
Circuit breaker, specification ....52
Control lockout lever switch, specifications....54
Control pattern selector valve, specifications....56
Coolant pump, thermostat, specifications....58
Cooling fan motor, specifications....60
Cooling system, specifications....62
Counterweight, specifications_{02-24-16}....63
Counterweight, specifications_{02-24-30}....64
Counterweight, tightening torques-[2559]....65
Counterweight, tightening torques....67
Current_pressure, specifications....69
Diesel coolant heater (10kw), specifications....71
Dipper arm cylinder, specifications....73
Dipper arm, specifications....75
Electric horn, specifications ....76
Electrical system, specifications....78
Electronic climate control unit ECC, specification....80
Emergency engine speed control switch, specifications ....82
Engine - Pump control, specification....84
Engine control unit E-ECU, specifications ....86
Engine speed control switch, specifications....88
Engine, specifications....90
Engine, weights....91
Flywheel, weight....92
Frame and track unit, specifications....94
Fuel feed pump, specifications....95
Fuel filler pump, specifications....98
Fuel pressure, specifications....100
Fuel system, tightening torques....104
Fuel tank, specifications....108
Fuse, specifications ....109
Hammer return filter, specifications....111
Hour counter, specifications....112
Hydraulic oil cooling system, specifications....114
Hydraulic pressure, specifications....116
Hydraulic pump, specifications....117
Hydraulic tank, specifications....118
Keypad, specification....119
Line rupture valve (arm), specifications....122
Line rupture valve (boom), specifications....124
Lower wiper motor, specifications ....126
Lubrication system, specifications....128
Main control valve, specifications....131
Measurement conversion tables....133
Preheating, specifications ....142
Pressure accumulator, specifications....144
Proportional solenoid valve, specifications-[2034]....146
Proportional solenoid valve, specifications....149
Radio with CD and MP3 player, specifications....151
Radio with tape or CD player, specifications....154
Recommended hydraulic oil, specifications....157
Regulator, specifications....160
Relay, specifications_{04-10-04}....161
Relay, specifications_{04-10-18}....163
Remote control valve (Lever), specifications....165
Remote control valve (pedal), specifications....167
Rotating beacon, specifications ....169
Rotator pump, specifications....171
Servo hydraulic selector valve, specifications....172
Servo pump, specifications....174
Slew gearbox, specifications_{04-05-36}....176
Slew gearbox, specifications_{04-05-49}....177
Solenoid valve for rotator....178
Solenoid valve, specifications....179
Start switch, specifications ....180
Starter motor, specifications ....182
Swing motor, specifications....183
Tightening torque, specifications....184
Tightening torques....186
Track gearbox, specifications....195
Track motor, specifications_{04-04-47}....196
Track motor, specifications_{04-05-01}....198
Travel alarm, specifications ....200
Upper wiper motor, specifications ....202
Valve system specifications....204
Windscreen flusher pump, specifications ....205
Wiper controller, specifications ....207
Wireless control unit W-ECU, specification....209
Work lights and extra lights, specifications ....211
07 - STANDARD TIME....213
Operation numbers for additional work....214
08 - TOOL....216
E-tools, NET 8940-00300 Swing ring gear guide pin....217
E-tools, NET 8940-00330 Swing motor guide pin....219
NET 8940-00200 Replace tool for the remote control valve joint....221
NET 8940-00290 Track motor guide pin....223
09 - MISCELLANEOUS....225
Control units, changing....226
Hydraulic cylinders, dieseling....228
Service positions....232
Welding on the machine....235
001 - STANDARD PARTS, SERVICE....238
16 - LUBRICANT; FUEL; OTHER FLUID....239
Alternative fuels....240
Coolant with freezing and corrosion protection....243
Grease....247
Recommended lubricants....251
17 - SERVICE....254
Air cleaner primary filter, change....257
Air cleaner primary filter, clean....259
Air cleaner secondary filter, change....261
Air conditioner main filter, change....263
Air conditioner main filter, clean....267
Arrival Inspection, according to Inspection Programme....271
Battery condition, check....276
Bearings....279
Cab prefilter, cleaning....283
Cab prefilter, replacing....285
Cab; door, covers, hinges, joints and locks, lubricate....287
Cleaning prior to repair....289
Coasting left and right swing....293
Coolant anti-freeze resistance, checking ....295
Coolant level, check....299
Coolant, change....300
Creeping of hydraulic cylinder....303
Cylinder speed....305
Delivery Inspection, according to Inspection Programme....308
Engine oil and filter, changing....312
Engine, oil level, check....315
Fuel filter extra (water separator element), check_drain....317
Fuel filter, change....319
Fuel tank air ventilation filter, change....321
Fuel tank sediment, drain....323
Hoses and tubes....325
Hydraulic oil drain filter, change....329
Hydraulic oil level, check....330
Hydraulic oil return filter, replacing....332
Hydraulic oil servo filter, change....335
Hydraulic oil suction strainer, clean....337
Hydraulic oil tank breather filter, replacing....339
Hydraulic oil, changing....342
Hydraulic pressure, checking....344
Loose and loss of bolts, check....346
Lubrication, see lubrication chart....349
MATRIS, reading, export reading....351
Maintenance of Stored Machines, according to Inspection Programme....354
Maintenance service, daily....358
Maintenance service, every 1000 hours....359
Maintenance service, every 2000 hours....361
Maintenance service, every 250 hours....363
Maintenance service, every 4000 hours....365
Maintenance service, every 50 hours....367
Maintenance service, every 500 hours....368
Maintenance service, every 6000 hours....370
Measuring condition....372
Measuring of swing bearing clearance....374
Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change....377
Oil-bath air cleaner's reservoir (optional equipment), filter insert, clean....380
Oil-bath air cleaner's reservoir (optional equipment), oil, check....383
Pressure testing....385
Radiator outside_hydraulic oil cooler outside, cleaning....389
Replacement parts....392
Safety when servicing....396
Service methods....400
Service....404
Starting engine with booster cables ....406
Straight traveling performance....410
Swing bath grease, check....412
Swing gearbox oil level, check....413
Swing motor gearbox, changing oil....415
Swing ring gear bearing, lubricate_{01-24-32}....417
Swing ring gear bearing, lubricate_{01-24-54}....419
Swing speed....422
Test-run and check....423
The machine, check for external damages, cracks and wear damages....426
Track gearbox oil level, check....429
Track motor gearbox, changing oil....431
Track running speed_{01-07-44}....433
Track running speed_{01-08-05}....435
Track shoe bolts, check....437
Track tension_condition, check....440
Travel Speed....442
VCADS Pro, logged errors, read off....444
Valve clearance, check_adjust....447
Warranty inspection 100 hours....456
Warranty inspection 1000 hours....458
Warranty inspection....460
Washer fluid level, check....462
Water separator filter element, change....464
X1 return filter (optional equipment), change....466
19 - GENERAL....468
CE-marking, EMC-directive....469
Checklist after a fire or heat exposure....472
Decontamination....476
Environmental handling for the future....480
Environmentally hazardous fluids....484
Environmentally safe handling....488
Fire prevention measures....491
Health hazards with paint, plastics and rubber....497
Safety concerns everybody!....502
Safety rules when servicing....506
Safety when handling oils and fuel....510
Safety when handling the machine....514
Safety when handling the waste handler....521
Safety when using lifting equipment....523
Safety when working with air conditioning refrigerant....527
Safety when working with batteries....532
Safety when working with hydraulic systems....537
Starting with booster batteries....541
Waste handling....545
Working in environmentally contaminated areas....549
002 - ENGINE WITH MOUNTING AND EQUIPMENT....553
020 - GENERAL....554
Component locations....555
E-ECU MID 128 non-programmed, replacing....558
E-ECU MID 128 pre-programmed, replacing....561
Engine, description....564
Engine, identification....566
Engine, tightening torques....567
Engine, weights ....571
Fuel system, tightening torques ....572
021 - ENGINE....576
Basic check, Engine....577
Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope....579
Camshaft, description....585
Connecting rod, description....588
Crankshaft, description....591
Cylinder block, description....594
Cylinder head gasket, description....596
Cylinder head, description....598
Cylinder liner, description....600
Engine characteristic curve....602
Engine mounting....604
Engine timing gear, description....608
Engine, specifications....611
Engine, weights....612
Flywheel, weight....613
Internal Exhaust Gas Recirculation (IEGR), description....615
Oil level sensor, replacing....621
Oil sump, description....625
Piston cooling....627
Piston rings, description....629
Pistons, description....631
Troubleshooting....633
Valve system specifications....636
Valves, adjusting....637
Valves, description....647
Vibration damper, description....649
022 - LUBRICATING SYSTEM....652
Lubrication oil pressure, checking with pressure gauge....653
Lubrication system, description....656
Lubrication system, principle of operation....659
Lubrication system, specifications....663
Oil cooler, replacing....666
023 - FUEL SYSTEM....672
Carbon dioxide in fuel system, checking....673
Feed pump pressure, checking....676
Feed pump, replacing....679
Fuel control valve (FCV), description....682
Fuel control valve (FCV), replacing....684
Fuel feed pump, description....690
Fuel feed pump, specifications....693
Fuel filler pump, description....696
Fuel filler pump, specifications....699
Fuel filling pump, installing....701
Fuel filling pump, removing....703
Fuel filter extra, replacing....705
Fuel filter, checking....709
Fuel filters, replacing....712
Fuel lines, description....715
Fuel pressure, specifications....717
Fuel pump, inspecting....722
Fuel rail pressure sensor, replacing....726
Fuel rail pressure, checking....729
Fuel system, bleeding....733
Fuel system, description....736
Fuel system, tightening torques....741
Fuel tank, description....745
Fuel tank, specifications....747
Injector, replacing one....748
Injectors, description....752
Instructions for working with electronic fuel injection....756
Pressure relief valve (PRV), inspecting....759
025 - INLET & EXHAUST SYSTEM....761
Cab air pre-cleaner, description....762
Charge air cooler connection (hose, tube), replacing....764
Charge air cooler, description....766
Charge air cooler, replacing....768
Charge air system, inspection....778
Dual stage precleaner, description....781
Exhaust pipe flexible tube, replacing....783
Exhaust system, description....787
Inlet system, description....789
Preheating coil, replacing....791
Silencer, replacing....794
Turbocharger, description....798
Turbocharger, inspecting....801
Turbocharger, replacing....803
026 - COOLING SYSTEM....807
Coolant anti-freeze resistance, checking....808
Coolant pump, replacing....813
Coolant pump, thermostat, specifications....816
Coolant, changing....818
Cooling fan motor, specifications....821
Cooling system, description ....823
Cooling system, description....825
Cooling system, flushing....827
Cooling system, specifications....832
Engine block heater, description....833
Expansion tank, replacing....835
Fan belt and_or alternator belt, replacing....838
Fan belt and_or alternator-, compressor belt, replacing all belts....841
Fan motor, description....844
Maintenance....846
Radiator hose upper, replacing....848
Radiator hoses lower, replacing....850
Radiator, replacing....853
Reversible cooling fan, description....856
Thermostat, checking....858
Thermostat, replacing....862
027 - ENGINE CONTROL....865
Engine - Pump control, specification....866
Engine speed control switch, description....868
Engine speed control switch, inspection....871
Engine speed control switch, specifications....873
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....875
30 - GENERAL....876
11 666 140 Multimeter....881
8883 0028 Adapter cable....883
999 0014 Adapter cable....885
999 0025 Adapter cable....888
999 0062 Extension cable....890
999 3893 Adapter cable....892
999 3894 Template....894
999 8699 Multi-pin breaker box....896
AL3201, description and measuring....898
Auto Idle....902
Auxiliary start....904
BA3101, description and measuring....907
Boom float position, description....909
CU9901, description and measuring....911
Collection of basic data....913
Communication with data buses....916
Component descriptions....919
Component troubleshooting, checking component....923
Component troubleshooting, checking subsystem (circuit)....926
Component troubleshooting, checking wiring harness and input_output on ECU....929
Connecting special tools....932
Data buses, function....936
Electrical cables and connectors, checking....942
Electrical system, description....948
Electrical system, special instructions for servicing, action when working on machine....950
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator....952
Electrical system, special instructions for servicing, electrical components, batteries....954
Electrical system, special instructions for servicing, electronic components....957
Electrical system, special instructions for servicing, general....959
Electrical system, specifications....962
Electro hydraulic pump control, description....964
Electronic control system, description....966
Emergency operation, description....969
Engine - Pump control, specification....972
Engine Protection....975
Error code information, general....978
Error codes, build-up....981
FU18, description and measuring....986
FU26, description and measuring....988
Fire extinguisher, description....990
Fire extinguisher, fault indication....991
HE2501, description and measuring....993
MA2301–MA2306, description and measuring....995
MA2504, description and measuring....998
MA2602, description and measuring....1000
MA9103, description and measuring....1002
MA9104, description and measuring....1004
MA9105, description and measuring....1006
MA9107, description and measuring....1008
MA9109, description and measuring_{11-08-18}....1010
MA9109, description and measuring_{11-09-05}....1013
MA9116, description and measuring....1015
MA9117, description and measuring....1017
MA9118, description and measuring....1019
MA9120, description and measuring....1021
MID 128 SID 230, description and measuring....1023
MID 140 PID 251, description and measuring....1026
MID 140 PPID 1144, description and measuring....1029
MO3301, description and measuring....1031
Measuring symbols, description....1033
Measuring, general....1037
Mode selection, description....1039
PPID1336, description and measuring....1042
PWM2303, description and measuring....1044
PWM9101, description and measuring....1046
PWM9103, description and measuring....1048
PWM9105, description and measuring....1050
PWM9106, description and measuring....1052
PWM9109, description and measuring....1054
PWM9123, description and measuring....1056
PWM9124, description and measuring....1058
Power Boost control, description....1060
Quick fit control, description....1062
RE2501, description and measuring-[4806]....1064
RE2501, description and measuring....1067
RE3101, description and measuring_{10-45-01}....1070
RE3101, description and measuring_{10-45-49}....1072
RE3301, description and measuring_{10-43-18}....1074
RE3301, description and measuring_{10-44-08}....1076
RE4206, description and measuring_{10-41-29}....1078
RE4206, description and measuring_{10-42-14}....1080
SAE J1708_1587 information link, description and measuring....1082
SAE J1939_CAN control link, description and measuring....1086
SAE code, conversion for component designation, E-ECU....1089
SE2202, description and measuring....1091
SE2203, description and measuring....1094
SE2205, description and measuring....1097
SE2301, description and measuring....1099
SE2302, description and measuring....1102
SE2303, description and measuring....1105
SE2309, description and measuring....1108
SE2501, description and measuring....1110
SE2502, description and measuring....1113
SE2507, description and measuring....1116
SE2508, description and measuring....1119
SE2603, description and measuring....1122
SE2606, description and measuring....1125
SE2701, description and measuring....1128
SE2703, description and measuring....1131
SE8701, description and measuring....1134
SE8702, description and measuring....1137
SE8705, description and measuring....1140
SE8706, description and measuring....1143
SE9105, description and measuring....1146
SE9401, description and measuring....1149
SID211, description and measuring....1151
SID232, description and measuring....1154
SW2701, description and measuring....1157
SW3301, description and measuring....1160
SW9160, description and measuring....1162
SW9161, description and measuring....1165
SW9162, description and measuring....1168
Service connection and programming connection....1171
Software parameters, description....1174
Special tools for troubleshooting....1182
Start lock, description....1184
Troubleshooting strategy....1186
Troubleshooting tools....1189
Troubleshooting, general....1191
VCADS Pro service tool....1194
VCADS Pro, 17030-3 - Parameter, programming....1199
X1 control, description....1202
X3 control, description....1207
31 - BATTERY....1210
Batteries, replacing....1211
Battery charging capacity, checking....1215
Battery, charging....1219
Battery, description....1221
Battery, specifications....1223
Battery, storage....1225
Earth lead to battery, replacing....1227
Starter motor lead to battery, replacing....1230
Starting engine with booster cables....1233
32 - ALTERNATOR; CHARGE REGULATOR....1237
Alternator, description....1238
Alternator, replacing incl function checking....1240
Alternator, specifications....1243
Alternator, testing....1245
Charging, description....1248
33 - STARTING SYSTEM....1250
Preheating, description....1251
Preheating, specifications....1253
Starter motor, description....1255
Starter motor, replacing....1257
Starter motor, specifications....1259
Starter motor, testing....1260
Starter relay, replacing....1263
Starter switch (engine start switch), replacing....1265
Starter switch, testing_{09-55-39}....1267
Starter switch, testing_{09-55-52}....1270
Starting operation....1273
35 - LIGHTING....1276
Work lighting headlamp assembly, replacing_{09-52-58}....1277
Work lighting headlamp assembly, replacing_{09-53-11}....1279
Work lights and extra lights, description....1281
Work lights and extra lights, specifications....1283
36 - OTHER ELECTRICAL EQUIPMENT....1285
Auto_Manual pump control switch, description....1287
Auto_Manual pump control switch, specifications....1289
Connectors, overview....1291
Control lockout lever switch, replacing....1305
Control units changing, precaution....1308
Electric horn, description....1310
Electric horn, specifications....1312
Electronic climate control unit ECC, description....1314
Electronic climate control unit ECC, specification_{09-38-17}....1316
Electronic climate control unit ECC, specification_{09-38-30}....1318
Emergency engine speed control switch, description....1321
Emergency engine speed control switch, specifications....1323
Emergency stop switch, description....1325
Engine control unit E-ECU, function description....1327
Engine control unit E-ECU, specifications....1329
Engine speed control switch, replacing....1331
Horn, replacing....1335
I-ECU MID 140 non-programmed, replacing....1337
I-ECU MID 140 pre-programmed, replacing....1339
Instrument control unit I-ECU, functional description....1341
Instrument control unit I-ECU, specifications....1344
Lower wiper motor, description....1347
Lower wiper motor, specifications....1349
Pre-heating relay, replacing....1351
Rotating beacon, description....1353
Rotating beacon, replacing....1355
Rotating beacon, specifications....1357
Start switch, description....1359
Start switch, specifications....1362
Strobe beacon, description....1364
Travel alarm, description....1366
Travel alarm, replacing....1368
Travel alarm, specifications....1370
Upper wiper motor, description....1372
Upper wiper motor, specifications....1374
V-ECU MID 187 non-programmed, replacing....1376
V-ECU MID 187 pre-programmed, replacing....1380
Vehicle control unit V-ECU, functional description....1384
Vehicle control unit V-ECU, specifications....1386
Window limit switch, description....1389
Windscreen flusher pump, replacing....1392
Windscreen flusher pump, specifications....1394
Windscreen wiper controller, replacing....1396
Windscreen wiper switch, replacing....1398
Windscreen wiper, description....1400
Wiper controller, description....1402
Wiper controller, specifications....1404
37 - CABLE; FUSE; RELAY....1406
Circuit breaker, description....1410
Circuit breaker, specification....1412
Component designations....1414
Component list Alternator, batteries, capacitors, electronic units, voltage outlet....1416
Component list Control lights_warning lights_{09-31-42}....1418
Component list Control lights_warning lights_{09-31-54}....1419
Component list, Heating coils....1420
Component list, Miscellaneous....1421
Component list, Solenoid valves_{09-28-34}....1422
Component list, Solenoid valves_{09-28-45}....1424
Component list, Switches_{09-27-59}....1426
Component list, Switches_{09-28-11}....1428
Component list, fuses_{09-31-11}....1430
Component list, fuses_{09-31-22}....1432
Component list, lights....1434
Component list, motors....1435
Component list, relays....1436
Component list, sensors_{09-29-08}....1437
Component list, sensors_{09-29-19}....1439
Control system diagram....1441
Electrical distribution box, description_{09-14-51}....1444
Electrical distribution box, description_{09-15-04}....1446
Electrical distribution box, description_{09-15-16}....1448
Electrical distribution box_{09-13-47}....1450
Electrical distribution box_{09-14-01}....1453
Electrical distribution box_{09-14-14}....1456
Electrical distribution box_{09-14-29}....1458
Electrical symbols and designations....1461
Explanation of wiring diagrams....1465
Fuse, description....1468
Fuse, specifications....1470
Grounding points, frame connections_{09-10-38}....1472
Grounding points, frame connections_{09-10-51}....1474
Grounding points, frame connections_{09-11-04}....1476
Main switch, replacing....1478
Relay, description_{09-12-23}....1482
Relay, description_{09-12-36}....1484
Relay, specifications_{09-11-53}....1486
Relay, specifications_{09-12-04}....1488
Waste handler, electrical circuit_{09-16-45}....1490
Waste handler, electrical circuit_{09-16-58}....1492
Waste handler, electrical circuit_{09-17-11}....1494
Waste handler, electrical circuit_{09-17-24}....1496
Wiring diagram 1, main diagram, positive feed _ chassis connection - Image....1499
Wiring diagram 10, function group 3, electrical, lighting etc. - Image....1501
Wiring diagram 11, function group 8, cab - Image....1502
Wiring diagram 12, function group 8, cab - Image....1503
Wiring diagram 13, function group 8, cab - Image....1504
Wiring diagram 14, function group 9, hydraulics - Image....1505
Wiring diagram 15, function group 9, hydraulics - Image....1506
Wiring diagram 16, function group 9, hydraulics - Image....1507
Wiring diagram 17, communication - Image....1508
Wiring diagram 18, automatic greasing system - Image....1509
Wiring diagram 2, positive feed _ chassis connection, control units - Image....1510
Wiring diagram 3, function group 2, engine - Image....1511
Wiring diagram 4, function group 2, engine - Image....1513
Wiring diagram 5, function group 2, engine - Image....1514
Wiring diagram 6, function group 2, engine - Image....1515
Wiring diagram 7, function group 2, engine - Image....1516
Wiring diagram 8, function group 3, electrical, lighting etc. - Image....1517
Wiring diagram 9, function group 3, electrical, lighting etc. - Image....1518
Wiring diagram SCH01_{09-26-00}....1519
Wiring diagram SCH01_{09-26-13}....1522
Wiring diagram SCH02....1525
Wiring diagram SCH03....1528
Wiring diagram SCH04_{09-24-38}....1531
Wiring diagram SCH04_{09-24-53}....1534
Wiring diagram SCH07....1537
Wiring diagram SCH08....1540
Wiring diagram SCH10_{09-23-12}....1545
Wiring diagram SCH10_{09-23-27}....1548
Wiring diagram SCH11_{09-22-39}....1551
Wiring diagram SCH11_{09-22-51}....1554
Wiring diagram SCH12_{09-21-53}....1557
Wiring diagram SCH12_{09-22-06}....1560
Wiring diagram SCH12_{09-22-19}....1563
Wiring diagram SCH13_{09-21-20}....1566
Wiring diagram SCH13_{09-21-33}....1569
Wiring diagram SCH14_{09-20-41}....1572
Wiring diagram SCH14_{09-20-55}....1575
Wiring diagram SCH15_{09-20-09}....1578
Wiring diagram SCH15_{09-20-22}....1581
Wiring diagram SCH16_{09-19-36}....1584
Wiring diagram SCH16_{09-19-49}....1587
Wiring diagram SCH17_{09-19-04}....1590
Wiring diagram SCH17_{09-19-16}....1593
Wiring diagram SCH18....1596
Wiring diagram SCH20....1599
Wiring diagram SCH22....1601
Wiring diagram SCH23....1603
Wiring diagram, electrical distribution box_{09-26-33}....1606
Wiring diagram, electrical distribution box_{09-26-46}....1610
Wiring diagram....1613
Wiring harnesses_{09-16-00}....1615
Wiring harnesses_{09-16-14}....1620
Wiring harnesses_{09-16-26}....1625
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....1627
Booting sequence....1629
Control levers, description....1632
Control lockout lever switch, description....1634
Control lockout lever switch, specifications ....1637
Control types for X001 and X3 operation....1639
Display unit, content....1642
Electrical system....1649
Engine rotation speed sensor (camshaft), replacing....1652
Engine rotation speed sensor, replacing....1654
Engine system....1657
HVAC system....1659
Hour counter, description....1662
Hour counter, specifications ....1664
Hydraulic system....1666
Instruments and controls, front instrument panel....1669
Instruments and controls, left instrument panel....1671
Instruments and controls, overview....1673
Instruments and controls, rear instrument panel_{007-17-00}....1675
Instruments and controls, rear instrument panel_{007-17-13}....1677
Instruments and controls, right instrument panel_{007-17-32}....1679
Instruments and controls, right instrument panel_{007-17-45}....1682
Keypad, description_{007-09-48}....1684
Keypad, description_{007-10-08}....1687
Keypad, description_{007-10-44}....1690
Keypad, description_{007-11-04}....1694
Keypad, description_{007-11-25}....1698
Keypad, specification ....1701
Language_{007-06-43}....1704
Language_{007-06-56}....1708
MAIN MENU....1711
Menu tree....1714
Pop-up screen....1716
SETUP....1719
Service mode....1728
Terminology....1731
Theft protection....1758
39 - MISCELLANEOUS....1761
Antenna, replacing....1762
Audio remote controller, description_{007-04-17}....1765
Audio remote controller, description_{007-04-30}....1768
Audio remote controller, specifications_{007-03-47}....1771
Audio remote controller, specifications_{007-03-58}....1773
CareTrack system, description....1776
DC–DC converter, description....1779
DC–DC converter, specifications....1781
Radio with CD and MP003 player, description....1787
Radio with CD and MP003 player, specifications ....1791
Radio with tape or CD player, descriptions....1794
Radio with tape or CD player, specifications ....1797
Radio with tape player, description....1800
Radio, description....1803
Radio, replacing_{007-02-28}....1806
Radio, replacing_{007-02-40}....1809
Speaker, replacing....1813
Voltage converter, replacing....1815
W-ECU, MID142, changing non-programmed ECU....1817
W-ECU, MID142, changing pre-programmed ECU....1820
Wireless control unit W-ECU, specification_{007-00-10}....1823
Wireless control unit W-ECU, specification_{007-00-22}....1825
004 - POWER TRANSMISSION....1827
40 - GENERAL....1828
Tightening torque, specifications ....1829
43 - GEARBOX....1831
Slew gearbox, description_{007-47-22}....1832
Slew gearbox, lubrication....1836
Slew gearbox, specifications_{007-47-55}....1838
Slew gearbox, specifications_{007-48-06}....1839
Swing gearbox, assembly....1840
Swing gearbox, description_{007-47-37}....1847
Swing gearbox, disassembly....1850
Swing gearbox, maintenance standard....1856
Swing gearbox, replacing....1859
Track gearbox cover, replacing....1864
Track gearbox, assembly....1867
Track gearbox, description....1876
Track gearbox, disassembly_{007-50-42}....1879
Track gearbox, disassembly_{008-29-45}....1886
Track gearbox, disassembly_{008-30-45}....1890
Track gearbox, installation_{008-32-24}....1894
Track gearbox, installation_{008-32-37}....1896
Track gearbox, maintenance standard....1898
Track gearbox, precautions for operation_{008-34-01}....1901
Track gearbox, precautions for operation_{008-34-16}....1904
Track gearbox, removal....1907
Track gearbox, specifications ....1910
Track gearbox, troubleshooting....1911
Track unit, replacing....1913
44 - HYDROSTATIC DRIVE....1916
Center passage hose (center passage – motor), replacing....1918
Center passage hose (valve – center passage), replacing....1921
Center passage, assembly....1923
Center passage, description....1930
Center passage, disassembly....1934
Center passage, inspection and troubleshooting....1939
Center passage, replacing seal kit....1944
Center passage, replacing....1950
Center passage, tightening torques ....1957
Hydraulic pump coupling, description....1960
Pump gearbox coupling assembly, replacing....1963
Slew motor, troubleshooting....1965
Swing motor relief valve, replacing_{007-37-11}....1969
Swing motor relief valve, replacing_{007-37-23}....1971
Swing motor, assembly....1973
Swing motor, description....1984
Swing motor, disassembly....1990
Swing motor, principle of operation....2000
Swing motor, replacing brake piston seal....2005
Swing motor, replacing....2009
Swing motor, specifications ....2013
Tools....2014
Track motor relief valve, replacing....2016
Track motor, assembly_{007-40-05}....2018
Track motor, assembly_{007-40-23}....2033
Track motor, description_{007-43-55}....2050
Track motor, disassembly_{007-41-37}....2061
Track motor, disassembly_{007-41-54}....2076
Track motor, maintenance standard....2095
Track motor, precautions for operation....2102
Track motor, specifications_{007-44-14}....2104
Track motor, specifications_{007-44-25}....2106
Track motor, troubleshooting....2108
49 - MISCELLANEOUS....2113
Swing ring gear grease pipe, replacing_{007-29-54}....2114
Swing ring gear grease pipe, replacing_{007-30-07}....2117
Swing ring gear inner seal, replacing....2119
Swing ring gear outer seal, replacing_{007-29-06}....2123
Swing ring gear outer seal, replacing_{007-29-20}....2126
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....2133
70 - GENERAL....2134
Frame and track unit, specifications ....2135
71 - FRAME....2136
Counterweight, installing_{011-56-08}....2137
Counterweight, installing_{011-56-43}....2139
Counterweight, removing_{012-03-14}....2142
Counterweight, removing_{012-16-26}....2144
Counterweight, specifications_{012-16-59}....2146
Counterweight, specifications_{012-17-12}....2147
Counterweight, tightening torques ....2148
Machine weight, specifications....2150
Superstructure, installing....2152
Superstructure, removing....2157
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....2162
Bottom roller, assembly....2164
Bottom roller, description_{008-47-37}....2168
Bottom roller, description_{008-48-00}....2171
Bottom roller, disassembly....2174
Bottom roller, measurement of wear....2178
Bottom roller, replacing one....2181
Bottom roller, replacing seal....2185
Bottom roller, wear limit....2191
Idler, assembly....2194
Idler, description_{011-54-35}....2198
Idler, description_{011-55-00}....2201
Idler, disassembly....2204
Idler, measurement of wear....2208
Idler, tools for disassembly and assembly....2212
Selection of track shoes....2214
Spring package, assembly....2216
Spring package, disassembly_001....2219
Spring package, disassembly_002....2221
Sprocket, measurement of wear....2223
Sprocket, replacing one....2227
Tools & equipment....2229
Top roller, assembly....2234
Top roller, description....2238
Top roller, disassembly....2241
Top roller, measurement of wear....2244
Top roller, replacing one....2247
Track chain assembly, installing....2252
Track chain assembly, removing....2257
Track chain, description....2262
Track chain, measurement of wear....2264
Track chain, wear limit....2269
Track guard, replacing one....2271
Track shoe, replacing one....2274
Track, adjusting track sag_1....2277
Track, adjusting track sag_2....2279
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....2284
90 - GENERAL....2285
Description, general....2286
Hydraulic components, storing and transporting....2288
Hydraulic oil, description....2292
Hydraulic oil, storage and handling....2296
Hydraulic pressure, specifications ....2300
Hydraulic system, cleanliness when handling hydraulic components....2301
Hydraulic system, description....2305
Hydraulic system, repair of hydraulic components in workshop....2309
Recommended hydraulic oil, specifications ....2314
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....2318
002 stage port relief valve, adjustment....2325
002 stage port relief valve, description....2328
002 stage port relief valve, disassembly and assembly....2334
002-pump flow selector valve ....2338
Accumulator, replacing....2340
Adjustable boom (001st boom), description....2342
Adjustable boom (002nd boom), description....2346
Adjustable boom and cylinder, specifications ....2349
Adjustable boom selector valve ....2351
Adjustable boom valve, description....2353
Adjustable boom valve, disassembly....2358
Arm holding valve, description....2367
Arm holding valve, disassembly and assembly....2371
Arm parallel conflux check valve, disassembly and assembly....2374
Arm parallel conflux valve, disassembly and assembly....2376
Arm regenerating and arm conflux check valve, disassembly....2378
Arm regenerating valve, description....2380
Boom back pressure check valve, disassembly and assembly....2384
Boom cylinder, rupture valve, replacing....2386
Boom float position, description ....2391
Boom float position, hydraulic circuits....2392
Boom holding valve, description....2395
Boom holding valve, disassembly....2399
Boom regenerating valve, description....2403
Breather, replacing....2405
Center bypass valve, disassembly and assembly....2408
Check valve, description....2410
Checking and Adjusting procedure....2412
Control pattern selector valve, description....2415
Control pattern selector valve, specifications ....2418
Current_pressure, specifications ....2420
Dipper arm cylinder, rupture valve, replacing....2422
Disassembly and assembly, general....2427
Examples, hydraulic system....2429
Examples, power transmission....2439
Fan motor, assembly....2449
Fan motor, description ....2456
Fan motor, disassembly....2462
Fan motor, tools....2470
Fan motor, troubleshooting....2473
Fan pump, assembly_{011-04-44}....2476
Fan pump, assembly_{011-05-23}....2478
Fan pump, description....2481
Fan pump, disassembly_{011-05-42}....2485
Fan pump, disassembly_{011-06-02}....2487
Fan pump, parts inspection....2490
Foot relief valve (flow sensing valve), description....2493
Foot relief valve (flow sensing valve), disassembly....2495
General, precautions....2498
General, tools....2503
Hammer and Shears (X001 Line option), description....2505
Hammer and shear pedal valve (RCV), replacing....2507
Hammer and shear selector and shuttle valve, description....2511
Hammer return filter, description....2512
Hammer return filter, specifications ....2514
Hydraulic circuits, arm in conflux - Image....2515
Hydraulic circuits, arm in_boom raise - Image....2518
Hydraulic circuits, arm out - Image....2522
Hydraulic circuits, boom lower - Image....2523
Hydraulic circuits, boom raise conflux (internal) - Image....2524
Hydraulic circuits, bucket - Image....2527
Hydraulic circuits, slew (left) - Image....2528
Hydraulic circuits, slew priority (slew right _ arm in) - Image....2530
Hydraulic circuits, standard - Image....2532
Hydraulic circuits, straight travel (low _ auto shift) - Image....2533
Hydraulic circuits, straight travel _ arm (straight travel auto shift, arm in) - Image....2535
Hydraulic circuits, with option parts - Image....2536
Hydraulic components, description....2537
Hydraulic diagram, schematic - Image....2540
Hydraulic diagram, schematic....2541
Hydraulic oil cooler, replacing....2544
Hydraulic oil cooling system, description....2550
Hydraulic oil cooling system, specifications ....2553
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump....2555
Hydraulic pump (removed), changing shaft seal....2559
Hydraulic pump regulator, replacing....2562
Hydraulic pump, description....2564
Hydraulic pump, maintenance standard, Specifications....2570
Hydraulic pump, replacing....2575
Hydraulic pump, specifications ....2582
Hydraulic system, position of main components....2583
Hydraulic system, work instructions....2586
Hydraulic tank, description....2591
Hydraulic tank, specifications ....2595
Line rupture valve (arm), description....2596
Line rupture valve (arm), disassembly....2603
Line rupture valve (arm), specifications ....2605
Line rupture valve (arm), troubleshooting....2607
Line rupture valve (boom), description....2608
Line rupture valve (boom), disassembly....2617
Line rupture valve (boom), specifications ....2619
Line rupture valve (boom), troubleshooting....2621
Line rupture valve, adjustment....2623
Load check valve – single, disassembly and assembly....2625
Load check valve, disassembly and assembly_{010-36-53}....2627
Load check valve, disassembly and assembly_{010-37-10}....2629
Logic valve, description-[3848]....2631
Logic valve, description....2634
Logic valve, disassembly and assembly....2637
Main control valve troubleshooting....2640
Main control valve, description....2644
Main control valve, specifications ....2652
Main pressure relief valve, replacing....2654
Main relief valve, adjustment....2656
Main relief valve, description....2659
Main relief valve, disassembly....2662
Main spool, disassembly and assembly....2664
Oil cooler line bypass valve (check valve), replacing....2667
Oil level gauge, replacing....2670
Overload warning device, operation....2672
Pipe and hose (pump - valve), replacing....2674
Port relief valve pressure, measurement....2677
Port relief valve, adjustment....2680
Port relief valve, description....2682
Port relief valve, disassembly....2685
Power Take Off (PTO, option), description....2688
Pressure accumulator, description....2690
Pressure accumulator, specifications ....2694
Pressure relief valve, troubleshooting....2696
Proportional relief valve, description....2700
Proportional solenoid valve (power shift), replacing....2704
Proportional solenoid valve, description....2708
Proportional solenoid valve, measuring and adjustment....2710
Proportional solenoid valve, specifications ....2712
Proportional solenoid valve, troubleshooting....2714
Pump, assembly....2716
Pump, disassembly....2722
Pump, installation....2728
Pump, tools....2730
Pump, troubleshooting....2732
Regulator, assembly....2737
Regulator, description....2742
Regulator, disassembly....2751
Regulator, maintenance....2758
Regulator, specifications ....2763
Remote control valve (Lever), assembly....2764
Remote control valve (Lever), description....2777
Remote control valve (Lever), disassembly....2787
Remote control valve (Lever), maintenance standard, Specifications....2800
Remote control valve (Lever), specifications ....2802
Remote control valve (Lever), troubleshooting....2804
Remote control valve (lever), replacing....2806
Remote control valve (pedal), assembly....2810
Remote control valve (pedal), description....2817
Remote control valve (pedal), disassembly....2824
Remote control valve (pedal), maintenance standard, Specifications....2835
Remote control valve (pedal), replacing....2837
Remote control valve (pedal), specifications ....2841
Remote control valve (pedal), troubleshooting....2843
Rotator (X003 Line option), description_{09-35-54}....2845
Rotator (X003 Line option), description_{09-36-08}....2847
Rotator pump, assembly....2849
Rotator pump, description....2850
Rotator pump, disassembly....2851
Rotator pump, parts inspection....2852
Rotator pump, specifications ....2853
Rotator valve, adjustment_{009-35-19}....2854
Rotator valve, adjustment_{009-35-34}....2857
Servo hydraulic pressure, adjustment....2860
Servo hydraulic selector valve, description....2862
Servo hydraulic selector valve, specifications ....2864
Servo pump, description....2866
Servo pump, parts inspection....2870
Servo pump, replacing....2873
Servo pump, specifications ....2875
Shuttle valve block, description....2877
Solenoid valve (001) for hammer and shear selection....2883
Solenoid valve (002) for hammer and shear 2-pump flow....2886
Solenoid valve for rotator ....2888
Solenoid valve, description....2889
Solenoid valve, disassembly and assembly....2892
Solenoid valve, inspection....2896
Solenoid valve, replacing....2899
Solenoid valve, specifications ....2901
Solenoid valve, troubleshooting....2902
Standard of the setting pressure....2906
Stop valve....2908
Straight travel changeover valve, disassembly and assembly....2910
Troubleshooting, diagnosing procedure....2912
Valve block, description....2917
92 - MECHANICAL EQUIPMENT_ATTACHMENT....2921
Attachment quick coupler solenoid valve, description....2922
Attachment quick coupler solenoid valve, specification ....2924
Attachment quick coupler, adjustment....2925
Attachment quick coupler, description_{009-31-26}....2928
Attachment quick coupler, description_{009-31-40}....2931
Attachment quick coupler, operation....2933
Quickfit, installing....2935
Quickfit, removing....2939
97 - UNIT, DIGGING....2942
Adapter, installing....2944
Adapter, removing....2946
Boom cylinder, installing....2948
Boom cylinder, removing....2950
Boom cylinder, replacing....2952
Boom lifting cylinder, description....2955
Boom lifting cylinder, specifications ....2957
Boom, description....2959
Boom, installing....2962
Boom, removing....2967
Boom, replacing....2972
Boom, specifications ....2975
Bucket assembly, installing....2976
Bucket assembly, removing....2979
Bucket assembly, replacing....2982
Bucket cylinder, description....2986
Bucket cylinder, installing....2989
Bucket cylinder, removing....2992
Bucket cylinder, replacing....2995
Bucket cylinder, specifications ....2999
Bucket operation_{009-18-09}....3001
Bucket operation_{009-18-23}....3003
Connecting rod yoke, installing....3005
Connecting rod yoke, removing....3008
Connecting rod yoke, replacing....3011
Cylinder, description....3015
Cylinder, troubleshooting....3019
Digging unit, maintenance....3022
Dipper arm connecting rod, installing....3024
Dipper arm connecting rod, removing....3027
Dipper arm connecting rod, replacing....3031
Dipper arm cylinder, description....3036
Dipper arm cylinder, installing....3039
Dipper arm cylinder, removing....3041
Dipper arm cylinder, replacing....3044
Dipper arm cylinder, specifications ....3047
Dipper arm, description....3049
Dipper arm, installing....3052
Dipper arm, removing....3056
Dipper arm, replacing....3061
Dipper arm, specifications ....3064
Function description_{009-28-02}....3066
Function description_{009-28-16}....3068
Link, description....3070
99 - MISCELLANEOUS....3072
Automatic lubrication pump, installing....3073
Automatic lubrication pump, removing....3076
Automatic lubrication system, description....3079
Automatic lubrication system, specifications ....3081
Bleeding air....3084
Boom float position, hydraulic circuits....3085
Central lubrication system, description....3088
Explanations to hydraulic diagram....3092
Hydraulic diagram, arm in....3103
Hydraulic diagram, arm out....3106
Hydraulic diagram, boom lower....3109
Hydraulic diagram, boom raise....3112
Hydraulic diagram, bucket curl....3115
Hydraulic diagram, bucket dump....3118
Hydraulic diagram, control pattern selector valve....3121
Hydraulic diagram, neutral....3126
Hydraulic diagram, ports....3127
Hydraulic diagram, slew (left)....3139
Hydraulic diagram, standard....3142
Hydraulic diagram, straight travel....3146
Hydraulic diagram, travel....3149
Hydraulic diagram, with option components....3152
Hydraulic diagram, with reversible cooling fan....3156
Hydraulic quickfit....3160
Hydraulics diagram....3163
Maintenance service, general....3169
Overview....3172
Troubleshooting ....3175
Volvo EC240CL Excavators Repair Service Manual
