EC200E L Volvo Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for EC200E L Volvo Constructions Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
EC200E L Volvo Excavators workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,332 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
EC200E L Volvo Excavators Service Repair Manual.pdf
MAIN SECTIONS
000 - Foreword............2
000 - GENERAL............3
00 - DESCRIPTION; COMPLETE MACHINE............4
Machine view............5
Product plates............8
03 - SPECIFICATIONS............10
Tightening torques............11
Measurement conversion tables............22
Thermostat; specifications............31
07 - STANDARD TIME............33
Operation numbers for additional work............34
08 - TOOL............36
E-tools; NET 8940-00270 Replace tool for the swing ring gear............37
E-tools; NET 8940-00310 Replace tool for the swing ring gear............39
E-tools; NET 8940-00320 Swing motor guide pin and swing ring gear............41
09 - MISCELLANEOUS............43
Service positions............44
Welding on the machine............47
Hydraulic cylinders; dieseling............50
001 - STANDARD PARTS; SERVICE............54
16 - LUBRICANT; FUEL; OTHER FLUID............55
AdBlue®_DEF ............56
Engine oil............62
Fuel............64
Hydraulic oil............67
Lubricants; service capacities and intervals............72
Recommended lubricants............74
Coolant_{08-47-02}............78
Coolant_{08-46-40}............83
Coolant with freezing and corrosion protection............87
Grease............91
Alternative fuels............95
Change capacities............98
Air cleaner; description............99
17 - SERVICE............101
Bearings............104
Replacement parts............108
Safety when servicing............112
Service............116
Service methods............119
Pressure testing............123
Hoses and tubes............127
Cleaning prior to repair............131
Tech Tool; Operations............135
Arrival Inspection; according to Inspection Programme............137
Delivery Inspection; according to Inspection Programme............142
Maintenance of Stored Machines; according to Inspection Programme............146
Maintenance service; first 500 hours............150
Maintenance service; every 10 hours............151
Maintenance service; every 50 hours............152
Maintenance service; every 250 hours............153
Maintenance service; every 500 hours............154
Maintenance service; every 1000 hours............156
Maintenance service; every 2000 hours............158
Maintenance service; every 4000 hours............160
Maintenance service; every 6000 hours............162
Maintenance service; every 8000 hours............163
Service position............164
Lubrication; every 50 hours............167
Test running and checking............169
Valves; Adjusting............171
Engine oil and filter; changing............176
Fuel filter; replacing............179
Water separator filter; replacing............181
Fuel tank breather filter; replacing............183
Diesel particulate filter; regenerating............185
Diesel particulate filter; checking and cleaning............187
AdBlue®_DEF pump unit filter; replacing............193
AdBlue®_DEF tank breather filter; replacing............197
Engine air cleaner primary filter; replacing............200
Engine air cleaner secondary filter; replacing............202
Coolant; Changing............205
Coolant freezing point; checking............208
Fan_alternator belt; checking............211
Radiator and hydraulic oil cooler; cleaning............212
MATRIS and Tech Tool; reading............214
Software update; checking............217
Battery; checking............221
CareTrack backup battery; replacing_{07-59-10}............223
CareTrack backup battery; replacing_{07-57-59}............226
Track gearbox oil level; checking............231
Track gearbox oil; changing............233
Swing gearbox oil level; checking............235
Swing gearbox oil; changing............237
Swing ring gear bearing; lubricating............239
Swing bath grease; checking............241
Track tension and condition; checking............242
Cab door; covers; hinges; joints and locks; lubricating............244
Air conditioner main filter; cleaning............246
Air conditioner main filter; replacing............249
Cab prefilter; cleaning............252
Cab prefilter; replacing............254
Air conditioner compressor belt; checking............256
Hydraulic oil level; checking............258
Hydraulic oil; changing............260
Hydraulic oil suction strainer; cleaning............263
Hydraulic oil servo filter; replacing............265
Hydraulic oil return filter; replacing............266
Hydraulic return filter on X1 option circuit; replacing............269
Hydraulic oil tank breather filter; replacing............271
Measuring condition............273
19 - GENERAL............276
Safety concerns everybody!............277
CE-marking; EMC-directive............281
Cautions during operation............285
Safety when handling the machine............292
Safety rules when servicing............298
Move and operate machine safely............303
Fire prevention measures............306
Health hazards with paint; plastics and rubber............312
Checklist after a fire or heat exposure............317
Safety when using lifting equipment............321
Safety when handling oils and fuel............325
Safety when working with batteries............329
Starting with booster batteries............334
Safety when working with air conditioning refrigerant............338
Safety when working with hydraulic systems............343
Environmental handling for the future............347
Environmentally safe handling............351
Environmentally hazardous fluids............355
Working in environmentally contaminated areas............359
Decontamination............363
Waste handling............367
002 - ENGINE WITH MOUNTING AND EQUIPMENT............371
20 - GENERAL............372
Engine; description_{06-53-43}............373
Engine; description_{06-53-03}............380
Component locations............386
Tech Tool; operations_{06-50-58}............389
Tech Tool; operations_{06-50-38}............391
Engine control module (ECM); replacing pre-programmed............394
Engine control module (ECM); replacing non-programmed............396
Engine belts; replacing............399
21 - ENGINE............402
Engine; specifications............403
Engine rotation speed sensor (crank shaft); replacing............404
Engine rotation speed sensor (camshaft); replacing............406
Engine; removing............408
Engine; installing............418
Engine; replacing............427
Engine; tightening torques............430
Cylinder compression; testing............437
Crankcase ventilation; description............440
Valves; adjusting............444
Valve cover; removing............449
Valve cover; installing............452
Oil level sensor; replacing............455
22 - LUBRICATING SYSTEM............458
Lubrication system; description............459
Lubrication system; specifications............464
Lubrication system; component locations............466
Lubrication system; tightening torques............468
Lubrication oil pressure; checking with pressure gauge............471
Oil cooler; replacing............474
23 - FUEL SYSTEM............477
Fuel system; Description............478
Fuel system; description............485
Fuel system; specifications............493
Fuel system; tightening torques............495
Carbon dioxide in fuel system; checking............503
Fuel system basics; checking............509
Fuel system; component location............512
Feed pump pressure; checking............514
Fuel system; bleeding............516
Fuel filler pump; specifications............517
Water separator; specifications............518
Injectors; replacing............520
Injector sleeves; replacing............526
Fuel rail; replacing............534
Fuel rail pressure sensor; replacing............537
High pressure fuel pump; replacing............539
High pressure fuel pipes; replacing............542
Fuel control valve (FCV); replacing............544
Pressure relief valve (PRV); replacing............549
25 - INLET & EXHAUST SYSTEM............552
Inlet and exhaust system; description............554
Inlet and exhaust system; specification............560
Inlet and exhaust system; component location............562
Inlet and exhaust system; tightening torques............564
Exhaust pipe flexible tube; replacing............570
Exhaust Aftertreatment System; description............573
Exhaust Aftertreatment System; component location............586
Regeneration process; description............588
AdBlue®_DEF dosing injector; replacing............595
AdBlue®_DEF mixing tube; replacing............598
AdBlue®_DEF tank; replacing............602
AdBlue®_DEF; draining............604
Coolant valve; replacing............607
SCR (Selective catalytic reduction) muffler; replacing............610
AdBlue®_DEF quality; checking............615
SCR (Selective catalytic reduction) dosing system; checking............618
AdBlue®_DEF pump unit diagnostics; description............621
DPF (Diesel particulate filter); checking and cleaning............625
ACM (Aftertreatment control module) non-programmed; replacing............631
ACM (Aftertreatment control module) pre-programmed; replacing............634
Inlet throttle; replacing............636
DOC (Diesel oxidation catalyst); replacing............638
AdBlue®_DEF pump unit; replacing............641
AdBlue®_DEF tank armature; replacing............646
AdBlue®_DEF tank armature; cleaning............651
AdBlue®_DEF tank armature suction filter; replacing............654
AdBlue®_DEF hoses; replacing............656
AdBlue®_DEF............660
Crystallization of AdBlue®_DEF; checking............666
AdBlue®_DEF pump unit; filter; replacing............671
AdBlue®_DEF pump unit; flushing............675
AdBlue®_DEF pump unit; inlet nipple; replacing............678
Regeneration log; checking............681
AdBlue®_DEF tank; cleaning............693
Turbocharger; replacing............696
Wastegate; checking............699
Charge air cooler; replacing............701
26 - COOLING SYSTEM............707
Cooling system; description............708
Cooling system; specifications............712
Carbon dioxide in coolant system; checking............714
Cooling system; component location............720
Cooling system; tightening torques............722
Coolant with anti-freeze and corrosion protection; recommendation............725
Cooling system pressure; checking............728
Coolant; changing............730
Radiator; replacing............733
Expansion tank; replacing............735
Coolant pump; replacing............738
Thermostat; replacing............741
Cooling fan control............744
Cooling fan rpm; specifications............748
Cooling fan clutch; description............749
27 - ENGINE CONTROL............752
Engine - Pump control; specification............753
29 - MISCELLANEOUS............755
EGR venturi tube; cleaning............756
Exhaust Gas Recirculation (EGR); description............758
Exhaust gas recirculation (EGR); component location............764
EGR system; tightening torques............766
EGR reed valve; replacing............768
EGR cooler; replacing............774
EGR actuator; replacing............778
EGR venturi tube; replacing............780
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS............783
30 - GENERAL............784
Electrical system; special instructions for servicing; general............790
Electrical system; special instructions for servicing; electronic components............794
Electrical system; special instructions for servicing; electrical components; batteries............797
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator............801
Electrical system; special instructions for servicing; action when working on machine............804
Electrical system; description............807
Electronic control system; description............809
Auxiliary start............816
System voltage............820
Electrical system; specifications............823
Tech Tool; operations ............826
Power Boost control; description............828
Engine stops............831
CareTrack with anti-theft............833
Start lock; description............844
X1 control; description............846
X3 control; description............847
Electro hydraulic pump control; description............849
Power supply; description............854
Mode selection; description............859
Boom float position; description............863
Travel speed; description............864
Overload warning............866
Seat belt............869
Auto Idle............871
Attachment quick coupler............873
Intermittent wiper and washer............875
Grading and lifting control; description............879
ECO mode; description............883
Software parameters; description............885
Automatic engine shut-down............897
General fault diagnosis information............900
Troubleshooting strategy............902
Collection of basic data............904
Information display; check............908
Error code information; general............911
Error codes; build-up............922
Conditions when checking............924
Lead and connector checks............929
Special tools for troubleshooting............935
Tech Tool; operations............938
AL3201; description and measuring............940
BA3101; description and measuring............943
BB1 Communication bus; description and measuring............946
BB2 Communication bus; description and measuring............950
CU9909; description and measuring............953
CU9911; description and measuring............956
FX1005; description and measuring............958
FX1006; description and measuring............961
FX1007; description and measuring............965
FX1008; description and measuring............969
FX1054; description and measuring............973
FX1074; description and measuring............976
FX1079; description and measuring............980
FX1116; description and measuring............983
FX1117; description and measuring............986
HE2501; description and measuring............989
HE2511; description and measuring............992
HE2512; description and measuring............994
HE2513; description and measuring............996
Instrument Cluster (IC); description and measuring............998
MA2301-MA2304; description and measuring............1001
MA2517; description and measuring............1003
MA2519; description and measuring............1005
MA9109; description and measuring............1008
MA9116; description and measuring............1011
MA9117; description and measuring............1014
MA9120; description and measuring............1017
MA9125; description and measuring............1020
MO2505; description and measuring............1023
MO3301; description and measuring............1026
Power supply; ACM (Aftertreatment Control Module); description and measuring............1029
Power supply CCM; description and measuring............1031
Power supply ECM; description and measuring............1033
Power supply GPMECU 1; description and measuring............1036
Power supply HMICU; description and measuring............1039
Power supply SID; description and measuring............1042
Power supply W-ECU; description and measuring............1044
PWM2303; description and measuring............1047
PWM2602; description and measuring............1050
PWM9123; description and measuring............1053
PWM9124; description and measuring............1056
PWM9129; description and measuring............1059
PWM9141; description and measuring............1061
PWM9142; description and measuring............1064
PWM9145; description and measuring............1067
PWM9146; description and measuring............1070
PWM9156; description and measuring............1073
PWM9157; description and measuring............1075
RE2501; description and measuring............1078
RE3101; description and measuring............1081
RE3102; description and measuring............1084
RE3502; description and measuring............1087
RE3507; description and measuring............1090
RE3508; description and measuring............1092
RE3511; description and measuring............1095
RE3607; description and measuring............1098
RE3608; description and measuring............1101
RE3611; description and measuring............1104
RE4206; description and measuring............1107
SAE J1939-1 SubNet 1; description and measuring............1110
SE2203; description and measuring............1113
SE2301; description and measuring............1116
SE2303; description and measuring............1119
SE2309; description and measuring............1122
SE2511; description and measuring............1125
SE2512; description and measuring............1128
SE2513; description and measuring............1131
SE2515; description and measuring............1134
SE2516; description and measuring............1137
SE2519; description and measuring............1140
SE2521; description and measuring............1143
SE2522; description and measuring............1146
SE2533; description and measuring............1149
SE2543; description and measuring............1152
SE2544; description and measuring............1155
SE2603; description and measuring............1158
SE2604; description and measuring............1161
SE2606; description and measuring............1164
SE2701; description and measuring............1167
SE2703; description and measuring............1169
SE8701; description and measuring............1171
SE8702; description and measuring............1174
SE8705; description and measuring............1177
SE8706; description and measuring............1180
SE9105; description and measuring............1183
SE9121; description and measuring............1187
SE9122; description and measuring............1190
SE9123; description and measuring............1193
SE9124; description and measuring............1196
SE9125; description and measuring............1199
SE9126; description and measuring............1202
SE9127; description and measuring............1205
SE9128; description and measuring............1208
SE9131; description and measuring............1211
SE9132; description and measuring............1214
SE9136; description and measuring............1217
SE9138; description and measuring............1220
SE9141; description and measuring............1223
SE9142; description and measuring............1226
SE9401; description and measuring............1229
SW2506; description and measuring............1232
SW3301; description and measuring............1235
SW3802; description and measuring............1238
SW3803; description and measuring............1241
SW9161; description and measuring............1244
SW9162; description and measuring............1247
Tiltrotator detection; description and measuring............1249
VSV controller; description and measuring............1252
31 - BATTERY............1255
Battery; storage............1256
Battery; description............1259
Battery; specifications............1262
Battery condition; checking............1263
Battery; charging............1266
32 - ALTERNATOR; CHARGE REGULATOR............1269
Charging; description............1270
Alternator; specifications............1272
Alternator; description............1274
Alternator; testing............1277
33 - STARTING SYSTEM............1281
Starting operation............1282
Starter motor; description............1283
Starter motor; specifications............1285
Starter motor; testing............1287
Preheating; description............1291
Ignition switch; description and operation............1293
Ignition switch; specifications............1296
Starter switch; testing............1298
35 - LIGHTING............1301
Work lights and extra lights; specifications_{10-00-14}............1302
Work lights and extra lights; specifications_{09-59-54}............1305
36 - OTHER ELECTRICAL EQUIPMENT............1308
Electric pedal control on X1 (on_off); replacing............1309
Electric pedal control on X1 (proportional); replacing............1313
Travel alarm; description............1317
Electric horn; specifications............1320
Horn; replacing............1323
Rotating beacon; specifications_{09-55-26}............1325
Rotating beacon; specifications_{09-55-06}............1327
Rotating beacon; replacing............1329
Travel alarm; specifications............1332
Travel alarm; replacing............1335
Windscreen wiper front motor; replacing............1337
Windscreen wiper switch; replacing............1342
Windscreen flusher pump; replacing............1345
Windscreen wiper; description............1347
Upper wiper motor; description............1349
Upper wiper motor; specifications............1351
Lower wiper motor; description............1353
Lower wiper motor; specifications............1355
Windscreen flusher pump; specifications............1357
Window limit switch; description............1359
Connectors; overview............1362
Control lockout lever switch; replacing............1372
Ignition switch; replacing............1375
General purpose machine electronic control unit GPMECU; function description............1378
Human machine interface control unit HMICU; function description............1381
GPMECU1 non-programmed; replacing............1383
GPMECU1 pre-programmed; replacing............1386
HMICU non-programmed; replacing............1389
HMICU pre-programmed; replacing............1393
37 - CABLE; FUSE; RELAY............1397
Electrical symbols and designations............1399
Explanation of wiring diagrams............1404
Component designations............1407
Component list Alternator; batteries; capacitors; electronic units; voltage outlet............1409
Component list; Heating coils............1411
Component list; lights............1413
Component list; Miscellaneous............1415
Component list; motors............1417
Component list; relays............1419
Component list; sensors............1421
Component list; Solenoid valves............1424
Component list; Switches............1426
ACM; I_O list............1428
CCM; I_O list............1431
ECM (Engine Control Module); I_O list............1435
HMICU; I_O list............1440
IC (Instrument Cluster); I_O list............1443
W-ECU; I_O list............1445
Wiring diagram; electrical distribution box............1447
Wiring diagram SCH01............1451
Wiring diagram SCH02............1455
Wiring diagram SCH03............1460
Wiring diagram SCH04............1464
Wiring diagram SCH05............1469
Wiring diagram SCH07............1473
Wiring diagram SCH08............1477
Wiring diagram SCH10............1482
Wiring diagram SCH11............1485
Wiring diagram SCH12............1489
Wiring diagram SCH13............1493
Wiring diagram SCH14............1497
Wiring diagram SCH15............1502
Wiring diagram SCH16............1506
Wiring diagram SCH17............1509
Wiring diagram SCH18............1513
Wiring diagram SCH21............1516
Wiring diagram SCH24............1519
Wiring diagram SCH27............1522
Wiring diagram SCH28............1527
Wiring diagram SCH30............1531
Engine wire harness; replacing_{09-14-19}............1535
Engine wire harness; replacing_{09-13-56}............1541
Electrical battery disconnect switch; replacing............1547
Electrical distribution box............1551
Electrical distribution box; circuit board replacing............1554
Fuse; description............1558
Relay; description............1561
Relay; specifications............1564
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM............1566
Hour meter; replacing............1568
Control lockout lever switch; description............1571
Control lockout lever switch; specifications............1574
Engine temperature sensor; replacing............1577
Engine oil pressure sensor; replacing............1579
Hydraulic oil temperature sensor; replacing............1581
Keypad; description............1584
Keypad; specification............1586
Service mode............1588
Engine system............1591
Hydraulic system............1594
Electrical system............1598
Volvo Smart View............1603
Volvo Smart View; specification............1607
Volvo Smart View camera; replacing............1610
Volvo Smart View; calibrating............1614
Volvo Smart View accuracy; checking............1619
Volvo Co-Pilot; description............1625
Volvo Co-Pilot; component location............1629
Volvo Co-Pilot; specifications............1631
Volvo Co-Pilot; replacing............1633
Volvo Co-Pilot SIM card; installing............1637
USB tethering............1644
Volvo Co-Pilot Android software; updating online (OtA)............1651
Volvo Co-Pilot Android software; updating offline (USB)............1654
Volvo Co-Pilot; software updating............1657
Dig Assist; description............1661
Dig Assist; component location............1674
Dig Assist; software update............1675
Dig Assist connectors; overview............1676
Dig Assist; tightening torques............1681
Dig Assist IMU; teach-in............1684
36703-3 Dig Assist; calibration; body IMU............1692
36703-3 Dig Assist; calibration; linkage............1696
36703-3 Dig Assist; calibration; GNSS............1704
Dig Assist GNSS antenna; calibrating............1711
36705-3 Dig Assist; configuration............1718
Dig Assist Onboard Weighing system; calibrating............1726
Dig Assist Onboard Weighing; tool weight; calibrating............1736
Dig Assist accuracy; checking_{08-49-08}............1743
Dig Assist accuracy; checking_{08-48-38}............1751
Dig Assist IMU; checking............1759
Dig Assist quick coupler; measuring............1771
Dig Assist lift point; measuring............1778
Dig Assist Information Center; description............1784
Dig Assist; troubleshooting_{08-45-44}............1804
Dig Assist; troubleshooting_{08-45-25}............1810
Dig Assist RTK; troubleshooting............1816
3D applications for Dig Assist; troubleshooting............1823
Smart Receiver; replacing............1825
GNSS Antenna; replacing............1829
Inertial measurement unit (IMU); replacing_{08-43-26}............1832
Inertial measurement unit (IMU); replacing_{08-43-04}............1839
Laser catcher; replacing............1846
39 - MISCELLANEOUS............1848
Radio with MP3; description............1849
Radio with MP3; specifications............1853
Radio; replacing............1855
DC–DC converter; description............1860
DC–DC converter; specifications............1863
Voltage converter; replacing............1866
Antenna; replacing............1870
Speaker; replacing............1873
CareTrack W-ECU; description............1875
W-ECU; replacing; non-programmed............1880
W-ECU; replacing; pre-programmed............1884
CareTrack battery; replacing............1888
CareTrack antenna; replacing............1892
004 - POWER TRANSMISSION............1897
40 - GENERAL............1898
Tightening torque; Specifications............1899
Power transmission; description............1900
43 - GEARBOX............1903
Function description_{10-49-06}............1904
Function description_{10-48-43}............1906
Track gearbox; specifications............1908
Track gearbox; description............1909
Track gearbox; maintenance............1912
Track unit; replacing............1917
Track gearbox cover; replacing............1921
Track gearbox (removed); replacing floating seal............1924
Track gearbox; disassembly............1931
Track gearbox; assembly............1937
Swing gearbox; specifications............1944
Swing gearbox; description............1945
Swing gearbox; maintenance............1949
Swing unit; replacing............1952
Swing gearbox; replacing............1954
Swing gearbox removed; seal replacing............1959
Swing gearbox removed; replacing shaft............1962
Swing gearbox; disassembly............1975
Swing gearbox; assembly............1982
44 - HYDROSTATIC DRIVE............1988
Track motor; specifications............1990
Track motor; description............1991
Track motor; maintenance_{10-33-03}............1997
Track motor; maintenance_{10-32-32}............2003
Track motor; replacing............2006
Track motor relief valve; replacing............2013
Track motor; adjusting............2016
Track motor; disassembling............2018
Track motor; assembling............2026
Swing motor; specifications............2036
Swing motor; description............2037
Swing motor; maintenance_{10-27-38}............2045
Swing motor; maintenance_{10-27-14}............2047
Swing motor; maintenance_{10-26-49}............2054
Swing motor; replacing............2061
Swing motor pressure; checking and adjusting............2064
Swing motor removed; seal replacing............2066
Swing motor; replacing brake piston seal............2069
Swing motor; replacing plate (brake)............2073
Swing motor; disassembly............2077
Swing motor; assembly............2082
Hydraulic pump coupling; description............2089
Pump gearbox coupling assembly; replacing............2093
Center passage; tightening torques............2096
Center passage; specifications............2099
Center passage; description............2100
Center passage; maintenance............2103
Center passage; replacing............2107
Center passage; replacing seal kit............2112
Center passage; disassembling............2117
Center passage; assembling............2121
49 - MISCELLANEOUS............2128
Swing ring gear; specifications............2129
Swing ring gear; description............2130
Swing ring gear; replacing............2133
Swing ring gear grease pipe; replacing............2136
Swing ring gear inner seal; replacing............2138
Swing ring gear outer seal; replacing............2142
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT............2149
71 - FRAME............2150
Machine weight; specifications............2151
Superstructure; removing............2153
Superstructure; installing............2158
Tightening torque; specifications............2163
Counterweight; tightening torques............2165
Counterweight; specifications............2167
Counterweight; replacing............2168
Undercarriage; description............2171
72 - GENERAL............2173
Undercarriage; tightening torque............2174
Frame and track unit; specifications............2176
Frame and track unit; description............2177
77 - WHEELS; TRACKS; TYRE; HUB; DRUM............2178
Selection of track shoes............2180
Idler; description............2182
Front idler wear; measuring............2184
Front idler; replacing one............2187
Front idler wheel; disassembling............2190
Front idler wheel; assembling............2193
Sprocket; replacing one............2196
Sprocket wear; measuring tools_{10-01-14}............2198
Sprocket wear; measuring tools_{10-00-55}............2199
Sprocket wear; measuring............2202
Track link; specifications............2205
Track chain; description............2206
Track tension; adjusting............2207
Track chain wear; measuring............2210
Track shoe; replacing one............2215
Track links; replacing............2217
Track chain assembly; removing............2221
Track chain assembly; installing............2225
Top roller; description............2228
Top roller wear; measuring............2229
Top roller; replacing one............2232
Bottom roller; description............2236
Bottom roller wear; measuring............2237
Bottom roller; replacing one............2240
Bottom roller; replacing seal............2244
Track guard; description............2248
Track guard; replacing one............2249
Spring package assembly; specifications............2252
Recoil spring cylinder seal kit; replacing............2254
Track recoil spring (tensioner) assembly; replacing............2257
Spring package; disassembling............2260
Spring package; assembling............2262
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE............2265
80 - GENERAL............2266
Tech Tool; operations............2267
VCADS Pro; Operations............2269
81 - CAB; NAKED; CANOPY............2271
Cab; weight............2272
Cab; removing............2274
Cab; installing............2284
Cab suspension; description............2293
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING............2295
Rear-view mirror; replacing_{09-42-10}............2296
Rear-view mirror; replacing_{09-41-43}............2298
Rear-view mirror; replacing_{09-41-23}............2300
Windows; general............2302
Windscreen; replacing............2305
Side window; replacing............2319
Rear window; replacing............2326
Door window; replacing............2334
85 - CAB INTERIOR; UPHOLSTERY............2337
Seat; replacing............2338
Seat cushion; replacing............2341
Seat support; replacing............2347
Longitudinal adjustment cable; replacing............2354
Longitudinal suspension cable; replacing............2361
Backrest; replacing............2366
Driver's seat; description ............2371
Driver's seat; specifications ............2374
Seat heater; checking............2375
Driver's seat; specifications............2379
Driver's seat; description............2381
87 - AIR CONDITIONING UNIT............2384
HVAC system............2385
Air conditioning unit; specifications............2389
Air conditioning unit; description............2391
Performance test; AC unit............2398
Air conditioning unit; maintenance............2404
CCM pre-programmed ECU; replacing............2407
CCM non-programmed ECU; replacing............2412
Air conditioning unit; refrigerant check and recharging............2417
Air distribution; description............2425
Cab filter; replacing............2428
Heating system; description............2432
Fan motor; replacing............2434
Heater core; replacing............2438
Cooler and Heater assembly; replacing............2445
Receiver; replacing incl draining and filling............2452
Condenser; replacing incl draining and filling............2456
Evaporator; replacing incl draining and filling............2459
Expansion valve; replacing incl draining and filling............2467
Vent actuator; replacing............2475
Mode (foot) actuator; replacing............2478
Intake actuator; replacing............2481
Air mix door actuator; replacing............2484
Compressor; replacing magnetic clutch (compressor removed)............2487
Auxiliary heater; specifications............2493
Auxiliary heater; description............2495
Auxiliary heater; principles............2498
Troubleshooting_{09-17-45}............2501
Troubleshooting_{09-17-22}............2511
88 - INTERIOR EQUIPMENT............2521
Instrument panel (left); replacing............2522
Instrument panel (right); replacing............2526
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS............2530
90 - GENERAL............2531
Hydraulic diagram; with option components - Image............2532
Hydraulic diagram; standard - Image............2533
Explanations to hydraulic diagram............2534
Hydraulic diagram; standard............2541
Hydraulic diagram; with option components............2544
Hydraulic system; position of main components............2547
Hydraulic system; cleanliness when handling hydraulic components............2550
Description; general............2554
Hydraulic system; description............2555
Recommended hydraulic oil; specifications............2559
Hydraulic pressure; specifications............2563
Hydraulic system; repair of hydraulic components in workshop............2565
Hydraulic oil; storage and handling............2570
Hydraulic components; storing and transporting............2574
Tech Tool; operations............2578
91 - WORKING HYDRAULIC; SERVO HYDRAULICS............2580
Hydraulic system; work instructions............2586
Hydraulic components; description............2591
Hydraulic tank; specifications............2593
Hydraulic tank; description............2594
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump............2597
Oil level gauge; replacing............2600
Breather; replacing............2602
Servo hydraulic block............2604
Shuttle valve block; description............2605
Check valve; description............2609
Oil cooler line bypass valve (check valve); replacing............2611
Hydraulic oil cooling system; specifications............2618
Hydraulic oil cooling system; description............2619
Hydraulic oil cooler; description............2620
Hydraulic oil cooler; replacing............2621
Main control valve; port size and tightening torque............2622
Main control valve; specifications............2625
Main control valve; description............2627
Pressure relief valve; troubleshooting............2638
Main control valve troubleshooting............2642
General; precautions............2647
General; tools............2652
Main spool; disassembly and assembly............2654
Main relief valve; description............2656
Main relief valve; adjustment............2659
Main relief valve; disassembly and assembly............2662
Port relief valve; description............2665
Port relief valve pressure; checking and adjusting............2668
Port relief valve; disassembly and assembly............2671
2 stage port relief valve; description............2674
2 stage port relief valve; adjustment............2680
2 stage port relief valve; disassembly and assembly............2683
X1 Pre-set relief valve; description............2685
X1 Pre-set relief valve; adjusting............2690
X1 Pre-set relief valve; disassembly and assembly............2694
Boom holding valve; description............2697
Boom holding valve; disassembly............2702
Boom regenerating valve; description............2704
Boom back pressure check valve; disassembly............2706
Arm holding valve; description............2708
Arm holding valve; disassembly and assembly............2711
Arm regenerating valve; description............2713
Arm regenerating valve; disassembly............2716
Arm parallel conflux valve; disassembly and assembly............2718
Arm parallel conflux check valve; disassembly and assembly............2720
Conflux check valve; description............2722
Main control valve adjustor; adjusting............2724
Bucket regenerating valve; description............2727
Bucket regenerating valve; disassembly............2729
Bucket flow control valve; description............2731
Bucket flow control valve; disassembly............2734
Center bypass valve; description............2738
Center bypass valve; disassembly and assembly............2741
Load check valve - single; description............2743
Load check valve – single; disassembly and assembly............2746
Control valve; replacing............2749
Tightening torques ............2758
Tightening Torques ............2762
Line rupture valve (boom); specifications............2766
Line rupture valve (boom); description............2767
Line rupture valve pressure; checking and adjusting............2773
Port relief valve pressure; adjustment (when installing or dismantling the line rupture valve)............2776
Line rupture valve (boom); air breathing............2778
Boom cylinder; rupture valve; replacing............2781
Disassembly and assembly; general............2788
Line rupture valve (boom); disassembly............2791
Line rupture valve (boom); assembly............2794
Line rupture valve (boom); troubleshooting............2797
Line rupture valve (arm); specifications............2800
Line rupture valve (arm); description............2802
Line rupture valve relief pressure; measurement............2808
Line rupture valve (arm); air breathing............2810
Dipper arm cylinder; rupture valve; replacing............2813
Line rupture valve (arm); disassembly............2820
Line rupture valve (arm); assembly............2823
Line rupture valve (arm); troubleshooting............2826
Hydraulic pump; specifications............2828
Hydraulic pump; description............2829
Hydraulic pump; maintenance standard; Specifications............2835
Pump; troubleshooting............2839
Pump; tools............2844
Pump; disassembly............2846
Pump; assembly............2851
Pump; installation............2856
Regulator; description............2858
Regulator; maintenance............2865
Regulator; disassembly and assembly............2868
Proportional solenoid valve; Specifications............2875
Current_pressure; specifications............2876
Proportional solenoid valve; Description............2877
Proportional solenoid valve; measuring and adjustment............2881
Proportional solenoid valve; troubleshooting............2884
Hydraulic pump (removed); changing shaft seal............2887
Hydraulic pump; replacing............2890
Hydraulic pump regulator; replacing............2901
Proportional solenoid valve (power shift); replacing............2905
Servo pump; specifications............2909
Servo pump; description............2910
Servo pump; parts inspection............2913
Servo hydraulic pressure; adjustment............2915
Servo pump; disassembly............2918
Servo pump; assembly............2924
Servo pump; replacing............2931
Single stage gear pump; replacing............2935
Pressure accumulator; specifications............2941
Pressure accumulator; description............2942
Accumulator; replacing............2944
Tightening Torques............2946
Remote control valve (Lever); specifications............2952
Remote control valve (Lever); description............2956
Remote control valve (Lever); maintenance standard; Specifications............2969
Remote control valve (lever); replacing............2973
Remote control valve (Lever); disassembly............2983
Remote control valve (Lever); assembly............2995
Remote control valve (Lever); troubleshooting............3007
Remote control valve (pedal); specifications............3010
Remote control valve (pedal); description............3011
Remote control valve (pedal); maintenance standard; Specifications............3019
Remote control valve (pedal); replacing............3022
Remote control valve (pedal); disassembly............3027
Remote control valve (pedal); assembly............3037
Remote control valve (pedal); troubleshooting............3049
Solenoid valve; specifications ............3052
Solenoid valve; description ............3053
Solenoid valve; inspection............3056
Solenoid valve; troubleshooting............3059
Solenoid valve; replacing............3063
Tightening torque; specifications............3065
Main dimensions............3069
Specifications............3071
Tiltrotator control system; description............3073
91618-3 Tiltrotator calibration............3081
Tightening torques-............3084
X1 Line; description............3087
Hammer and shear pedal valve (RCV); replacing............3092
Hammer return filter; specifications............3095
Hammer return filter; description............3096
Solenoid valve; specifications............3098
Solenoid valve; description............3099
3 way selector valve; specifications............3100
3 way selector valve; description............3102
Proportional solenoid valve; specifications............3105
Proportional solenoid valve; description............3107
Stop valve............3110
Control pattern selector valve; specifications............3112
Control pattern selector valve; description............3114
Solenoid valve for rotator............3118
Rotator pump; specifications............3120
Rotator pump; description............3121
Rotator pump; disassembly............3123
Rotator pump; assembly............3124
Rotator pump; parts inspection............3125
Rotator (X3 Line option); description............3127
Rotator valve; adjustment............3131
Solenoid valve; boom float............3133
Boom float position; description............3135
92 - MECHANICAL EQUIPMENT_ATTACHMENT............3138
Attachment quick coupler; description............3139
Attachment quick coupler; operation............3143
Attachment quick coupler; replacing............3145
Attachment quick coupler solenoid valve; description_{11-18-13}............3154
Attachment quick coupler solenoid valve; description_{11-17-50}............3159
97 - UNIT; DIGGING............3161
Tightening torques............3163
Function description............3171
Digging unit; maintenance............3174
Bushing general; replacing............3178
Cylinder; description............3183
Cylinder; disassembly and assembly............3188
Cylinder; troubleshooting............3207
Boom; specifications............3211
Boom; description............3212
Boom; replacing............3215
Boom cylinder; specifications............3232
Boom cylinder; description............3233
Boom cylinder; replacing............3235
Lower boom cylinder bushing; replacing............3245
Upper boom cylinder bushing; replacing............3250
Dipper arm; specifications............3254
Dipper arm; description............3255
Dipper arm; replacing............3258
Link; description............3269
Dipper arm connecting rod; replacing............3271
Connecting rod yoke; replacing............3279
Dipper arm cylinder; specifications............3286
Dipper arm cylinder; description............3287
Dipper arm cylinder; replacing............3289
Dipper arm cylinder bushing on boom; replacing............3300
Dipper arm cylinder bushing on dipper arm; replacing............3304
Bucket cylinder; specifications............3308
Bucket cylinder; description............3309
Bucket cylinder; replacing............3311
Bucket cylinder bushing on dipper arm; replacing............3323
Bucket cylinder bushing lever-link; replacing............3329
EC200E L Volvo Excavators Repair Service Manual
