EC230C Volvo Excavators Repair Service Manual

Make: 
Model: 
Price: US$ 59.00

Complete service repair manual with Electrical Wiring Diagrams for EC230C Volvo Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

EC230C 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.

EC230C Volvo Excavators Service Repair Manual.pdf

PRODUCT DETAILS:
Total Pages: 2,693 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
0 - Foreword................2
0 - GENERAL................3
  00 - DESCRIPTION; COMPLETE MACHINE................4
    Description; complete machine................5
    Component locations................6
    Product plates................8
  03 - SPECIFICATIONS................9
    Tightening torques................13
    Conversion tables................19
    Engine; specifications ................27
    Engine; weights ................28
    Valve system specifications ................29
    Flywheel; weight ................31
    Lubrication system; specifications-................33
    Fuel pressure; specifications-................34
    Fuel tank; specification-................36
    Injectors; specifications-................37
    Cooling system; specifications-................38
    Coolant pump; thermostat; specifications-................39
    Engine speed control switch; specifications-................41
    Electrical system; specifications-................42
    Engine control unit E-ECU; specifications-................44
    Electronic climate control unit ECC; specification-................46
    Wireless control unit W-ECU; specification_{11-42-34}................48
    Wireless control unit W-ECU; specification_{11-42-11}................50
    Wireless control unit W-ECU; specification_{11-41-49}................51
    Keypad; specification-................53
    Alternator; specifications-................56
    Starter motor; specifications-................58
    Electric horn; specifications-................59
    Rotating beacon; specifications-................61
    Travel alarm; specifications-................62
    Wiper controller; specifications-................64
    Windscreen flusher pump; specifications-................66
    Start switch; specifications-................68
    Control lockout lever switch; specifications-................70
    Emergency engine speed control switch; specifications-................72
    Auto_Manual pump control switch; specifications-................73
    Relay; specifications-................74
    Circuit breaker; specification-................76
    Audio remote controller; specifications_{11-35-10}................78
    Audio remote controller; specifications_{11-34-48}................81
    Machine weights................83
    Capacities................84
    Specifications; weight................85
    Engine; oil and filter; change.-................86
    Radio with tape or CD player; specifications-................89
    DC–DC converter; specifications-................92
    Travel motor; specifications-................93
    Propeller shaft; specifications-................95
    Front axle; specification-................96
    Rear axle; specification-................97
    Slew ring gear; specifications-................98
    Steering axle; specifications-................99
    Counterweight; specifications-................100
    Engine; volume-................101
    Air cleaner; specification-................102
    Air cleaner; specification ................103
    Fuel filler pump; specifications-................104
    Engine control; specifications ................105
    Instrument control unit I-ECU; specifications ................106
    Vehicle control unit V-ECU; specifications ................108
    Battery; specifications ................113
    Preheating; specifications ................114
    Lighting; specifications ................115
    Lower wiper motor; specifications ................116
    Battery disconnect switch; specifications ................117
    Multi-function lever switch; specifications ................118
    Control levers; specifications ................119
    Manual travel control switch; specifications ................126
    Control lockout solenoid valve; specifications ................127
    Stabiliser solenoid valve; specifications ................128
    Electric center passage; specification ................129
    Power outlet; specifications ................130
    Flasher relay; specifications ................131
    Hydraulic oil filter pressure switch; specifications ................132
    Auto idle pressure switch; specifications-................133
    Slew position sensor; specfications-................134
    Rear view camera; specifications................135
    Slew motor; specifications................136
    Travel gearbox; specifications-................137
    Wheels; specifications ................138
    Cab; specifications................139
    Cab; weight-................142
    Air conditioning unit; specifications ................144
    Diesel coolant heater (5kw); specifications ................145
    Automatic lubrication system; specifications ................147
    Brake pump; specifications ................149
    Steering pump; specifications ................150
    Control valve (steering unit); specification ................151
    Hydraulic pressure; specifications ................152
    X1; Specifications................154
    Cruise control; specifications................158
    Hydraulic tank; specifications ................159
    Working pump; specifications ................160
    Servo pump; specifications ................161
    Digging equipment bearings; specifications ................162
    Cylinder data ................164
    Hydraulic oil cooling system; specifications ................165
    Lifting instructions................167
  05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION................169
    Lifting instructions................170
  07 - STANDARD TIME................172
    Operation numbers for additional work................173
  08 - TOOL................175
    E-tool; 3500 Support plate for travel gearbox and motor................176
    E-tool; 3501 Puller for gear wheel fan pump................178
    E-tool; 3502 Plate for turning crankshaft................179
    E-tool; 3506 Flange................181
    E-tool; 3507 Plug................182
    Infrared Thermometer................183
  09 - MISCELLANEOUS................185
    Service positions-................186
    Welding on the machine................189
    Hydraulic cylinders; dieseling................192
    Control units; changing................194
1 - STANDARD PARTS; SERVICE................196
  16 - LUBRICANT; FUEL; OTHER FLUID................197
    Coolant with freezing and corrosion protection................198
    Recommended lubricants................199
    Coolant................202
    Alternative fuels................207
  17 - SERVICE................210
    Bearings................213
    Elimination of trapped hydraulic pressure................217
    Replacement parts................219
    Service................223
    Service methods................224
    Pressure testing................228
    Hoses and tubes................232
    Cleaning prior to repair ................236
    Arrival Inspection; according to Inspection Programme................237
    Delivery Inspection; according to Inspection Programme................242
    Cleaning prior to repair................244
    Maintenance of Stored Machines; according to Inspection Programme................245
    Warranty inspection 100 hours................247
    Warranty inspection 1000 hours................248
    Periodic maintenance................249
    Maintenance service; daily................251
    Maintenance service; every 50 hours................252
    Maintenance service; every 250 hours................253
    Maintenance service; first 500 hours................254
    Maintenance service; every 500 hours................255
    Maintenance service; every 1000 hours................256
    Maintenance service; every 4000 hours................257
    Maintenance service; every 6000 hours................258
    Tyres; wear and air pressure; checking................259
    Checking for cracks and leaks................261
    Check engine oil level................262
    Test-run and check................263
    Grease points on dipper arm; lubrication................264
    Grease points on booms; lubrication................267
    Grease points on undercarriage; lubrication................269
    Grease points on superstructure; lubrication................271
    Hydraulic system; checking oil level................272
    Water separator; drain................274
    Coolant level; check................276
    Axles; checking oil level................277
    Axle hubs; checking oil level................279
    Travel gearbox oil level; checking................281
    Fuel tank water and sediment; drain................283
    Battery condition; check................285
    Door hinges; lubricate with grease................288
    Cab; prefilter; clean................290
    Axles; changing oil................292
    Hub reduction gear; changing oil................294
    Engine; oil and filter; change.................296
    Fuel filters; primary and secondary filter; replace_{09-37-37}................299
    Fuel filters; primary and secondary filter; replace_{09-36-56}................301
    Radiator and coolers; cleaning................303
    Condenser; clean (with compressed air) (optional equipment)................306
    Cab; main filter; clean................308
    Belts and belt tension; check; replace when needed.................310
    Service journal (included in Operator's manual); fill in................313
    Wheel nuts; check torque................314
    Brake system; checking function................315
    Air cleaner primary filter; change................316
    Air conditioning unit; maintenance-................319
    MATRIS; reading; export reading................320
    VCADS Pro; logged errors; read off................322
    Swing bath grease; check................324
    Travel gearbox; changing oil................327
    Brake discs; checking wear................329
    Air cleaner secondary filter; change................332
    Cab; prefilter; replace................334
    Cab main filter; replacing................336
    Fuel tank breather filter; replacing................338
    Hydraulic oil return filter; changing_{08-05-58}................340
    Hydraulic oil return filter; changing_{08-05-03}................342
    Hydraulic tank breather filter; changing................344
    Hydraulic oil servo filter; change_{09-08-24}................346
    Hydraulic oil servo filter; change_{09-06-30}................350
    Coolant's freezing point; check................352
    Valve clearance and IEGR; check................354
    Hydraulic system; changing oil................355
    Hydraulic oil suction strainer; change................359
    Turbocharger inclusive inlet and exhaust systems; leakage; check................362
    Coolant; change................364
    CareTrack backup battery; replacing................368
    Creeping of hydraulic cylinder ................371
    Emergency operation; description................375
    Towing................378
    Secondary lowering of digging equipment................380
    Emergency operation slew function; description................382
    Starting engine with booster cables................386
  19 - GENERAL................388
    Safety concerns everybody!................389
    Service positions................391
    CE marking and declaration of conformity................394
    Safety when handling the machine................396
    Safety rules when servicing................400
    Checklist after a fire or heat exposure ................402
    Fire prevention measures................403
    Health hazards with paint; plastics and rubber................406
    Checklist after a fire or heat exposure................411
    Some simple rules regarding tyre handling................415
    Safety when using lifting equipment................417
    Safety when handling oils and fuel................421
    Safety when working with batteries................425
    Starting with booster batteries................430
    Safety when working with air conditioning refrigerant................434
    Safety when working with hydraulic systems................439
    Environmental handling for the future................441
    Environmentally safe handling................445
    Environmentally hazardous fluids................448
    Working in environmentally contaminated areas................452
    Decontamination................456
    Waste handling................460
2 - ENGINE WITH MOUNTING AND EQUIPMENT................464
  20 - GENERAL................465
    Engine; description................466
    E-ECU MID 128 pre-programmed; replacing................468
    E-ECU MID 128 non-programmed; replacing................471
    Engine; identification................474
    Engine; volume................475
    Engine; tightening torques................476
    Component locations................479
    Engine; weights ................481
  21 - ENGINE................482
    Engine; specifications................484
    Cylinder compression; PC test................485
    Engine characteristic curve................486
    Basic check; Engine................488
    Troubleshooting ................490
    Camshaft and flywheel signals; checking with Tech Tool and oscilloscope................493
    Engine; removing................499
    Engine; weights................509
    Cylinder head; description................510
    Cylinder head gasket; description................512
    Cylinder; description-................514
    Pistons; description................515
    Piston rings; description................517
    Piston cooling................519
    Valve system specifications................521
    Valves; description................524
    Internal Exhaust Gas Recirculation (IEGR); description................526
    Valves; adjusting................532
    Engine timing gear; description................545
    Camshaft; description................548
    Timing gear case new gasket; installing................551
    Flywheel; weight................558
    Crankshaft; description................560
    Vibration damper; description................563
    Connecting rod; description................566
    Crankshaft front oil seal; replacing................569
    Oil sump; description................578
    Oil sump; replacing................580
    Oil level sensor; replacing................585
    Engine mounting................589
    Engine mount front; replacing................592
    Engine mounting rear; changing................596
  22 - LUBRICATING SYSTEM................599
    Lubricating system; description................600
    Lubrication system; specifications................604
    Lubrication system; principle of operation................605
    Oil pump; replacing................609
    Lubrication oil pressure; checking with pressure gauge................621
    Oil cooler; replacing................623
    Oil cooler; description................626
  23 - FUEL SYSTEM................627
    Fuel system; description................629
    Fuel pressure; specifications................631
    Instructions for working with electronic fuel injection................633
    Fuel pressure; checking................634
    Fuel feed pump; description................637
    Fuel filter; description................638
    Feed pump pressure; checking................639
    Fuel filter; checking................643
    Fuel system; bleeding_{06-08-22}................645
    Fuel system; bleeding_{06-07-50}................647
    Feed pump; replacing................649
    Fuel filters; replacing................652
    Fuel filter extra; replacing_{06-04-40}................654
    Fuel filter extra; replacing_{06-03-59}................656
    Fuel tank; specification................658
    Fuel filler pump; specifications................659
    Fuel tank; description................660
    Fuel tank; replacing................661
    Air cleaner; specification ................668
    Fuel filler pump; description................669
    Fuel filling pump; removing................671
    Fuel filling pump; installing................674
    Fuel return pressure; checking................676
    Injectors; description................678
    Injectors; specifications................682
    Injectors; replacing................683
    High pressure fuel pump; checking................685
    Fuel rail; description................689
    Fuel rail; replacing................691
    Fuel rail pressure; checking................696
    Fuel rail pressure sensor; replacing................700
    High pressure fuel pump; replacing................702
    Fuel control valve (FCV); description................710
    Fuel control valve (FCV); checking................712
    Fuel control valve (FCV); replacing................716
    Pressure relief valve (PRV); inspecting................719
    Pressure relief valve (PRV); replacing................723
  25 - INLET & EXHAUST SYSTEM................726
    Inlet system; description................727
    Exhaust system; description................728
    Induction manifold gasket; replacing................729
    Exhaust manifold gasket; replacing................732
    Silencer; replacing................737
    Exhaust pipe flexible tube; replacing................741
    Turbocharger; description................743
    Turbocharger; inspecting................746
    Turbocharger; replacing................750
    Air cleaner; description................754
    Air cleaner; specification................755
    Preheating coil; replacing................756
    Charge air cooler; specifications................758
    Charge air cooler; description................759
    Charge air cooler; replacing................761
  26 - COOLING SYSTEM................766
    Cooling system; description................767
    Cooling system; flushing................769
    Cooling system; specifications................774
    Coolant anti-freeze resistance; checking................775
    Radiator; replacing................777
    Radiator hose upper; replacing................783
    Radiator hoses lower; replacing................787
    Expansion tank; replacing................791
    Coolant pump; thermostat; specifications................794
    Coolant pump; replacing................796
    Thermostat; inspecting................801
    Thermostat; replacing................804
    Fan belt and_or alternator belt; replacing................807
    Fan belt and_or alternator-; compressor belt; replacing all belts................810
  27 - ENGINE CONTROL................813
    Engine control; specifications................814
    Engine speed control switch; specifications................815
    Engine speed control switch; description ................816
    Engine speed control; function checking................817
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS................818
  30 - GENERAL................819
    Electrical system; special instructions for servicing; general................825
    Electrical system; special instructions for servicing; electronic components................828
    Electrical system; special instructions for servicing; electrical components; batteries................830
    Electrical system; special instructions for servicing; electrical components; alternator and charging regulator................832
    Electrical system; special instructions for servicing; action when working on machine................834
    Electrical system; description................836
    Electronic control system; description................838
    Communication with data buses................841
    Auxiliary start................844
    Data buses; function................847
    Service connection and programming connection................853
    Data links; fault tracing with Oscilloscope................856
    Electrical system; specifications................866
    Power Boost control; description................868
    Engine Protection................870
    Start lock; description_{09-12-07}................872
    Start lock; description_{09-11-45}................874
    Power OFF................875
    Quick fit control; description................876
    Limp Home................877
    Auto idle device; setting instructions................878
    Parking brake; description ................879
    Control lockout system; description................880
    Forward _ Reverse _ Neutral................881
    Main pump pressure; checking and adjusting................882
    Axle lock_{09-07-11}................883
    Axle lock_{09-06-04}................887
    Axle lock_{09-04-52}................890
    Overload warning................893
    VCADS Pro; parameter programming................895
    Software parameters; description................897
    Troubleshooting strategy................906
    Troubleshooting; general................909
    Collection of basic data................912
    Error code information; general................914
    Electrical cables and connectors; checking................917
    Troubleshooting tools................923
    Special tools for troubleshooting................924
    VCADS Pro service tool................926
    VCADS Pro; Operations................931
    Connecting special tools................933
    999 8699 Multi-pin breaker box................937
    999 0014 Adapter cable................938
    999 0025 Adapter cable................941
    999 0062 Extension cable................943
    8883 0028 Adapter cable................944
    88890040 Oscilloscope for VCADS Pro................946
    999 3893 Adapter cable................947
    999 3894 Template................949
    11 666 140 Multimeter................950
    Measuring; general................951
    Measuring symbols; description................953
    Component descriptions................957
    Component troubleshooting; structure; description................961
    Component troubleshooting; checking wiring harness and input_output on ECU................963
    Component troubleshooting; checking component................966
    Component troubleshooting; checking subsystem (circuit)................969
    AL3201; description and measuring................972
    BA3101; description and measuring................974
    CU9901; description and measuring................976
    FU6; description and measuring................978
    FU18; description and measuring................979
    FU26; description and measuring................980
    HE2501; description and measuring................981
    MA2301–MA2306; description and measuring................983
    MA2504; description and measuring ................985
    MA2602; description and measuring................987
    MA2504; description and measuring................988
    MA4214; description and measuring................990
    MA4218; description and measuring................992
    MA4219; description and measuring................994
    MA4302; description and measuring................996
    MA4303; description and measuring................998
    MA5205; description and measuring................1000
    MA5503; description and measuring................1002
    MA9103; description and measuring................1003
    MA9104; description and measuring................1005
    MA9107; description and measuring................1007
    MA9109; description and measuring................1009
    MA9120; description and measuring................1011
    MA9152; description and measuring................1013
    MA9164; description and measuring................1015
    MA9165; description and measuring................1017
    MA9615; description and measuring................1019
    MID 128 SID 230; description and measuring................1021
    MID 140 PPID 1144; description and measuring................1022
    MO3301; description and measuring................1023
    PPID1336; description and measuring................1025
    PWM2303; description and measuring................1027
    PWM9103; description and measuring ................1029
    PWM4211; description and measuring................1031
    PWM6603; description and measuring................1033
    PWM9101; description and measuring................1034
    PWM9103; description and measuring................1036
    PWM9104; description and measuring................1038
    PWM9105; description and measuring................1039
    PWM9106; description and measuring................1041
    PWM9109; description and measuring................1043
    PWM9129; description and measuring................1045
    RE2501; description and measuring................1047
    RExxxx; Relays general; description and measuring................1049
    SAE J1708_1587 information link; description and measuring................1051
    SAE J1939_CAN control link; description and measuring................1054
    SE2202; description and measuring................1057
    SE2203; description and measuring................1059
    SE2205; description and measuring................1061
    SE2301; description and measuring................1063
    SE2302; description and measuring................1065
    SE2303; description and measuring................1067
    SE4217; description and measuring ................1069
    SE2309; description and measuring................1071
    SE2501; description and measuring................1073
    SE2502; description and measuring................1075
    SE2507; description and measuring................1077
    SE2508; description and measuring................1079
    SE2510; description and measuring................1081
    SE2511; description and measuring................1083
    SE2603; description and measuring................1085
    SE2606; description and measuring_{06-17-14}................1087
    SE2606; description and measuring_{06-16-01}................1089
    SE2701; description and measuring................1091
    SE2703; description and measuring................1093
    SE2707; description and measuring................1095
    SE4213; description and measuring................1097
    SE4217; description and measuring................1099
    SE4218; description and measuring................1101
    SE5201; description and measuring................1103
    SE5205; description and measuring................1105
    SE6401; description and measuring................1107
    SE8701; description and measuring................1109
    SE8702; description and measuring................1111
    SE8705; description and measuring................1113
    SE8706; description and measuring................1115
    SE9101; description and measuring................1117
    SE9105; description and measuring................1119
    SE9106; description and measuring................1121
    SE9126; description and measuring................1123
    SE9401; description and measuring................1125
    SID211; description and measuring................1127
    SID232; description and measuring................1128
    SW2701; description and measuring................1129
    SW3301; description and measuring................1131
    SW3611; description and measuring................1133
    SW4202; description and measuring................1135
    SW4205; description and measuring................1137
    SW9160; description and measuring................1139
    SW9161; description and measuring................1141
    SW9162; description and measuring................1143
    Error codes; build-up................1145
    Error code information; description................1150
    E-ECU (MID128) Engine control unit; active measuring conditions................1152
    E-ECU (MID128) Engine control unit; passive measuring conditions................1156
    I-ECU (MID140) Instrument control unit; active measuring conditions................1160
    I-ECU (MID140) Instrument control unit; passive measuring conditions................1162
    W-ECU (MID142) Wireless control unit; active measuring conditions................1164
    W-ECU (MID142) Wireless control unit; passive measuring conditions................1166
    Care Track can not communicate with the machine................1168
    ECC (MID146) Electronic climate control unit; active measuring conditions................1170
    ECC (MID146) Electronic climate control unit; passive measuring conditions................1173
    V-ECU (MID187) Vehicle control unit; active measuring conditions................1176
    V-ECU (MID 187) Vehicle control unit; passive measuring; conditions................1181
  31 - BATTERY................1186
    Battery; storage................1187
    Battery; description................1190
    Battery; specifications................1192
    Battery; charging................1193
    Batteries; replacing................1195
  32 - ALTERNATOR; CHARGE REGULATOR................1199
    Charging; description................1200
    Alternator; specifications................1202
    Alternator; description................1204
    Alternator; replacing incl function checking................1206
    Alternator; testing................1210
  33 - STARTING SYSTEM................1212
    Starting operation................1213
    Starter switch (engine start switch); replacing................1215
    Starter motor; description................1217
    Starter motor; specifications................1218
    Starter motor; testing................1219
    Starter relay; replacing................1221
    Starter motor; replacing................1222
    Preheating; description................1224
    Preheating; specifications................1225
  35 - LIGHTING................1226
    Lighting; specifications................1227
    Headlights; adjusting................1228
    Rotating beacon; specifications................1230
    Rotating beacon; replacing ................1231
  36 - OTHER ELECTRICAL EQUIPMENT................1233
    Electric horn; description................1235
    Electric horn; specifications................1237
    Horn; replacing................1239
    Rotating beacon; description................1241
    Rotating beacon; replacing................1243
    Travel alarm; description................1245
    Travel alarm; specifications................1246
    Travel alarm; replacing................1248
    Windscreen wiper; description................1251
    Wiper controller; description................1253
    Wiper controller; specifications................1255
    Windscreen wiper controller; replacing................1257
    Upper wiper motor; description................1259
    Upper wiper motor; specifications................1261
    Windscreen wiper front motor; replacing................1263
    Windscreen wiper switch; replacing................1266
    Windscreen flusher pump; replacing................1268
    Lower wiper motor; description................1270
    Lower wiper motor; specifications................1272
    Windscreen flusher pump; specifications................1273
    Windscreen wiper; components location................1275
    Window limit switch; description................1277
    Connectors; overview................1279
    Switch; replacing................1293
    Battery disconnect switch; description................1296
    Battery disconnect switch; specifications................1298
    Start switch; description................1299
    Start switch; specifications................1302
    Engine speed control switch; description................1304
    Emergency engine speed control switch; description................1305
    Emergency engine speed control switch; specifications................1307
    Multi-function lever switch; description................1308
    Multi-function lever switch; specifications................1310
    Control levers; specifications................1311
    Manual travel control switch; description................1318
    Manual travel control switch; specifications................1319
    Auto_Manual pump control switch; description................1320
    Auto_Manual pump control switch; specifications................1321
    Control lockout solenoid valve; specifications................1322
    Stabiliser solenoid valve; specifications................1323
    Electric center passage; specification................1324
    Electric center passage; description................1325
    Power outlet; specifications................1327
    Electric center passage; replacing................1328
    Electronic climate control unit ECC; description-................1331
    Engine control unit E-ECU; function description................1333
    Instrument control unit I-ECU; functional description................1335
    Vehicle control unit V-ECU; functional description................1337
    Electronic climate control unit ECC; specification ................1339
    Engine control unit E-ECU; specifications................1341
    Instrument control unit I-ECU; specifications................1343
    Vehicle control unit V-ECU; specifications................1345
    Control units changing; precaution................1350
    I-ECU MID 140 non-programmed; replacing................1351
    I-ECU MID 140 pre-programmed; replacing................1353
    V-ECU MID 187 non-programmed; replacing................1355
    V-ECU MID 187 pre-programmed; replacing................1359
    ECC (Electronic Climate Control); replacing ................1363
  37 - CABLE; FUSE; RELAY................1366
    Wiring harnesses - Image................1368
    Wiring diagram; electrical distribution box - Image................1369
    Control system diagram - Image................1370
    Electrical symbols and designations................1371
    Explanation of wiring diagrams................1375
    Component designations................1378
    Component list Alternator; batteries; capacitors; electronic units; voltage outlet................1380
    Component list Control lights_warning lights................1381
    Component list; fuses................1383
    Component list; Heating coils................1385
    Component list; lights................1386
    Component list; Miscellaneous................1387
    Component list; motors................1388
    Component list; relays................1389
    Component list; sensors................1390
    Component list; Solenoid valves................1393
    Component list; Switches_{04-18-09}................1396
    Component list; Switches_{04-17-47}................1398
    Wiring diagram; general................1400
    Control system diagram................1402
    Wiring diagram; electrical distribution box................1405
    Wiring diagram SCH01................1408
    Wiring diagram SCH02................1411
    Wiring diagram SCH03................1414
    Wiring diagram SCH04................1417
    Wiring diagram SCH05................1422
    Wiring diagram SCH06................1425
    Wiring diagram SCH07................1428
    Wiring diagram SCH08................1431
    Wiring diagram SCH09................1434
    Wiring diagram SCH10................1437
    Wiring diagram SCH11................1440
    Wiring diagram SCH12................1442
    Wiring diagram SCH13................1445
    Wiring diagram SCH14................1448
    Wiring diagram SCH15................1451
    Wiring diagram SCH16................1454
    Wiring diagram SCH17................1456
    Wiring diagram SCH18................1459
    Wiring diagram SCH19................1461
    Wiring diagram SCH20................1464
    Wiring diagram SCH21................1466
    Wiring diagram SCH22................1469
    Wiring diagram 23................1471
    Wiring diagram SCH24................1474
    Wiring diagram SCH25_{04-02-49}................1476
    Wiring diagram SCH25_{04-02-24}................1479
    Wiring harnesses................1481
    Electrical distribution box; description................1484
    Electrical distribution box; circuit board replacing................1487
    Fuse; description................1490
    Relay; description................1492
    Relay; specifications................1494
    Flasher relay; specifications................1496
    Circuit breaker; description................1497
    Circuit breaker; specification................1498
    Grounding points; frame connections................1500
  38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM................1502
    Instruments and controls; overview................1504
    Instruments and controls; front instrument panel................1505
    Instruments and controls; left instrument panel................1507
    Instruments and controls; right instrument panel................1509
    Instruments and controls; rear instrument panel................1512
    Control levers; description................1514
    Hour counter; description................1516
    Hour counter; specifications................1518
    Slew position sensor; specfications................1520
    Control lockout lever switch; description................1521
    Control lockout lever switch; specifications................1524
    Hydraulic oil filter pressure switch; specifications................1526
    Auto idle pressure switch; specifications................1527
    Engine oil pressure sensor; replacing................1528
    Engine rotation speed sensor; replacing_{03-46-37}................1530
    Engine rotation speed sensor; replacing_{03-46-13}................1532
    Engine rotation speed sensor (camshaft); replacing................1535
    Hydraulic oil temperature sensor; replacing................1538
    Boost pressure _ charge-air temperature sensor; replacing................1541
    Temperature sensor cooling system; replacing................1543
    Booting sequence................1545
    MAIN MENU................1548
    Menu tree................1551
    Display unit; content................1553
    SETUP................1560
    Control types for X1 and X3 operation................1569
    Pop-up screen................1572
    Keypad; description................1575
    Keypad; specification................1578
    HVAC system-................1581
    Theft protection................1584
    Service mode................1587
    Engine system................1589
    Hydraulic system................1591
    Electrical system................1593
    Language................1597
    Terminology................1599
  39 - MISCELLANEOUS................1626
    CareTrack system; description................1627
    DC–DC converter; specifications................1630
    DC–DC converter; description................1631
    Radio with tape player; description................1633
    Radio with tape or CD player; descriptions................1636
    Radio with tape or CD player; specifications................1639
    Audio remote controller; description_{03-25-22}................1642
    Audio remote controller; description_{03-24-57}................1645
    Audio remote controller; specifications_{03-24-20}................1648
    Audio remote controller; specifications_{03-23-59}................1651
    Antenna; replacing................1653
    Speaker; replacing................1655
    Wireless control unit W-ECU; specification_{03-22-05}................1657
    Wireless control unit W-ECU; specification_{03-21-41}................1659
    Wireless control unit W-ECU; specification_{03-21-20}................1660
    W-ECU; MID 142; replacing................1662
4 - POWER TRANSMISSION................1665
  40 - GENERAL................1666
    Power transmission; description................1667
  42 - TRANSMISSION; HYDRAULIC CONTROL................1668
    Transmission mode; function check................1669
  43 - GEARBOX................1671
    Travel gearbox; bleeding................1672
    Travel gearbox; removing................1675
    Travel gearbox; installing................1679
    Travel gearbox; description................1685
    Travel gearbox; specifications................1695
    Travel gearbox; troubleshooting................1696
  44 - HYDROSTATIC DRIVE................1697
    Swing motor; removing................1698
    Swing motor; installing_{03-10-13}................1701
    Swing motor; installing_{03-09-46}................1706
    Travel motor; description................1711
    Travel motor removed; seal replacing................1717
    Retardation valve; replacing................1720
    Travel motor; specifications................1724
    Travel motor pressure; checking and adjusting................1726
    Travel motor; removing................1730
    Travel motor; installing................1734
    Slew motor; description_{03-03-52}................1740
    Slew motor; description_{03-03-27}................1746
    Slew lock; description_{03-01-54}................1752
    Slew lock; description_{03-01-29}................1754
    Slew pressure; checking and adjusting................1756
    Pump coupling; removing................1757
    Pump coupling; installing................1759
    Centre passage; description................1761
    Centre passage; removing................1764
    Centre passage; installing................1769
    Center passage; disassembling and assembling................1773
  45 - PROPELLER SHAFT................1778
    Propeller shaft; specifications................1779
    Propeller shaft front; replacing................1780
    Propeller shaft rear; replacing................1782
  46 - FRONT AXLE; REAR AXLE................1784
    Front axle; specification................1785
    Front axle; description................1786
    Front axle; removing................1788
    Front axle; installing................1793
    King pin and bushing; replacing................1797
    Input shaft seal; replacing................1799
    Rear axle; specification................1801
    Shaft seals; replacing................1802
    Slew ring gear; specifications................1803
  49 - MISCELLANEOUS................1804
    Slew ring gear; specifications................1805
    Swing ring gear outer seal; replacing................1806
5 - BRAKE................1809
  52 - HYDRAULIC BRAKE SYSTEM................1810
    Electrical digging brake; description................1811
    Hydraulic brake system; description................1814
    Brake system circuit pressure; checking and adjusting................1820
    Brake system bleeding................1826
    Service brakes function; checking................1829
    Foot brake valve; replacing................1831
    Brake accumulator; specifications................1836
    Brake accumulator; description................1838
    Discarded accumulators-................1839
    Accumulator; removing................1841
    Accumulator; installing................1844
    Brake accumulator charging pressure; adjusting................1846
    Brake pump; specifications................1849
  55 - PARKING BRAKE................1850
    Parking brake; description................1851
    Parking brake; manually releasing................1856
    Parking brake function; checking................1859
6 - STEERING................1861
  60 - GENERAL................1862
    Steering system function; checking................1863
  62 - STEERING AXLE................1865
    Steering axle; specifications................1866
    Steering axle; description................1867
  64 - STEERING................1869
    Steering system; description................1870
    Steering system working pressure; checking................1875
    Steering valve; removing................1878
    Steering valve; installing................1882
    Steering pump; removing................1887
    Steering pump; installing................1891
    Steering pump; specifications................1895
    Control valve (steering unit); specification................1896
    Control valve (steering unit); description................1897
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT................1901
  71 - FRAME................1902
    Counterweight; specifications................1903
    Counterweight; removing................1904
    Counterweight; installing................1906
    Undercarriage; description................1908
  76 - SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL _ SIDE CONTROL................1909
    Pivot axle lock cylinder; description................1910
    Pivot axle lock cylinder; removing................1917
    Pivot axle lock cylinder; installing................1920
    Pivot axle lock cylinder; releasing for towing................1923
    Pivot axle lock cylinder seals; changing................1926
    Pivot axle lock; function check................1931
  77 - WHEELS; TRACKS; TYRE; HUB; DRUM................1933
    Wheels; specifications................1934
    Wheel; removing................1935
    Wheel; installing................1938
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE................1941
  81 - CAB; NAKED; CANOPY................1942
    Cab; weight................1943
    Cab; removing................1945
    Cab; installing................1948
    Cab suspension; description_{02-14-03}................1950
    Cab suspension; description_{02-13-39}................1952
  83 - DOORS; HATCH; COVER PLATE; (all)................1954
    Cab door; removing door catch................1955
    Cab door; installing door catch................1958
  84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING................1961
    Windows; general................1962
    Windscreen; replacing................1964
    Side window; replacing................1971
    Rear window; replacing................1978
    Door window; replacing................1984
  85 - CAB INTERIOR; UPHOLSTERY................1987
    Seat; replacing_{02-06-13}................1988
    Seat; replacing_{02-05-48}................1991
    Seat cushion; replacing................2001
    Seat support; replacing................2006
    Longitudinal adjustment cable; replacing................2013
    Longitudinal suspension cable; replacing................2019
    Backrest; replacing................2023
    Seat belt; replacing................2027
  87 - AIR CONDITIONING UNIT................2030
    Electronic climate control unit ECC; description................2031
    Electronic climate control unit ECC; specification................2033
    Wiring diagram................2035
    HVAC system................2037
    Air conditioning unit; specifications................2040
    Air conditioning unit; description................2041
    Air conditioning unit; maintenance................2047
    ECC (Electronic Climate Control); replacing................2049
    Air conditioning unit; refrigerant check and recharging................2052
    Air distribution; description................2060
    Cab filter; replacing................2063
    Heating system; description................2065
    Fan motor; replacing................2067
    Heater core; replacing................2073
    Cooler and Heater assembly; replacing................2075
    Compressor; replacing incl draining and filling................2078
    Receiver; replacing incl draining and filling................2083
    Condenser; replacing incl draining and filling................2087
    Evaporator; replacing incl draining and filling................2091
    Expansion valve; replacing incl draining and filling................2097
    Vent actuator; replacing................2103
    Mode (foot) actuator; replacing................2106
    Intake actuator; replacing................2109
    Air mix door actuator; replacing................2112
    Diesel coolant heater (5kw); specifications................2115
    Diesel coolant heater (5kw); description................2117
    Diesel coolant heater (5kw); principles................2120
    Troubleshooting (5kw)................2125
  88 - INTERIOR EQUIPMENT................2134
    Instrument panel (left); replacing................2135
    Instrument panel (right); replacing................2140
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS................2144
  90 - GENERAL................2145
    Hydraulic diagram; dozer blade and outrigger - Image................2147
    Hydraulic diagram; quick fit - Image................2148
    Hydraulic diagram; X3 - Image................2150
    Hydraulic diagram; X1 with flow control - Image................2151
    Hydraulic diagram; cruise control - Image................2152
    Hydraulic diagram; control pattern selector valve - Image................2154
    Hydraulic diagram; boom float valve - Image................2155
    Hydraulic diagram; slew system - Image................2156
    Hydraulic diagram; complete - Image................2157
    Hydraulic system; cleanliness when handling hydraulic components................2160
    Hydraulic diagram; component list................2162
    Hydraulic system; position of main components on superstructure................2165
    Hydraulic diagram; complete_{01-39-59}................2167
    Hydraulic diagram; complete_{01-39-35}................2170
    Hydraulic diagram; complete_{01-39-11}................2173
    Hydraulic diagram; slew system................2176
    Hydraulic diagram; boom float valve................2179
    Hydraulic diagram; control pattern selector valve................2182
    Hydraulic diagram; cruise control_{01-37-05}................2185
    Hydraulic diagram; cruise control_{01-36-40}................2188
    Hydraulic diagram; X1 with flow control................2191
    Hydraulic diagram; X1 with pressure control................2194
    Hydraulic diagram; X3................2197
    Hydraulic diagram; quick fit................2200
    Hydraulic diagram; grab piping................2205
    Hydraulic diagram; dozer blade and outrigger................2208
    Hydraulic oil; description................2211
    Hydraulic system; repair of hydraulic components in workshop................2215
    Hydraulic oil; storage and handling................2220
    Hydraulic components; storing and transporting................2221
    Vacuum pump; connection................2222
    Vacuum pump; disconnection................2225
    Hydraulic system; warming up................2227
    Measuring tools and techniques................2231
  91 - WORKING HYDRAULIC; SERVO HYDRAULICS................2236
    Hydraulic system; work instructions................2239
    Hydraulic pressure; specifications................2240
    Load holding valve; description................2242
    Hydraulic oil; cleaning................2245
    Hydraulic oil cooling system; description................2247
    Hydraulic oil cooling system; specifications................2248
    Hydraulically driven cooling fan; description................2250
    Hydraulic tank; specifications................2254
    Hydraulic oil tank; description................2255
    Hydraulic oil tank; releasing pressure................2257
    Thermostatic function hydraulic oil; description................2258
    Cooling fan speed; checking and adjusting with VCADS Pro................2263
    Hydraulic oil cooler; removing................2268
    Hydraulic oil cooler; installing................2273
    Cooling fan pump; removing................2278
    Cooling fan pump; installing................2281
    Oil cooler fan motor; removing................2284
    Hydraulic oil tank; removing................2287
    Hydraulic oil tank; installing................2291
    Main control valve block; description................2296
    Main control valve; removing................2301
    Main control valve; installing................2305
    Back-up valves_{01-16-19}................2308
    Back-up valves_{01-15-56}................2311
    Back-up valve; checking and adjusting................2314
    Shock and anti-cavitation valve; description................2320
    Line rupture valve (boom); description................2323
    Line rupture valve for dipper arm cylinder; description................2326
    Line rupture valve for 2-piece boom cylinder X2; description................2331
    Line rupture valve (boom); troubleshooting................2336
    Line rupture valve pressure; checking and adjusting................2338
    Working pressure; checking and adjusting................2344
    Secondary pressure limiting valve; checking................2355
    Shock valve removed; checking................2358
    Boom cylinder; rupture valve; replacing................2361
    Dipper arm cylinder; rupture valve; replacing................2364
    Rupture valve; replacing (2pcs boom tilt cylinder)................2367
    Dipper arm in speed; checking and adjusting................2371
    Pressure relief valves; description................2373
    LS-pressure relief valve; replacing................2378
    Unload valve; replacing................2383
    Unload valve; checking and adjusting................2387
    Working pump; description................2390
    Pump; removing................2393
    Pump; installing................2397
    Hydraulic pump (removed); changing shaft seal................2400
    Working pump; specifications................2404
    Swing pump; removing................2405
    Swing pump; installing................2408
    Swing pump pressure; checking and adjusting................2411
    Swash plate angle sensor; replacing................2420
    Servo system; description_{12-58-08}................2423
    Servo system; description_{12-57-44}................2425
    Servo valve; removing_{12-57-09}................2427
    Servo valve; removing_{12-56-45}................2429
    Servo valve; installing_{12-56-10}................2431
    Servo valve; installing_{12-55-46}................2433
    Pressure accumulator; description................2436
    Servo accumulator; removing................2439
    Servo accumulator; installing................2440
    Discarded accumulators................2441
    Servo pressure; checking and adjusting................2442
    Servo pump; replacing_{12-53-10}................2445
    Pressure relief valve; checking and adjusting_{12-52-49}................2450
    Control lockout lever; function check................2456
    Servo Accumulator................2458
    Servo pump; specifications................2459
    Remote control valve (pedal); specifications................2460
    Remote control valve (pedal); description................2462
    Control lever; removing................2464
    Control lever; installing................2474
    Control pattern selector valve; description................2484
    X1; description................2489
    VCADS Pro; 91610-3 – X1 hydraulic pressure control system; test................2506
    X1; function check................2511
    Calibration of X1 hydraulic with flow control................2513
    Calibration of X1 hydraulic with pressure control................2516
    X3; description................2518
    X3; function check................2526
    X3 pressure and flow; adjusting................2528
    X3 shock and refilling valves; adjusting................2533
    Boom float position; description................2537
    Cruise control; description_{12-41-01}................2541
    Cruise control; description_{12-40-37}................2547
    Calibration of cruise control................2553
    Reversible cooling fan; description................2555
    Grab bucket; description................2559
    Grab equipment; tool change................2565
  92 - MECHANICAL EQUIPMENT_ATTACHMENT................2567
    Hydraulic quickfit; description................2568
    Cylinder for hydraulic quickfit S1; removing................2576
    Cylinder for hydraulic quickfit S1; installing................2578
    Cylinder for hydraulic quickfit Universal; removing................2580
    Cylinder for hydraulic quickfit Universal; installing................2584
    Quickfit; function check................2588
  97 - UNIT; DIGGING................2590
    Cylinder; description................2591
    Cylinder; troubleshooting_{12-33-27}................2594
    Cylinder; troubleshooting_{12-33-06}................2596
    Cylinder data................2598
    Boom lifting cylinder; description................2599
    Dipper arm cylinder; description................2601
    Bucket cylinder; description................2603
    Digging equipment bearings; measuring radial clearance................2605
    Digging equipment bearings; specifications................2608
    Bushing general; replacing................2610
    Digging equipment bearings; shimming................2613
    Creeping of hydraulic cylinder................2615
    Stabilisers and stabiliser blade; description................2619
    Stabilisers; installing................2631
    Stabilisers; hydraulic cylinder; removing................2637
    Boom cylinder; removing................2642
    Boom cylinder; installing................2646
    Dipper arm; removing................2651
    Dipper arm; installing................2654
    Dipper arm cylinder; removing................2657
    Dipper arm cylinder; installing................2659
    Bucket cylinder; removing................2661
    Bucket cylinder; installing................2665
  99 - MISCELLANEOUS................2669
    Automatic lubrication system; specifications................2670
    Automatic lubrication system; description................2672
    Control unit; description................2680
    Control units; software functions................2682
    Maintenance service; general................2688
    Troubleshooting................2691
    Bleeding air................2693

EC230C Volvo Excavators Repair Service Manual

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