EC230C Volvo Excavators Repair Service Manual
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
