Volvo EW180E Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Constructions EW180E Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo EW180E Excavators workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Volvo EW180E Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,431 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
Complete machine; descriptions................5
Product identification plates................7
Machine view................8
03 - SPECIFICATIONS................10
Measurement conversion tables................11
Tightening torques................15
Machine weights................21
Specifications; weight................22
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION................23
Lifting instructions................24
Measurements before transporting machine................26
Tying down machine................27
07 - STANDARD TIME................29
Operation numbers for additional work................30
08 - TOOL................32
E-tool; 3500 Support plate for travel gearbox and motor................33
E-tool; 3502 Plate for turning crankshaft................35
Infrared Thermometer................37
88830268 User Instruction................39
88830540 User Instruction................42
E-3509................45
E-3508................47
09 - MISCELLANEOUS................49
Service positions................50
Welding on the machine................51
Hydraulic cylinders; dieseling................52
1 - STANDARD PARTS; SERVICE................54
16 - LUBRICANT; FUEL; OTHER FLUID................55
AdBlue®_DEF................56
Fuel................62
Coolant with freezing and corrosion protection................63
Recommended lubricants................65
Coolant................68
Alternative fuels................73
Fuel; lubricant and filling capacities_{31-23}................76
Fuel; lubricant and filling capacities_{31-04}................78
Air cleaner; description................80
17 - SERVICE................82
Bearings................86
Elimination of trapped hydraulic pressure................87
Replacement parts................90
Service................91
Service methods................92
Pressure testing................93
Hoses and tubes................94
Cleaning prior to repair................95
Tech Tool; operations................96
Arrival Inspection; according to Inspection Programme................97
Delivery Inspection; according to Inspection Programme................102
Maintenance of Stored Machines; according to Inspection Programme................104
Maintenance service; first 500 hours................106
Maintenance service; every 10 hours................107
Maintenance service; every 50 hours................108
Maintenance service; every 100 hours................109
Maintenance service; every 250 hours................110
Maintenance service; every 500 hours_{23-49}................111
Maintenance service; every 500 hours_{23-30}................113
Maintenance service; every 1000 hours_{23-02}................115
Maintenance service; every 1000 hours_{22-43}................117
Maintenance service; every 2000 hours_{22-10}................119
Maintenance service; every 2000 hours_{21-51}................122
Maintenance service; every 4000 hours_{21-22}................125
Maintenance service; every 4000 hours_{21-03}................128
Maintenance service; every 5000 hours................131
Maintenance service; every 6000 hours_{20-17}................132
Maintenance service; every 6000 hours_{19-58}................133
Maintenance service; every 8000 hours................134
Service position ................135
Lubrication; every 50 hours................138
Lubrication; every 100 hours................143
Lubrication; every 500 hours................147
Test running and checking................148
Leakage; checking................150
Engine belt tension; checking................151
Valves; adjusting ................153
Engine oil level; checking................161
Engine oil and filter; changing................162
Water separator; checking................165
Fuel filters; replacing................166
Fuel tank breather filter; replacing................168
Fuel tank sediment; draining................170
Diesel particulate filter; regenerating................172
Diesel particulate filter; checking and cleaning................174
AdBlue®_DEF pump unit filter; replacing................182
AdBlue®_DEF tank breather filter; replacing................186
Engine air cleaner primary filter; replacing................189
Engine air cleaner secondary filter; replacing................191
Coolant level; checking................193
Coolant; changing................195
Coolant freezing point; checking................199
Radiator; cleaning................202
MATRIS and Tech Tool; reading................204
Software update; checking................206
Battery; checking................210
CareTrack backup battery; replacing................212
Travel gearbox oil level; checking................215
Travel gearbox oil; changing................217
Swing ring gear lubrication; checking................219
Swing gearbox oil level; checking................221
Swing gearbox oil; changing................223
Drive axles and hubs oil level; checking................225
Drive axles and hubs oil; changing................228
Brake disc wear; measuring................232
Brake pressure and function; checking................235
Tyre wear and air pressure; checking................239
Wheel nuts torque; checking................241
Cab prefilter; cleaning................242
Cab prefilter; replacing................244
Cab main filter; cleaning................246
Cab main filter; replacing................250
Air conditioner compressor belt; checking................254
Hydraulic oil level; checking................256
Hydraulic oil; changing................258
Hydraulic oil drain filter; replacing................263
Hydraulic oil servo filter; replacing................265
In-line hydraulic oil filter; cleaning................268
Hydraulic oil return filter; replacing................271
Hydraulic oil tank breather filter; replacing................273
Boom suspension accumulator; checking................275
Trailer hitch; checking_{54-49}................280
Trailer hitch; checking_{54-28}................285
Universal quick coupler; checking................290
Measuring condition................292
Cylinder speed................293
Creeping of hydraulic cylinder................296
Swing speed................299
Measuring of swing bearing clearance................301
Coasting left and right swing................302
Travel Speed................304
Towing................305
Secondary lowering of digging equipment................308
Starting engine with booster cables................310
19 - GENERAL................312
Safety concerns everybody!................313
CE-marking; EMC-directive................315
Safety when handling the machine_{46-19}................317
Safety when handling the machine_{45-59}................320
Safety rules when servicing................324
Service position................327
Checklist after a fire or heat exposure................330
Fire prevention measures................331
Health hazards with paint; plastics and rubber................334
Some simple rules regarding tyre handling................336
Safety when using lifting equipment................338
Safety when handling oils and fuel................339
Safety when working with batteries................340
Starting with booster batteries................342
Safety when working with air conditioning refrigerant................343
Safety when working with hydraulic systems................345
Environmental handling for the future................347
Environmentally safe handling................348
Environmentally hazardous fluids................350
Working in environmentally contaminated areas................351
Decontamination................352
Waste handling................353
2 - ENGINE WITH MOUNTING AND EQUIPMENT................354
20 - GENERAL................355
Engine; description_{36-49}................356
Engine; description_{36-28}................364
Component locations................371
Tech Tool; operations_{35-31}................373
Tech Tool; operations_{35-12}................376
Engine control module (ECM); replacing pre-programmed................378
Engine control module (ECM); replacing non-programmed................381
Engine; reference values................384
21 - ENGINE................387
Engine; specifications................388
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope................389
Engine; removing................395
Engine; installing................405
Engine; replacing_{030-50}................415
Engine; replacing_{030-32}................419
Engine; tightening torques................422
Cylinder compression; testing................429
Crankcase ventilation; description................432
Valve system; specifications................436
Valves; adjusting................437
Valve cover; removing................445
Valve cover; installing................449
Oil level sensor; replacing................453
Engine mount front; replacing................455
Engine mounting rear; changing................460
Engine mounting; tightening torque................463
22 - LUBRICATING SYSTEM................465
Lubrication system; description................466
Lubrication system; specifications................471
Lubrication oil consumption; checking................473
Lubrication system; component locations................477
Lubrication system; tightening torques................479
Lubrication oil pressure; checking with pressure gauge................482
23 - FUEL SYSTEM................484
Fuel system; description................485
Fuel system; specifications................492
Fuel system; tightening torques................494
Carbon dioxide in fuel system; checking................500
Fuel system; component location................506
Feed pump pressure; checking................508
Fuel system; bleeding................510
Fuel tank; specification................512
Fuel filler pump; specifications................513
Fuel tank; description................514
Fuel tank; replacing................515
Fuel filling pump; removing................520
Fuel filling pump; installing................523
Injectors; replacing................525
Injector sleeves; replacing................530
Fuel rail; replacing................539
Fuel rail pressure sensor; replacing................542
High pressure fuel pump; replacing................544
High pressure fuel pipes; replacing................547
Fuel control valve (FCV); replacing................549
Pressure relief valve (PRV); replacing................554
25 - INLET & EXHAUST SYSTEM................558
Inlet and exhaust system; description................560
Inlet and exhaust system; specification................566
Inlet and exhaust system; component location................568
Inlet and exhaust system; tightening torques................570
Exhaust pipe flexible tube; replacing................576
Exhaust Aftertreatment System; description................578
Exhaust Aftertreatment System; component location_{005-36}................592
Exhaust Aftertreatment System; component location_{005-16}................594
Regeneration process; description................596
AdBlue®_DEF dosing injector; replacing................603
AdBlue®_DEF mixing tube; replacing................606
AdBlue®_DEF tank; replacing_{003-27}................609
AdBlue®_DEF tank; replacing_{003-05}................618
AdBlue®_DEF; draining................627
Coolant valve; replacing_{002-15}................630
Coolant valve; replacing_{001-55}................633
SCR (Selective catalytic reduction) muffler; replacing................636
AdBlue®_DEF quality; checking................639
SCR (Selective catalytic reduction) dosing system; checking................642
AdBlue®_DEF pump unit diagnostics; description................645
Exhaust aftertreatment system muffler unit; removing................649
Exhaust aftertreatment system muffler unit; installing................653
DPF (Diesel particulate filter); checking and cleaning................656
ACM (Aftertreatment control module) non-programmed; replacing................658
ACM (Aftertreatment control module) pre-programmed; replacing................660
Inlet throttle; replacing................662
DOC (Diesel oxidation catalyst); replacing................664
AdBlue®_DEF pump unit; replacing................668
AdBlue®_DEF tank armature; replacing_{057-09}................673
AdBlue®_DEF tank armature; replacing_{056-50}................678
AdBlue®_DEF tank armature; cleaning................684
AdBlue®_DEF tank armature suction filter; replacing................687
AdBlue®_DEF hoses; replacing................689
Crystallization of AdBlue®_DEF; checking................693
AdBlue®_DEF pump unit; flushing................698
AdBlue®_DEF pump unit; inlet nipple; replacing................702
Regeneration log; checking................706
AdBlue®_DEF tank; cleaning................718
Turbocharger; replacing................722
Wastegate; checking................726
Preheating coil; replacing................728
26 - COOLING SYSTEM................732
Cooling system; description................733
Cooling system; specifications................737
Carbon dioxide in coolant system; checking................739
Cooling system; component location................745
Cooling system; tightening torques................748
Cooling system pressure; checking................751
Radiator; description................753
Expansion tank; replacing................755
Radiator; removing................758
Radiator; installing................764
Radiator; disassembling................771
Radiator; assembling................775
Coolant pump; replacing................780
Thermostat; replacing................787
Cooling fan; description................790
Cooling fan control................791
Cooling fan rpm; specifications................794
Fan belt and_or alternator belt; replacing................795
AC compressor belt; replacing................798
Cooling fan clutch; description................800
Cooling fan clutch; replacing................802
27 - ENGINE CONTROL................808
Engine speed control; description_{09-34-48}................809
Engine speed control; description_{09-34-21}................813
Engine speed control; description_{09-33-56}................816
Engine control; specifications_{09-33-19}................819
Engine control; specifications_{09-32-58}................821
Engine control; specifications_{09-32-37}................823
29 - MISCELLANEOUS................824
EGR venturi tube; cleaning................825
Exhaust Gas Recirculation (EGR); description................827
Exhaust gas recirculation (EGR); component location................833
EGR system; tightening torques................835
EGR reed valve; replacing................837
EGR cooler; replacing................839
EGR valve; replacing................844
EGR venturi tube; replacing................846
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS................849
30 - GENERAL................850
Electrical system; special instructions for servicing; general................858
Electrical system; special instructions for servicing; electronic components................860
Electrical system; special instructions for servicing; electrical components; batteries................861
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator................863
Electrical system; special instructions for servicing; action when working on machine................864
Electrical system; description................865
Electronic control system; description_{09-20-10}................867
Electronic control system; description_{09-18-57}................878
Electrical system; specifications................886
Tech Tool; operations ................887
Control units; software functions................888
Auto idle control; description_{09-16-37}................890
Auto idle control; description_{09-16-11}................892
Automatic engine shut down; description_{09-15-35}................894
Automatic engine shut down; description_{09-15-11}................897
Power Boost control; description_{09-14-34}................900
Power Boost control; description_{09-14-09}................903
Limp Home Control................906
Start lock; description................910
Power supply; description................911
Machine shutdown................916
Mode selection; description................918
Travel speed control; description................920
Travel Direction Control_{09-09-28}................925
Travel Direction Control_{09-09-03}................927
Control lockout system; description................929
Overload warning................932
Attachment quick coupler................935
ECO mode; description................938
Software parameters; description_{09-06-02}................940
Software parameters; description_{09-05-39}................952
Software parameters; description_{09-05-17}................964
Troubleshooting strategy................975
Troubleshooting; general................977
Collection of basic data................979
Information display; check................981
Error codes; build-up................985
Electrical cables and connectors; checking................986
Special tools for troubleshooting................991
Tech Tool; operations................993
Connecting special tools................994
Measuring; general................997
Measuring symbols; description................998
Component descriptions................1001
Component troubleshooting; structure; description................1004
Component troubleshooting; checking wiring harness and input_output on ECU................1006
Component troubleshooting; checking component................1008
Component troubleshooting; checking subsystem (circuit)................1010
AL3201; description and measuring-[5156]................1012
AL3201; description and measuring................1014
BA3101; description and measuring................1017
BB1 Communication bus; description and measuring................1019
BB2 Communication bus; description and measuring................1022
CAN PN1; description and measuring................1025
CAN PN2; description and measuring................1029
CU6401; description and measuring................1032
CU9901; description and measuring_{08-35-55}................1034
CU9901; description and measuring_{08-35-14}................1036
CU9909; description and measuring................1038
Engine CAN; description and measuring................1040
FX1005; description and measuring................1043
FX1006; description and measuring................1045
FX1007; description and measuring_{08-28-02}................1048
FX1007; description and measuring_{08-26-38}................1052
FX1008; description and measuring................1056
FX1020; description and measuring................1059
FX1021; description and measuring................1061
FX1074; description and measuring................1063
FX1079; description and measuring................1066
FX1116; description and measuring................1069
FX1117; description and measuring................1071
HE2501; description and measuring................1073
HE2511; description and measuring................1075
HE2512; description and measuring................1077
HE2513; description and measuring................1079
Instrument Cluster (IC); description and measuring................1081
LA3619; description and measuring................1083
LA3620; description and measuring................1085
LA5201; description and measuring................1087
LA5202; description and measuring................1089
MA2301-MA2306; description and measuring................1091
MA2517; description and measuring................1093
MA2519; description and measuring................1095
MA2602; description and measuring................1097
MA4214; description and measuring................1099
MA4226; description and measuring_{07-56-57}................1101
MA4226; description and measuring_{07-56-08}................1103
MA4227; description and measuring_{07-55-06}................1105
MA4227; description and measuring_{07-54-18}................1107
MA4302; description and measuring_{07-53-12}................1109
MA4302; description and measuring_{07-52-15}................1111
MA4303; description and measuring................1113
MA5205; description and measuring................1115
MA6603; description and measuring................1117
MA8901; description and measuring................1119
MA8903; description and measuring................1121
MA9109; description and measuring_{07-43-14}................1123
MA9109; description and measuring_{07-42-18}................1126
MA9120; description and measuring................1129
MA9125; description and measuring_{07-39-28}................1131
MA9125; description and measuring_{07-38-40}................1133
MA9152; description and measuring................1135
MA9153; description and measuring_{07-36-15}................1137
MA9153; description and measuring_{07-35-29}................1139
MA9154; description and measuring_{07-34-20}................1141
MA9154; description and measuring_{07-33-35}................1143
MA9155; description and measuring_{07-32-35}................1145
MA9155; description and measuring_{07-31-51}................1147
MA9156; description and measuring_{07-30-53}................1149
MA9156; description and measuring_{07-30-07}................1151
MA9164; description and measuring................1153
MA9174; description and measuring................1155
MA9616; description and measuring................1157
MA9618; description and measuring_{07-25-03}................1159
MA9618; description and measuring_{07-24-16}................1161
MA9619; description and measuring................1163
MA9620; description and measuring................1165
MA9964; description and measuring................1167
MA9965; description and measuring................1169
MA9966; description and measuring................1171
MA9968; description and measuring................1173
MA9969; description and measuring................1175
MO2503; description and measuring................1177
MO2505; description and measuring................1179
MO3301; description and measuring................1182
Power supply; ACM (Aftertreatment Control Module); description and measuring................1184
Power supply CCM; description and measuring................1186
Power supply ECM; description and measuring................1188
Power supply GPMECU 1; description and measuring................1190
Power supply GPMECU 2; description and measuring................1192
Power supply HMICU; description and measuring................1194
Power supply W-ECU; description and measuring................1196
PWM2303; description and measuring................1198
PWM2602; description and measuring_{07-02-42}................1200
PWM2602; description and measuring_{07-02-05}................1202
PWM4219; description and measuring................1204
PWM4220; description and measuring................1206
PWM9123; description and measuring_{06-59-15}................1208
PWM9123; description and measuring_{06-58-37}................1210
PWM9124; description and measuring................1212
PWM9129; description and measuring_{06-56-43}................1214
PWM9129; description and measuring_{06-56-05}................1216
PWM9130; description and measuring................1218
PWM9141; description and measuring_{06-54-15}................1220
PWM9141; description and measuring_{06-53-37}................1222
PWM9143; description and measuring................1224
PWM9145; description and measuring................1226
PWM9146; description and measuring................1228
PWM9163; description and measuring................1230
PWM9165; description and measuring................1232
RE2501; description and measuring................1234
RExxxx; Relays general; description and measuring................1236
SA4206; description and measuring................1238
SAE J1939-1 SubNet 1; description and measuring................1240
SE2203; description and measuring................1243
SE2301; description and measuring................1246
SE2303; description and measuring................1249
SE2309; description and measuring................1252
SE2511; description and measuring................1255
SE2512; description and measuring................1257
SE2513; description and measuring................1259
SE2515; description and measuring................1262
SE2516; description and measuring................1265
SE2519; description and measuring................1268
SE2521; description and measuring................1271
SE2522; description and measuring................1274
SE2533; description and measuring................1277
SE2543; description and measuring................1280
SE2544; description and measuring................1283
SE2603; description and measuring................1286
SE2604; description and measuring_{06-23-07}................1288
SE2604; description and measuring_{06-22-25}................1291
SE2606; description and measuring................1293
SE2701; description and measuring................1295
SE2703; description and measuring................1297
SE2704; description and measuring................1299
SE4216; description and measuring_{06-17-40}................1301
SE4216; description and measuring_{06-17-03}................1303
SE4217; description and measuring................1305
SE4307; description and measuring_{06-15-08}................1307
SE4307; description and measuring_{06-14-25}................1309
SE5201; description and measuring................1311
SE5221; description and measuring................1313
SE6404; description and measuring_{06-11-13}................1315
SE6404; description and measuring_{06-10-44}................1317
SE6413; description and measuring................1319
SE8701; description and measuring................1321
SE8702; description and measuring................1323
SE8705; description and measuring................1325
SE8706; description and measuring................1328
SE9105; description and measuring................1331
SE9109; description and measuring................1334
SE9116; description and measuring................1336
SE9136; description and measuring_{06-02-48}................1338
SE9136; description and measuring_{06-02-06}................1341
SE9141; description and measuring................1344
SE9142; description and measuring................1346
SE9152; description and measuring................1348
SE9188; description and measuring................1350
SE9192; description and measuring................1353
SE9196; description and measuring................1355
SE9401; description and measuring................1357
SE9726; description and measuring................1360
SE9727; description and measuring................1362
SE9728; description and measuring................1364
SE9729; description and measuring................1366
SE9730; description and measuring................1368
SE9731; description and measuring................1370
SE9732; description and measuring................1372
SE9733; description and measuring................1374
SE9734; description and measuring................1377
SE9968; description and measuring................1380
SE9969; description and measuring................1382
SE9970; description and measuring................1384
SE9973; description and measuring................1386
SW3301; description and measuring................1388
SW3619; description and measuring................1391
SW3802; description and measuring_{05-42-11}................1393
SW3802; description and measuring_{05-41-42}................1395
SW3803; description and measuring................1397
SW4202; description and measuring................1399
SW4205; description and measuring................1401
SW4216; description and measuring................1403
SW9161; description and measuring................1405
SW9162; description and measuring................1407
Tiltrotator detection; description and measuring................1409
31 - BATTERY................1411
Battery; storage................1412
Battery; description................1413
Battery; specifications................1415
Battery; charging................1416
Batteries; replacing................1418
32 - ALTERNATOR; CHARGE REGULATOR................1420
Charging; description................1421
Alternator; specifications................1422
Alternator; description................1423
Alternator; replacing incl function checking................1425
Alternator; testing................1430
33 - STARTING SYSTEM................1432
Starter motor; description................1433
Starter motor; specifications................1434
Starter motor; testing................1435
Starter motor; tightening torques................1439
Starter motor; replacing................1442
35 - LIGHTING................1444
Lights; specifications................1445
Headlights; adjusting................1446
Remote welcome lights; description................1448
36 - OTHER ELECTRICAL EQUIPMENT................1452
X1 electronic pedal; replacing................1454
Electric horn; specifications................1457
Horn; replacing................1458
Travel alarm; description_{05-23-55}................1460
Travel alarm; description_{05-23-34}................1462
Travel alarm; specifications................1464
Travel alarm; replacing................1465
Windscreen wiper; description_{05-22-05}................1467
Windscreen wiper; description_{05-21-41}................1472
Window limit switch; description................1475
Windscreen wiper front motor; replacing................1477
Windscreen flusher pump; replacing................1481
Windscreen flusher pump; specifications................1483
Connectors; overview_{05-19-07}................1484
Connectors; overview_{05-17-48}................1503
Connectors; overview_{05-16-34}................1521
Connectors; position_{05-15-11}................1538
Connectors; position_{05-14-45}................1551
Connectors; position_{05-14-20}................1562
Electric center passage; description_{05-13-38}................1570
Electric center passage; description_{05-13-05}................1575
Electric center passage; description_{05-12-35}................1580
Electric center passage; specification_{05-11-59}................1584
Electric center passage; specification_{05-11-39}................1585
Electric center passage; replacing_{05-11-06}................1586
Electric center passage; replacing_{05-10-41}................1593
Electric center passage; replacing_{05-10-17}................1600
Ignition switch; description and operation................1604
Multi-function lever switch; description................1606
Control levers; description_{05-08-45}................1608
Control levers; description_{05-08-19}................1614
Ignition switch; replacing................1623
Switch; replacing................1626
General purpose machine electronic control unit GPMECU; function description................1629
Human machine interface control unit HMICU; function description................1631
Control units changing; precaution................1633
GPMECU1 non-programmed; replacing................1634
GPMECU1 pre-programmed; replacing................1637
GPMECU2 non-programmed; replacing................1640
GPMECU2 pre-programmed; replacing................1643
HMICU non-programmed; replacing................1645
HMICU pre-programmed; replacing................1648
37 - CABLE; FUSE; RELAY................1651
Wiring diagram WD995 - Image................1664
Page 1................1664
Wiring diagram WD994 - Image................1665
Page 1................1665
Wiring diagram WD993 - Image................1666
Page 1................1666
Wiring diagram WD990 - Image C................1667
Page 1................1667
Wiring diagram WD990 - Image B................1668
Page 1................1668
Wiring diagram WD990 - Image A................1669
Page 1................1669
Wiring diagram WD912 - Image................1670
Page 1................1670
Wiring diagram WD911 - Image C................1671
Page 1................1671
Wiring diagram WD911 - Image B................1672
Page 1................1672
Wiring diagram WD911 - Image A................1673
Page 1................1673
Wiring diagram WD910 - Image C................1674
Page 1................1674
Wiring diagram WD910 - Image B................1675
Page 1................1675
Wiring diagram WD910 - Image A................1676
Page 1................1676
Wiring diagram WD909 - Image C................1677
Page 1................1677
Wiring diagram WD909 - Image B................1678
Page 1................1678
Wiring diagram WD909 - Image A................1679
Page 1................1679
Wiring diagram WD908 - Image C................1680
Page 1................1680
Wiring diagram WD908 - Image B................1681
Page 1................1681
Wiring diagram WD908 - Image A................1682
Page 1................1682
Wiring diagram WD907 - Image C................1683
Page 1................1683
Wiring diagram WD907 - Image B................1684
Page 1................1684
Wiring diagram WD907 - Image A................1685
Page 1................1685
Wiring diagram WD906 - Image C................1686
Page 1................1686
Wiring diagram WD906 - Image B................1687
Page 1................1687
Wiring diagram WD906 - Image A................1688
Page 1................1688
Wiring diagram WD905 - Image C................1689
Page 1................1689
Wiring diagram WD905 - Image B................1690
Page 1................1690
Wiring diagram WD905 - Image A................1691
Page 1................1691
Wiring diagram WD904 - Image C................1692
Page 1................1692
Wiring diagram WD904 - Image B................1693
Page 1................1693
Wiring diagram WD904 - Image A................1694
Page 1................1694
Wiring diagram WD903 - Image C................1695
Page 1................1695
Wiring diagram WD903 - Image B................1696
Page 1................1696
Wiring diagram WD903 - Image A................1697
Page 1................1697
Wiring diagram WD902 - Image C................1698
Page 1................1698
Wiring diagram WD902 - Image B................1699
Page 1................1699
Wiring diagram WD902 - Image A................1700
Page 1................1700
Wiring diagram WD901 - Image D................1701
Page 1................1701
Wiring diagram WD901 - Image C................1702
Page 1................1702
Wiring diagram WD901 - Image B................1703
Page 1................1703
Wiring diagram WD901 - Image A................1704
Page 1................1704
Wiring diagram WD803 - Image C................1705
Page 1................1705
Wiring diagram WD803 - Image B................1706
Page 1................1706
Wiring diagram WD803 - Image A................1707
Page 1................1707
Wiring diagram WD802 - Image D................1708
Page 1................1708
Wiring diagram WD802 - Image C................1709
Page 1................1709
Wiring diagram WD802 - Image B................1710
Page 1................1710
Wiring diagram WD802 - Image A................1711
Page 1................1711
Wiring diagram WD801 - Image C................1712
Page 1................1712
Wiring diagram WD801 - Image B................1713
Page 1................1713
Wiring diagram WD801 - Image A................1714
Page 1................1714
Wiring diagram WD601 - Image................1715
Page 1................1715
Wiring diagram WD501 - Image C................1716
Page 1................1716
Wiring diagram WD501 - Image B................1717
Page 1................1717
Wiring diagram WD501 - Image A................1718
Page 1................1718
Wiring diagram WD402 - Image C................1719
Page 1................1719
Wiring diagram WD402 - Image B................1720
Page 1................1720
Wiring diagram WD402 - Image A................1721
Page 1................1721
Wiring diagram WD401 - Image C................1722
Page 1................1722
Wiring diagram WD401 - Image B................1723
Page 1................1723
Wiring diagram WD401 - Image A................1724
Page 1................1724
Wiring diagram WD315 - Image................1725
Page 1................1725
Wiring diagram WD314 - Image................1726
Page 1................1726
Wiring diagram WD313 - Image................1727
Page 1................1727
Wiring diagram WD312 - Image D................1728
Page 1................1728
Wiring diagram WD312 - Image C................1729
Page 1................1729
Wiring diagram WD312 - Image B................1730
Page 1................1730
Wiring diagram WD312 - Image A................1731
Page 1................1731
Wiring diagram WD311 - Image D................1732
Page 1................1732
Wiring diagram WD311 - Image C................1733
Page 1................1733
Wiring diagram WD311 - Image B................1734
Page 1................1734
Wiring diagram WD311 - Image A................1735
Page 1................1735
Wiring diagram WD310 - Image C................1736
Page 1................1736
Wiring diagram WD310 - Image B................1737
Page 1................1737
Wiring diagram WD310 - Image A................1738
Page 1................1738
Wiring diagram WD309 - Image C................1739
Page 1................1739
Wiring diagram WD309 - Image B................1740
Page 1................1740
Wiring diagram WD309 - Image A................1741
Page 1................1741
Wiring diagram WD308 - Image C................1742
Page 1................1742
Wiring diagram WD308 - Image B................1743
Page 1................1743
Wiring diagram WD308 - Image A................1744
Page 1................1744
Wiring diagram WD307 - Image C................1745
Page 1................1745
Wiring diagram WD307 - Image B................1746
Page 1................1746
Wiring diagram WD307 - Image A................1747
Page 1................1747
Wiring diagram WD306 - Image C................1748
Page 1................1748
Wiring diagram WD306 - Image B................1749
Page 1................1749
Wiring diagram WD306 - Image A................1750
Page 1................1750
Wiring diagram WD305 - Image C................1751
Page 1................1751
Wiring diagram WD305 - Image B................1752
Page 1................1752
Wiring diagram WD305 - Image A................1753
Page 1................1753
Wiring diagram WD304 - Image C................1754
Page 1................1754
Wiring diagram WD304 - Image B................1755
Page 1................1755
Wiring diagram WD304 - Image A................1756
Page 1................1756
Wiring diagram WD303 - Image C................1757
Page 1................1757
Wiring diagram WD303 - Image B................1758
Page 1................1758
Wiring diagram WD303 - Image A................1759
Page 1................1759
Wiring diagram WD302 - Image C................1760
Page 1................1760
Wiring diagram WD302 - Image B................1761
Page 1................1761
Wiring diagram WD302 - Image A................1762
Page 1................1762
Wiring diagram WD301 - Image C................1763
Page 1................1763
Wiring diagram WD301 - Image B................1764
Page 1................1764
Wiring diagram WD301 - Image A................1765
Page 1................1765
Wiring diagram WD300 - Image C................1766
Page 1................1766
Wiring diagram WD300 - Image B................1767
Page 1................1767
Wiring diagram WD300 - Image A................1768
Page 1................1768
Wiring diagram WD209 - Image C................1769
Page 1................1769
Wiring diagram WD209 - Image B................1770
Page 1................1770
Wiring diagram WD209 - Image A................1771
Page 1................1771
Wiring diagram WD208 - Image C................1772
Page 1................1772
Wiring diagram WD208 - Image B................1773
Page 1................1773
Wiring diagram WD208 - Image A................1774
Page 1................1774
Wiring diagram WD207 - Image C................1775
Page 1................1775
Wiring diagram WD207 - Image B................1776
Page 1................1776
Wiring diagram WD207 - Image A................1777
Page 1................1777
Wiring diagram WD206 - Image C................1778
Page 1................1778
Wiring diagram WD206 - Image B................1779
Page 1................1779
Wiring diagram WD206 - Image A................1780
Page 1................1780
Wiring diagram WD205 - Image C................1781
Page 1................1781
Wiring diagram WD205 - Image B................1782
Page 1................1782
Wiring diagram WD205 - Image A................1783
Page 1................1783
Wiring diagram WD204 - Image C................1784
Page 1................1784
Wiring diagram WD204 - Image B................1785
Page 1................1785
Wiring diagram WD204 - Image A................1786
Page 1................1786
Wiring diagram WD203 - Image C................1787
Page 1................1787
Wiring diagram WD203 - Image B................1788
Page 1................1788
Wiring diagram WD203 - Image A................1789
Page 1................1789
Wiring diagram WD202 - Image C................1790
Page 1................1790
Wiring diagram WD202 - Image B................1791
Page 1................1791
Wiring diagram WD202 - Image A................1792
Page 1................1792
Wiring diagram WD201 - Image C................1793
Page 1................1793
Wiring diagram WD201 - Image B................1794
Page 1................1794
Wiring diagram WD201 - Image A................1795
Page 1................1795
Wiring diagram WD120 - Image C................1796
Page 1................1796
Wiring diagram WD120 - Image B................1797
Page 1................1797
Wiring diagram WD120 - Image A................1798
Page 1................1798
Wiring diagram WD1001 - Image................1799
Page 1................1799
Wiring diagram; electrical distribution box - Image................1800
Page 1................1800
Control system diagram - Image B2................1801
Page 1................1801
Control system diagram - Image B1................1802
Page 1................1802
Control system diagram - Image A................1803
Page 1................1803
Electrical symbols and designations................1804
Explanation of wiring diagrams................1807
Component designations................1810
Electrical system component locations................1812
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{02-11-16}................1813
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{02-10-55}................1815
Component list; fuses_{02-10-23}................1817
Component list; fuses_{02-10-01}................1819
Component list; Heating coils_{02-09-29}................1821
Component list; Heating coils_{02-09-08}................1822
Component list; lights_{02-08-29}................1823
Component list; lights_{02-08-07}................1825
Component list; Miscellaneous_{02-07-34}................1827
Component list; Miscellaneous_{02-07-13}................1829
Component list; motors_{02-06-40}................1831
Component list; motors_{02-06-18}................1833
Component list; relays_{02-05-34}................1834
Component list; relays_{02-05-13}................1836
Component list; sensors_{02-04-39}................1837
Component list; sensors_{02-04-18}................1841
Component list; Solenoid valves_{02-03-45}................1844
Component list; Solenoid valves_{02-03-24}................1847
Component list; Switches_{02-02-45}................1849
Component list; Switches_{02-02-24}................1852
ACM; I_O list_{02-01-51}................1854
ACM; I_O list_{02-01-27}................1858
CCM; I_O list_{02-00-50}................1861
CCM; I_O list_{02-00-26}................1865
ECM (Engine Control Module); I_O list_{01-59-45}................1867
ECM (Engine Control Module); I_O list_{01-59-20}................1872
GPMECU1; I_O list_{01-58-44}................1877
GPMECU1; I_O list_{01-58-19}................1882
GPMECU2; I_O list_{01-57-43}................1886
GPMECU2; I_O list_{01-57-18}................1891
HMICU; I_O list_{01-56-43}................1895
HMICU; I_O list_{01-56-18}................1898
IC (Instrument Cluster); I_O list_{01-55-42}................1901
IC (Instrument Cluster); I_O list_{01-55-18}................1903
W-ECU; I_O list_{01-54-42}................1905
W-ECU; I_O list_{01-54-18}................1907
Wiring diagram; general_{01-53-37}................1909
Wiring diagram; general_{01-53-15}................1911
Control system diagram_{01-52-42}................1913
Control system diagram_{01-52-17}................1918
Wiring diagram; electrical distribution box................1921
Wiring diagram WD120_{01-50-59}................1924
Wiring diagram WD120_{01-50-34}................1928
Wiring diagram WD120_{01-50-10}................1932
Wiring diagram WD201_{01-49-33}................1936
Wiring diagram WD201_{01-49-09}................1939
Wiring diagram WD201_{01-48-45}................1942
Wiring diagram WD202_{01-47-57}................1945
Wiring diagram WD202_{01-47-32}................1948
Wiring diagram WD202_{01-47-07}................1951
Wiring diagram WD203_{01-46-31}................1954
Wiring diagram WD203_{01-46-06}................1957
Wiring diagram WD203_{01-45-42}................1960
Wiring diagram WD204_{01-45-06}................1963
Wiring diagram WD204_{01-44-42}................1966
Wiring diagram WD204_{01-44-17}................1969
Wiring diagram WD205_{01-43-41}................1972
Wiring diagram WD205_{01-43-16}................1975
Wiring diagram WD205_{01-42-52}................1978
Wiring diagram WD206_{01-42-16}................1981
Wiring diagram WD206_{01-41-51}................1984
Wiring diagram WD206_{01-41-26}................1987
Wiring diagram WD207_{01-40-50}................1990
Wiring diagram WD207_{01-40-25}................1993
Wiring diagram WD207_{01-40-01}................1996
Wiring diagram WD208_{01-39-25}................1999
Wiring diagram WD208_{01-39-00}................2002
Wiring diagram WD208_{01-38-36}................2005
Wiring diagram WD209_{01-37-59}................2008
Wiring diagram WD209_{01-37-35}................2011
Wiring diagram WD209_{01-37-10}................2014
Wiring diagram WD300_{01-36-28}................2017
Wiring diagram WD300_{01-36-03}................2020
Wiring diagram WD300_{01-35-38}................2023
Wiring diagram WD301_{01-35-02}................2026
Wiring diagram WD301_{01-34-38}................2029
Wiring diagram WD301_{01-34-13}................2032
Wiring diagram WD302_{01-33-32}................2035
Wiring diagram WD302_{01-33-07}................2038
Wiring diagram WD302_{01-32-42}................2041
Wiring diagram WD303_{01-32-06}................2044
Wiring diagram WD303_{01-31-42}................2047
Wiring diagram WD303_{01-31-17}................2050
Wiring diagram WD304_{01-30-29}................2053
Wiring diagram WD304_{01-30-05}................2056
Wiring diagram WD304_{01-29-40}................2059
Wiring diagram WD305_{01-29-04}................2062
Wiring diagram WD305_{01-28-40}................2065
Wiring diagram WD305_{01-28-15}................2068
Wiring diagram WD306_{01-27-39}................2071
Wiring diagram WD306_{01-27-15}................2075
Wiring diagram WD306_{01-26-50}................2078
Wiring diagram WD307_{01-26-14}................2081
Wiring diagram WD307_{01-25-49}................2084
Wiring diagram WD307_{01-25-25}................2087
Wiring diagram WD308_{01-24-48}................2090
Wiring diagram WD308_{01-24-24}................2093
Wiring diagram WD308_{01-23-59}................2096
Wiring diagram WD309_{01-23-23}................2099
Wiring diagram WD309_{01-22-58}................2103
Wiring diagram WD309_{01-22-34}................2107
Wiring diagram WD310_{01-21-58}................2111
Wiring diagram WD310_{01-21-33}................2114
Wiring diagram WD310_{01-21-08}................2117
Wiring diagram WD311_{01-20-27}................2120
Wiring diagram WD311_{01-20-02}................2123
Wiring diagram WD311_{01-19-37}................2126
Wiring diagram WD311_{01-19-13}................2129
Wiring diagram WD312_{01-18-31}................2132
Wiring diagram WD312_{01-18-06}................2135
Wiring diagram WD312_{01-17-42}................2138
Wiring diagram WD312_{01-17-17}................2141
Wiring diagram WD313................2144
Wiring diagram WD314................2147
Wiring diagram WD315................2150
Wiring diagram WD401_{01-14-59}................2153
Wiring diagram WD401_{01-14-34}................2156
Wiring diagram WD401_{01-14-10}................2159
Wiring diagram WD402_{01-13-34}................2162
Wiring diagram WD402_{01-13-10}................2165
Wiring diagram WD402_{01-12-45}................2168
Wiring diagram WD501_{01-11-57}................2171
Wiring diagram WD501_{01-11-32}................2174
Wiring diagram WD501_{01-11-08}................2177
Wiring diagram WD601................2180
Wiring diagram WD801_{01-10-02}................2183
Wiring diagram WD801_{01-09-37}................2186
Wiring diagram WD801_{01-09-13}................2189
Wiring diagram WD802_{01-08-37}................2192
Wiring diagram WD802_{01-08-12}................2195
Wiring diagram WD802_{01-07-48}................2198
Wiring diagram WD802_{01-07-24}................2201
Wiring diagram WD803_{01-06-47}................2204
Wiring diagram WD803_{01-06-23}................2207
Wiring diagram WD803_{01-05-59}................2210
Wiring diagram WD901_{01-05-23}................2213
Wiring diagram WD901_{01-04-58}................2216
Wiring diagram WD901_{01-04-34}................2219
Wiring diagram WD901_{01-04-09}................2223
Wiring diagram WD902_{01-03-33}................2227
Wiring diagram WD902_{01-03-09}................2230
Wiring diagram WD902_{01-02-44}................2233
Wiring diagram WD903_{01-02-09}................2236
Wiring diagram WD903_{01-01-44}................2239
Wiring diagram WD903_{01-01-20}................2242
Wiring diagram WD904_{01-00-44}................2245
Wiring diagram WD904_{01-00-20}................2249
Wiring diagram WD904_{12-59-55}................2253
Wiring diagram WD905_{12-59-19}................2257
Wiring diagram WD905_{12-58-55}................2261
Wiring diagram WD905_{12-58-30}................2264
Wiring diagram WD906_{12-57-48}................2267
Wiring diagram WD906_{12-57-24}................2270
Wiring diagram WD906_{12-56-59}................2273
Wiring diagram WD907_{12-56-24}................2276
Wiring diagram WD907_{12-55-59}................2280
Wiring diagram WD907_{12-55-35}................2284
Wiring diagram WD908_{12-54-58}................2288
Wiring diagram WD908_{12-54-34}................2291
Wiring diagram WD908_{12-54-10}................2294
Wiring diagram WD909_{12-53-22}................2297
Wiring diagram WD909_{12-52-58}................2300
Wiring diagram WD909_{12-52-33}................2303
Wiring diagram WD910_{12-51-57}................2306
Wiring diagram WD910_{12-51-32}................2309
Wiring diagram WD910_{12-51-08}................2312
Wiring diagram WD911_{12-50-26}................2315
Wiring diagram WD911_{12-50-01}................2318
Wiring diagram WD911_{12-49-37}................2321
Wiring diagram WD912................2324
Wiring diagram WD990_{12-48-32}................2327
Wiring diagram WD990_{12-48-07}................2330
Wiring diagram WD990_{12-47-43}................2333
Wiring diagram WD992................2336
Wiring diagram WD993................2337
Wiring diagram WD994................2341
Wiring diagram WD995................2345
Wiring diagram WD1001................2348
Wiring harnesses................2351
Battery disconnect switch; description................2352
Electrical battery disconnect switch; description................2354
Electrical battery disconnect switch; replacing................2356
Electrical distribution box; description_{12-42-37}................2358
Electrical distribution box; description_{12-42-13}................2360
Electrical distribution box; description_{12-41-43}................2362
Electrical distribution box; description_{12-41-19}................2364
Electrical distribution box; description_{12-40-49}................2366
Electrical distribution box; description_{12-40-25}................2368
Electrical distribution box; circuit board replacing................2370
Fuse; description................2372
Relays; description_{12-38-19}................2374
Relays; description_{12-37-55}................2377
Relays; description_{12-37-25}................2380
Relays; description_{12-37-01}................2383
Relays; specifications_{12-36-26}................2386
Relays; specifications_{12-36-05}................2387
Flasher relay; specifications_{12-35-27}................2388
Flasher relay; specifications_{12-35-06}................2389
Component location_{12-34-34}................2390
Component location_{12-34-13}................2392
Component location_{12-33-46}................2394
Component location_{12-33-26}................2396
Component location 1_{12-32-53}................2398
Component location 1_{12-32-30}................2401
Component location 2................2404
Component location 3_{12-31-24}................2406
Component location 3_{12-31-00}................2410
Component location 4_{12-30-23}................2414
Component location 4_{12-29-59}................2421
Component location 5_{12-29-24}................2426
Component location 5_{12-29-00}................2429
Component location 6_{12-28-24}................2432
Component location 6_{12-27-59}................2436
Component location 7................2441
Component location 8_{12-26-48}................2444
Component location 8_{12-26-15}................2449
Component location 9................2453
Component location 10................2455
Component location 11_{12-24-39}................2457
Component location 11_{12-24-16}................2460
Component location 12_{12-23-29}................2462
Component location 12_{12-23-05}................2464
Component location 13_{12-22-30}................2465
Component location 13_{12-22-06}................2468
Component location 14................2471
Component location 15_{12-21-00}................2476
Component location 15_{12-20-36}................2479
Component location 16_{12-20-01}................2482
Component location 16_{12-19-37}................2484
Component location 17................2486
Component location 18................2490
Component location 19................2493
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM................2496
Instruments and controls; overview_{12-17-27}................2499
Instruments and controls; overview_{12-17-03}................2501
Instruments and controls; overview_{12-16-37}................2503
Instruments and controls; overview_{12-16-13}................2505
Instruments and controls; front instrument panel................2507
Instruments and controls; left instrument panel_{12-15-11}................2509
Instruments and controls; left instrument panel_{12-14-50}................2512
Instruments and controls; right instrument panel_{12-14-17}................2514
Instruments and controls; right instrument panel_{12-13-54}................2517
Instruments and controls; rear instrument panel................2519
Hour meter; replacing-[1249]................2520
Hour meter; replacing................2522
Fuel level sensor; specifications-[1152]................2524
Fuel level sensor; specifications................2526
Fuel level sender; replacing................2528
Control lockout lever switch; description................2530
Engine oil pressure sensor; replacing................2532
Engine rotation speed sensor; replacing_{12-09-48}................2534
Engine rotation speed sensor; replacing_{12-09-27}................2536
Engine rotation speed sensor (camshaft); replacing................2539
Hydraulic oil temperature sensor; replacing................2541
Keypad; description_{12-08-01}................2543
Keypad; description_{12-07-38}................2545
Keypad; description_{12-07-08}................2551
Keypad; description_{12-06-44}................2553
Keypad; specification_{12-06-09}................2559
Keypad; specification_{12-05-48}................2560
Service mode_{12-05-16}................2561
Service mode_{12-04-52}................2564
Engine system_{12-04-17}................2567
Engine system_{12-03-53}................2569
Hydraulic system_{12-03-18}................2571
Hydraulic system_{12-02-54}................2574
Electrical system_{12-02-18}................2577
Electrical system_{12-01-49}................2584
Electrical system_{12-01-18}................2591
Instrument cluster (display unit); replacing................2596
Volvo Smart View; description................2598
Volvo Co-Pilot; description................2599
Volvo Co-Pilot; component location................2603
Volvo Co-Pilot; specifications................2605
Volvo Co-Pilot; replacing................2607
Volvo Co-Pilot SIM card; installing................2611
USB tethering................2618
Volvo Co-Pilot Android software; updating online (OtA)................2625
Volvo Co-Pilot Android software; updating offline (USB)................2628
Volvo Co-Pilot; software updating................2631
Dig Assist; description................2635
Dig Assist; component location................2648
Dig Assist connectors; overview................2652
Dig Assist; tightening torques................2657
Dig Assist IMU; teach-in................2660
36703-3 Dig Assist; calibration; body IMU................2668
36703-3 Dig Assist; calibration; linkage................2672
36703-3 Dig Assist; calibration; GNSS................2679
Dig Assist GNSS antenna; calibrating................2686
36705-3 Dig Assist; configuration................2693
Dig Assist Onboard Weighing system; calibrating................2700
Dig Assist Onboard Weighing; tool weight; calibrating................2710
Dig Assist accuracy; checking................2717
Dig Assist IMU; checking................2725
Dig Assist quick coupler; measuring................2737
Dig Assist lift point; measuring................2744
Dig Assist Information Center; description................2750
Dig Assist; troubleshooting_{11-46-55}................2770
Dig Assist; troubleshooting_{11-46-34}................2776
Dig Assist RTK; troubleshooting................2782
3D applications for Dig Assist; troubleshooting................2789
Smart Receiver; replacing................2791
GNSS Antenna; replacing................2794
Inertial measurement unit (IMU); replacing_{11-44-34}................2797
Inertial measurement unit (IMU); replacing_{11-44-10}................2804
Laser catcher; replacing................2811
39 - MISCELLANEOUS................2813
Radio with MP3; specifications................2814
Audio remote controller; description................2815
Radio with MP3; description................2817
Radio; replacing................2819
DC–DC converter; specifications................2823
DC–DC converter; description................2824
Antenna; replacing................2826
Speaker; replacing................2828
CareTrack W-ECU; description................2830
W-ECU; replacing; non-programmed................2834
W-ECU; replacing; pre-programmed................2837
CareTrack battery; replacing................2840
CareTrack antenna; replacing................2843
4 - POWER TRANSMISSION................2846
40 - GENERAL................2847
Power transmission; description................2848
Tech Tool; operations26................2849
42 - TRANSMISSION; HYDRAULIC CONTROL................2850
Transmission mode; function check................2851
43 - GEARBOX................2853
Travel gearbox; specifications................2854
Travel gearbox; description................2855
Travel gearbox; bleeding................2865
Travel gearbox; removing................2867
Travel gearbox; installing................2871
Travel gearbox; troubleshooting................2875
44 - HYDROSTATIC DRIVE................2876
Swing motor; specifications................2878
Swing motor; description................2879
Swing unit; removing................2884
Swing unit; installing................2888
Swing motor; removing................2892
Swing motor; installing................2896
Swing motor pressure; checking and adjusting................2899
Swing motor; principle of operation................2903
Travel motor; description................2910
Travel motor (electric proportional control); description................2916
Travel motor pressure; checking and adjusting................2923
Travel motor; calibrating................2928
Travel motor; specifications................2932
Travel motor regulation start; checking and adjusting................2933
Travel motor; removing_{38-04}................2938
Travel motor; removing_{37-43}................2942
Travel motor; installing_{36-54}................2946
Travel motor; installing_{36-33}................2951
Travel motor removed; seal replacing................2956
Repair instructions................2959
Retardation valve; replacing................2966
Pump coupling; removing................2971
Pump coupling; installing................2973
Center passage; specifications11................2975
Center passage; specifications................2977
Center passage; description................2980
Centre passage; removing_{30-40}................2982
Centre passage; removing_{30-20}................2986
Centre passage; installing_{29-38}................2990
Centre passage; installing_{29-17}................2994
Center passage; disassembling and assembling_{28-40}................2999
Center passage; disassembling and assembling_{28-19}................3003
45 - PROPELLER SHAFT................3008
Propeller shaft; specifications................3009
Propeller shaft front; replacing................3011
Propeller shaft rear; replacing................3014
46 - FRONT AXLE; REAR AXLE................3017
Front axle; specification................3018
Front axle; description................3020
Front axle; removing_{24-09}................3022
Front axle; removing_{23-41}................3027
Front axle; installing_{22-57}................3032
Front axle; installing_{22-36}................3037
King pin and bushing; replacing................3040
Front axle with steerable mudguards................3041
Input shaft seal; replacing ................3044
Front axle knuckle_{20-23}................3047
Front axle knuckle_{20-02}................3050
Input shaft seal; replacing................3052
Rear axle; specifications................3053
Axle; removing................3054
Axle; installing................3057
49 - MISCELLANEOUS................3060
Tightening torque; specifications................3061
Swing ring gear; specifications................3062
Swing ring gear; description................3063
Swing ring; removing................3067
Swing ring; installing................3069
Swing ring gear inner seal; replacing................3071
Swing ring gear outer seal; replacing................3073
Measuring rotational clearance................3075
Swing ring; measuring axial clearance................3079
5 - BRAKE................3083
52 - HYDRAULIC BRAKE SYSTEM................3084
Brake system; component location................3085
Electrical digging brake; description_{11-21}................3088
Electrical digging brake; description_{11-00}................3092
Hydraulic brake system; description................3096
Brake system circuit pressure; checking and adjusting................3102
Brake system; bleeding................3108
Service brakes function; checking................3110
Foot brake valve; replacing................3112
Foot brake valve; description................3117
Foot brake valve; overhaul................3120
Brake accumulator; specifications................3123
Brake accumulator; description................3125
Accumulator (removed) charging pressure; checking................3127
Accumulator; removing................3128
Accumulator; installing................3130
Brake accumulator charging pressure; adjusting................3132
Hydraulic oil filter; replacing ................3136
55 - PARKING BRAKE................3138
Parking brake; description................3139
Parking brake; manually releasing................3145
Parking brake function; checking................3148
6 - STEERING................3150
60 - GENERAL................3151
Steering system function; checking................3152
64 - STEERING................3154
Steering system; description_{58-29}................3155
Steering system; description_{58-03}................3160
Steering system; component location................3165
Steering control unit; removing_{56-06}................3167
Steering control unit; removing_{55-45}................3170
Steering control unit; installing_{55-08}................3173
Steering control unit; installing_{54-45}................3178
Control valve (steering unit); description_{54-11}................3183
Control valve (steering unit); description_{53-49}................3189
Steering system working pressure; checking and adjusting_{53-19}................3193
Steering system working pressure; checking and adjusting_{52-58}................3198
Steering valve; removing................3202
Steering valve; installing................3205
Hydraulic oil filter; replacing................3207
66 - LEVEL STEERING................3209
Comfort Drive Control (CDC); description................3210
Lever steering (CDC); specifications................3220
Comfort Drive Control (CDC); component location................3222
Comfort drive control (CDC) angle sensor; changing................3226
Comfort Drive Control (CDC) control valve; removing................3229
Comfort drive control (CDC) control valve; installing................3232
CDC control valve; checking and adjusting................3235
Lever steering (CDC) function; checking................3238
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT................3240
71 - FRAME................3241
Superstructure; removing................3242
Superstructure; installing................3247
Counterweight; specifications_{44-07}................3251
Counterweight; specifications_{43-47}................3253
Counterweight; removing_{42-30}................3255
Counterweight; removing_{42-09}................3259
Counterweight; installing_{41-39}................3263
Counterweight; installing_{41-18}................3267
Undercarriage; specifications................3271
Undercarriage; description................3273
Undercarriage; tightening torque................3275
Step; removing_{39-08}................3277
Step; removing_{38-47}................3279
Step; installing_{38-17}................3281
Step; installing_{37-56}................3284
76 - SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL _ SIDE CONTROL................3286
Pivot axle lock cylinder; specifications................3287
Pivot axle lock cylinder; description................3289
Pivot axle lock cylinder; removing................3297
Pivot axle lock cylinder; installing................3299
Pivot axle lock cylinder; releasing for towing................3301
Pivot axle lock cylinder seals; changing................3304
Pivot axle lock; function check................3308
77 - WHEELS; TRACKS; TYRE; HUB; DRUM................3310
Wheels; specifications................3311
Wheel; removing................3313
Wheel; installing................3315
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE................3317
80 - GENERAL................3318
Tech Tool; operations ................3319
81 - CAB; NAKED; CANOPY................3320
Cab; weight................3321
Cab; removing................3322
Cab; installing................3331
Cabin; tightening torques................3339
82 - ENGINE HOOD; MUDGUARD; FOOT STEP................3342
Engine hood; replacing................3343
83 - DOORS; HATCH; COVER PLATE; (all)................3345
Door; replacing................3346
Front cover; replacing................3349
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING................3353
Windows; general................3354
Windscreen; replacing................3355
Side window; replacing................3368
Rear window; replacing................3374
Door window; replacing................3379
Cab roof window; replacing................3381
85 - CAB INTERIOR; UPHOLSTERY................3384
Seat heater pad; replacing................3385
Seat; replacing................3392
Seat cushion; replacing................3401
Seat support; replacing................3406
Longitudinal adjustment cable; replacing................3412
Longitudinal suspension cable; replacing................3418
Backrest; replacing................3422
Seat belt; replacing................3426
87 - AIR CONDITIONING UNIT................3429
Driver's seat; description_{17-20}................3431
Driver's seat; description_{16-59}................3434
Driver's seat; specifications_{16-24}................3437
Driver's seat; specifications_{16-06}................3438
Seat heater; checking................3439
HVAC system................3442
CCM pre-programmed ECU; replacing................3445
CCM non-programmed ECU; replacing................3448
Air distribution; description................3451
Cab filter; replacing................3453
Heating system; description................3454
Fan motor; replacing................3456
Heater core; replacing................3462
Air conditioning; description................3468
Air conditioning; specifications................3474
Air conditioning unit; maintenance................3475
Air conditioning unit; refrigerant check and recharging................3477
Air conditioning; component location................3484
Air conditioning; tightening torques................3486
Cooling unit; leak detection................3488
Cooler and Heater assembly; replacing................3490
Compressor; replacing incl draining and filling................3497
Receiver; replacing incl draining and filling................3502
Condenser; replacing incl draining and filling................3505
Evaporator; replacing incl draining and filling................3508
Expansion valve; replacing incl draining and filling................3516
Vent actuator; replacing................3523
Mode (foot) actuator; replacing................3525
Intake actuator; replacing................3527
Air mix door actuator; replacing................3529
Refrigerant; draining................3532
Refrigerant; filling incl vacuum pumping................3534
Troubleshooting; air conditioning unit (AC)................3537
Auxiliary heater; specifications_{58-34}................3541
Auxiliary heater; specifications_{58-14}................3544
Auxiliary heater; specifications_{57-53}................3548
Auxiliary heater; specifications_{57-32}................3552
Auxiliary heater; description_{57-04}................3553
Auxiliary heater; description_{56-43}................3558
Auxiliary heater; description_{56-23}................3563
Auxiliary heater; principles................3567
Troubleshooting (5kw)_{55-26}................3570
Troubleshooting (5kw)_{54-47}................3580
Troubleshooting (5kw)_{54-01}................3589
Instrument panel (left); replacing_{52-41}................3593
Instrument panel (left); replacing_{52-21}................3596
Instrument panel (right); replacing_{51-51}................3598
Instrument panel (right); replacing_{51-31}................3601
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS................3604
90 - GENERAL................3605
Hydraulic diagram; X003 - Image B................3608
Page 1................3608
Hydraulic diagram; X003 - Image A................3609
Page 1................3609
Hydraulic diagram; X001 with pressure control - Image B................3610
Page 1................3610
Hydraulic diagram; X001 with pressure control - Image A................3611
Page 1................3611
Hydraulic diagram; with reversible cooling fan - Image b................3612
Page 1................3612
Hydraulic diagram; with reversible cooling fan - Image A................3613
Page 1................3613
Hydraulic diagram; travel (low speed) - Image B................3614
Page 1................3614
Hydraulic diagram; travel (low speed) - Image A................3615
Page 1................3615
Hydraulic diagram; steering with CDC - Image................3616
Page 1................3616
Hydraulic diagram; single acting trailer hydraulic - Image 002................3617
Page 1................3617
Hydraulic diagram; single acting trailer hydraulic - Image 001................3618
Page 1................3618
Hydraulic diagram; quick fit - Image 003................3619
Page 1................3619
Hydraulic diagram; quick fit - Image 002................3620
Page 1................3620
Hydraulic diagram; quick fit - Image 001................3621
Page 1................3621
Hydraulic diagram; joystick controlled support - Image................3622
Page 1................3622
Hydraulic diagram; grapple bucket changeover - Image................3623
Page 1................3623
Hydraulic diagram; grab piping - Image B................3624
Page 1................3624
Hydraulic diagram; grab piping - Image A................3625
Page 1................3625
Hydraulic diagram; four outriggers - Image................3626
Page 1................3626
Hydraulic diagram; dozer blade - Image................3627
Page 1................3627
Hydraulic diagram; dozer blade and outrigger - Image................3628
Page 1................3628
Hydraulic diagram; cruise control - Image B................3629
Page 1................3629
Hydraulic diagram; cruise control - Image A................3630
Page 1................3630
Hydraulic diagram; control pattern selector valve - Image................3631
Page 1................3631
Hydraulic diagram; complete - Image B................3632
Page 1................3632
Hydraulic diagram; complete - Image A................3633
Page 1................3633
Hydraulic diagram; Boom Suspension System - Image B................3634
Page 1................3634
Hydraulic diagram; Boom Suspension System - Image A................3635
Page 1................3635
Hydraulic diagram; boom float valve - Image B................3636
Page 1................3636
Hydraulic diagram; boom float valve - Image A................3637
Page 1................3637
Explanations to hydraulic diagram................3638
Hydraulic system; cleanliness when handling hydraulic components................3649
Hydraulic diagram; component list................3651
Hydraulic system; position of main components................3653
Hydraulic diagram; complete_{045-55}................3656
Hydraulic diagram; complete_{045-34}................3659
Hydraulic diagram; single acting trailer hydraulic................3662
Hydraulic diagram; with reversible cooling fan_{044-34}................3667
Hydraulic diagram; with reversible cooling fan_{044-14}................3670
Hydraulic diagram; travel (low speed)_{043-44}................3673
Hydraulic diagram; travel (low speed)_{043-23}................3676
Hydraulic diagram; steering with CDC................3679
Hydraulic diagram; boom float valve_{042-19}................3682
Hydraulic diagram; boom float valve_{041-58}................3685
Hydraulic diagram; Boom Suspension System_{041-28}................3688
Hydraulic diagram; Boom Suspension System_{041-08}................3691
Hydraulic diagram; joystick controlled support................3694
Hydraulic diagram; control pattern selector valve................3697
Hydraulic diagram; cruise control_{039-43}................3700
Hydraulic diagram; cruise control_{039-22}................3703
Hydraulic diagram; X001 with pressure control_{38-52}................3706
Hydraulic diagram; X001 with pressure control_{38-32}................3709
Hydraulic diagram; X003_{38-02}................3712
Hydraulic diagram; X003_{37-42}................3715
Hydraulic diagram; quick fit................3718
Hydraulic diagram; grapple bucket changeover................3725
Hydraulic diagram; grab piping_{036-04}................3728
Hydraulic diagram; grab piping_{035-44}................3731
Hydraulic diagram; dozer blade................3734
Hydraulic diagram; dozer blade and outrigger................3737
Hydraulic diagram; four outriggers................3740
Description; general................3743
Hydraulic oil; description................3744
Hydraulic system; repair of hydraulic components in workshop................3745
Hydraulic oil; storage and handling................3750
Hydraulic components; storing and transporting................3751
Vacuum pump; connection................3752
Vacuum pump; disconnection................3754
Hydraulic system; warming up................3756
Tech Tool; operations................3759
Measuring tools and techniques................3760
Hydraulic system; flushing................3765
91 - WORKING HYDRAULIC; SERVO HYDRAULICS................3766
Hydraulic system; bleeding04................3771
Hydraulic system; bleeding................3775
Hydraulic system; work instructions................3779
Hydraulic system; description................3780
Hydraulic pressure; specifications_{28-17}................3781
Hydraulic pressure; specifications_{27-56}................3787
Hydraulic oil; cleaning................3792
Changing the hydraulic oil................3794
Hydraulic oil cooling system; description................3797
Hydraulically driven cooling fan; description................3798
Hydraulic tank; specifications................3799
Hydraulic oil tank; description................3800
Hydraulic oil tank; releasing pressure................3802
Cooling fan speed; checking and adjusting................3803
Hydraulic oil cooler; removing................3804
Hydraulic oil cooler; installing................3805
Hydraulic oil tank; removing................3806
Hydraulic oil tank; installing................3809
Shock and anti-cavitation valve................3813
Shock and anti-cavitation valve; checking and adjusting................3816
Main control valve block; description................3819
Main control valve; removing_{20-53}................3832
Main control valve; removing_{20-32}................3837
Main control valve; installing_{19-58}................3842
Main control valve; installing_{19-37}................3847
Back-up valves................3852
Back-up valve; checking and adjusting................3855
Main control valve section................3861
Unload valve; checking and adjusting_{17-32}................3865
Unload valve; checking and adjusting_{17-12}................3868
Unload valve; replacing................3871
Shock and anti-cavitation valve; description................3872
Line rupture valve (boom); description................3875
Line rupture valve for dipper arm cylinder; description................3882
Line rupture valve for 2-piece boom cylinder X2; description................3886
Line rupture valve pressure; checking and adjusting................3887
Line rupture valve relief pressure (arm); adjusting................3892
Working pressure; checking and adjusting_{13-03}................3895
Working pressure; checking and adjusting_{12-37}................3904
Boom cylinder; rupture valve; replacing................3914
Dipper arm cylinder; rupture valve; replacing................3917
Rupture valve; replacing (2pcs boom tilt cylinder)................3920
LS-pressure relief valve; replacing................3923
Pressure relief valves; description................3926
Hydraulic pump; specifications_{09-54}................3929
Hydraulic pump; specifications_{09-34}................3931
Hydraulic pump; specifications_{09-08}................3933
Hydraulic pump; specifications_{08-48}................3935
Working pump; description_{08-18}................3937
Working pump; description_{07-54}................3944
Pump; removing_{07-23}................3949
Pump; removing_{07-03}................3952
Pump; installing_{06-33}................3955
Pump; installing_{06-13}................3958
Hydraulic pump (removed); changing shaft seal................3961
Hydraulic pump regulator; replacing_{05-14}................3964
Hydraulic pump regulator; replacing_{04-54}................3967
Accumulator removed; checking19................3970
Accumulator removed; checking................3972
Servo system; description_{03-24}................3974
Servo system; description_{03-04}................3977
Servo valve; removing................3980
Servo valve; installing................3982
Servo pump; removing................3984
Servo pump; installing................3986
Accumulator; description................3988
Servo accumulator; removing................3990
Servo accumulator; installing................3992
Discarded accumulators................3994
Servo pressure; checking and adjusting................3995
Control lockout lever; function check................3998
Servo Accumulator................4000
Accumulator precharge pressure; checking and adjusting................4001
Remote control valve (pedal); specifications................4003
Control levers; description................4005
Control lever; changing................4010
Adjustable boom; description................4016
Control pattern selector valve; description................4019
X1; description_{54-50}................4025
X1; description_{54-23}................4037
X1; description_{53-56}................4047
X1; Specifications_{53-24}................4055
X1; Specifications_{53-04}................4059
X1; Specifications_{52-44}................4063
Option X1 pressure control_{52-14}................4066
Option X1 pressure control_{51-53}................4071
Option X1 pressure control_{51-33}................4076
X1; function check................4081
X1 Pre-set relief valve; description................4083
X1 pressure relief valve; adjusting_{50-10}................4087
X1 pressure relief valve; adjusting_{49-50}................4092
X1 pressure relief valve; replacing................4095
X3; description_{48-53}................4098
X3; description_{48-28}................4107
X3; description_{48-03}................4115
X3; specifications................4121
X3; function check................4123
X3 pressure and flow; adjusting................4125
Boom float position; description_{46-26}................4129
Boom float position; description_{46-05}................4134
Float position valve; checking and adjusting_{45-36}................4138
Float position valve; checking and adjusting_{45-16}................4141
Float position valve; replacing................4144
Cruise control; specifications................4146
Cruise control; description_{43-03}................4148
Cruise control; description_{42-43}................4154
Reversible cooling fan; description................4160
Reversible cooling fan; checking and adjusting................4164
Grab bucket; description................4168
Tiltrotator; specifications_{40-53}................4172
Tiltrotator; specifications_{40-33}................4174
Tiltrotator display main menu_{40-06}................4176
Tiltrotator display main menu_{39-45}................4181
Tiltrotator control system; description_{39-14}................4194
Tiltrotator control system; description_{38-53}................4203
Boom Suspension System; description................4208
Boom Suspension System; specifications_{37-51}................4217
Boom Suspension System; specifications_{37-31}................4219
Boom suspension system; component location................4221
Boom suspension accumulator; checking and adjusting................4224
Boom suspension system; changing accumulator................4228
Boom suspension system; solenoid valve test................4232
Trailer towing solution (TTS)................4234
Single acting trailer hydraulic_{35-04}................4242
Single acting trailer hydraulic_{34-44}................4249
Grapple bucket changeover; description................4254
Joystick controlled support; description_{33-48}................4259
Joystick controlled support; description_{33-27}................4265
91603-3 Cruise Control................4271
91604-3 X1 Hydraulic Pressure_{32-35}................4273
91604-3 X1 Hydraulic Pressure_{32-15}................4275
91607-3 X1 Hydraulic Flow................4277
91618-3 Tiltrotator calibration................4279
91620-3 Boom suspension system; solenoid valve................4281
91623-3 X1 max hydraulic flow................4282
91624-3 X3 Hydraulic flow................4285
92 - MECHANICAL EQUIPMENT_ATTACHMENT................4287
Steelwrist quick coupler; specifications................4288
Standard quick coupler................4290
Universal quick coupler................4296
Steelwrist quick coupler................4302
Hydraulic quickfit cylinder; removing................4310
Hydraulic quickfit cylinder; installing................4314
Cylinder for hydraulic quickfit S1; removing................4317
Cylinder for hydraulic quickfit S1; installing................4319
Cylinder for hydraulic quickfit Universal; removing................4321
Cylinder for hydraulic quickfit Universal; installing................4324
Cylinder for hydraulic quickfit S6; removing................4327
Cylinder for hydraulic quickfit S6; installing................4330
Quickfit; replacing_{24-16}................4333
Quickfit; replacing_{23-56}................4336
Quickfit; function check................4340
Dozer blade cylinder check valve; replacing................4342
Dozer blade; description................4344
94 - UNIT; LOAD HANDLING................4348
Component location 3_{22-09}................4349
Component location_{21-49}................4353
97 - UNIT; DIGGING................4355
Digging unit; maintenance................4356
Cylinder; specifications................4359
Cylinder; description................4362
Digging equipment bearings; shimming................4365
Stabilisers and stabiliser blade; description................4368
Stabilisers; hydraulic cylinder; removing................4374
Stabilisers; hydraulic cylinder; installing................4378
Boom; specifications................4383
2-piece boom; removing................4384
2-piece boom; installing................4388
Dipper arm; removing................4392
Dipper arm; installing................4395
99 - MISCELLANEOUS................4397
Automatic lubrication system; specifications................4398
Automatic lubrication system; description................4400
Control unit; description................4409
Control units; software functions................4411
Maintenance service; general................4417
Automatic lubrication pump; removing................4420
Automatic lubrication pump; installing................4422
Troubleshooting................4428
Bleeding air................4430
Volvo EW180E Excavators Repair Service Manual
