Volvo EW180C Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EW180C Wheeled Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions EW180C 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 EW180C Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,376 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
Product plates........5
Component locations-........6
Description; complete machine........8
03 - SPECIFICATIONS........9
Hydraulic oil cooling system; specifications........13
Cylinder data........16
Digging equipment bearings; specifications........17
Servo pump; specifications........19
Working pump; specifications........20
Hydraulic tank; specifications........21
Cruise control; specifications........22
X1; Specifications........23
Hydraulic pressure; specifications_{11-33}........27
Hydraulic pressure; specifications_{11-53}........29
Hydraulic pressure; specifications_{12-13}........31
Control valve (steering unit); specification........35
Steering pump; specifications........36
Brake pump; specifications........37
Automatic lubrication system; specifications........38
Diesel coolant heater (5kw); specifications........40
Air conditioning unit; specifications........42
Cab; weight........43
Cab; specifications........45
Wheels; specifications........48
Travel gearbox; specifications........49
Rear view camera; specifications........50
Slew position sensor; specfications-17........51
Slew unit; specifications........52
Auto idle pressure switch; specifications-00........53
Hydraulic oil filter pressure switch; specifications-23........54
Flasher relay; specifications-46........55
Power outlet; specifications-09........56
Electric center passage; specification-41........57
Stabiliser solenoid valve; specifications_{20-08}........58
Stabiliser solenoid valve; specifications_{20-28}........59
Control lockout solenoid valve; specifications-53........60
Manual travel control switch; specifications-17........61
Control levers; specifications-19........62
Multi-function lever switch; specifications-43........69
Battery disconnect switch; specifications-06........70
Lower wiper motor; specifications-30........71
Lighting; specifications........72
Preheating; specifications-11........73
Battery; specifications-48........74
Vehicle control unit V-ECU; specifications-28........75
Instrument control unit I-ECU; specifications-09........80
Engine control; specifications-32........82
Fuel filler pump; specifications-55........83
Air cleaner; specification-23........84
Air cleaner; specification-47........85
Engine; volume-09........86
Counterweight; specifications_{29-41}........87
Counterweight; specifications_{30-01}........88
Steering axle; specifications........89
Slew ring gear; specifications........90
Rear axle; specification_{31-08}........91
Rear axle; specifications_{31-28}........92
Front axle; specification_{32-02}........93
Front axle; specification_{32-21}........94
Propeller shaft; specifications........95
Centre passage; specification........96
Travel motor; specifications........97
Radio with tape or CD player; specifications........99
Specifications; weight_{43-53}........102
Specifications; weight_{44-13}........103
Capacities........104
Audio remote controller; specifications_{45-15}........105
Audio remote controller; specifications_{45-34}........107
Hour counter; specifications-01........110
Circuit breaker; specification-29........112
Relay; specifications-02........114
Auto_Manual pump control switch; specifications-25........116
Emergency engine speed control switch; specifications_{47-52}........117
Emergency engine speed control switch; specifications_{48-12}........119
Control lockout lever switch; specifications-39........120
Start switch; specifications-02........122
Windscreen flusher pump; specifications-30........124
Wiper controller; specifications-58........126
Travel alarm; specifications-22........128
Rotating beacon; specifications-46........130
Electric horn; specifications-09........131
Starter motor; specifications-33........133
Alternator; specifications-56........134
Keypad; specification-37........136
Wireless control unit W-ECU; specification_{53-17}........139
Wireless control unit W-ECU; specification_{53-38}........141
Wireless control unit W-ECU; specification_{54-07}........142
Electronic climate control unit ECC; specification-50........144
Engine control unit E-ECU; specifications-32........146
Electrical system; specifications-56........148
Engine speed control switch; specifications-20........150
Coolant pump; thermostat; specifications-43........151
Cooling system; specifications-06........153
Injectors; specifications-30........154
Fuel tank; specification-54........155
Fuel pressure; specifications-18........156
Lubrication system; specifications ........158
Flywheel; weight ........159
Valve system specifications ........161
Engine; weights-........163
Engine; specifications_{00-21}........164
Engine; specifications_{00-41}........165
Conversion tables........166
Tightening torques........174
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION........180
Lifting instructions........181
07 - STANDARD TIME........183
Operation numbers for additional work........184
08 - TOOL........186
Infrared Thermometer........187
E-tool; 3507 Plug........189
E-tool; 3506 Flange........190
E-tool; 3502 Plate for turning crankshaft........191
E-tool; 3501 Puller for gear wheel fan pump........193
E-tool; 3500 Support plate for travel gearbox and motor........194
E-tool; 1802 Extractor for pressure limiting valve........196
09 - MISCELLANEOUS........197
Control units; changing........198
Hydraulic cylinders; dieseling........200
Welding on the machine........202
Service positions-........205
1 - STANDARD PARTS; SERVICE........208
16 - LUBRICANT; FUEL; OTHER FLUID........209
Coolant with freezing and corrosion protection........210
Recommended lubricants_{54-23}........211
Recommended lubricants_{53-32}........214
Coolant........217
Alternative fuels........222
17 - SERVICE........225
Bearings........229
Elimination of trapped hydraulic pressure........233
Replacement parts........235
Service_{50-00}........239
Service_{49-42}........240
Service methods........241
Pressure testing........245
Hoses and tubes........249
Cleaning prior to repair........253
Arrival Inspection; according to Inspection Programme........254
Delivery Inspection; according to Inspection Programme........259
Maintenance of Stored Machines; according to Inspection Programme........261
Warranty inspection 100 hours........263
Warranty inspection 1000 hours........264
Periodic maintenance........265
Maintenance service; daily_{44-52}........267
Maintenance service; daily_{44-33}........268
Maintenance service; every 50 hours_{44-04}........269
Maintenance service; every 50 hours_{43-44}........270
Maintenance service; first 100 hours........271
Maintenance service; every 250 hours_{42-52}........272
Maintenance service; every 250 hours_{42-33}........273
Maintenance service; first 500 hours_{42-05}........274
Maintenance service; first 500 hours_{41-45}........275
Maintenance service; every 500 hours_{41-17}........276
Maintenance service; every 500 hours_{40-58}........278
Maintenance service; first 1000 hours........279
Maintenance service; every 1000 hours_{40-02}........280
Maintenance service; every 1000 hours_{39-42}........282
Maintenance service; every 2000 hours_{39-14}........283
Maintenance service; every 2000 hours_{38-55}........285
Maintenance service; every 4000 hours_{38-26}........286
Maintenance service; every 4000 hours_{38-07}........288
Maintenance service; every 6000 hours_{37-37}........289
Maintenance service; every 6000 hours_{37-19}........290
Tyres; wear and air pressure; checking........291
Checking for cracks and leaks........293
Check engine oil level........294
Test-run and check........295
Lubrication........296
Grease points on dipper arm; lubrication........297
Grease points on booms; lubrication........300
Grease points on undercarriage; lubrication_{33-01}........302
Grease points on undercarriage; lubrication_{32-33}........304
Grease points on superstructure; lubrication_{31-43}........306
Grease points on superstructure; lubrication_{31-17}........308
Grease points on superstructure; lubrication_{30-52}........309
Hydraulic system; checking oil level........310
Water separator; drain........312
Coolant level; check........314
Axles; checking oil level_{28-18}........315
Axles; checking oil level_{27-25}........318
Axle hubs; checking oil level........320
Travel gearbox oil level; checking_{26-13}........322
Travel gearbox oil level; checking_{25-36}........324
Fuel tank water and sediment; drain-01........326
Fuel tank water and sediment; drain........328
Battery condition; check_{23-27}........330
Battery condition; check_{22-49}........333
Door hinges; lubricate with grease........336
Cab; prefilter; clean........338
Axles; changing oil_{20-18}........340
Axles; changing oil_{19-31}........344
Hub reduction gear; changing oil........346
Engine; oil and filter; change.........348
Fuel filters; primary and secondary filter; replace_{16-36}........351
Fuel filters; primary and secondary filter; replace_{16-12}........353
Radiator and coolers; cleaning........355
Condenser; clean (with compressed air) (optional equipment)........358
Cab; main filter; clean........360
Belts and belt tension; check; replace when needed.........362
Swing ring gear; grease check........365
Swing gearbox oil level; checking........367
Swing gearbox oil; changing........369
Service journal (included in Operator's manual); fill in........371
Wheel nuts; check torque........372
Brake system; checking function........373
Air cleaner primary filter; change........374
Air conditioning unit; maintenance........377
MATRIS; reading; export reading........378
VCADS Pro; logged errors; read off........380
Swing bath grease; check........382
Travel gearbox; changing oil........385
Brake discs; checking wear_{03-02}........387
Brake discs; checking wear_{02-32}........390
Air cleaner secondary filter; change-58........393
Air cleaner secondary filter; change........395
Cab; prefilter; replace........397
Cab main filter; replacing........399
Fuel tank breather filter; replacing........401
Hydraulic oil return filter; changing_{58-29}........403
Hydraulic oil return filter; changing_{58-03}........405
Hydraulic tank breather filter; changing........407
Hydraulic oil servo filter; change_{56-35}........409
Hydraulic oil servo filter; change_{55-50}........413
Hydraulic oil drain filter; change........415
Coolant's freezing point; check........417
Valve clearance and IEGR; check........419
Hydraulic system; changing oil........420
Hydraulic oil suction strainer; change........424
Turbocharger inclusive inlet and exhaust systems; leakage; check........427
Coolant; change........429
CareTrack backup battery; replacing........433
Creeping of hydraulic cylinder-07........436
Creeping of hydraulic cylinder........440
Emergency operation; description-36........444
Emergency operation; description-44........447
Emergency operation; description........450
Towing........453
Secondary lowering of digging equipment_{42-44}........455
Secondary lowering of digging equipment_{42-11}........457
Starting engine with booster cables........459
19 - GENERAL........461
Safety concerns everybody!........462
Service positions........464
CE marking and declaration of conformity........467
Safety when handling the machine........469
Safety rules when servicing........473
Checklist after a fire or heat exposure-059........475
Fire prevention measures........476
Health hazards with paint; plastics and rubber........479
Checklist after a fire or heat exposure........484
Some simple rules regarding tyre handling........488
Safety when using lifting equipment........490
Safety when handling oils and fuel........494
Safety when working with batteries........498
Starting with booster batteries........503
Safety when working with air conditioning refrigerant........507
Safety when working with hydraulic systems........512
Environmental handling for the future........514
Environmentally safe handling........518
Environmentally hazardous fluids........521
Working in environmentally contaminated areas........525
Decontamination........529
Waste handling........533
2 - ENGINE WITH MOUNTING AND EQUIPMENT........537
20 - GENERAL........538
Engine; description........539
E-ECU MID 128 pre-programmed; replacing_{25-46}........541
E-ECU MID 128 pre-programmed; replacing_{25-26}........543
E-ECU MID 128 non-programmed; replacing_{24-51}........545
E-ECU MID 128 non-programmed; replacing_{24-30}........548
Engine; identification........550
Engine; volume........551
Engine; tightening torques........552
Component locations........555
Engine; weights ........557
21 - ENGINE........558
Engine; specifications_{020-44}........560
Engine; specifications_{020-25}........561
Cylinder compression; PC test........562
Engine characteristic curve........563
Basic check; Engine........565
Troubleshooting........567
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope........570
Engine and transmission; installing........576
Engine; weights........586
Cylinder head; description........587
Cylinder head gasket; description........589
Cylinder; description........591
Pistons; description........593
Piston rings; description........595
Piston cooling........597
Valve system specifications........599
Valves; description........602
Internal Exhaust Gas Recirculation (IEGR); description........604
Valves; adjusting........610
Engine timing gear; description........623
Camshaft; description........626
Timing gear case new gasket; installing........629
Flywheel; weight........646
Crankshaft; description........648
Vibration damper; description........651
Connecting rod; description........654
Crankshaft front oil seal; replacing........657
Crankshaft rear oil seal; replacing........666
Oil sump; description........677
Oil sump; replacing........679
Oil level sensor; replacing........684
Engine mounting........688
Engine mount front; replacing........691
Engine mounting rear; changing........695
22 - LUBRICATING SYSTEM........698
Lubricating system; description........699
Lubrication system; specifications........703
Lubrication system; principle of operation........704
Oil pump; replacing........708
Lubrication oil pressure; checking with pressure gauge........720
Oil cooler; replacing-........722
Oil cooler; replacing........725
Oil cooler; description........728
23 - FUEL SYSTEM........729
Fuel system; description........731
Fuel pressure; specifications........733
Instructions for working with electronic fuel injection........735
Fuel pressure; checking........736
Fuel feed pump; description ........739
Fuel feed pump; description........740
Fuel filter; description........741
Feed pump pressure; checking........742
Fuel filter; checking........746
Fuel system; bleeding_{042-29}........748
Fuel system; bleeding_{042-08}........750
Feed pump; replacing........752
Fuel filters; replacing........755
Fuel filter extra; replacing_{040-45}........757
Fuel filter extra; replacing_{040-25}........759
Fuel tank; specification........761
Fuel filler pump; specifications........762
Fuel tank; description........763
Fuel tank; replacing_{038-16}........765
Fuel tank; replacing_{037-04}........772
Air cleaner; specification-........775
Fuel filler pump; description........776
Fuel filling pump; removing_{045-04}........778
Fuel filling pump; removing_{044-42}........781
Fuel filling pump; installing........784
Fuel return pressure; checking........786
Injectors; description........788
Injectors; specifications........792
Injectors; replacing........793
High pressure fuel pump; checking........795
Fuel rail; description........799
Fuel rail; replacing........801
Fuel rail pressure; checking........806
Fuel rail pressure sensor; replacing........810
High pressure fuel pump; replacing........812
Fuel control valve (FCV); description........820
Fuel control valve (FCV); checking........822
Fuel control valve (FCV); replacing........826
Pressure relief valve (PRV); inspecting........829
Pressure relief valve (PRV); replacing........833
25 - INLET & EXHAUST SYSTEM........836
Inlet system; description........837
Exhaust system; description........838
Induction manifold gasket; replacing........839
Exhaust manifold gasket; replacing........842
Silencer; replacing........847
Exhaust pipe flexible tube; replacing........851
Turbocharger; description........853
Turbocharger; inspecting........856
Turbocharger; replacing........860
Air cleaner; description........864
Air cleaner; specification........865
Preheating coil; replacing........866
Charge air cooler; specifications........868
Charge air cooler; description........869
Charge air cooler; replacing........871
26 - COOLING SYSTEM........876
Cooling system; description........877
Cooling system; specifications........879
Coolant anti-freeze resistance; checking........880
Radiator; replacing........882
Radiator hose upper; replacing........888
Radiator hoses lower; replacing........892
Expansion tank; replacing........896
Coolant pump; thermostat; specifications........899
Coolant pump; replacing........901
Thermostat; inspecting........906
Thermostat; replacing........909
Fan belt and_or alternator belt; replacing........912
Fan belt and_or alternator-; compressor belt; replacing all belts........915
27 - ENGINE CONTROL........918
Engine control; specifications........919
Engine speed control switch; specifications........920
Engine speed control switch; description ........921
Engine speed control; function checking........922
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS........923
30 - GENERAL........924
Electrical system; special instructions for servicing; general........930
Electrical system; special instructions for servicing; electronic components........933
Electrical system; special instructions for servicing; electrical components; batteries........935
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator........937
Electrical system; special instructions for servicing; action when working on machine........939
Electrical system; description........941
Electronic control system; description........943
Communication with data buses........946
Auxiliary start........949
Data buses; function........952
Service connection and programming connection........958
Data links; fault tracing with Oscilloscope........961
Electrical system; specifications........971
Power Boost control; description........973
Engine Protection........975
Start lock; description_{002-34}........977
Start lock; description_{002-15}........979
Power OFF........980
Quick fit control; description........981
Boom float position; description........982
Limp Home........984
Auto idle device; setting instructions........985
Parking brake; description........986
Control lockout system; description........987
Forward _ Reverse _ Neutral........988
Main pump pressure; checking and adjusting........989
Axle lock........990
Overload warning........992
VCADS Pro; parameter programming........994
Software parameters; description........996
Troubleshooting strategy-007........1005
Troubleshooting strategy........1007
Troubleshooting; general........1010
Collection of basic data........1013
Error code information; general........1015
Electrical cables and connectors; checking........1018
Troubleshooting tools........1024
Special tools for troubleshooting........1025
VCADS Pro service tool........1027
VCADS Pro; Operations........1032
Connecting special tools........1034
999 8699 Multi-pin breaker box........1038
999 0014 Adapter cable........1039
999 0025 Adapter cable........1042
999 0062 Extension cable........1044
8883 0028 Adapter cable........1045
88890040 Oscilloscope for VCADS Pro........1047
999 3893 Adapter cable........1048
999 3894 Template........1050
011 666 140 Multimeter........1051
Measuring; general........1052
Measuring symbols; description........1054
Component descriptions........1058
Component troubleshooting; structure; description........1062
Component troubleshooting; checking wiring harness and input_output on ECU........1064
Component troubleshooting; checking component........1067
Component troubleshooting; checking subsystem (circuit)........1070
AL3201; description and measuring........1073
BA3101; description and measuring........1075
CU9901; description and measuring........1077
FU006; description and measuring........1079
FU018; description and measuring........1080
FU026; description and measuring........1081
HE2501; description and measuring........1082
MA2301–MA2306; description and measuring........1084
MA2602; description and measuring........1086
MA2504; description and measuring........1088
MA4214; description and measuring........1090
MA4218; description and measuring........1092
MA4219; description and measuring........1094
MA4302; description and measuring........1096
MA4303; description and measuring........1098
MA5205; description and measuring........1100
MA9103; description and measuring........1102
MA9104; description and measuring........1104
MA9107; description and measuring........1106
MA9109; description and measuring........1108
MA9120; description and measuring........1110
MA9152; description and measuring........1112
MA9164; description and measuring........1114
MA9165; description and measuring........1116
MA9615; description and measuring........1118
MID 128 SID 230; description and measuring........1120
MID 140 PPID 1144; description and measuring........1121
MO3301; description and measuring........1122
PPID1336; description and measuring........1124
PWM2303; description and measuring........1126
PWM4211; description and measuring........1128
PWM6603; description and measuring........1130
PWM9101; description and measuring........1131
PWM9103; description and measuring........1133
PWM9104; description and measuring........1135
PWM9105; description and measuring........1136
PWM9106; description and measuring........1138
PWM9109; description and measuring........1140
PWM9129; description and measuring........1142
RE2501; description and measuring........1144
RExxxx; Relays general; description and measuring........1146
SAE J1708_1587 information link; description and measuring........1148
SAE J1939_CAN control link; description and measuring........1151
SE2202; description and measuring........1154
SE2203; description and measuring........1156
SE2205; description and measuring........1158
SE2301; description and measuring........1160
SE2302; description and measuring........1162
SE2303; description and measuring........1164
SE4217; description and measuring-18........1166
SE2309; description and measuring........1168
SE2501; description and measuring........1170
SE2502; description and measuring........1172
SE2507; description and measuring........1174
SE2508; description and measuring........1176
SE2510; description and measuring........1178
SE2511; description and measuring........1180
SE2603; description and measuring........1182
SE2606; description and measuring_{07-59}........1184
SE2606; description and measuring_{07-17}........1186
SE2701; description and measuring........1188
SE2703; description and measuring........1190
SE2707; description and measuring........1192
SE4213; description and measuring........1194
SE4217; description and measuring........1196
SE4218; description and measuring........1198
SE5201; description and measuring........1200
SE5205; description and measuring........1202
SE8701; description and measuring........1204
SE8702; description and measuring........1206
SE8705; description and measuring........1208
SE8706; description and measuring........1210
SE9101; description and measuring........1212
SE9105; description and measuring........1214
SE9106; description and measuring........1216
SE9401; description and measuring........1218
SID211; description and measuring........1220
SID232; description and measuring........1221
SW2701; description and measuring........1222
SW3301; description and measuring........1224
SW3611; description and measuring........1226
SW4202; description and measuring........1228
SW4205; description and measuring........1230
SW9160; description and measuring........1232
SW9161; description and measuring........1234
SW9162; description and measuring........1236
Error codes; build-up........1238
Error code information; description........1243
E-ECU (MID128) Engine control unit; active measuring conditions........1245
E-ECU (MID128) Engine control unit; passive measuring conditions........1249
I-ECU (MID140) Instrument control unit; active measuring conditions........1253
I-ECU (MID140) Instrument control unit; passive measuring conditions........1255
W-ECU (MID142) Wireless control unit; active measuring conditions........1257
W-ECU (MID142) Wireless control unit; passive measuring conditions........1259
Care Track can not communicate with the machine........1261
ECC (MID146) Electronic climate control unit; active measuring conditions........1263
ECC (MID146) Electronic climate control unit; passive measuring conditions........1266
V-ECU (MID187) Vehicle control unit; active measuring conditions........1269
V-ECU (MID 187) Vehicle control unit; passive measuring; conditions........1274
31 - BATTERY........1279
Battery; storage........1280
Battery; description........1283
Battery; specifications........1285
Battery; charging........1286
Batteries; replacing_{029-03}........1288
Batteries; replacing_{028-42}........1293
32 - ALTERNATOR; CHARGE REGULATOR........1296
Charging; description........1297
Alternator; specifications-032........1299
Alternator; specifications........1300
Alternator; description........1302
Alternator; replacing incl function checking........1304
Alternator; testing........1308
33 - STARTING SYSTEM........1310
Starting operation........1311
Starter switch (engine start switch); replacing........1313
Starter motor; description........1315
Starter motor; specifications........1316
Starter motor; testing........1317
Starter relay; replacing_{022-59}........1319
Starter relay; replacing_{022-39}........1321
Starter motor; replacing........1323
Preheating; description........1325
Preheating; specifications........1326
35 - LIGHTING........1327
Lighting; specifications_{020-12}........1328
Lighting; specifications_{019-54}........1329
Headlights; adjusting........1330
Rotating beacon; specifications........1332
Rotating beacon; replacing-........1333
36 - OTHER ELECTRICAL EQUIPMENT........1335
Electric horn; description........1338
Electric horn; specifications........1340
Horn; replacing_{015-52}........1342
Horn; replacing_{015-31}........1345
Rotating beacon; description........1347
Rotating beacon; replacing........1349
Travel alarm; description........1351
Travel alarm; specifications........1353
Travel alarm; replacing........1355
Windscreen wiper; description........1357
Wiper controller; description........1359
Wiper controller; specifications........1361
Windscreen wiper controller; replacing_{010-51}........1363
Windscreen wiper controller; replacing_{010-30}........1365
Upper wiper motor; description........1367
Upper wiper motor; specifications........1369
Windscreen wiper front motor; replacing........1371
Windscreen wiper switch; replacing........1374
Windscreen flusher pump; replacing_{008-30}........1376
Windscreen flusher pump; replacing_{008-10}........1378
Lower wiper motor; description........1380
Lower wiper motor; specifications........1382
Windscreen flusher pump; specifications........1383
Windscreen wiper; components location........1385
Window limit switch; description........1387
Connectors; overview........1389
Switch; replacing........1403
Battery disconnect switch; description........1406
Battery disconnect switch; specifications........1408
Start switch; description........1409
Start switch; specifications........1412
Engine speed control switch; description........1414
Emergency engine speed control switch; description........1415
Emergency engine speed control switch; specifications_{001-10}........1417
Emergency engine speed control switch; specifications_{000-52}........1418
Multi-function lever switch; description........1420
Multi-function lever switch; specifications........1422
Control levers; specifications........1423
Manual travel control switch; description........1430
Manual travel control switch; specifications........1431
Auto_Manual pump control switch; description........1432
Auto_Manual pump control switch; specifications........1433
Control lockout solenoid valve; specifications........1434
Stabiliser solenoid valve; specifications_{057-29}........1435
Stabiliser solenoid valve; specifications_{057-11}........1436
Electric center passage; specification-046........1437
Electric center passage; specification........1438
Electric center passage; description_{056-10}........1439
Electric center passage; description_{055-49}........1441
Power outlet; specifications........1443
Electric center passage; replacing........1444
Electronic climate control unit ECC; description........1447
Engine control unit E-ECU; function description_{053-56}........1449
Engine control unit E-ECU; function description_{053-35}........1451
Instrument control unit I-ECU; functional description........1453
Vehicle control unit V-ECU; functional description........1455
Electronic climate control unit ECC; specification........1457
Engine control unit E-ECU; specifications........1459
Instrument control unit I-ECU; specifications........1461
Vehicle control unit V-ECU; specifications........1463
Control units changing; precaution........1468
I-ECU MID 140 non-programmed; replacing........1469
I-ECU MID 140 pre-programmed; replacing........1471
V-ECU MID 187 non-programmed; replacing........1473
V-ECU MID 187 pre-programmed; replacing........1477
ECC (Electronic Climate Control); replacing........1481
37 - CABLE; FUSE; RELAY........1484
Wiring diagram SCH25 - Image 2........1490
Page 1........1490
Wiring diagram SCH25 - Image 1........1491
Page 1........1491
Wiring diagram SCH24 - Image 2........1492
Page 1........1492
Wiring diagram SCH24 - Image 1........1493
Page 1........1493
Wiring diagram SCH22 - Image B1........1494
Page 1........1494
Wiring diagram SCH22 - Image A1........1495
Page 1........1495
Wiring diagram SCH21 - Image 2........1496
Page 1........1496
Wiring diagram SCH21 - Image 1........1497
Page 1........1497
Wiring diagram SCH20 - Image 2........1498
Page 1........1498
Wiring diagram SCH20 - Image 1........1499
Page 1........1499
Wiring diagram SCH19 - Image B1........1500
Page 1........1500
Wiring diagram SCH19 - Image A1........1501
Page 1........1501
Wiring diagram SCH18 - Image 2........1502
Page 1........1502
Wiring diagram SCH18 - Image 1........1503
Page 1........1503
Wiring diagram SCH17 - Image 2........1504
Page 1........1504
Wiring diagram SCH17 - Image 1........1505
Page 1........1505
Wiring diagram SCH16 - Image B2........1506
Page 1........1506
Wiring diagram SCH16 - Image B1........1507
Page 1........1507
Wiring diagram SCH16 - Image A2........1508
Page 1........1508
Wiring diagram SCH16 - Image A1........1509
Page 1........1509
Wiring diagram SCH15 - Image 2........1510
Page 1........1510
Wiring diagram SCH15 - Image 1........1511
Page 1........1511
Wiring diagram SCH14 - Image C3........1512
Page 1........1512
Wiring diagram SCH14 - Image B2........1513
Page 1........1513
Wiring diagram SCH14 - Image A2........1514
Page 1........1514
Wiring diagram SCH13 - Image B2........1515
Page 1........1515
Wiring diagram SCH13 - Image B1........1516
Page 1........1516
Wiring diagram SCH13 - Image A2........1517
Page 1........1517
Wiring diagram SCH13 - Image A1........1518
Page 1........1518
Wiring diagram SCH12 - Image B2........1519
Page 1........1519
Wiring diagram SCH12 - Image B1........1520
Page 1........1520
Wiring diagram SCH12 - Image A2........1521
Page 1........1521
Wiring diagram SCH12 - Image A1........1522
Page 1........1522
Wiring diagram SCH11 - Image B2........1523
Page 1........1523
Wiring diagram SCH11 - Image B1........1524
Page 1........1524
Wiring diagram SCH11 - Image A2........1525
Page 1........1525
Wiring diagram SCH11 - Image A1........1526
Page 1........1526
Wiring diagram SCH10 - Image B2........1527
Page 1........1527
Wiring diagram SCH10 - Image B1........1528
Page 1........1528
Wiring diagram SCH10 - Image A2........1529
Page 1........1529
Wiring diagram SCH10 - Image A1........1530
Page 1........1530
Wiring diagram SCH09 - Image B2........1531
Page 1........1531
Wiring diagram SCH09 - Image B1........1532
Page 1........1532
Wiring diagram SCH09 - Image A2........1533
Page 1........1533
Wiring diagram SCH09 - Image A1........1534
Page 1........1534
Wiring diagram SCH08 - Image B2........1535
Page 1........1535
Wiring diagram SCH08 - Image B1........1536
Page 1........1536
Wiring diagram SCH08 - Image A2........1537
Page 1........1537
Wiring diagram SCH08 - Image A1........1538
Page 1........1538
Wiring diagram SCH07 - Image B2........1539
Page 1........1539
Wiring diagram SCH07 - Image B1........1540
Page 1........1540
Wiring diagram SCH07 - Image A2........1541
Page 1........1541
Wiring diagram SCH07 - Image A1........1542
Page 1........1542
Wiring diagram SCH06 - Image B2........1543
Page 1........1543
Wiring diagram SCH06 - Image B1........1544
Page 1........1544
Wiring diagram SCH06 - Image A2........1545
Page 1........1545
Wiring diagram SCH06 - Image A1........1546
Page 1........1546
Wiring diagram SCH05 - Image B1........1547
Page 1........1547
Wiring diagram SCH05 - Image A1........1548
Page 1........1548
Wiring diagram SCH04 - Image B........1549
Page 1........1549
Wiring diagram SCH04 - Image A........1550
Page 1........1550
Wiring diagram SCH03 - Image B2........1551
Page 1........1551
Wiring diagram SCH03 - Image B1........1552
Page 1........1552
Wiring diagram SCH03 - Image A2........1553
Page 1........1553
Wiring diagram SCH03 - Image A1........1554
Page 1........1554
Wiring diagram SCH02 - Image B2........1555
Page 1........1555
Wiring diagram SCH02 - Image B1........1556
Page 1........1556
Wiring diagram SCH02 - Image A2........1557
Page 1........1557
Wiring diagram SCH02 - Image A1........1558
Page 1........1558
Wiring diagram SCH01 - Image B........1559
Page 1........1559
Wiring diagram SCH01 - Image A........1560
Page 1........1560
Control system diagram - Image........1561
Page 1........1561
Wiring harnesses - Image B........1562
Page 1........1562
Wiring harnesses - Image A........1563
Page 1........1563
Wiring diagram SCH22 - Image B2........1564
Page 1........1564
Wiring diagram SCH22 - Image A2........1565
Page 1........1565
Wiring diagram SCH19 - Image B2........1566
Page 1........1566
Wiring diagram SCH19 - Image A2........1567
Page 1........1567
Wiring diagram SCH14 - Image C1........1568
Page 1........1568
Wiring diagram SCH14 - Image B1........1569
Page 1........1569
Wiring diagram SCH14 - Image A1........1570
Page 1........1570
Wiring diagram SCH05 - Image B2........1571
Page 1........1571
Wiring diagram SCH05 - Image A2........1572
Page 1........1572
Wiring diagram; electrical distribution box - Image........1573
Page 1........1573
Electrical symbols and designations........1574
Explanation of wiring diagrams........1578
Component designations........1581
Component list Alternator; batteries; capacitors; electronic units; voltage outlet........1583
Component list Control lights_warning lights........1584
Component list; fuses_{042-16}........1586
Component list; fuses_{041-57}........1588
Component list; Heating coils........1590
Component list; lights........1591
Component list; Miscellaneous........1593
Component list; motors........1594
Component list; relays........1595
Component list; sensors........1596
Component list; Solenoid valves........1598
Component list; Switches........1601
Wiring diagram; general........1603
Control system diagram........1605
Wiring diagram; electrical distribution box........1608
Wiring diagram SCH001_{37-47}........1611
Wiring diagram SCH001_{37-27}........1614
Wiring diagram SCH002_{36-57}........1617
Wiring diagram SCH002_{36-37}........1620
Wiring diagram SCH003_{36-07}........1623
Wiring diagram SCH003_{35-47}........1626
Wiring diagram SCH004_{35-17}........1629
Wiring diagram SCH004_{34-56}........1634
Wiring diagram SCH005_{34-26}........1639
Wiring diagram SCH005_{34-06}........1642
Wiring diagram SCH006_{33-37}........1645
Wiring diagram SCH006_{33-16}........1648
Wiring diagram SCH007_{32-42}........1651
Wiring diagram SCH007_{32-22}........1654
Wiring diagram SCH008_{31-53}........1657
Wiring diagram SCH008_{31-33}........1660
Wiring diagram SCH009_{31-03}........1663
Wiring diagram SCH009_{30-43}........1666
Wiring diagram SCH010_{30-14}........1669
Wiring diagram SCH010_{29-54}........1672
Wiring diagram SCH011_{29-20}........1675
Wiring diagram SCH011_{28-59}........1677
Wiring diagram SCH012_{28-24}........1679
Wiring diagram SCH012_{28-04}........1682
Wiring diagram SCH013_{27-35}........1685
Wiring diagram SCH013_{27-10}........1688
Wiring diagram SCH014_{26-32}........1691
Wiring diagram SCH014_{26-11}........1694
Wiring diagram SCH014_{25-53}........1697
Wiring diagram SCH015........1700
Wiring diagram SCH016_{24-53}........1703
Wiring diagram SCH016_{24-33}........1705
Wiring diagram SCH017........1707
Wiring diagram SCH018........1710
Wiring diagram SCH019_{23-20}........1712
Wiring diagram SCH019_{23-00}........1715
Wiring diagram SCH020........1718
Wiring diagram SCH021........1720
Wiring diagram SCH022_{21-30}........1723
Wiring diagram SCH022_{21-10}........1725
Wiring diagram SCH024........1727
Wiring diagram SCH025........1729
Wiring harnesses_{019-56}........1731
Wiring harnesses_{019-36}........1734
Electrical distribution box; description_{019-07}........1737
Electrical distribution box; description_{018-47}........1739
Fuse; description........1742
Relay; description........1744
Relay; specifications........1746
Flasher relay; specifications........1748
Circuit breaker; description........1749
Circuit breaker; specification........1751
Grounding points; frame connections........1753
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM........1755
Instruments and controls; overview........1757
Instruments and controls; front instrument panel........1758
Instruments and controls; left instrument panel........1760
Instruments and controls; right instrument panel........1762
Instruments and controls; rear instrument panel........1765
Control levers; description........1767
Hour counter; description........1769
Hour counter; specifications........1771
Slew position sensor; specfications........1773
Control lockout lever switch; description........1774
Control lockout lever switch; specifications........1777
Hydraulic oil filter pressure switch; specifications........1779
Auto idle pressure switch; specifications........1780
Engine oil pressure sensor; replacing........1781
Engine rotation speed sensor; replacing_{006-47}........1783
Engine rotation speed sensor; replacing_{006-29}........1785
Engine rotation speed sensor (camshaft); replacing_{006-00}........1788
Engine rotation speed sensor (camshaft); replacing_{005-42}........1791
Boost pressure _ charge-air temperature sensor; replacing........1793
Booting sequence........1795
MAIN MENU........1798
Menu tree........1801
Display unit; content........1803
SETUP........1810
Control types for X001 and X3 operation........1819
Pop-up screen........1822
Keypad; description_{001-41}........1825
Keypad; description_{001-14}........1828
Keypad; description_{000-47}........1832
Keypad; description_{000-10}........1836
Keypad; description_{059-43}........1839
Keypad; specification........1842
HVAC system........1845
Theft protection........1848
Service mode........1851
Engine system........1853
Hydraulic system........1855
Electrical system........1857
Language........1861
Terminology........1863
39 - MISCELLANEOUS........1890
CareTrack system; description........1891
Radio with MP003; specifications........1894
Radio with MP003; description........1895
DC–DC converter; specifications........1897
DC–DC converter; description........1898
Radio with tape player; description........1900
Radio with CD and MP003 player; description_{53-22}........1903
Radio with tape or CD player; descriptions_{053-02}........1905
Radio with CD and MP003 player; specifications_{52-25}........1908
Radio with tape or CD player; specifications_{052-08}........1910
Audio remote controller; description_{051-40}........1913
Audio remote controller; description_{051-22}........1916
Audio remote controller; specifications_{050-52}........1919
Audio remote controller; specifications_{050-34}........1922
Antenna; replacing........1924
Speaker; replacing........1926
Wireless control unit W-ECU; specification_{049-13}........1928
Wireless control unit W-ECU; specification_{048-53}........1930
Wireless control unit W-ECU; specification_{048-35}........1931
W-ECU; MID 142; replacing........1933
4 - POWER TRANSMISSION........1936
40 - GENERAL........1937
Power transmission; description........1938
42 - TRANSMISSION; HYDRAULIC CONTROL........1939
Transmission mode; function check........1940
43 - GEARBOX........1942
Travel gearbox; bleeding........1943
Travel gearbox; removing........1946
Travel gearbox; installing........1950
Travel gearbox; description........1956
Travel gearbox; specifications........1966
Travel gearbox; troubleshooting........1967
44 - HYDROSTATIC DRIVE........1968
Swing motor; specifications........1969
Swing motor; description_{52-08}........1970
Swing motor; description_{51-44}........1974
Swing motor; removing_{51-02}........1980
Swing motor; removing_{50-30}........1984
Swing motor; installing_{49-58}........1987
Swing motor; installing_{49-30}........1992
Swing motor pressure; checking and adjusting-........1995
Swing motor; principle of operation........1999
Travel motor; description_{47-30}........2006
Travel motor; description_{47-02}........2012
Travel motor speed; checking and adjusting_{46-29}........2018
Travel motor speed; checking and adjusting_{46-02}........2021
Travel motor; removing-........2024
Travel motor; installing-........2028
Travel motor removed; seal replacing........2032
Travel motor; specifications........2035
Brake valve (counter balance valve)........2037
Travel motor pressure; checking and adjusting........2039
Travel motor; removing........2043
Travel motor; installing........2047
Slew unit; specifications........2052
Swing motor; description........2053
Swing motor pressure; checking and adjusting........2059
Pump coupling; removing........2063
Pump coupling; installing........2066
Centre passage; description........2070
Centre passage; removing........2073
Centre passage; installing........2078
Center passage; disassembling and assembling........2082
45 - PROPELLER SHAFT........2087
Propeller shaft; specifications........2088
Propeller shaft front; replacing........2089
Propeller shaft rear; replacing........2091
46 - FRONT AXLE; REAR AXLE........2093
Front axle; specification_{26-33}........2094
Front axle; specification_{26-12}........2096
Front axle; description........2097
Front axle; removing_{25-09}........2099
Front axle; removing_{24-32}........2104
Front axle; installing_{23-50}........2109
Front axle; installing_{23-25}........2112
King pin and bushing; replacing........2116
Input shaft seal; replacing........2118
Rear axle; specifications_{20-57}........2120
Rear axle; specification_{20-37}........2121
Axle; removing_{20-08}........2122
Axle; removing_{19-41}........2125
Axle; installing_{19-05}........2128
Axle; installing_{18-41}........2131
Shaft seals; replacing........2134
49 - MISCELLANEOUS........2135
Slew ring gear; specifications........2136
Tightening torque; specifications_{17-11}........2137
Tightening torque; specifications_{16-50}........2138
Swing ring gear; specifications........2139
Swing ring gear; description_{16-05}........2140
Slew ring gear; description_{15-44}........2144
Swing ring; removing........2146
Swing ring; installing........2148
Swing ring gear inner seal; replacing........2150
Swing ring gear outer seal; replacing........2152
Slew ring; rotational clearance........2155
Slew ring; axial clearance........2156
Measuring rotational clearance_{12-48}........2157
Measuring rotational clearance_{12-20}........2161
Swing ring; measuring axial clearance_{11-38}........2164
Swing ring; measuring axial clearance_{11-06}........2168
5 - BRAKE........2171
52 - HYDRAULIC BRAKE SYSTEM........2172
Electrical digging brake; description........2173
Hydraulic brake system; description........2176
Brake system circuit pressure; checking and adjusting........2182
Brake system bleeding........2188
Service brakes function; checking........2191
Foot brake valve; replacing........2193
Brake accumulator; specifications........2198
Brake accumulator; description........2200
Brake accumulator charging pressure; adjusting........2201
Hydraulic oil filter; replacing-........2204
Brake pump; specifications-........2206
Brake pump; specifications........2207
55 - PARKING BRAKE........2208
Parking brake; description........2209
Parking brake; manually releasing........2214
Parking brake function; checking........2217
6 - STEERING........2219
60 - GENERAL........2220
Steering system function; checking........2221
62 - STEERING AXLE........2223
Steering axle; specifications........2224
Steering axle; description........2225
64 - STEERING........2227
Steering system; description_{56-36}........2228
Steering system; description_{56-09}........2233
Steering system working pressure; checking_{54-35}........2238
Steering system working pressure; checking_{54-10}........2241
Steering valve; removing........2244
Steering valve; installing........2248
Hydraulic oil filter; replacing........2253
Steering pump; specifications........2255
Control valve (steering unit); specification........2256
Control valve (steering unit); description........2257
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT........2261
71 - FRAME........2262
Superstructure; removing........2263
Superstructure; installing........2268
Counterweight; specifications_{47-08}........2272
Counterweight; specifications_{46-47}........2273
Counterweight; removing_{46-19}........2274
Counterweight; removing_{45-56}........2276
Counterweight; installing_{45-23}........2279
Counterweight; installing_{45-00}........2281
Undercarriage; description_{43-33}........2284
Undercarriage; description_{43-12}........2286
Undercarriage; tightening torque........2287
Step; removing........2289
Step; installing........2291
76 - SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL _ SIDE CONTROL........2293
Pivot axle lock cylinder; description........2294
Pivot axle lock cylinder; removing_{39-51}........2301
Pivot axle lock cylinder; removing_{39-28}........2304
Pivot axle lock cylinder; installing_{38-46}........2307
Pivot axle lock cylinder; installing_{38-26}........2309
Pivot axle lock cylinder; releasing for towing_{37-55}........2312
Pivot axle lock cylinder; releasing for towing_{37-33}........2315
Pivot axle lock cylinder seals; changing........2318
Pivot axle lock; function check........2323
77 - WHEELS; TRACKS; TYRE; HUB; DRUM........2325
Wheels; specifications........2326
Wheel; removing........2327
Wheel; installing........2330
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE........2333
81 - CAB; NAKED; CANOPY........2334
Cab; weight........2335
Cab; removing........2337
Cab; installing........2340
Cab suspension; description_{31-05}........2342
Cab suspension; description_{30-43}........2344
83 - DOORS; HATCH; COVER PLATE; (all)........2346
Cab door; removing door catch........2347
Cab door; installing door catch........2350
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING........2353
Windows; general........2354
Windscreen; replacing........2356
Side window; replacing........2363
Rear window; replacing........2370
Door window; replacing........2376
Seat; replacing_{25-27}........2379
Seat; replacing_{25-05}........2382
Seat; replacing_{24-39}........2392
Seat; replacing_{24-18}........2395
85 - CAB INTERIOR; UPHOLSTERY........2405
Seat cushion; replacing........2406
Seat support; replacing........2411
Longitudinal adjustment cable; replacing........2418
Longitudinal suspension cable; replacing........2424
Backrest; replacing........2428
Seat belt; replacing........2432
87 - AIR CONDITIONING UNIT........2435
Electronic climate control unit ECC; description........2436
Electronic climate control unit ECC; specification........2438
Wiring diagram........2440
HVAC system........2442
Air conditioning unit; specifications........2445
Air conditioning unit; description........2446
Air conditioning unit; maintenance........2452
ECC (Electronic Climate Control); replacing........2454
Air conditioning unit; refrigerant check and recharging........2457
Air distribution; description........2465
Cab filter; replacing........2468
Heating system; description........2470
Fan motor; replacing........2472
Heater core; replacing........2478
Cooler and Heater assembly; replacing........2480
Compressor; replacing incl draining and filling........2483
Receiver; replacing incl draining and filling........2488
Condenser; replacing incl draining and filling........2492
Evaporator; replacing incl draining and filling........2496
Expansion valve; replacing incl draining and filling........2502
Vent actuator; replacing........2508
Mode (foot) actuator; replacing........2511
Intake actuator; replacing........2514
Air mix door actuator; replacing........2517
Diesel coolant heater (5kw); specifications........2520
Diesel coolant heater (5kw); description........2522
Diesel coolant heater (5kw); principles........2525
Troubleshooting (5kw)........2530
88 - INTERIOR EQUIPMENT........2539
Instrument panel (left); replacing........2540
Instrument panel (right); replacing........2545
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS........2549
90 - GENERAL........2550
Tiltrotator control system; diagram - Image F........2553
Page 1........2553
Tiltrotator control system; diagram - Image E........2554
Page 1........2554
Tiltrotator control system; diagram - Image D........2555
Page 1........2555
Tiltrotator control system; diagram - Image C........2556
Page 1........2556
Tiltrotator control system; diagram - Image B........2557
Page 1........2557
Tiltrotator control system; diagram - Image A........2558
Page 1........2558
Hydraulic diagram; X3 - Image........2559
Page 1........2559
Hydraulic diagram; X1 with pressure control - Image B........2560
Page 1........2560
Hydraulic diagram; X1 with pressure control - Image A........2561
Page 1........2561
Hydraulic diagram; X1 with flow control - Image........2562
Page 1........2562
Hydraulic diagram; with reversible cooling fan - Image........2563
Page 1........2563
Hydraulic diagram; quick fit - Image B2........2564
Page 1........2564
Hydraulic diagram; quick fit - Image B1........2565
Page 1........2565
Hydraulic diagram; quick fit - Image A2........2566
Page 1........2566
Hydraulic diagram; quick fit - Image A1........2567
Page 1........2567
Hydraulic diagram; grab piping - Image........2568
Page 1........2568
Hydraulic diagram; dozer blade and outrigger - Image B........2569
Page 1........2569
Hydraulic diagram; dozer blade and outrigger - Image A........2570
Page 1........2570
Hydraulic diagram; cruise control - Image B........2571
Page 1........2571
Hydraulic diagram; cruise control - Image A........2572
Page 1........2572
Hydraulic diagram; control pattern selector valve - Image........2573
Page 1........2573
Hydraulic diagram; complete - Image D........2574
Page 1........2574
Hydraulic diagram; complete - Image C........2575
Page 1........2575
Hydraulic diagram; complete - Image B........2576
Page 1........2576
Hydraulic diagram; complete - Image A........2577
Page 1........2577
Hydraulic diagram; boom float valve - Image B........2578
Page 1........2578
Hydraulic diagram; boom float valve - Image A........2579
Page 1........2579
Hydraulic system; cleanliness when handling hydraulic components........2580
Hydraulic diagram; component list_{01-26}........2582
Hydraulic diagram; component list_{01-07}........2585
Hydraulic system; position of main components........2588
Hydraulic system; position of main components on superstructure........2591
Hydraulic diagram; complete_{59-44}........2593
Hydraulic diagram; complete_{59-23}........2596
Hydraulic diagram; complete_{59-03}........2599
Hydraulic diagram; complete_{58-42}........2602
Hydraulic diagram; with reversible cooling fan........2605
Hydraulic diagram; boom float valve_{57-47}........2608
Hydraulic diagram; boom float valve_{57-26}........2611
Hydraulic diagram; control pattern selector valve........2614
Hydraulic diagram; cruise control_{56-25}........2617
Hydraulic diagram; cruise control_{56-04}........2620
Hydraulic diagram; X1 with flow control........2623
Hydraulic diagram; X1 with pressure control_{55-09}........2626
Hydraulic diagram; X1 with pressure control_{54-48}........2629
Hydraulic diagram; X3........2632
Hydraulic diagram; quick fit_{53-48}........2635
Hydraulic diagram; quick fit_{53-26}........2640
Hydraulic diagram; grab piping........2645
Hydraulic diagram; dozer blade and outrigger_{52-30}........2648
Hydraulic diagram; dozer blade and outrigger_{52-09}........2651
Tiltrotator control system; diagram........2654
Description; general........2667
Optional hydraulic equipment; index........2668
Hydraulic oil; description........2670
Hydraulic system; repair of hydraulic components in workshop........2674
Hydraulic oil; storage and handling........2679
Hydraulic components; storing and transporting........2680
Vacuum pump; connection........2681
Vacuum pump; disconnection........2684
Hydraulic system; warming up........2686
Measuring tools and techniques........2690
91 - WORKING HYDRAULIC; SERVO HYDRAULICS........2695
Hydraulic system; work instructions........2699
Hydraulic system; description........2700
Hydraulic pressure; specifications_{45-57}........2701
Hydraulic pressure; specifications_{45-38}........2705
Hydraulic pressure; specifications_{45-20}........2707
Load holding valve; description........2709
Hydraulic oil; cleaning........2712
Hydraulic oil cooling system; specifications........2714
Cooling fan control valve; checking........2717
Oil cooler fan motor; checking........2721
Hydraulically driven cooling fan; description........2726
Hydraulic tank; specifications........2730
Hydraulic oil tank; description_{41-16}........2731
Hydraulic oil tank; description_{40-55}........2734
Hydraulic oil tank; releasing pressure........2737
Thermostatic function hydraulic oil; description........2738
Cooling fan speed; checking and adjusting_{39-30}........2743
Cooling fan speed; checking and adjusting with VCADS Pro_{39-02}........2748
Hydraulic oil cooler; removing_{38-21}........2752
Hydraulic oil cooler; removing_{37-58}........2757
Hydraulic oil cooler; installing_{37-11}........2766
Hydraulic oil cooler; installing_{36-50}........2771
Cooling fan pump; removing........2779
Cooling fan pump; installing........2784
Oil cooler fan motor; removing........2789
Oil cooler fan motor; installing........2792
Hydraulic oil tank; removing........2796
Hydraulic oil tank; installing........2800
Main control valve block; description_{32-13}........2805
Main control valve block; description_{31-52}........2810
Main control valve block; description_{31-31}........2815
Main control valve; removing........2818
Main control valve; installing........2822
Back-up valves_{28-35}........2825
Back-up valves_{28-14}........2828
Back-up valve; checking and adjusting_{27-44}........2831
Back-up valve; checking and adjusting_{27-24}........2834
Unload valve; checking and adjusting ........2840
Unload valve; replacing ........2843
Shock and anti-cavitation valve; description........2847
Directional and line rupture valve for boom cylinder; description........2850
Line rupture valve (boom); description........2856
Line rupture valve for dipper arm cylinder; description........2859
Line rupture valve (boom); troubleshooting........2864
Line rupture valve pressure; checking and adjusting........2866
Working pressure; checking and adjusting........2872
Secondary pressure limiting valve; checking........2883
Shock valve removed; checking........2886
Boom cylinder; rupture valve; replacing........2889
Dipper arm cylinder; rupture valve; replacing........2892
Rupture valve; replacing (2pcs boom tilt cylinder)........2895
Dipper arm in speed; checking and adjusting........2899
LS-pressure relief valve; replacing........2901
Pressure relief valves; description........2904
LS-pressure relief valve; replacing_{17-19}........2910
LS-pressure relief valve; replacing_{16-55}........2915
Safety relief valve; replacing_{16-20}........2920
Safety relief valve; replacing_{15-56}........2925
Unload valve; replacing........2930
Unload valve; checking and adjusting........2934
Working pump; description........2937
Pump; removing........2940
Pump; installing........2946
Hydraulic pump (removed); changing shaft seal........2951
Working pump; specifications........2955
Hydraulic pump; standby pressure; checking and adjusting........2956
Servo system; description_{09-44}........2958
Servo system; description_{09-24}........2960
Servo valve; removing_{08-49}........2962
Servo valve; removing_{08-29}........2964
Servo valve; installing_{07-59}........2967
Servo valve; installing_{07-39}........2969
Servo pump; removing........2972
Servo pump; installing........2974
Pressure accumulator; description........2977
Servo accumulator; removing........2981
Servo accumulator; installing........2982
Discarded accumulators........2983
Servo pressure; checking and adjusting........2984
Control lockout lever; function check........2988
Servo Accumulator........2990
Servo pump; specifications........2991
Servo pump; troubleshooting........2992
Remote control valve (pedal); specifications........2994
Remote control valve (pedal); description........2996
Control lever; removing........2998
Control lever; installing........3008
Control pattern selector valve; description........3018
X1; description_{58-40}........3023
X1; description_{58-04}........3040
VCADS Pro; 91610-3 – X1 hydraulic pressure control system; test........3057
X1; function check........3062
Calibration of X1 hydraulic with flow control........3064
Calibration of X1 hydraulic with pressure control........3067
X1 pressure relief valve; adjusting-39........3069
X1 pressure relief valve; adjusting........3072
X3; description........3076
X3; function check........3084
X3 pressure and flow; adjusting........3086
X3 shock and refilling valves; adjusting........3091
Boom float position; description_{52-55}........3095
Boom float position; description_{52-34}........3099
Cruise control; description_{52-04}........3103
Cruise control; description_{51-43}........3109
Calibration of cruise control........3115
Reversible cooling fan; description........3117
Grab bucket; description........3121
Grab equipment; tool change........3127
Tiltrotator control system; description........3129
92 - MECHANICAL EQUIPMENT_ATTACHMENT........3144
Hydraulic quickfit; description........3145
Universal quick coupler_{47-34}........3149
Universal quick coupler_{47-13}........3155
Cylinder for hydraulic quickfit S1; removing........3159
Cylinder for hydraulic quickfit S1; installing........3161
Cylinder for hydraulic quickfit Universal; removing........3163
Cylinder for hydraulic quickfit Universal; installing........3167
Cylinder for hydraulic quickfit S6; removing........3171
Cylinder for hydraulic quickfit S6; installing........3178
Quickfit; removing........3181
Quickfit; installing........3183
Quickfit; function check........3186
97 - UNIT; DIGGING........3188
Cylinder; description........3190
Cylinder; troubleshooting_{41-30}........3193
Cylinder; troubleshooting_{41-12}........3195
Cylinder data........3197
Boom lifting cylinder; description........3198
Dipper arm cylinder; description........3200
Bucket cylinder; description........3202
Digging equipment bearings; measuring radial clearance........3204
Digging equipment bearings; specifications........3207
Bushing general; replacing........3209
Digging equipment bearings; shimming........3213
Creeping of hydraulic cylinder........3215
Stabilisers and stabiliser blade; description........3219
Stabilisers; installing........3231
Stabilisers; hydraulic cylinder; removing........3237
Boom; removing_{34-25}........3242
Boom; removing_{34-05}........3248
Boom; installing_{33-27}........3254
Boom; installing_{33-05}........3262
Boom foot bushing; replacing........3270
2-piece boom; removing_{32-04}........3271
2-piece boom; removing_{31-44}........3275
2-piece boom; installing_{31-10}........3284
2-piece boom; installing_{30-49}........3288
Boom cylinder; removing........3298
Boom cylinder; installing........3303
Lower boom cylinder bushing; replacing........3308
Upper boom cylinder bushing; replacing........3309
Tilt cylinder 2-piece boom; removing........3310
Tilt cylinder 2-piece boom; installing........3315
Tilt cylinder 2-piece boom; rear bushing; replacing........3320
Tilt cylinder 2-piece boom; front bushing; replacing........3321
Dipper arm; removing........3322
Dipper arm; installing........3325
Dipper arm bushing-boom; replacing........3328
Dipper arm bushing-bucket; replacing........3329
Dipper arm bushing-lever; replacing........3330
Dipper arm cylinder; removing........3331
Dipper arm cylinder; installing........3335
Dipper arm cylinder bushing on boom; replacing........3338
Dipper arm cylinder bushing on dipper arm; replacing........3339
Bucket cylinder; removing........3340
Bucket cylinder; installing........3344
Bucket cylinder bushing on dipper arm; replacing........3348
Bucket cylinder bushing lever-link; replacing........3349
Lever link bushing-bucket cylinder; replacing........3350
Lever bushing-bucket; replacing........3351
99 - MISCELLANEOUS........3352
Automatic lubrication system; specifications........3353
Automatic lubrication system; description........3355
Control unit; description........3363
Control units; software functions........3365
Maintenance service; general........3371
Troubleshooting........3374
Bleeding air........3376
Volvo EW180C Excavators Repair Service Manual
