Volvo ECR145E L Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for ECR145E L Volvo Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
ECR145E L Volvo Constructions 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.
ECR145E L Volvo Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,513 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
Machine view_{04-56-59}....5
Machine view_{04-57-25}....7
Product plates....9
03 - SPECIFICATIONS....11
Measurement conversion tables....12
Tightening Torques.....21
07 - STANDARD TIME....32
Operation numbers for additional work....33
08 - TOOL....35
E-tools; NET 8940-00310 Replace tool for the swing ring gear....36
E-tools; NET 8940-00320 Swing motor guide pin....38
Infrared Thermometer....39
NET 8940-00190 Travel motor guide pin....43
09 - MISCELLANEOUS....44
Hydraulic cylinders; dieseling....45
Service positions....49
Welding on the machine....52
1 - STANDARD PARTS; SERVICE....55
16 - LUBRICANT; FUEL; OTHER FLUID....56
AdBlue®_DEF ....57
Engine oil....63
Fuel....65
Hydraulic oil....68
Lubricants; service capacities and intervals....73
Recommended lubricants....75
Coolant_{01-55-29}....79
Coolant_{01-55-03}....84
Coolant with freezing and corrosion protection....88
Grease....92
Alternative fuels....96
Change capacities....99
17 - SERVICE....100
Bearings....103
Replacement parts....107
Safety when servicing....111
Service....115
Service methods....118
Pressure testing....122
Hoses and tubes....126
Cleaning prior to repair....130
Tech Tool; operations-....134
Arrival Inspection; according to Inspection Programme....136
Delivery Inspection; according to Inspection Programme....141
Maintenance of Stored Machines; according to Inspection Programme....145
Maintenance service; first 500 hours....149
Maintenance service; every 10 hours....150
Maintenance service; every 50 hours....151
Maintenance service; every 250 hours....152
Maintenance service; every 500 hours_{01-45-33}....153
Maintenance service; every 500 hours_{01-45-13}....155
Maintenance service; every 1000 hours_{01-44-36}....157
Maintenance service; every 1000 hours_{01-44-17}....159
Maintenance service; every 2000 hours_{01-43-40}....161
Maintenance service; every 2000 hours_{01-43-20}....163
Maintenance service; every 4000 hours_{01-42-32}....165
Maintenance service; every 4000 hours_{01-42-12}....167
Maintenance service; every 6000 hours_{01-41-24}....169
Maintenance service; every 6000 hours_{01-41-04}....170
Maintenance service; every 8000 hours_{01-40-21}....171
Maintenance service; every 8000 hours_{01-40-02}....172
Service position....173
Lubrication; every 50 hours....176
Test running and checking....178
Valves; adjusting-....180
Engine oil and filter; changing....185
Fuel filter; replacing....188
Water separator filter; replacing....190
Fuel tank breather filter; replacing....192
Diesel particulate filter; regenerating....194
Diesel particulate filter; checking and cleaning....196
AdBlue®_DEF pump unit filter; replacing....200
AdBlue®_DEF tank breather filter; replacing....203
Engine air cleaner primary filter; replacing....205
Engine air cleaner secondary filter; replacing....207
Coolant; changing....209
Coolant freezing point; checking....211
Fan_alternator belt; checking....214
Radiator and hydraulic oil cooler; cleaning....215
MATRIS and Tech Tool; reading....217
Software update; checking....218
Battery; checking....222
CareTrack backup battery; replacing_{01-29-42}....224
CareTrack backup battery; replacing_{01-29-19}....227
Track gearbox oil level; checking....230
Track gearbox oil; changing....232
Swing gearbox oil level; checking....234
Swing gearbox oil; changing....236
Swing ring gear bearing; lubricating....238
Swing bath grease; checking_{01-26-46}....240
Swing bath grease; checking_{01-26-24}....241
Track shoe bolts; checking....243
Track tension and condition; checking....245
Cab door; covers; hinges; joints and locks; lubricating....247
Air conditioner main filter; cleaning....249
Air conditioner main filter; replacing....251
Cab prefilter; cleaning....253
Cab prefilter; replacing....255
Air conditioner compressor belt; checking....257
Hydraulic oil level; checking....259
Hydraulic oil; changing....260
Hydraulic oil suction strainer; cleaning....263
Hydraulic oil drain filter; replacing....265
Hydraulic oil servo filter; replacing....266
Hydraulic oil return filter; replacing....267
Hydraulic oil tank breather filter; replacing....270
Measuring condition....272
Cylinder speed....275
Creeping of hydraulic cylinder....278
Swing speed....280
Coasting left and right swing....281
Measuring of swing bearing clearance....283
Travel Speed....286
Track running speed....288
Straight traveling performance....289
19 - GENERAL....291
Safety concerns everybody!....292
CE-marking; EMC-directive....296
Cautions during operation....300
Safety when handling the machine....307
Safety rules when servicing....313
Move and operate machine safely....318
Fire prevention measures....321
Health hazards with paint; plastics and rubber....327
Checklist after a fire or heat exposure....332
Safety when using lifting equipment....336
Safety when handling oils and fuel....340
Safety when working with batteries....344
Starting with booster batteries....349
Safety when working with air conditioning refrigerant....353
Safety when working with hydraulic systems....358
Environmental handling for the future....362
Environmentally safe handling....366
Environmentally hazardous fluids....370
Working in environmentally contaminated areas....374
Decontamination....378
Waste handling....382
2 - ENGINE WITH MOUNTING AND EQUIPMENT....386
20 - GENERAL....387
Engine; description_{01-01-59}....388
Engine; description_{01-01-36}....395
Component locations....401
Tech Tool; Operations....403
Engine control module (ECM); replacing pre-programmed....405
Engine control module (ECM); replacing non-programmed....407
Engine; reference values....411
Engine belts; replacing....414
21 - ENGINE....416
Engine; specifications....417
Engine rotation speed sensor (crank shaft); replacing....418
Engine rotation speed sensor (camshaft); replacing....420
Engine; removing....422
Engine; installing....434
Engine; replacing_{12-55-32}....445
Engine; replacing_{12-55-12}....449
Engine; tightening torques....452
Cylinder compression; testing....459
Crankcase ventilation; description....462
Valves; adjusting....466
Valve cover; removing....471
Valve cover; installing....474
22 - LUBRICATING SYSTEM....477
Lubrication system; description....478
Lubrication system; specifications....483
Lubrication system; component locations....485
Lubrication system; tightening torques....487
Lubrication oil pressure; checking with pressure gauge....490
Oil cooler; replacing....493
23 - FUEL SYSTEM....495
Fuel system; description....496
Fuel system; specifications....504
Fuel system; tightening torques....506
Carbon dioxide in fuel system; checking....514
Fuel system basics; checking....520
Fuel system; component location....523
Feed pump pressure; checking....525
Fuel system; bleeding....527
Water separator; specifications....529
Injectors; replacing....531
Fuel rail; replacing....537
Fuel rail pressure sensor; replacing....540
High pressure fuel pump; replacing....542
High pressure fuel pipes; replacing....545
Fuel control valve (FCV); replacing....548
Pressure relief valve (PRV); replacing....553
25 - INLET & EXHAUST SYSTEM....556
Inlet and exhaust system; description....558
Inlet and exhaust system; specification....564
Inlet and exhaust system; component location....565
Inlet and exhaust system; tightening torques....567
Exhaust pipe flexible tube; replacing....573
Exhaust Aftertreatment System; description_{04-51-42}....576
Exhaust Aftertreatment System; description_{04-40-07}....590
Exhaust Aftertreatment System; component location....604
Regeneration process; description....606
AdBlue®_DEF dosing injector; replacing....613
AdBlue®_DEF mixing tube; replacing....616
AdBlue®_DEF tank; replacing....620
AdBlue®_DEF; draining....622
Coolant valve; replacing....624
SCR (Selective catalytic reduction) muffler; replacing....627
AdBlue®_DEF quality; checking....634
SCR (Selective catalytic reduction) dosing system; checking....637
AdBlue®_DEF pump unit diagnostics; description....640
DPF (Diesel particulate filter); checking and cleaning....644
ACM (Aftertreatment control module) non-programmed; replacing....648
ACM (Aftertreatment control module) pre-programmed; replacing....652
Inlet throttle; replacing....654
DOC (Diesel oxidation catalyst); replacing....656
AdBlue®_DEF pump unit; replacing....658
AdBlue®_DEF tank armature; replacing....661
AdBlue®_DEF tank armature; cleaning....666
AdBlue®_DEF-[3634]....669
AdBlue®_DEF-[3526]....671
AdBlue®_DEF....675
Crystallization of AdBlue®_DEF; checking....681
AdBlue®_DEF pump unit; filter; replacing....686
AdBlue®_DEF pump unit; flushing....689
AdBlue®_DEF pump unit; inlet nipple; replacing....691
AdBlue®_DEF tank; cleaning-[2006]....694
AdBlue®_DEF tank; cleaning....704
Turbocharger; Replacing....706
Turbocharger; replacing....710
Wastegate; checking....714
Charge air cooler; replacing....716
26 - COOLING SYSTEM....726
Cooling system; description....727
Cooling system; specifications....731
Carbon dioxide in coolant system; checking....733
Coolant with anti-freeze and corrosion protection; recommendation....739
Cooling system pressure; checking....742
Radiator; replacing....744
Expansion tank; replacing....746
Coolant pump; replacing....749
Thermostat; replacing....752
Cooling fan control....755
Reversible cooling fan; description....759
Cooling fan rpm; specifications....762
27 - ENGINE CONTROL....763
Engine - Pump control; specification....764
29 - MISCELLANEOUS....766
EGR venturi tube; cleaning....767
Exhaust Gas Recirculation (EGR); description....769
Exhaust gas recirculation (EGR); component location....775
EGR system; tightening torques....777
EGR reed valve; replacing....779
EGR cooler; replacing....785
EGR actuator; replacing....789
EGR venturi tube; replacing....791
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....795
30 - GENERAL....796
Electrical system; special instructions for servicing; general....802
Electrical system; special instructions for servicing; electronic components....806
Electrical system; special instructions for servicing; electrical components; batteries....809
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator....813
Electrical system; special instructions for servicing; action when working on machine....816
Electrical system; description....819
Electronic control system; description....821
Auxiliary start....827
System voltage....831
Electrical system; specifications....834
Tech Tool; Operations-.....837
Power Boost control; description....839
Engine stops....842
CareTrack with anti-theft....844
Start lock; description....855
X1 control; description....857
X3 control; description....861
Electro hydraulic pump control; description....863
Power supply; description....868
Mode selection; description....873
Boom float position; description....877
Limp home....879
Shockless boom control; description....882
Travel Speed; description....884
Overload warning....886
Seat belt....889
Auto Idle....891
Attachment quick coupler....894
Intermittent wiper and washer....896
Grading and lifting control; description....900
ECO mode; description....904
Software parameters; description....906
Automatic engine shut-down....918
General fault diagnosis information....921
Troubleshooting strategy....923
Collection of basic data....925
Information display; check....929
Error code information; general_{05-33-51}....932
Error code information; general_{05-33-24}....941
Error codes; build-up....952
Conditions when checking....954
Lead and connector checks....959
Special tools for troubleshooting....965
Tech Tool; operations ....968
AL3201; description and measuring....970
BA3101; description and measuring....973
BB1 Communication bus; description and measuring....975
BB2 Communication bus; description and measuring....978
CU9901; description and measuring....980
CU9909; description and measuring....982
CU9911; description and measuring....985
FX1005; description and measuring....987
FX1006; description and measuring....990
FX1007; description and measuring....993
FX1008; description and measuring....996
FX1054; description and measuring....1000
FX1074; description and measuring....1003
FX1079; description and measuring....1006
FX1116; description and measuring....1009
FX1117; description and measuring....1012
HE2501; description and measuring....1015
HE2511; description and measuring....1017
HE2512; description and measuring....1019
HE2513; description and measuring....1021
Instrument Cluster (IC); description and measuring....1023
MA2301-MA2304; description and measuring....1025
MA2517; description and measuring....1027
MA2519; description and measuring....1029
MA2523; description and measuring....1032
MA2524; description and measuring....1034
MA2602; description and measuring....1036
MA9109; description and measuring....1038
MA9116; description and measuring....1041
MA9117; description and measuring....1044
MA9120; description and measuring....1047
MA9125; description and measuring....1050
MO2505; description and measuring....1053
MO2510; description and measuring....1056
MO3301; description and measuring....1058
Power supply; ACM (Aftertreatment Control Module); description and measuring....1060
Power supply CCM; description and measuring....1062
Power supply ECM; description and measuring....1064
Power supply GPMECU 1; description and measuring....1066
Power supply HMICU; description and measuring....1068
Power supply W-ECU; description and measuring....1070
PWM2303; description and measuring....1072
PWM9109; description and measuring....1075
PWM9123; description and measuring....1077
PWM9124; description and measuring....1080
PWM9129; description and measuring....1083
PWM9141; description and measuring_{06-58-08}....1085
PWM9141; description and measuring_{06-54-04}....1088
PWM9141; description and measuring_{06-28-09}....1091
PWM9142; description and measuring_{06-17-07}....1093
PWM9142; description and measuring_{06-13-32}....1096
PWM9143; description and measuring....1099
PWM9145; description and measuring....1101
PWM9146; description and measuring....1104
PWM9156; description and measuring....1107
PWM9157; description and measuring....1109
RE2501; description and measuring....1112
RE3101; description and measuring....1115
RE3102; description and measuring....1118
RE3502; description and measuring....1121
RE3507; description and measuring....1123
RE3508; description and measuring....1125
RE3511; description and measuring....1128
RE3607; description and measuring....1130
RE3611; description and measuring....1132
RE4206; description and measuring_{07-34-29}....1135
RE4206; description and measuring_{07-30-33}....1137
SAE J1939-1 SubNet 1; description and measuring....1140
SE2203; description and measuring....1143
SE2301; description and measuring....1146
SE2303; description and measuring....1149
SE2309; description and measuring....1152
SE2511; description and measuring....1155
SE2512; description and measuring....1158
SE2513; description and measuring....1161
SE2515; description and measuring....1164
SE2516; description and measuring....1167
SE2519; description and measuring....1170
SE2521; description and measuring....1173
SE2522; description and measuring....1176
SE2533; description and measuring....1179
SE2543; description and measuring....1182
SE2544; description and measuring....1185
SE2603; description and measuring....1187
SE2606; description and measuring....1189
SE2701; description and measuring....1192
SE2703; description and measuring....1194
SE8701; description and measuring....1196
SE8702; description and measuring....1199
SE8705; description and measuring....1202
SE8706; description and measuring....1205
SE8708; description and measuring....1208
SE9105; description and measuring....1211
SE9121; description and measuring....1214
SE9122; description and measuring....1216
SE9123; description and measuring....1218
SE9124; description and measuring....1221
SE9125; description and measuring_{03-36-15}....1224
SE9125; description and measuring_{03-30-53}....1226
SE9126; description and measuring....1229
SE9127; description and measuring....1232
SE9128; description and measuring....1235
SE9130; description and measuring....1237
SE9131; description and measuring....1240
SE9132; description and measuring....1243
SE9136; description and measuring....1246
SE9138; description and measuring....1249
SE9141; description and measuring....1252
SE9142; description and measuring....1254
SE9401; description and measuring....1256
SW2506; description and measuring....1258
SW3301; description and measuring....1261
SW3802; description and measuring....1264
SW3803; description and measuring....1267
SW9161; description and measuring....1269
SW9162; description and measuring....1271
Tiltrotator detection; description and measuring....1273
VSV controller; description and measuring....1276
31 - BATTERY....1279
Battery; storage....1280
Battery; description....1283
Battery; specifications....1286
Battery condition; checking....1287
Battery; charging....1290
Batteries; replacing....1293
Earth lead to battery; replacing....1296
32 - ALTERNATOR; CHARGE REGULATOR....1298
Charging; description....1299
Alternator; specifications....1301
Alternator; description....1303
Alternator; replacing incl function checking....1306
Alternator; testing....1309
33 - STARTING SYSTEM....1313
Starting operation....1314
Starter motor; description....1315
Starter motor; specifications....1317
Starter motor; testing....1319
Starter motor; replacing....1323
Preheating; description....1325
Ignition switch; description and operation....1327
Ignition switch; specifications....1330
Starter switch; testing....1332
35 - LIGHTING....1335
Work lights and extra lights; description....1336
Work lights and extra lights; specifications....1339
Work lighting headlamp assembly; replacing....1342
36 - OTHER ELECTRICAL EQUIPMENT....1344
Electric pedal control on X1 (on_off); replacing....1346
Electric pedal control on X1 (proportional); replacing....1350
Travel alarm; description....1354
Electric horn; specifications....1357
Horn; replacing....1360
Rotating beacon; specifications_{11-22-40}....1362
Rotating beacon; specifications_{11-22-19}....1364
Rotating beacon; specifications_{11-21-58}....1366
Rotating beacon; replacing....1368
Travel alarm; specifications-[1906]....1371
Travel alarm; specifications....1372
Travel alarm; replacing....1373
Windscreen wiper front motor; replacing....1375
Windscreen wiper switch; replacing....1380
Windscreen wiper; description....1383
Upper wiper motor; description....1385
Upper wiper motor; specifications....1387
Lower wiper motor; description....1389
Lower wiper motor; specifications....1391
Windscreen flusher pump; specifications....1393
Window limit switch; description....1395
Connectors; overview-[0601]....1398
Connectors; overview....1407
Pre-heating relay; replacing....1417
Control lockout lever switch; replacing....1419
Ignition switch; replacing....1422
Engine limp home switch; description....1425
Engine limp home switch; specifications....1427
General purpose machine electronic control unit GPMECU; function description....1429
Human machine interface control unit HMICU; function description....1432
GPMECU1 non-programmed; replacing....1434
GPMECU1 pre-programmed; replacing....1437
HMICU non-programmed; replacing....1440
HMICU pre-programmed; replacing....1444
Mini-Pipelayer kit....1448
37 - CABLE; FUSE; RELAY....1455
Electrical symbols and designations....1458
Explanation of wiring diagrams....1462
Component designations....1465
Component list Alternator; batteries; capacitors; electronic units; voltage outlet....1466
Component list; fuses....1468
Component list; Heating coils....1470
Component list; lights....1471
Component list; Miscellaneous_{10-01-22}....1472
Component list; Miscellaneous_{10-01-01}....1473
Component list; motors....1474
Component list; relays_{10-00-05}....1475
Component list; relays_{09-59-45}....1476
Component list; sensors....1477
Component list; Solenoid valves_{09-58-43}....1479
Component list; Solenoid valves_{09-58-22}....1481
Component list; Switches....1483
ACM; I_O list....1485
CCM; I_O list....1488
ECM (Engine Control Module); I_O list....1491
GPMECU1; I_O list_{09-54-57}....1496
GPMECU1; I_O list_{09-54-30}....1499
HMICU; I_O list_{09-53-51}....1502
HMICU; I_O list_{09-53-22}....1505
IC (Instrument Cluster); I_O list....1508
W-ECU; I_O list....1510
Wiring diagram....1512
Wiring diagram; electrical distribution box....1514
Wiring diagram SCH01_{09-50-01}....1517
Wiring diagram SCH01....1521
Wiring diagram SCH02....1525
Wiring diagram SCH03_{09-47-33}....1529
Wiring diagram SCH03_{09-47-00}....1533
Wiring diagram SCH04....1537
Wiring diagram SCH05_{09-44-55}....1542
Wiring diagram SCH05_{09-44-20}....1547
Wiring diagram SCH05_{09-43-45}....1552
Wiring diagram SCH07_{09-42-59}....1557
Wiring diagram SCH07_{09-42-16}....1561
Wiring diagram SCH08_{09-41-24}....1565
Wiring diagram SCH08_{09-40-43}....1570
Wiring diagram SCH10....1575
Wiring diagram SCH11_{09-38-54}....1578
Wiring diagram SCH11_{09-38-22}....1582
Wiring diagram SCH12_{09-37-31}....1586
Wiring diagram SCH12_{09-36-50}....1590
Wiring diagram SCH12_{09-36-10}....1594
Wiring diagram SCH13....1598
Wiring diagram SCH14_{09-34-09}....1601
Wiring diagram SCH14_{09-33-17}....1606
Wiring diagram SCH15_{09-32-08}....1611
Wiring diagram SCH15_{09-31-26}....1615
Wiring diagram SCH15_{09-30-46}....1619
Wiring diagram SCH16_{09-29-54}....1623
Wiring diagram SCH16_{09-29-15}....1627
Wiring diagram SCH17_{09-28-11}....1631
Wiring diagram SCH17_{09-27-30}....1635
Wiring diagram SCH18....1639
Wiring diagram SCH20_{09-25-39}....1642
Wiring diagram SCH20_{09-24-59}....1645
Wiring diagram SCH21_{09-24-08}....1648
Wiring diagram SCH21_{09-23-27}....1652
Wiring diagram SCH24....1655
Wiring diagram SCH25....1658
Wiring diagram SCH27....1661
Wiring diagram SCH28....1667
Wiring diagram SCH30_{09-17-57}....1674
Wiring diagram SCH30_{09-17-18}....1677
Wiring diagram SCH30_{09-16-39}....1680
Wiring diagram SCH31....1683
Engine wire harness; replacing....1688
Electrical battery disconnect switch; replacing....1693
Electrical distribution box....1696
Electrical distribution box; circuit board replacing....1699
Fuse; description....1703
Relay; description_{09-01-18}....1706
Relay; description_{09-00-42}....1709
Relay; specifications....1712
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....1714
Instruments and controls; overview....1715
Instruments and controls; front instrument panel....1717
Instruments and controls; left instrument panel....1719
Instruments and controls; right instrument panel....1721
Instruments and controls; rear instrument panel....1723
Hour meter; replacing....1724
Fuel level sender; replacing....1727
Control lockout lever switch; description....1730
Control lockout lever switch; specifications....1733
Engine temperature sensor; replacing....1736
Engine oil pressure sensor; replacing....1738
Hydraulic oil temperature sensor; replacing....1740
Keypad; description....1742
Keypad; specification....1744
Service mode....1746
Engine system....1749
Hydraulic system....1752
Electrical system....1756
Load pin; calibrating....1760
Dual axis sensor; calibrating....1763
Volvo Smart View....1766
Volvo Smart View; specification....1770
Volvo Smart View camera; replacing....1773
Volvo Smart View; calibrating....1777
Volvo Smart View accuracy; checking....1782
39 - MISCELLANEOUS....1788
Radio with MP3; description....1789
Radio with MP3; specifications....1792
DC–DC converter; description....1793
DC–DC converter; specifications....1796
Voltage converter; replacing....1799
Antenna; replacing....1802
Speaker; replacing....1805
CareTrack W-ECU; description....1807
W-ECU; replacing; non-programmed....1812
W-ECU; replacing; pre-programmed....1816
CareTrack battery; replacing....1820
CareTrack antenna; replacing....1823
4 - POWER TRANSMISSION....1828
40 - GENERAL....1829
Tightening torque; Specifications ....1830
Power transmission; description....1832
43 - GEARBOX....1835
Function description-....1836
Track gearbox; specifications....1838
Track gearbox; description....1839
Track gearbox; maintenance standard....1845
Track unit; replacing....1848
Track gearbox cover; replacing....1852
Track gearbox; disassembly....1855
Track gearbox; assembly....1861
Function Description ....1869
Swing gearbox; specifications....1871
Swing gearbox; description....1872
Swing gearbox; maintenance standard....1876
Swing gearbox; replacing....1879
Swing gearbox removed; seal replacing....1884
Swing gearbox removed; replacing shaft....1888
Swing gearbox; disassembly....1901
Swing gearbox; assembly....1910
44 - HYDROSTATIC DRIVE....1918
Travel speed; description....1920
Track motor; specifications....1923
Track motor; description....1924
Track motor; maintenance standard....1935
Track motor relief valve; replacing....1943
Track motor; disassembly....1945
Track motor; assembly....1962
Swing motor; specifications_{07-07-30}....1978
Swing motor; specifications_{07-07-10}....1979
Swing motor; description_{07-06-37}....1980
Swing motor; description_{07-05-43}....1987
Swing motor; principle of operation....1995
Swing brake; description....2000
Swing motor; replacing....2002
Swing motor relief valve; replacing_{07-01-56}....2006
Swing motor relief valve; replacing_{07-01-27}....2008
Slew motor; adjustment_{07-00-42}....2010
Slew motor; adjustment_{07-00-14}....2012
Swing motor removed; seal replacing....2015
Swing motor; replacing brake piston seal....2019
Swing motor; replacing plate (brake)....2024
Swing motor; disassembly....2029
Swing motor; assembly....2036
Hydraulic pump coupling; description-[4751]....2049
Hydraulic pump coupling; description....2051
Pump gearbox coupling assembly; replacing....2053
Tightening torque; specifications_{06-42-52}....2055
Tightening torque; specifications_{06-42-14}....2059
Tightening torque; specifications_{06-41-51}....2061
Center passage; specifications_{06-41-15}....2063
Center passage; specifications_{06-40-54}....2065
Center passage; specifications_{06-40-34}....2067
Center passage; specifications_{06-40-13}....2068
Center passage; description_{06-39-41}....2069
Center passage; description_{06-39-14}....2072
Center passage; description_{06-38-52}....2075
Center passage; description_{06-38-23}....2078
Center passage; maintenance standard....2081
Center passage; replacing_{06-36-35}....2086
Center passage; replacing_{06-35-55}....2092
Center passage; replacing seal kit....2099
Center passage; disassembly_{06-34-05}....2105
Center passage; disassembly_{06-32-19}....2110
Center passage; assembly_{06-21-00}....2116
Center passage; assembly_{04-34-56}....2123
49 - MISCELLANEOUS....2130
Swing ring gear; specifications....2131
Swing ring gear; description....2132
Swing ring gear; replacing....2135
Swing ring gear grease pipe; replacing....2138
Swing ring gear inner seal; replacing....2143
Swing ring gear outer seal; replacing....2146
Measuring rotational clearance....2153
Swing ring; measuring axial clearance....2156
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....2160
70 - GENERAL....2161
Undercarriage; tightening torque_{04-24-38}....2162
Undercarriage; tightening torque_{04-24-12}....2164
Frame and track unit; specifications_{04-23-33}....2166
Frame and track unit; specifications_{04-23-13}....2167
Frame and track unit; description....2168
71 - FRAME....2170
Machine weight; specifications....2171
Superstructure; removing....2173
Superstructure; installing....2179
Tightening torque; Specifications....2185
Counterweight; tightening torques....2187
Counterweight; specifications....2189
Counterweight; description....2190
Counterweight; removing....2192
Counterweight; installing....2195
Undercarriage; description_{04-13-17}....2199
Undercarriage; description_{04-12-53}....2202
Undercarriage; description_{04-12-29}....2205
Undercarriage; description_{04-11-55}....2207
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....2210
Selection of track shoes_{04-08-24}....2212
Selection of track shoes_{04-08-04}....2214
Idler; description....2216
Idler; measurement of wear....2218
Front idler; replacing one....2221
Idler; disassembly....2224
Idler; assembly....2228
Tools & equipment....2231
Sprocket; measurement of wear....2236
Sprocket; replacing one....2239
Track chain; description....2241
Track link; dimension....2243
Track; adjusting track sag....2244
Track chain; measurement of wear....2246
Track shoe; replacing one....2251
Track links; replacing....2255
Track chain assembly; removing....2260
Track chain assembly; installing....2264
Rubber shoe_pad usage....2267
Rubber pads_{03-53-55}....2269
Rubber pads_{03-53-32}....2271
Rubber pads_{03-53-09}....2273
Top roller; description....2275
Top roller; measurement of wear....2277
Top roller; replacing one....2280
Top roller; disassembly....2285
Top roller; assembly....2288
Bottom roller; description....2292
Bottom roller; measurement of wear....2294
Bottom roller; replacing one....2297
Bottom roller; replacing seal....2302
Bottom roller; disassembly....2307
Bottom roller; assembly....2311
Track guards....2314
Track guard; replacing one....2315
Spring package; assembly dimension....2319
Track recoil spring (tensioner) assembly; replacing....2321
Spring package; disassembling_{03-36-47}....2324
Spring package; disassembly_{03-36-18}....2327
Spring package; assembly....2330
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....2333
81 - CAB; NAKED; CANOPY....2334
Cab suspension; description....2335
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....2336
Windows; general....2337
Windscreen; replacing....2340
Side window; replacing....2354
Rear window; replacing....2361
Door window; replacing....2369
85 - CAB INTERIOR; UPHOLSTERY....2372
Seat; replacing....2373
Seat cushion; replacing....2380
Driver's seat; description....2386
Driver's seat; specifications....2391
Seat heater; checking....2395
87 - AIR CONDITIONING UNIT....2399
HVAC system....2400
Air conditioning unit; specifications....2404
Air conditioning unit; description....2405
Performance test; AC unit....2410
Air conditioning unit; maintenance....2416
CCM pre-programmed ECU; replacing....2419
CCM non-programmed ECU; replacing....2421
Air conditioning unit; refrigerant check and recharging....2423
Air distribution; description_{03-13-05}....2431
Air distribution; description_{03-12-41}....2434
Air distribution; description....2435
Air distribution; description_{03-11-49}....2438
Heating system; description....2439
Fan motor; replacing....2441
Heater core; replacing....2443
Water valve; replacing....2451
Cooler and Heater assembly; replacing....2454
Compressor; replacing incl draining and filling....2461
Condenser; replacing incl draining and filling....2465
Auxiliary heater; description....2468
Auxiliary heater; principles....2471
Troubleshooting_{03-00-45}....2474
Troubleshooting_{02-59-37}....2484
88 - INTERIOR EQUIPMENT....2494
Instrument panel (left); replacing....2495
Instrument panel (right); replacing....2499
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....2503
90 - GENERAL....2504
Explanations to hydraulic diagram....2505
Hydraulic diagram; standard....2516
Hydraulic diagram; with option components_{02-49-06}....2519
Hydraulic diagram; with option components_{02-48-42}....2522
Hydraulic diagram; with option components_{02-48-14}....2528
Hydraulic system; position of main components....2534
Hydraulic system; cleanliness when handling hydraulic components....2537
Description; general....2541
Hydraulic system; description....2542
Recommended hydraulic oil; specifications....2543
Hydraulic pressure; specifications....2547
Hydraulic system; repair of hydraulic components in workshop....2549
Hydraulic oil; storage and handling....2554
Hydraulic components; storing and transporting....2558
Tech Tool; operations....2562
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....2564
2 stage port relief valve; adjustment....2571
2 stage port relief valve; description....2574
2 stage port relief valve; disassembly and assembly....2578
3 way selector valve; description....2581
3 way selector valve; specifications....2583
91618-3 Tiltrotator calibration....2584
Accumulator; replacing....2587
Adjustable boom (1st boom); description....2589
Adjustable boom (2nd boom); description....2591
Adjustable boom cylinder; description....2593
Adjustable boom cylinder; specifications....2596
Adjustable boom valve; description....2598
Adjustable boom valve; disassembly....2603
Adjustable boom; specifications....2612
Arm holding valve; description....2614
Arm holding valve; disassembly and assembly....2615
Arm parallel conflux changeover valve; disassembly....2616
Arm parallel conflux check valve; disassembly and assembly....2618
Arm regenerating valve; description....2620
Arm regenerating valve; disassembly....2624
Boom back pressure check valve; disassembly....2626
Boom cylinder; rupture valve; replacing....2628
Boom float position; description_{12-51-40}....2635
Boom float position; description_{12-52-03}....2638
Boom holding valve; description....2641
Boom holding valve; disassembly and assembly....2645
Boom regenerating check valve; disassembly....2648
Boom regenerating valve; description....2650
Breather; replacing....2652
Bucket flow control valve; description....2654
Bucket flow control valve; disassembly....2656
Bucket regenerating valve; description....2659
Bucket regenerating valve; disassembly....2663
Center bypass valve; disassembly and assembly....2665
Check valve; description....2667
Conflux check valve; disassembly....2669
Control pattern selector valve; description....2671
Control pattern selector valve; specifications....2675
Current_pressure; specifications....2676
Dipper arm cylinder; rupture valve; replacing....2677
Disassembly and assembly....2681
Disassembly and assembly; general....2709
Fan motor; assembly....2712
Fan motor; description....2719
Fan motor; disassembly....2725
Fan motor; tools....2733
Fan motor; troubleshooting....2736
Fan pump; description....2739
Flow control valve; description....2742
Flow control valve; disassembly and assembly....2744
Function Description....2747
General maintenance instructions....2750
General; tools....2753
Hammer and shear pedal valve (RCV); replacing....2757
Hydraulic components; description....2758
Hydraulic cooling fan control; specifications....2761
Hydraulic oil cooler; description....2763
Hydraulic oil cooling system; description....2764
Hydraulic oil cooling system; specifications....2766
Hydraulic oil tank; description....2768
Hydraulic oil tank; specifications....2771
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump....2772
Hydraulic pump (removed); changing shaft seal....2776
Hydraulic pump regulator; replacing....2778
Hydraulic pump; description....2781
Hydraulic pump; maintenance standard; Specifications....2787
Hydraulic pump; specifications....2791
Hydraulic system; work instructions....2792
Line rupture valve (arm); air breathing....2797
Line rupture valve (arm); assembly....2799
Line rupture valve (arm); description....2802
Line rupture valve (arm); disassembly....2804
Line rupture valve (arm); specifications....2807
Line rupture valve (arm); troubleshooting....2808
Line rupture valve (boom); air breathing....2810
Line rupture valve (boom); assembly....2812
Line rupture valve (boom); description....2815
Line rupture valve (boom); disassembly....2820
Line rupture valve (boom); specifications....2823
Line rupture valve (boom); troubleshooting....2824
Line rupture valve pressure; checking and adjusting....2827
Line rupture valve relief pressure; measurement....2830
Load check valve – single; disassembly and assembly....2832
Main control valve adjustor; adjusting....2834
Main control valve troubleshooting....2836
Main control valve; description....2839
Main control valve; specifications....2855
Main dimensions....2857
Main pressure relief valve; replacing....2859
Main relief valve; adjustment....2861
Main relief valve; assembly....2864
Main relief valve; description....2867
Main relief valve; disassembly....2870
Main spool; disassembly and assembly....2873
Oil cooler fan motor; replacing....2876
Oil cooler fan pump; replacing....2880
Oil cooler line bypass valve (check valve); replacing....2883
Oil level gauge; replacing....2886
Operating cycle; description....2888
Port relief valve pressure; adjustment (when installing or dismantling the line rupture valve)....2890
Port relief valve pressure; measuring and adjusting....2893
Port relief valve; description....2896
Port relief valve; disassembly and assembly....2899
Pressure accumulator; description....2902
Pressure accumulator; specifications....2904
Pressure relief valve; troubleshooting....2905
Proportional relief valve; description....2909
Proportional relief valve; specifications....2912
Proportional solenoid valve (power shift); replacing....2913
Proportional solenoid valve; Description....2915
Proportional solenoid valve; Specifications....2918
Proportional solenoid valve; description....2921
Proportional solenoid valve; measuring and adjustment....2924
Proportional solenoid valve; specifications....2929
Proportional solenoid valve; troubleshooting....2932
Pump; assembly....2935
Pump; disassembly....2942
Pump; installation....2948
Pump; tools....2950
Pump; troubleshooting....2952
Regulator; description....2957
Regulator; disassembly and assembly....2963
Remote control valve (Lever); assembly_{01-32-18}....2973
Remote control valve (Lever); assembly_{01-32-52}....2986
Remote control valve (Lever); description_{01-37-00}....2998
Remote control valve (Lever); description_{01-37-42}....3008
Remote control valve (Lever); disassembly_{01-33-59}....3021
Remote control valve (Lever); disassembly_{01-34-28}....3034
Remote control valve (Lever); maintenance standard; Specifications_{01-35-46}....3046
Remote control valve (Lever); maintenance standard; Specifications_{01-36-06}....3049
Remote control valve (Lever); specifications_{01-38-27}....3053
Remote control valve (Lever); specifications_{01-38-46}....3055
Remote control valve (Lever); troubleshooting_{01-30-47}....3059
Remote control valve (Lever); troubleshooting_{01-31-07}....3062
Remote control valve (lever); replacing....3065
Remote control valve (pedal); assembling_{01-25-51}....3077
Remote control valve (pedal); assembly_{01-25-27}....3086
Remote control valve (pedal); description_{01-29-02}....3098
Remote control valve (pedal); description_{01-29-26}....3106
Remote control valve (pedal); disassembling_{01-27-28}....3112
Remote control valve (pedal); disassembly_{01-27-05}....3122
Remote control valve (pedal); maintenance standard; Specifications....3133
Remote control valve (pedal); replacing....3136
Remote control valve (pedal); specifications....3141
Remote control valve (pedal); specifications_{01-29-57}....3143
Remote control valve (pedal); specifications_{01-30-17}....3145
Remote control valve (pedal); troubleshooting_{01-23-51}....3146
Remote control valve (pedal); troubleshooting_{01-24-10}....3149
Rotator (X3 Line option); description....3151
Rotator pump; assembly....3155
Rotator pump; description....3158
Rotator pump; disassembly....3162
Rotator pump; parts inspection....3165
Rotator pump; specifications....3167
Rotator valve; adjustment....3169
Servo hydraulic block....3172
Servo hydraulic pressure; adjustment....3174
Servo pump; description....3177
Servo pump; parts inspection....3181
Servo pump; replacing....3184
Servo pump; specifications....3187
Shuttle valve block; description....3188
Single pedal stopper position....3191
Solenoid valve for rotator....3193
Solenoid valve; boom float....3195
Solenoid valve; description-....3197
Solenoid valve; description....3200
Solenoid valve; disassembly and assembly....3204
Solenoid valve; inspection....3208
Solenoid valve; replacing....3211
Solenoid valve; specifications-....3213
Solenoid valve; specifications....3214
Solenoid valve; troubleshooting....3216
Specifications....3220
Stop valve....3222
Straight travel pedal; description....3224
Theory of hoist operation; description....3228
Tightening Torques ....3231
Tightening Torques-....3235
Tightening Torques....3237
Tightening torque; specifications....3240
Tightening torques-....3244
Tightening torques_{01-39-22}....3246
Tightening torques_{01-39-46}....3251
Tiltrotator control system; description....3257
Winch assembly; replacing....3265
Winch assembly; specifications....3269
Winch dimensions....3270
Winch troubleshooting guide....3272
X1 Line; description....3276
X1 Pre-set relief valve; adjusting....3282
X1 Pre-set relief valve; description....3284
X1 Pre-set relief valve; disassembly and assembly....3288
92 - MECHANICAL EQUIPMENT_ATTACHMENT....3290
Attachment quick coupler; description_{12-49-50}....3291
Attachment quick coupler; description_{12-49-19}....3304
Attachment quick coupler; operation....3315
Attachment quick coupler; replacing_{12-48-02}....3318
Attachment quick coupler; replacing_{12-47-39}....3327
Attachment quick coupler; adjustment....3337
Attachment quick coupler solenoid valve; description_{12-46-30}....3341
Attachment quick coupler solenoid valve; description_{12-46-08}....3346
Tightening torques....3348
Remote control valve (dozer blade); specifications....3350
Remote control valve (dozer blade); description....3351
Control lever (dozer blade); replacing....3354
Dozer blade; specifications....3361
Dozer blade; description....3362
Dozer blade cylinder; specifications....3365
Dozer blade cylinder; description....3367
Dozer blade cylinder; replacing....3369
Check valve; replacing....3376
94 - UNIT; LOAD HANDLING....3381
Load block; description_{12-39-14}....3382
Load block; description_{12-38-55}....3384
Flag block; description....3386
97 - UNIT; DIGGING....3387
Tightening torques_{12-36-39}....3389
Tightening torques_{12-36-16}....3391
Function description....3399
Digging unit; maintenance....3401
Bushing general; replacing....3405
Cylinder; description....3410
Cylinder; disassembly and assembly....3415
Cylinder; troubleshooting....3432
Boom; specifications_{12-31-51}....3436
Boom; specifications_{12-31-32}....3437
Boom; description_{12-31-02}....3438
Boom; description_{12-30-34}....3440
Boom; replacing....3443
Boom (pipe layer); replacing....3454
Boom cylinder; specifications....3458
Boom cylinder; description....3459
Boom cylinder; replacing....3461
Lower boom cylinder bushing; replacing....3470
Upper boom cylinder bushing; replacing....3475
Dipper arm; specifications....3479
Dipper arm; description....3480
Dipper arm; replacing....3483
Link; description....3496
Dipper arm connecting rod; replacing....3498
Connecting rod yoke; replacing....3505
Dipper arm cylinder; specifications....3514
Dipper arm cylinder; description....3515
Dipper arm cylinder; replacing....3517
Dipper arm cylinder bushing on boom; replacing....3527
Dipper arm cylinder bushing on dipper arm; replacing....3532
Tiltable ditching bucket; description....3536
Tiltable ditching bucket cylinder; specifications....3541
Tiltable ditching bucket cylinder; description....3543
Hydraulic Cylinder; disassembling and assembling....3546
Bucket cylinder; specifications....3554
Bucket cylinder; description....3555
Bucket cylinder; replacing....3557
Bucket cylinder bushing on dipper arm; replacing....3568
Bucket cylinder bushing lever-link; replacing....3573
99 - MISCELLANEOUS....3577
Wire rope; specifications....3578
Wire rope; proper use....3580
Wire rope; description....3584
Wire rope; maintenance....3589
Wire rope; replacing....3592
Volvo ECR145E L Excavators Repair Service Manual
