Volvo EC480D Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EC480D, EC480DL Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions EC480D, EC480DL 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 EC480D, EC480DL Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,890 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
000 - Foreword....2
000 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Machine view_{05-06}....5
Machine view_{04-37}....7
Product plates....9
General description....12
07 - STANDARD TIME....13
Operation numbers for additional work....14
08 - TOOL....16
E-tools; NET 8940-00290 Swing motor guide pin....17
09 - MISCELLANEOUS....19
Service positions....20
Welding on the machine....23
Hydraulic cylinders; dieseling....26
001 - STANDARD PARTS; SERVICE....31
16 - LUBRICANT; FUEL; OTHER FLUID....32
Recommended lubricants....33
Grease....36
Hydraulic oil_{53-59}....41
Hydraulic oil_{53-32}....47
Specification; filling capacities_{52-59}....50
Specification; filling capacities_{52-30}....51
Engine oil_{51-57}....52
Engine oil_{51-31}....54
Engine oil_{51-02}....57
Fuel_{50-30}....59
Fuel_{50-04}....63
Alternative fuels....65
Coolant_49-10....76
Coolant....82
Coolant with freezing and corrosion protection....86
17 - SERVICE....91
Bearings....95
Replacement parts....100
Safety when servicing....105
Service....110
Service methods....114
Pressure testing....119
Hoses and tubes....124
Cleaning prior to repair....129
VCADS Pro; Operations....134
Arrival Inspection; according to Inspection Programme....136
Delivery Inspection; according to Inspection Programme....141
Maintenance of Stored Machines; according to Inspection Programme....146
Measuring condition....151
Cylinder speed_{43-53}....155
Cylinder speed_{43-22}....158
Creeping of hydraulic cylinder....161
Swing speed....163
Coasting left and right swing....164
Measuring of swing bearing clearance....166
Travel Speed_{40-58}....169
Travel Speed_{40-28}....171
Track running speed_{39-53}....173
Track running speed_{39-24}....175
Straight traveling performance....177
Maintenance service; first 500 hours_{04-29}....179
Maintenance service; first 500 hours_{04-01}....180
Maintenance service; daily_{03-29}....181
Maintenance service; daily_{03-04}....182
Maintenance service; every 50 hours_{01-19}....183
Maintenance service; every 50 hours_{00-53}....185
Maintenance service; every 250 hours_{00-21}....187
Maintenance service; every 250 hours_{59-55}....189
Maintenance service; every 500 hours_{59-23}....191
Maintenance service; every 500 hours_{58-57}....193
Maintenance service; every 1000 hours_{58-25}....195
Maintenance service; every 1000 hours_{58-00}....197
Maintenance service; every 2000 hours_{49-56}....199
Maintenance service; every 2000 hours_{49-29}....202
Maintenance service; every 4000 hours_{48-57}....205
Maintenance service; every 4000 hours_{48-32}....208
Maintenance service; every 4500 hours....211
Maintenance service; every 6000 hours_{54-40}....212
Maintenance service; every 6000 hours_{54-15}....213
Maintenance service; every 8000 hours....214
Maintenance service; every 12000 hours....215
Test-run and check....216
MATRIS; reading; export reading....219
VCADS Pro; logged errors; read off....222
The machine; check for external damages; cracks and wear damages....225
Washer fluid level; check....228
Engine; oil level; check....229
Coolant level; check_{51-27}....231
Coolant level; check_{51-00}....233
Hydraulic oil level; check_{50-28}....235
Hydraulic oil level; check_{50-01}....237
Fuel filter; change....239
Water separator; check_drain....241
Extra water separator (optional equipment); check_drain....243
Water separator filter element; change....245
Extra water separator (optional equipment); filter element; change....247
Fuel tank sediment; drain....250
Fuel tank air ventilation filter; change....252
Hydraulic oil servo filter; change....254
Engine air cleaner primary filter; cleaning_{47-06}....256
Engine air cleaner primary filter; cleaning_{46-35}....258
Engine air cleaner primary filter; replacing_{46-00}....260
Engine air cleaner primary filter; replacing_{45-29}....262
Engine air cleaner secondary filter; replacing_{44-55}....264
Engine air cleaner secondary filter; replacing_{44-23}....267
Battery condition; check_{23-47}....270
Battery condition; check_{23-16}....274
Belts and belt tension; check; replace when needed._{22-39}....278
Belts and belt tension; check; replace when needed._{22-10}....280
Radiator; cleaning....282
Hydraulic oil cooler outside; cleaning....284
Hydraulic oil drain filter; change....287
Hydraulic oil suction strainer; clean....289
Valves; adjusting_{20-09}....291
Valves; adjusting_{19-35}....298
Coolant anti-freeze resistance; checking_....304
Coolant; change....308
Diesel particulate filter; replacing_....311
Air dryer cartridge; change....315
Air pump oil level; check....318
Air pump oil; change....320
Spark plug cable; replacing_....323
Spark plug; replacing_....325
EGR venturi tube; checking_....328
Air conditioner main filter; clean....331
Air conditioner main filter; change....335
Cab prefilter; cleaning....339
Cab prefilter; replacing....341
Lubrication; see lubrication chart....343
Swing gearbox oil level; check....345
Swing motor gearbox; changing oil....347
Swing ring gear bearing; lubricate....350
Swing bath grease; check....351
Cab; door; covers; hinges; joints and locks; lubricate....352
Track shoe bolts; check....354
Track tension_condition; check....357
Track gearbox oil level; check....359
Track motor gearbox; changing oil ....361
Loose and loss of bolts; check....363
Oil-bath air cleaner's reservoir (optional equipment); oil; check....366
Oil-bath air cleaner's reservoir (optional equipment); clean; and oil; change....368
Oil-bath air cleaner's reservoir (optional equipment); filter insert; clean....371
X1 return filter (optional equipment); change_{06-45}....374
X1 return filter (optional equipment); change_{06-16}....377
Service history (included in the respective Operator's manual); fill in...379
Engine oil and filter; changing....382
CareTrack backup battery; replacing....385
Hydraulic oil; changing....390
Hydraulic oil return filter; replacing....394
Hydraulic oil tank breather filter; replacing....398
Starting engine with booster cables_....400
19 - GENERAL....404
Safety concerns everybody!....405
CE-marking; EMC-directive....410
Safety when handling the machine....414
Safety rules when servicing....421
Move and operate machine safely....426
Welding and grinding work....430
Fire prevention measures....434
Checklist after a fire or heat exposure....441
Safety when handling oils and fuel....446
Safety when using lifting equipment....451
Safety when working with hydraulic systems....456
Safety when working with air conditioning refrigerant....461
Starting with booster batteries....467
Safety when working with batteries....472
Environmental handling for the future....478
Environmentally safe handling....483
Environmentally hazardous fluids....488
Health hazards with paint; plastics and rubber....493
Working in environmentally contaminated areas....499
Decontamination....504
Waste handling....509
Cautions during operation....514
002 - ENGINE WITH MOUNTING AND EQUIPMENT....521
20 - GENERAL....522
Engine; description_{50-12}....523
Engine; description_{49-46}....528
VCADS Pro; Operations_{49-13}....533
VCADS Pro; Operations_{48-47}....535
Component locations_{48-15}....538
Component locations_{47-47}....541
Engine; identification....544
E-ECU MID 128 pre-programmed; replacing_{46-55}....546
E-ECU MID 128 pre-programmed; replacing_{46-24}....550
E-ECU MID 128 non-programmed; replacing_{35-50}....554
E-ECU MID 128 non-programmed; replacing_{35-19}....558
21 - ENGINE....562
Engine; specifications_{32-54}....564
Engine; specifications_{32-28}....565
Engine rotation speed sensor (crankshaft); replacing....566
Engine rotation speed sensor (camshaft); replacing ....569
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope....573
Engine; removing_{30-37}....579
Engine; removing_{29-59}....591
VCADS Pro; MID 128; programming E-ECU_{29-16}....603
VCADS Pro; MID 128; programming E-ECU_{28-51}....605
Engine; installing_{28-18}....607
Engine; installing_{27-49}....617
Valve cover; tightening torques....628
Cylinder head; tightening torques....630
Cylinder head; description....633
Crankcase ventilation; description_{24-52}....636
Crankcase ventilation; description_{24-23}....641
Crankcase ventilation separator; replacing....644
Valve mechanism; tightening torques....647
Valve mechanism; specifications_{22-51}....650
Valve system; specifications_{22-24}....654
Rocker arms; replacing....657
Rocker arm shaft; tightening torques....660
Valves; adjusting_{21-09}....662
Valves; adjusting_{20-36}....669
Valve cover; removing....675
Valve cover; installing....679
Engine transmission; tightening torque....684
Engine transmission; specification....690
Camshaft; replacing....693
Timing gear plate; replacing_{17-31}....704
Timing gear plate; replacing_{33-49}....737
Crank mechanism; description....773
Flywheel; tightening torques....777
Crankshaft front oil seal; replacing....780
Crankshaft rear oil seal; replacing....792
Oil level sensor; replacing_{18-38}....798
Oil level sensor; replacing_{18-10}....801
Oil sump; tightening torque....804
Engine mounting; tightening torque_{15-14}....806
Engine mounting; tightening torque_{14-48}....808
22 - LUBRICATING SYSTEM....810
Lubrication system; description_{10-28}....811
Lubrication system; description_{09-50}....817
Lubrication system; description_{09-20}....824
Lubrication system; specifications....831
Lubrication oil consumption; checking....833
Lubrication system; component locations_{08-06}....838
Lubrication system; component locations_{07-41}....840
Lubrication oil pressure; checking with pressure gauge....842
Oil cooler; tightening torques....845
23 - FUEL SYSTEM....847
Fuel system; description....848
Fuel system; specifications....854
Fuel system; tightening torques....855
Air in fuel system; checking....862
Carbon dioxide in fuel system; checking....865
Fuel system; component locations_{03-03}....871
Fuel system; component locations_{02-36}....873
Fuel feed pump; description....875
Feed pump pressure; checking....877
Feed pump; replacing....879
Fuel pump; inspecting....881
Fuel system; bleeding_{19-11}....886
Fuel system; bleeding_{18-44}....888
Feed pump bearing housing; replacing....890
Fuel tank; specifications....899
Fuel filler pump; specifications....900
Fuel tank; description....902
Fuel filling pump; removing....903
Fuel filling pump; installing....905
Unit injectors; description....907
Unit injector pretension; adjusting....910
Injectors; checking....912
Yoke; injector; checking....924
Injectors; replacing_{12-39}....929
Injectors; replacing_{12-02}....938
Overflow valve; replacing....948
Injector sleeves; replacing_{10-51}....950
Injector sleeves; replacing_{10-00}....959
25 - INLET & EXHAUST SYSTEM....966
Inlet and exhaust system; description_{07-06}....968
Inlet and exhaust system; description_{06-32}....972
Inlet and exhaust system; component locations_{05-57}....977
Inlet and exhaust system; component locations_{05-32}....979
Inlet and exhaust system; tightening torques_{04-59}....981
Inlet and exhaust system; tightening torques_{04-31}....983
Exhaust manifold; tightening torques_{02-58}....985
Exhaust manifold; tightening torques_{02-33}....987
Exhaust pipe flexible tube; replacing....989
Exhaust aftertreatment system; description....992
Exhaust aftertreatment system; component locations....1000
Regeneration process; description....1002
Exhaust aftertreatment system; specifications....1005
Perform a service regeneration....1008
Diesel particulate filter; replacing....1011
Exhaust aftertreatment system; tightening torques....1015
ACM (Aftertreatment control module) non-programmed; replacing....1019
ACM (Aftertreatment control module) pre-programmed; replacing....1021
Atomization unit; replacing....1023
Spark plug; inspecting....1027
Spark plug; replacing....1030
Spark plug cable; replacing....1033
Air pump flow; checking....1035
Air pump; replacing....1037
Burner; replacing....1041
Compressor; replacing....1048
Exhaust aftertreatment system fuel pump; replacing....1052
ASU (Aftertreatment support unit); replacing....1057
High pressure air system pressure; checking....1061
Compressed-air system; specifications....1064
Exhaust aftertreatment system fuel flow; checking....1066
Exhaust aftertreatment fuel injector; replacing....1070
Turbocharger; description_{52-14}....1075
Turbocharger; description_{51-49}....1078
Turbocharger; specifications_{51-12}....1084
Turbocharger; specifications_{50-47}....1086
Turbocharger; inspecting....1088
Turbocharger; replacing_{49-58}....1090
Turbocharger; replacing_{49-30}....1096
Turbocharger; tightening torques_{48-55}....1102
Turbocharger; tightening torques_{48-30}....1104
Variable turbocharger actuator; replacing....1107
Preheating coil; replacing_{46-28}....1114
Preheating coil; replacing_{46-00}....1117
Charge air cooler; replacing_{44-22}....1120
Charge air cooler; replacing_{43-52}....1128
26 - COOLING SYSTEM....1136
Cooling system; description....1137
Carbon dioxide in coolant system; checking....1142
Cooling system; component locations_{42-06}....1149
Cooling system; component locations_{41-41}....1151
Cooling system; tightening torques_{41-09}....1153
Cooling system; tightening torques_{40-43}....1155
Cooling system leakage; checking....1157
Radiator; description_{39-52}....1159
Radiator; description_{39-27}....1162
Coolant anti-freeze resistance; checking....1164
Coolant; changing....1170
Radiator; replacing....1173
Radiator hose upper; replacing....1176
Radiator hoses lower; replacing....1178
Expansion tank; replacing....1181
Thermostat; replacing....1184
Thermostat; checking....1187
Thermostat; specifications_{34-52}....1191
Thermostat; specifications_{34-26}....1193
Cooling fan control....1194
Fan belt and_or alternator belt; replacing....1196
Fan belt and_or alternator-; compressor belt; replacing all belts_{32-52}....1198
Fan belt and_or alternator-; compressor belt; replacing all belts_{32-24}....1202
27 - ENGINE CONTROL....1206
Engine - Pump control; specification_{31-48}....1207
Engine - Pump control; specification_{31-22}....1209
28 - IGNITION AND CONTROL SYSTEM....1211
Cable harness O-ring; replacing....1212
29 - MISCELLANEOUS....1217
EGR (Exhaust Gas Recirculation); description....1218
EGR (Exhaust Gas Recirculation); component locations....1225
EGR system; tightening torques....1227
EGR cooler; replacing....1229
EGR cooler pressure; testing....1239
EGR pressure sensor; replacing....1243
EGR valve; replacing....1246
EGR venturi tube; checking....1250
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....1253
30 - GENERAL....1254
Electrical system; special instructions for servicing; general....1259
Electrical system; special instructions for servicing; electronic components....1263
Electrical system; special instructions for servicing; electrical components; batteries....1267
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator....1272
Electrical system; special instructions for servicing; action when working on machine....1276
Electrical system; description....1280
Electronic control system; description....1282
Communication with data buses_{20-08}....1285
Communication with data buses_{19-41}....1288
Auxiliary start....1291
Data buses; function....1296
Service connection and programming connection_{18-10}....1302
Service connection and programming connection_{17-42}....1305
VCADS Pro; Operations_{17-07}....1308
VCADS Pro; Operations_{16-41}....1311
Electrical system; specifications....1313
Power Boost control; description....1316
Emergency operation; description....1318
Anti-theft system....1320
CareTrack with anti-theft....1322
Start lock; description....1331
Safe start and stop; description....1333
X1 control; description....1335
X1 pressure control; description....1339
X3 control; description....1341
Quick fit control; description....1344
Mode selection; description_{11-47}....1346
Mode selection; description_{11-21}....1350
Boom float position; description....1354
Overload warning....1356
Auto Idle....1357
ECO mode; description....1359
Power derating....1362
VCADS Pro; 17030-3 - Parameter; programming....1365
Software parameters; description....1368
Automatic engine shut-down....1374
DPF regeneration control....1377
General fault diagnosis information....1385
Troubleshooting strategy....1387
Collection of basic data....1390
Information display; check....1395
Error codes; build-up....1398
Conditions when checking....1403
Lead and connector checks....1408
Troubleshooting tools_{03-00}....1415
Troubleshooting tools_{02-35}....1418
Special tools for troubleshooting....1420
VCADS Pro service tool....1423
AL3201; description and measuring....1427
BA3101; description and measuring_{00-29}....1429
CU9901; description and measuring....1432
FU18; description and measuring_{58-40}....1434
FU18; description and measuring_{58-07}....1436
FU26; description and measuring....1438
FX1005; description and measuring....1440
FX1006; description and measuring....1443
FX1007; description and measuring....1446
FX1008; description and measuring....1450
FX1032; description and measuring....1453
HE2501; description and measuring....1456
IG2501; description and measuring....1458
MA2301-MA2306; description and measuring....1460
MA2506; description and measuring....1463
MA2507; description and measuring....1465
MA4212; description and measuring....1467
MA9109; description and measuring....1469
MA9110; description and measuring....1471
MA9111; description and measuring....1473
MA9116; description and measuring....1475
MA9117; description and measuring....1477
MA9118; description and measuring....1479
MA9120; description and measuring....1481
MA9121; description and measuring....1483
MA9122; description and measuring....1485
MA9123; description and measuring....1487
MA9125; description and measuring....1489
MID128 SID230; description and measuring_{32-21}....1491
MID140 PID251; description and measuring_{31-25}....1494
MID140 PPID1144; description and measuring....1499
MO2501; description and measuring....1501
MO2504; description and measuring....1503
MO3301; description and measuring....1505
Power supply; ACM (Aftertreatment Control Module); description and measuring....1507
Power supply ECC; description and measuring....1509
Power supply E-ECU; description and measuring_{26-36}....1511
Power supply I-ECU; description and measuring....1514
Power supply V-ECU; description and measuring....1516
Power supply W-ECU; description and measuring....1518
PPID1336; description and measuring....1520
PWM2503; description and measuring....1523
PWM9109; description and measuring....1525
PWM9123; description and measuring....1527
PWM9124; description and measuring....1529
PWM9129; description and measuring....1531
PWM9130; description and measuring....1533
PWM9141; description and measuring....1535
PWM9143; description and measuring....1537
PWM9145; description and measuring....1539
PWM9146; description and measuring....1541
RE2501; description and measuring....1543
RE3101; description and measuring....1545
RE3301; description and measuring....1548
RE3302; description and measuring....1551
RE4206; description and measuring_{12-37}....1553
SAE J1708_1587 Information link; description and measuring_{11-44}....1558
SAE J1708_1587 Information link; description and measuring_{46-05}....1561
SAE J1939_CAN control link; description and measuring....1564
SAEJ1939_CAN7 Control link; description and measuring....1567
SE2203; description and measuring_{58-06}....1570
SE2203; description and measuring_{57-16}....1573
SE2301; description and measuring....1576
SE2303; description and measuring....1579
SE2509; description and measuring....1582
SE2510; description and measuring....1585
SE2514; description and measuring....1587
SE2515; description and measuring....1589
SE2516; description and measuring....1591
SE2519; description and measuring....1594
SE2521; description and measuring....1596
SE2522; description and measuring....1598
SE2527; description and measuring....1600
SE2528; description and measuring....1602
SE2529; description and measuring....1604
SE2603; description and measuring....1607
SE2606; description and measuring....1609
SE2701; description and measuring....1612
SE2703; description and measuring....1614
SE8701; description and measuring....1616
SE8702; description and measuring....1618
SE8705; description and measuring....1621
SE8706; description and measuring....1623
SE9105; description and measuring....1625
SE9136; description and measuring....1628
SE9401; description and measuring....1632
SID211; description and measuring....1635
SID232; description and measuring_{36-56}....1637
SID232; description and measuring_{36-17}....1639
SW2506; description and measuring....1641
SW2701; description and measuring....1643
SW3301; description and measuring....1645
SW9160; description and measuring....1647
SW9161; description and measuring....1649
SW9162; description and measuring....1651
VCADS Pro socket; measuring....1653
VCADS Pro; connecting problems....1656
31 - BATTERY....1659
Starting engine with booster cables....1660
Battery; storage....1664
Battery; description....1668
Battery; specifications....1672
Battery charging capacity; checking_{26-14}....1674
Battery charging capacity; checking_{25-49}....1676
Battery; charging_{25-17}....1679
Battery; charging_{24-50}....1681
Batteries; replacing....1685
Earth lead to battery; replacing_{23-59}....1688
Earth lead to battery; replacing_{23-34}....1691
32 - ALTERNATOR; CHARGE REGULATOR....1694
Charging; description ....1695
Alternator; specifications ....1697
Alternator; description_{21-50}....1698
Alternator; description_{21-24}....1701
Alternator; replacing incl function checking ....1705
Alternator; testing ....1709
33 - STARTING SYSTEM....1711
Starting operation ....1712
Starter motor; description ....1714
Starter motor; specifications ....1716
Starter motor; testing ....1717
Starter relay; replacing_{18-22}....1719
Starter relay; replacing_{17-56}....1721
Starter motor; replacing_{17-24}....1723
Starter motor; replacing_{16-59}....1725
Preheating; description_{15-03}....1727
Preheating; description_{14-37}....1729
Preheating; description_{14-10}....1731
Starter switch; testing ....1734
35 - LIGHTING....1737
Work lights and extra lights; description ....1738
Work lights and extra lights; specifications_{12-12}....1741
Work lights and extra lights; specifications_{11-47}....1744
Work lighting headlamp assembly; replacing ....1747
36 - OTHER ELECTRICAL EQUIPMENT....1750
Interface for external equipment (Attachment Link); description ....1752
Electric horn; specifications ....1755
Horn; replacing ....1758
Rotating beacon; specifications ....1760
Rotating beacon; replacing ....1762
Travel alarm; specifications ....1764
Travel alarm; replacing ....1767
Travel alarm; description ....1769
Windscreen wiper; description ....1771
Wiper controller; description ....1773
Wiper controller; specifications ....1775
Upper wiper motor; description ....1777
Upper wiper motor; specifications ....1779
Lower wiper motor; description ....1781
Lower wiper motor; specifications ....1783
Windscreen flusher pump; specifications ....1785
Window limit switch; description ....1788
Windscreen wiper front motor; replacing ....1791
Windscreen wiper switch; replacing ....1796
Windscreen flusher pump; replacing ....1799
Windscreen wiper controller; replacing ....1801
Start switch; description ....1806
Start switch; specifications ....1809
Engine limp home switch; description ....1811
Engine limp home switch; specifications ....1813
Auto_Manual pump control switch; description ....1815
Auto_Manual pump control switch; specifications ....1817
Connectors; overview_{00-54}....1819
Connectors; overview_{43-57}....1827
Pre-heating relay; replacing ....1836
Control lockout lever switch; replacing ....1838
Control levers; description ....1841
Ignition switch; replacing ....1843
Crimping tools ....1846
Dismantling tools ....1858
Electronic climate control unit ECC; description ....1870
Engine control unit E-ECU; function description_{06-52}....1872
Engine control unit E-ECU; function description_{06-25}....1874
GPS control unit GPS-ECU; description ....1876
Instrument control unit I-ECU; functional description ....1879
Vehicle control unit V-ECU; functional description_{05-12}....1882
Vehicle control unit V-ECU; functional description_{04-46}....1884
Electronic climate control unit ECC; specification ....1886
GPS control unit GPS-ECU; specifications ....1888
Instrument control unit I-ECU; specifications ....1890
I-ECU MID 140 non-programmed; replacing ....1892
I-ECU MID 140 pre-programmed; replacing ....1895
V-ECU MID 187 non-programmed; replacing ....1898
V-ECU MID 187 pre-programmed; replacing ....1902
Engine speed control switch; replacing ....1906
Battery charger; description ....1911
Battery charger; specifications ....1913
37 - CABLE; FUSE; RELAY....1914
Wiring diagram_{44-41}....1920
Wiring diagram_{44-29}....1922
Control system diagram_{44-10}....1924
Control system diagram_{43-58}....1927
Wiring diagram; electrical distribution box_{43-39}....1930
Wiring diagram SCH01_{11-11}....1933
Wiring diagram SCH01_{41-39}....1937
Wiring diagram SCH01_{41-25}....1941
Wiring diagram SCH01_{41-11}....1945
Wiring diagram SCH01_{40-56}....1949
Wiring diagram SCH01_{40-42}....1953
Wiring diagram SCH01_{40-27}....1957
Wiring diagram SCH02_{18-24}....1961
Wiring diagram SCH02_{38-24}....1964
Wiring diagram SCH02_{38-10}....1967
Wiring diagram SCH02_{37-56}....1970
Wiring diagram SCH02_{37-42}....1973
Wiring diagram SCH02_{37-28}....1976
Wiring diagram SCH03_{37-08}....1979
Wiring diagram SCH03_{36-54}....1983
Wiring diagram SCH03_{36-40}....1987
Wiring diagram SCH03_{36-26}....1991
Wiring diagram SCH03_{36-12}....1995
Wiring diagram SCH04_{35-51}....1999
Wiring diagram SCH04_{35-37}....2003
Wiring diagram SCH04_{35-23}....2007
Wiring diagram SCH04_{35-09}....2011
Wiring diagram SCH05_{34-48}....2015
Wiring diagram SCH05_{34-32}....2019
Wiring diagram SCH07_{34-14}....2023
Wiring diagram SCH07_{34-01}....2026
Wiring diagram SCH07_{33-47}....2029
Wiring diagram SCH07_{33-33}....2032
Wiring diagram SCH08_{33-13}....2035
Wiring diagram SCH08_{32-59}....2038
Wiring diagram SCH08_{32-46}....2041
Wiring diagram SCH08_{32-32}....2044
Wiring diagram SCH08_{32-18}....2047
Wiring diagram SCH08_{32-04}....2050
Wiring diagram SCH10_{31-44}....2053
Wiring diagram SCH10_{31-30}....2056
Wiring diagram SCH10_{31-17}....2059
Wiring diagram SCH10_{31-03}....2062
Wiring diagram SCH11_{30-43}....2065
Wiring diagram SCH11_{30-29}....2068
Wiring diagram SCH11_{30-16}....2071
Wiring diagram SCH11_{30-04}....2074
Wiring diagram SCH11_{29-50}....2077
Wiring diagram SCH12_{13-16}....2080
Wiring diagram SCH12_{23-59}....2084
Wiring diagram SCH12_{23-16}....2088
Wiring diagram SCH12_{23-56}....2092
Wiring diagram SCH12_{23-42}....2096
Wiring diagram SCH12_{23-27}....2100
Wiring diagram SCH12_{23-14}....2104
Wiring diagram SCH13_{22-53}....2108
Wiring diagram SCH13_{22-40}....2111
Wiring diagram SCH13_{22-24}....2114
Wiring diagram SCH14_{17-39}....2117
Wiring diagram SCH14_{17-49}....2120
Wiring diagram SCH14_{17-36}....2123
Wiring diagram SCH14_{17-23}....2126
Wiring diagram SCH15_{23-29}....2129
Wiring diagram SCH15_{13-23}....2133
Wiring diagram SCH15_{13-29}....2137
Wiring diagram SCH15_{13-16}....2142
Wiring diagram SCH15_{13-02}....2146
Wiring diagram SCH16_{08-30}....2150
Wiring diagram SCH16_{08-50}....2153
Wiring diagram SCH16_{08-17}....2156
Wiring diagram SCH16_{07-44}....2159
Wiring diagram SCH16_{07-11}....2162
Wiring diagram SCH17_{05-61}....2165
Wiring diagram SCH17_{03-41}....2169
Wiring diagram SCH17_{05-41}....2173
Wiring diagram SCH17_{05-08}....2177
Wiring diagram SCH17_{04-34}....2181
Wiring diagram SCH18_{02-32}....2185
Wiring diagram SCH18_{02-07}....2188
Wiring diagram SCH18_{01-42}....2191
Wiring diagram SCH20_{00-41}....2194
Wiring diagram SCH20_{00-42}....2197
Wiring diagram SCH22_{59-25}....2200
Wiring diagram SCH22_{59-00}....2202
Wiring diagram SCH24_{58-26}....2204
Wiring diagram SCH24_{58-00}....2206
Wiring diagram SCH24_{57-33}....2209
Wiring diagram SCH30_{56-59}....2211
Wiring diagram SCH30_{56-32}....2214
Wiring diagram SCH30_{56-05}....2217
Wiring harnesses_{55-34}....2220
Wiring harnesses_{55-09}....2223
Engine wire harness; replacing_{54-35}....2226
Engine wire harness; replacing_{54-07}....2236
Engine wire harness; replacing_{53-36}....2246
Engine wire harness; replacing_{53-08}....2256
Engine wire harness; replacing_{52-37}....2266
Engine wire harness; replacing_{52-10}....2276
Battery disconnector; replacing_{51-36}....2286
Battery disconnector; replacing_{51-11}....2290
Electrical distribution box_{50-38}....2294
Electrical distribution box_{50-12}....2297
Electrical distribution box_{49-45}....2299
Electrical distribution box_{49-18}....2301
Electrical distribution box_{48-47}....2303
Electrical distribution box_{48-20}....2306
Electrical distribution box_{47-53}....2308
Electrical distribution box_{47-26}....2310
Electrical distribution box_{46-56}....2312
Electrical distribution box_{46-29}....2315
Electrical distribution box_{46-02}....2317
Electrical distribution box_{45-35}....2319
Electrical distribution box_{45-04}....2321
Electrical distribution box_{44-37}....2324
Electrical distribution box_{44-10}....2326
Electrical distribution box_{43-43}....2328
Electrical distribution box_{43-12}....2330
Electrical distribution box_{42-45}....2333
Electrical distribution box_{42-18}....2335
Electrical distribution box_{41-52}....2337
Electrical distribution box; circuit board replacing....2339
Fuse; description_41-02....2343
Fuse; description_40-47....2347
Fuse; description....2349
Relay; description_{40-12}....2353
Relay; description_{39-41}....2359
Relay; description_{39-11}....2365
Relay; specifications....2371
Circuit breaker; specification....2373
Electrical symbols and designations ....2375
Explanation of wiring diagrams ....2378
Component designations ....2382
Component list Alternator; batteries; capacitors; electronic units; voltage outlet ....2385
Component list; fuses_{58-42}....2387
Component list; fuses_{58-17}....2389
Component list; Heating coils ....2391
Component list; lights ....2392
Component list; Miscellaneous_{57-12}....2394
Component list; Miscellaneous_{56-47}....2396
Component list; motors ....2397
Component list; relays_{55-57}....2399
Component list; relays_{55-32}....2400
Component list; sensors_{55-00}....2401
Component list; sensors_{54-35}....2404
Component list; sensors_{54-10}....2406
Component list; Solenoid valves_{53-38}....2408
Component list; Solenoid valves_{53-13}....2410
Component list; Switches_{52-42}....2412
Component list; Switches_{52-17}....2414
ECC; I_O list ....2416
E-ECU; I_O list ....2419
I-ECU; I_O list ....2422
V-ECU; I_O list_{50-48}....2425
V-ECU; I_O list_{50-21}....2429
V-ECU; I_O list_{49-54}....2432
W-ECU; I_O list ....2435
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....2437
Instruments and controls; overview_{23-04}....2439
Instruments and controls; overview_{22-36}....2441
Instruments and controls; front instrument panel_{22-01}....2443
Instruments and controls; front instrument panel_{21-31}....2445
Instruments and controls; left instrument panel_{20-54}....2447
Instruments and controls; left instrument panel_{20-25}....2449
Instruments and controls; right instrument panel_{19-53}....2451
Instruments and controls; right instrument panel_{19-24}....2454
Instruments and controls; rear instrument panel_{18-50}....2457
Instruments and controls; rear instrument panel_{18-20}....2459
Hour counter; specifications....2461
Hour meter; replacing....2463
Fuel level sender; replacing....2466
Control lockout lever switch; description....2469
Control lockout lever switch; specifications....2472
Engine temperature sensor; replacing....2476
Engine oil pressure sensor; replacing_{15-21}....2478
Engine oil pressure sensor; replacing_{14-54}....2480
Engine rotation speed sensor; replacing....2482
Engine rotation speed sensor (camshaft); replacing....2484
Hydraulic oil temperature sensor; replacing....2487
Auto idling sensor; replacing....2489
Menu tree....2491
Control types for X1 and X3 operation....2494
Keypad; description_{12-07}....2497
Keypad; description_{03-06}....2501
Keypad; description....2504
Keypad; specification....2506
Service mode_{55-59}....2509
Service mode_{55-31}....2511
Engine system....2513
Hydraulic system....2516
Electrical system....2519
Vehicle information....2523
Rear view camera; specifications....2525
Rear view camera; replacing....2526
39 - MISCELLANEOUS....2530
Audio remote controller; description....2531
Audio remote controller; specifications....2534
Radio; description....2536
Radio with CD and MP3 player; description_{48-47}....2539
Radio with CD and MP3 player; description_{48-16}....2542
Radio with CD and MP3 player; specifications....2545
Radio; replacing....2547
DC–DC converter; description....2552
DC–DC converter; specifications_{46-09}....2556
DC–DC converter; specifications_{45-43}....2559
Voltage converter; replacing....2565
Antenna; replacing....2570
Speaker; replacing....2573
CareTrack antenna; replacing....2576
CareTrack W-ECU; description....2581
Wireless control unit W-ECU; specification....2586
W-ECU MID 142 non-programmed; replacing_{41-59}....2588
W-ECU MID 142 non-programmed; replacing_{41-31}....2592
W-ECU MID 142 pre-programmed; replacing_{40-58}....2596
W-ECU MID 142 pre-programmed; replacing_{40-32}....2600
CareTrack battery; replacing....2604
004 - POWER TRANSMISSION....2608
40 - GENERAL....2609
Tightening torque; specifications....2610
Power transmission; description....2612
43 - GEARBOX....2615
Function description ....2617
Track gearbox; specifications_{36-40}....2619
Track gearbox; specifications_{36-14}....2620
Track gearbox; specifications_{35-49}....2621
Track gearbox; description_{35-16}....2622
Track gearbox; description_{34-40}....2628
Track gearbox; description_{34-13}....2630
Track gearbox; maintenance standard_{33-36}....2633
Track gearbox; maintenance standard_{33-03}....2636
Track unit; replacing_{32-28}....2640
Track unit; replacing_{31-59}....2644
Track gearbox; replacing....2648
Track gearbox cover; replacing_{31-03}....2652
Track gearbox cover; replacing_{30-33}....2655
Track gearbox (removed); replacing floating seal....2658
Track gearbox; disassembly_{29-37}....2663
Track gearbox; disassembly_{29-09}....2671
Track gearbox; assembly_{28-34}....2679
Track gearbox; assembly_{28-03}....2690
Function description....2701
Swing gearbox; specifications_{26-47}....2704
Swing gearbox; specifications_{26-21}....2705
Swing gearbox; description_{36-28}....2706
Swing gearbox; description_{35-58}....2710
Swing gearbox; description_{35-21}....2715
Swing gearbox; maintenance standard....2721
Swing unit; replacing....2725
Swing gearbox; replacing....2730
Swing gearbox removed; seal replacing....2735
Swing gearbox; disassembly_{33-12}....2739
Swing gearbox; disassembly_{30-57}....2747
Swing gearbox; disassembly_{27-13}....2755
Swing gearbox; assembly_{12-14}....2762
Swing gearbox; assembly_{00-47}....2772
Swing gearbox; assembly_{45-05}....2783
Hydraulic pump coupling; description ....2794
Pump coupling; replacing ....2796
Pump gearbox flange; replacing ....2798
44 - HYDROSTATIC DRIVE....2800
Track motor; specifications_{09-18}....2802
Track motor; specifications_{08-52}....2803
Track motor; specifications_{08-27}....2805
Track motor; description_{07-54}....2806
Track motor; description_{07-28}....2814
Track motor; description_{07-01}....2816
Track motor; maintenance standard_{06-27}....2822
Track motor; maintenance standard_{05-58}....2826
Track motor; maintenance standard_{05-27}....2829
Track motor; maintenance standard_{04-46}....2839
Track motor; replacing_{04-13}....2844
Track motor; replacing_{58-46}....2852
Track motor; replacing_{58-19}....2856
Track motor relief valve; replacing_{57-45}....2858
Track motor relief valve; replacing_{57-14}....2861
Track motor relief valve; replacing_{56-46}....2864
Track motor; disassembly_{55-66}....2866
Track motor; disassembly_{55-46}....2873
Track motor; disassembly_{42-56}....2893
Track motor; assembly_{40-39}....2902
Track motor; assembly_{40-38}....2917
Track motor; assembly_{40-36}....2925
Swing motor; specifications....2939
Swing motor; description....2940
Swing motor; maintenance standard_{58-19}....2945
Swing motor; maintenance standard_{57-46}....2949
Swing motor; replacing....2951
Swing motor relief valve; replacing....2956
Swing motor removed; seal replacing....2958
Swing motor; disassembly....2962
Swing motor; assembly....2969
Track motor air; bleeding....2978
Track motor; flushing....2983
Swing motor air; bleeding....2990
Swing motor; flushing....2996
Hydraulic pump coupling; description....3003
Pump gearbox flange; replacing....3005
Pump coupling; replacing....3007
Tightening torque; specifications ....3009
Center passage; specifications....3011
Center passage; description....3013
Center passage; replacing....3016
Center passage; replacing seal kit....3020
Center passage; disassembly....3026
Center passage; assembly....3030
49 - MISCELLANEOUS....3037
Swing ring gear; specifications....3038
Swing ring gear; description....3039
Swing ring gear; replacing....3042
Swing ring gear grease pipe; replacing....3046
Swing ring gear inner seal; replacing_45-39....3049
Swing ring gear inner seal; replacing....3054
Swing ring gear outer seal; replacing....3057
Swing ring; measuring axial clearance....3062
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....3066
70 - GENERAL....3067
Undercarriage; tightening torque_{41-22}....3068
Undercarriage; tightening torque_{40-55}....3071
Undercarriage; tightening torque_{40-24}....3074
Undercarriage; tightening torque_{39-57}....3077
Frame and track unit; specifications....3080
Frame and track unit; description_{39-07}....3081
Frame and track unit; description_{38-40}....3083
71 - FRAME....3085
Machine weight; specifications....3086
Superstructure; removing....3088
Superstructure; installing....3094
Tightening torque; specifications ....3099
Counterweight; tightening torques_{34-57}....3101
Counterweight; tightening torques_{34-30}....3103
Counterweight; specifications_{32-57}....3105
Counterweight; specifications_{32-32}....3106
Counterweight; description....3107
Counterweight; removing....3109
unterweight; installing....3113
Counterweight; installing....3116
Removable counterweight cylinder; specifications....3119
Removable counterweight cylinder; description....3121
Removable counterweight; removing....3124
Removable counterweight; installing....3129
Support information....3136
Undercarriage; description_{24-21}....3138
Undercarriage; description_{23-54}....3141
Undercarriage; description_{23-27}....3144
Undercarriage; description_{22-59}....3146
Retractable track; removing....3149
Retractable track; installing....3153
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....3155
Idler; description....3157
Idler; measurement of wear....3159
Front idler; removing....3162
Front idler; installing....3165
Front idler wheel; disassembling....3169
Front idler wheel; assembling....3174
Tools & equipment....3179
Sprocket; measurement of wear....3185
Sprocket; removing....3188
Sprocket; installing....3190
Sprocket; replacing one....3192
Track chain; description....3195
Track link; dimension....3197
Track; adjusting track sag....3198
Track chain; measurement of wear....3201
Track shoe; replacing one....3206
Track links; replacing....3210
Track shoes....3215
Track chain assembly; removing....3216
Track chain assembly; installing....3220
Top roller; description_{00-04}....3225
Top roller; description_{59-37}....3228
Top roller; measurement of wear_{58-04}....3230
Top roller; measurement of wear_{57-35}....3233
Top roller; replacing one....3236
Bottom roller; description....3240
Bottom roller; measurement of wear....3242
Bottom roller; replacing one....3245
Bottom roller; replacing seal....3249
Track guards_{54-14}....3254
Track guards_{53-48}....3256
Track guard; replacing one....3258
Full track guard; replacing....3261
Spring package; assembly dimension_{51-33}....3264
Spring package; assembly dimension_{51-05}....3266
Track recoil spring (tensioner) assembly; replacing_{49-34}....3268
Track recoil spring (tensioner) assembly; replacing_{49-02}....3272
Spring package; disassembling_{48-24}....3275
Spring package; disassembling_{47-55}....3278
Spring package; assembly....3283
Selection of track shoes....3287
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....3289
80 - GENERAL....3290
Tightening torque; specifications....3291
VCADS Pro; Operations ....3292
81 - CAB; NAKED; CANOPY....3294
Cab; weight....3295
Cab; removing....3296
Cab; installing....3306
Cab suspension; description....3315
Engine hood; replacing_{41-04}....3318
Engine hood; replacing_{40-37}....3321
Tool box assembly; replacing....3324
83 - DOORS; HATCH; COVER PLATE; (all)....3328
Door; replacing....3329
Cab door; changing door catch....3333
Under cover; superstructure....3340
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....3342
Rear-view mirror; replacing....3343
Windows; general....3345
Windscreen; replacing....3349
Side window; replacing....3363
Rear window; replacing....3370
Door window; replacing....3376
85 - CAB INTERIOR; UPHOLSTERY....3379
Driver's seat; description....3380
Driver's seat; specifications....3386
Seat; replacing_{31-58}....3391
Seat; replacing_{31-27}....3396
Seat cushion; replacing....3399
Seat support; replacing_{30-34}....3405
Seat support; replacing_{30-03}....3411
Longitudinal adjustment cable; replacing....3418
Longitudinal suspension cable; replacing....3425
Backrest; replacing....3430
Seat heater; checking....3435
87 - AIR CONDITIONING UNIT....3440
Electronic climate control unit ECC; description....3442
Electronic climate control unit ECC; specification....3444
Wiring diagram....3446
HVAC system....3448
Air conditioning unit; specifications_{25-46}....3452
Air conditioning unit; specifications_{25-20}....3454
Air conditioning unit; description....3456
Air conditioning unit; maintenance....3462
ECC MID 146 pre-programmed ECU; replacing....3465
ECC MID 146 non-programmed ECU; replacing....3469
Cooler and Heater assembly; replacing ....3473
Air distribution; description....3482
Cab filter; replacing....3485
Heating system; description....3489
Fan motor; replacing....3492
Heater core; replacing....3496
Air conditioning performance; checking....3503
Cooler and Heater assembly; replacing....3510
Compressor; replacing incl draining and filling....3519
Receiver; replacing incl draining and filling....3523
Condenser; replacing incl draining and filling....3528
Evaporator; replacing incl draining and filling....3532
Expansion valve; replacing incl draining and filling....3541
Vent actuator; replacing....3549
Mode (foot) actuator; replacing....3552
Intake actuator; replacing....3555
Air mix door actuator; replacing....3558
Compressor; replacing magnetic clutch (compressor removed)....3561
Auxiliary heater; specifications_{14-31}....3568
Auxiliary heater; specifications_{14-05}....3569
Auxiliary heater; description_{13-33}....3571
Auxiliary heater; description_{13-05}....3574
Auxiliary heater; principles_{12-32}....3577
Auxiliary heater; principles_{12-05}....3579
Troubleshooting_{10-03}....3582
Troubleshooting_{10-07}....3586
Troubleshooting_{10-02}....3594
Troubleshooting (10kw)....3599
88 - INTERIOR EQUIPMENT....3605
Instrument panel (left); replacing....3606
Instrument panel (right); replacing....3611
Seat belt; replacing....3615
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....3620
90 - GENERAL....3621
Hydraulic diagram; standard - Image....3622
Hydraulic diagram; with option components - Image....3625
Explanations to hydraulic diagram....3631
Hydraulic diagram; standard_{12-19}....3643
Hydraulic diagram; standard_{11-52}....3646
Hydraulic diagram; standard_{11-25}....3649
Hydraulic diagram; with option components_{10-51}....3652
Hydraulic diagram; with option components_{10-24}....3656
Hydraulic diagram; with option components_{09-57}....3660
Hydraulic diagram; with option components_{09-30}....3664
Hydraulic system; cleanliness when handling hydraulic components....3668
Hydraulic diagram; schematic....3673
Description; general....3676
Hydraulic system; description....3678
Hydraulic oil; description....3682
Recommended hydraulic oil; specifications....3686
VCADS Pro; Operations....3691
Hydraulic pressure; specifications....3692
Hydraulic system; repair of hydraulic components in workshop....3693
Hydraulic oil; storage and handling....3699
Hydraulic components; storing and transporting....3704
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....3709
Hydraulic system; work instructions....3716
Hydraulic components; description_{05-34}....3721
Hydraulic components; description_{05-09}....3724
Hydraulic system; position of main components_{04-37}....3727
Hydraulic system; position of main components_{04-10}....3730
Drain filter; description....3733
Servo filter; description....3739
Hydraulic oil tank; specifications_{02-55}....3745
Hydraulic oil tank; specifications_{02-29}....3746
Hydraulic oil tank; description_{00-07}....3747
Hydraulic oil tank; description_{59-39}....3750
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump....3753
Oil level gauge; replacing....3756
Air breather; description....3758
Breather; replacing....3761
Hydraulic oil tank; replacing_{57-35}....3763
Hydraulic oil tank; replacing_{57-04}....3774
Hydraulic oil tank; replacing_{56-32}....3783
Shock reducing valve; specifications....3794
Shock reducing valve; description....3796
Servo hydraulic block....3799
Shuttle valve block; description....3801
Check valve; description_{54-24}....3803
Check valve; description_{53-56}....3806
Oil cooler line bypass valve (check valve); replacing....3808
Pump suction hose and pipe; replacing....3811
Hydraulic oil cooling system; specifications_{51-48}....3815
Hydraulic oil cooling system; specifications_{51-22}....3817
Hydraulic cooling fan control; specifications....3819
Hydraulic oil cooling system; description_{50-34}....3821
Hydraulic oil cooling system; description_{50-04}....3826
Hydraulic oil cooler; description_{49-24}....3831
Hydraulic oil cooler; description_{48-58}....3832
Hydraulic oil cooler; replacing....3834
Fan pump; description....3845
Fan pump; parts inspection....3846
Fan pump; disassembly....3848
Fan pump; assembly....3850
Oil cooler fan pump; replacing....3852
Fan motor; description_{46-48}....3853
Fan motor; description_{46-21}....3856
Fan motor; tools_{45-44}....3862
Fan motor; tools_{45-16}....3864
Fan motor; disassembly_{44-43}....3866
Fan motor; disassembly_{44-16}....3872
Fan motor; assembly_{43-42}....3879
Fan motor; assembly_{43-13}....3887
Fan motor; troubleshooting....3893
Oil cooler fan motor; replacing....3895
Proportional relief valve; specifications_{42-06}....3902
Proportional relief valve; specifications_{41-41}....3903
Proportional relief valve; description_{41-11}....3905
Proportional relief valve; description_{40-43}....3907
Main control valve; port size and tightening torque_{40-06}....3911
Main control valve; port size and tightening torque_{39-40}....3915
Main control valve; specifications....3919
Hydraulic diagram; ports_{36-52}....3921
Hydraulic diagram; ports_{36-27}....3923
Main control valve; description_{35-54}....3925
Main control valve; description_{35-23}....3932
Main control valve troubleshooting....3939
Control valve; part inspection....3942
General; precautions....3945
General; tools....3948
Main control valve; disassembly and assembly....3950
Main relief valve; description....3954
Main relief valve; adjustment....3956
Main relief valve; disassembly....3959
Pressure relief valve; troubleshooting....3962
Main pressure relief valve; replacing....3967
Port relief valve; description....3969
Port relief valve pressure; measuring and adjusting....3972
Port relief valve; disassembly and assembly....3976
2 stage port relief valve; description....3978
2 stage port relief valve; adjustment....3984
2 stage port relief valve; disassembly and assembly....3987
Make up valve; description....3991
Boom and arm holding valve (Boom-1; Arm-1); description....3994
Boom and arm holding valve (Boom-1; Arm-1); disassembly....3998
Boom 2 conflux shut-off valve; disassembly....4002
Boom boost check valve; disassembly....4004
Cover assembly (for preventing Boom-1 spool rotation); disassembly....4006
Boom servo hydraulic check valve....4009
Arm regenerating valve; description_{26-28}....4011
Arm regenerating valve; description_{26-00}....4014
Arm parallel conflux changeover valve; disassembly....4019
Check valve (for arm parallel conflux; slew priority); disassembly....4021
Arm conflux check valve; disassembly....4022
Option confluence check....4024
Slew priority valve; disassembly....4026
Check valve (for straight travel changeover valve); disassembly....4028
Foot relief valve (flow sensing valve); description....4030
Center bypass valve; disassembly and assembly....4032
Center bypass valve (for bucket conflux); disassembly....4034
Control valve; replacing_{22-16}....4036
Control valve; replacing_{21-43}....4045
Line rupture valve (boom); specifications....4054
Line rupture valve (boom); description....4055
Line rupture valve pressure; checking and adjusting....4060
Port relief valve pressure; adjustment (when installing or dismantling the line rupture valve)_{19-49}....4062
Port relief valve pressure; adjustment (when installing or dismantling the line rupture valve)_{19-22}....4065
Line rupture valve (boom); air bleeding....4068
Boom cylinder; rupture valve; replacing....4070
Disassembly and assembly; general....4074
Line rupture valve (boom); disassembly....4077
Line rupture valve (boom); assembly....4080
Line rupture valve (boom); troubleshooting....4083
Line rupture valve (arm); specifications....4087
Line rupture valve (arm); description....4089
Line rupture valve (arm); air bleeding....4094
Dipper arm cylinder; rupture valve; replacing....4096
Line rupture valve (arm); disassembly....4099
Line rupture valve (arm); assembly....4102
Line rupture valve (arm); troubleshooting....4105
Hydraulic pump; specifications_{13-38}....4108
Hydraulic pump; specifications_{13-13}....4109
Hydraulic pump; description....4110
Hydraulic pump; maintenance standard; Specifications....4117
Pump; troubleshooting....4121
Pump; disassembly....4125
Pump; assembly_{11-14}....4131
Pump; assembly_{10-47}....4136
Pump; installation....4141
Regulator; description....4143
Regulator; maintenance....4151
Regulator; disassembly....4156
Regulator; assembly....4163
Proportional solenoid valve; specifications....4169
Current_pressure; specifications....4172
Proportional solenoid valve; description ....4173
Proportional solenoid valve; measuring and adjustment....4176
Proportional solenoid valve; troubleshooting....4179
Hydraulic pump (removed); changing shaft seal....4180
Hydraulic pump; replacing_{06-14}....4182
Hydraulic pump; replacing_{05-43}....4194
Hydraulic pump regulator; replacing....4207
Proportional solenoid valve (power shift); replacing....4209
Servo pump; specifications_{02-40}....4212
Servo pump; specifications_{02-15}....4213
Servo pump; description_{01-45}....4214
Servo pump; description_{01-15}....4218
Gear pump; maintenance standard....4223
Servo pump; parts inspection....4227
Servo hydraulic pressure; adjustment....4230
Servo pump; disassembly....4233
Servo pump; assembly....4240
Servo pump; replacing_{59-12}....4248
Servo pump; replacing_{58-43}....4254
Pressure accumulator; specifications....4259
Pressure accumulator; description....4261
Accumulator; replacing....4264
Tightening torques....4267
Remote control valve (Lever); specifications_{56-21}....4273
Remote control valve (Lever); specifications_{55-56}....4277
Remote control valve (Lever); description_{55-23}....4279
Remote control valve (Lever); description_{54-38}....4293
Remote control valve (Lever); maintenance standard; Specifications....4303
Remote control valve (lever); replacing....4306
Remote control valve (Lever); disassembly_{53-02}....4309
Remote control valve (Lever); disassembly_{52-30}....4322
Remote control valve (Lever); assembly_{51-31}....4335
Remote control valve (Lever); assembly_{50-58}....4347
Remote control valve (Lever); troubleshooting_{50-06}....4360
Remote control valve (Lever); troubleshooting_{49-41}....4364
Remote control valve (pedal); specifications_49-10....4367
Remote control valve (pedal); description....4368
Remote control valve (pedal); maintenance standard; Specifications....4375
Remote control valve (pedal); replacing....4379
Remote control valve (pedal); disassembly....4385
Remote control valve (pedal); assembly....4396
Remote control valve (pedal); troubleshooting....4409
Solenoid valve; specifications....4413
Solenoid valve; description....4415
Solenoid valve; inspection....4418
Solenoid valve; troubleshooting....4420
Solenoid valve; disassembly and assembly....4425
Solenoid valve; replacing....4428
X1 Line; description....4431
Hammer and shear pedal valve (RCV); replacing_{43-16}....4437
Hammer and shear pedal valve (RCV); replacing_{42-51}....4440
Hammer return filter; specifications_{42-16}....4445
Hammer return filter; specifications_{41-51}....4448
Hammer return filter; specifications_{41-26}....4450
Hammer return filter; description_{40-54}....4452
Hammer return filter; description_{40-29}....4453
Solenoid valve; specifications_{39-56}....4455
Solenoid valve; specifications_{39-31}....4456
Solenoid valve; specifications_{39-06}....4458
Solenoid valve; description_{38-34}....4460
Solenoid valve; description_{38-09}....4462
3 way selector valve; description....4465
Proportional solenoid valve; specifications_{37-16}....4467
Proportional solenoid valve; specifications_{36-51}....4468
Proportional solenoid valve; description....4470
Stop valve....4472
Remote control valve (pedal); specifications....4474
Straight travel pedal; description....4476
Control pattern selector valve; specifications_{34-54}....4479
Control pattern selector valve; specifications_{34-29}....4480
Control pattern selector valve; description....4481
Rotator pump; specifications....4485
Rotator pump; description....4486
Rotator pump; disassembly....4488
Rotator pump; assembly....4489
Rotator pump; parts inspection....4490
Rotator (X3 Line option); description....4493
Rotator valve; adjustment....4498
Boom float position; description....4501
92 - MECHANICAL EQUIPMENT_ATTACHMENT....4503
Attachment quick coupler; description_{27-36}....4504
Attachment quick coupler; description_{27-01}....4518
Attachment quick coupler; description_{26-27}....4529
Attachment quick coupler; operation....4540
Attachment quick coupler; adjustment....4543
Attachment quick coupler solenoid valve; description_{25-07}....4547
Attachment quick coupler solenoid valve; description_{24-42}....4552
Attachment quick coupler; replacing....4555
Quickfit; removing....4565
Quickfit; installing....4568
Bucket adapter maintenance guideline....4571
97 - UNIT; DIGGING....4582
Lower boom cylinder bushing; replacing....4585
Upper boom cylinder bushing; replacing....4591
Dipper arm; specifications_{19-13}....4595
Dipper arm; specifications_{18-46}....4597
Dipper arm; description....4598
Dipper arm; installing....4601
Dipper arm; replacing....4605
Link; description....4618
Dipper arm connecting rod; removing....4621
Dipper arm connecting rod; installing....4624
Dipper arm connecting rod; replacing....4627
Connecting rod yoke; installing....4635
Connecting rod yoke; replacing....4638
Dipper arm cylinder; specifications_{07-00}....4647
Dipper arm cylinder; specifications_{06-33}....4649
Dipper arm cylinder; description_{05-59}....4651
Dipper arm cylinder; description_{05-25}....4654
Dipper arm cylinder; removing....4657
Dipper arm cylinder; replacing....4660
Dipper arm cylinder; repacking in machine....4670
Dipper arm cylinder bushing on boom; replacing....4674
Dipper arm cylinder bushing on dipper arm; replacing....4680
Bucket cylinder; specifications_{53-36}....4684
Bucket cylinder; specifications_{53-09}....4686
Bucket cylinder; specifications_{52-42}....4688
Bucket cylinder; description_{52-08}....4690
Bucket cylinder; description_{51-34}....4693
Bucket cylinder; removing....4696
Bucket cylinder; replacing....4699
Bucket cylinder; repacking in machine....4710
Bucket cylinder bushing on dipper arm; replacing....4715
Bucket cylinder bushing lever-link; replacing....4720
Tightening torques_{20-19}....4724
Tightening torques_{19-45}....4732
Function description....4740
Digging unit; maintenance....4743
Bushing general; replacing....4747
Cylinder; description....4752
Cylinder; disassembly and assembly_{17-46}....4757
Cylinder; disassembly and assembly_{17-16}....4776
Cylinder; troubleshooting....4792
Hydraulic cylinder; replacing....4797
Boom; specifications_{14-05}....4804
Boom; specifications_{13-40}....4805
Boom; description_{13-06}....4806
Boom; description_{12-41}....4808
Boom; description_{12-16}....4811
Boom; removing_{11-43}....4814
Boom; removing_{11-16}....4818
Boom; removing_{10-49}....4822
Boom; installing_{10-16}....4826
Boom; installing_{09-50}....4830
Boom; installing_{09-23}....4834
Boom; replacing....4837
Boom cylinder; specifications_{08-31}....4839
Boom cylinder; specifications_{08-04}....4841
Boom cylinder; description_{06-36}....4843
Boom cylinder; description_{06-10}....4845
Boom cylinder; removing....4847
Boom cylinder; installing....4849
Boom cylinder; replacing_{05-02}....4851
Boom cylinder; replacing_{04-35}....4856
Boom cylinder; repacking in machine....4861
99 - MISCELLANEOUS....4864
Bleeding air....4865
Troubleshooting....4866
Maintenance service; general....4868
Overview....4870
Automatic lubrication system; specifications....4873
Automatic lubrication system; description....4876
Central lubrication system; description....4879
Control units; software functions....4883
Volvo EC480D Excavators Repair Service Manual
