Volvo Construction EC480E HR, EC480E L, EC480E LD, EC480E LR Excavators Workshop Service Repair manual with Electrical Wiring Diagrams (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnosis & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices. This manual contains high quality images, circuit diagrams, instructions to help you to maintenance, troubleshoot, diagnose, and repair. This document is printable, without restrictions, contains searchable text, bookmarks, crosslinks for easy navigation.

Volvo Construction EC480E Series Excavators Service Repair Manual.pdf

0 - Foreword
0 - GENERAL....3
  00 - DESCRIPTION; COMPLETE MACHINE....4
    Machine view....5
    Product plates....8
  03 - SPECIFICATIONS....9
    Volvo standard tightening torques....10
    Measurement conversion tables....19
    Flywheel; tightening torques....29
  07 - STANDARD TIME....32
    Operation numbers for additional work....33
  08 - TOOL....35
    E-tools; NET 8940-00290 Swing motor guide pin....36
    E-2016....38
    Infrared Thermometer....40
    88830540 User Instruction....46
    E-3511....50
  09 - MISCELLANEOUS....54
    Service positions....55
    Welding on the machine....58
    Hydraulic cylinders; dieseling....61
1 - STANDARD PARTS; SERVICE....66
  16 - LUBRICANT; FUEL; OTHER FLUID....67
    Recommended lubricants....68
    Grease....72
    Hydraulic oil....77
    Lubricants; service capacities and intervals....82
    Change capacities....84
    Fuel....85
    Alternative fuels....89
    Air cleaner; description....100
    Coolant....102
    Coolant with freezing and corrosion protection....108
  17 - SERVICE....113
    Bearings....116
    Replacement parts....121
    Safety when servicing....126
    Service....131
    Service methods....135
    Pressure testing....140
    Hoses and tubes....145
    Cleaning prior to repair....150
    Tech Tool; operations ....155
    Arrival Inspection; according to Inspection Programme....158
    Delivery Inspection; according to Inspection Programme....163
    Maintenance of Stored Machines; according to Inspection Programme....168
    Measuring condition_31-18....173
    Measuring condition_31-03....177
    Measuring condition....178
    Cylinder speed....182
    Creeping of hydraulic cylinder....185
    Swing speed....188
    Coasting left and right swing....190
    Measuring of swing bearing clearance....192
    Travel Speed....195
    Track running speed....197
    Straight traveling performance....199
    Washer fluid level; check....201
    Engine; oil level; check....202
    Coolant level; check....204
    Valves; adjusting ....206
    Maintenance service; first 500 hours....213
    Maintenance service; every 10 hours....215
    Maintenance service; every 50 hours....216
    Maintenance service; every 250 hours....217
    Maintenance service; every 500 hours....218
    Maintenance service; every 1000 hours....220
    Maintenance service; every 2000 hours....222
    Maintenance service; every 4000 hours....224
    Maintenance service; every 5000 hours....226
    Maintenance service; every 6000 hours....227
    Service position....228
    Lubrication; every 50 hours....231
    Test running and checking....233
    Engine belt condition; checking....235
    Engine oil and filter; changing....237
    Fuel filter; replacing....240
    Water separator filter; replacing....242
    Fuel tank breather filter; replacing....245
    Engine air cleaner primary filter; replacing....248
    Engine air cleaner secondary filter; replacing....250
    Oil-bath air cleaner reservoir oil; checking....253
    Oil-bath air cleaner reservoir oil; changing....255
    Oil-bath air cleaner reservoir filter insert; cleaning....258
    Coolant; Changing....261
    Coolant mixture; checking....264
    Radiator and hydraulic oil cooler; cleaning....268
    MATRIS and Tech Tool; reading....271
    Software update; checking....273
    Battery; checking....279
    PSR backup battery; replacing....281
    Track gearbox oil level; checking....284
    Track gearbox oil; changing....285
    Swing gearbox oil level; checking....287
    Swing gearbox oil; changing....289
    Swing ring gear bearing; lubricating....292
    Swing bath grease; checking....293
    Track shoe bolts; checking....294
    Track tension and condition; checking....297
    Cab door; covers; hinges; joints and locks; lubricating....299
    Air conditioner main filter; cleaning....302
    Air conditioner main filter; replacing....306
    Cab prefilter; cleaning....310
    Cab prefilter; replacing....313
    Hydraulic oil level; checking....316
    Hydraulic oil; changing....319
    Hydraulic oil suction strainer; cleaning....322
    Hydraulic oil drain filter; replacing....324
    Hydraulic oil servo filter; replacing....326
    Hydraulic oil return filter; replacing_....328
    Hydraulic oil return filter; replacing....333
    Hydraulic oil tank breather filter; replacing....335
  19 - GENERAL....338
    Safety concerns everybody!....339
    Safety when handling the machine....344
    Safety rules when servicing....350
    Move and operate machine safely....353
    Welding and grinding work....357
    Fire prevention measures....361
    Checklist after a fire or heat exposure....368
    Safety when handling oils and fuel....373
    Safety when using lifting equipment....378
    Safety when working with hydraulic systems....383
    Safety when working with air conditioning refrigerant....388
    Starting with booster batteries....394
    Safety when working with batteries....399
    Environmental handling for the future....405
    Environmentally safe handling....410
    Environmentally hazardous fluids....415
    Health hazards with paint; plastics and rubber....420
    Working in environmentally contaminated areas....426
    Decontamination....431
    Waste handling_07-03....436
    Waste handling....440
    Cautions during operation_06-36....445
    Cautions during operation....449
2 - ENGINE WITH MOUNTING AND EQUIPMENT....456
  20 - GENERAL....457
    Engine; description....458
    Tech Tool; Operations....462
    Component locations....463
    E-ECU MID 128 pre-programmed; replacing_02-52....466
    E-ECU MID 128 pre-programmed; replacing....467
    E-ECU MID 128 non-programmed; replacing....471
  21 - ENGINE....475
    Engine; specifications....476
    Engine rotation speed sensor (crankshaft); replacing....477
    Engine rotation speed sensor (camshaft); replacing....480
    Camshaft and flywheel signals; checking with Tech Tool and oscilloscope....484
    Engine; removing....492
    Engine; installing....502
    Engine; tightening torques....511
    Crankcase ventilation; description....522
    Valve mechanism; tightening torques....525
    Valve system; specifications....528
    Rocker arms; replacing....531
    Rocker arm shaft; tightening torques....534
    Valves; adjusting....536
    Valve cover; removing....542
    Valve cover; installing....546
    Timing gear plate; replacing....551
    Crank mechanism; description....584
    Flywheel; tightening torques....587
    Crankshaft front oil seal; replacing....590
    Crankshaft rear oil seal; replacing....602
    Oil level sensor; replacing ....608
    Oil level sensor; replacing....610
  22 - LUBRICATING SYSTEM....612
    Lubrication system; description....613
    Lubrication system; specifications....619
    Lubrication system; component locations....620
    Lubrication system; tightening torques....622
  23 - FUEL SYSTEM....626
    Fuel system; description....627
    Fuel system; specifications....633
    Fuel system; tightening torques....634
    Carbon dioxide in fuel system; checking....641
    Fuel system basics; checking_{16-21}....647
    Fuel system basics; checking_{15-56}....649
    Fuel system; component locations....652
    Fuel feed pump; description....654
    Feed pump; replacing....656
    Fuel system; bleeding....658
    Injectors; replacing....659
    Overflow valve; replacing....667
    Injector sleeves; replacing....669
  25 - INLET & EXHAUST SYSTEM....676
    Inlet and exhaust system; description....677
    Inlet and exhaust system; component locations....682
    Inlet and exhaust system; tightening torques....684
    Exhaust manifold; tightening torques....686
    Exhaust pipe flexible tube; replacing....688
    Muffler; replacing....690
    Turbocharger; description....692
    Turbocharger; specifications....695
    Turbocharger; inspecting....697
    Turbocharger; replacing....699
    Turbocharger; tightening torques....704
    Preheating coil; replacing....706
    Charge air cooler; replacing....709
  26 - COOLING SYSTEM....717
    Cooling system; description....718
    Carbon dioxide in coolant system; checking....723
    Cooling system; component locations....730
    Cooling system; tightening torques....732
    Cooling system leakage; checking....734
    Radiator; description....736
    Coolant anti-freeze resistance; checking_{02-24}....738
    Coolant anti-freeze resistance; checking_{01-54}....744
    Coolant; changing....746
    Radiator; replacing....749
    Expansion tank; replacing....752
    Thermostat; replacing....755
    Thermostat; specifications....758
    Cooling fan control....760
    Reversible cooling fan; description....764
    Fan belt and_or alternator-; compressor belt; replacing all belts....767
  27 - ENGINE CONTROL....770
    Engine - Pump control; specification....771
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....773
  30 - GENERAL....774
    Electrical system; special instructions for servicing; general....779
    Electrical system; special instructions for servicing; electronic components....783
    Electrical system; special instructions for servicing; electrical components; batteries....787
    Electrical system; special instructions for servicing; electrical components; alternator and charging regulator....792
    Electrical system; special instructions for servicing; action when working on machine....796
    Electrical system; description....800
    Electronic control system; description....803
    Auxiliary start....809
    Data buses; function....814
    System voltage....820
    Electrical system; specifications....823
    Tech Tool; operations_36-38....826
    Power Boost control; description_36-21....827
    Power Boost control; description....829
    Engine stops....831
    PSR system....833
    Start lock; description....840
    X1 control; description....841
    X3 control; description....845
    Electro hydraulic pump control; description....848
    Power supply; description....853
    Mode selection; description....856
    Boom float position; description....861
    Travel speed; description....863
    Overload warning....865
    Seat belt....866
    Auto Idle....868
    Attachment quick coupler....870
    Intermittent wiper and washer....872
    Grading and lifting control; description....875
    ECO mode; description....878
    Software parameters; description....880
    Automatic engine shut-down....891
    General fault diagnosis information_58-15....895
    General fault diagnosis information....896
    Troubleshooting strategy....899
    Collection of basic data....902
    Information display; check....907
    Error code information; general....909
    Error codes; build-up....920
    SAE error codes; translation to error messages; general....923
    Conditions when checking....925
    Lead and connector checks....930
    Troubleshooting tools_{54-14}....937
    Troubleshooting tools_{53-49}....940
    Special tools for troubleshooting....942
    Tech Tool; operations....944
    AL3201; description and measuring....947
    AN3905; description and measuring....950
    BA3101; description and measuring....952
    BB1 Communication bus; description and measuring....954
    BB2 Communication bus; description and measuring....957
    mGPM; description and measuring....960
    CU9901; description and measuring....963
    CU9911; description and measuring....965
    Dig Assist sensor network; description and measuring....967
    FX1005; description and measuring....971
    FX1006; description and measuring....973
    FX1007; description and measuring....976
    FX1008; description and measuring....980
    FX1130; description and measuring....983
    HE2501; description and measuring....986
    Instrument Cluster (IC); description and measuring....988
    MA2301-MA2306; description and measuring....991
    MA2602; description and measuring....994
    MA4212; description and measuring....996
    MA9109; description and measuring....998
    MA9110; description and measuring....1001
    MA9111; description and measuring....1003
    MA9116; description and measuring....1005
    MA9117; description and measuring....1007
    MA9120; description and measuring....1009
    MA9125; description and measuring....1011
    MO3301; description and measuring....1013
    Power supply CCM; description and measuring....1015
    Power supply ECM; description and measuring....1017
    Power supply GPMECU 1; description and measuring....1019
    Power supply HMICU; description and measuring....1021
    Power supply SID; description and measuring....1023
    Power supply PSR; description and measuring....1025
    PWM9123; description and measuring....1027
    PWM9124; description and measuring....1029
    PWM9129; description and measuring....1031
    PWM9141; description and measuring....1033
    PWM9142; description and measuring....1035
    PWM9143; description and measuring....1037
    PWM9145; description and measuring....1039
    PWM9146; description and measuring....1041
    PWM9156; description and measuring....1043
    PWM9157; description and measuring....1045
    RE01; description and measuring....1047
    RE03; description and measuring....1050
    RE05; description and measuring....1053
    RE07; description and measuring....1055
    RE08; description and measuring....1057
    RE09; description and measuring....1059
    RE2501; description and measuring....1062
    SAE J1708_1587 Information link; description and measuring....1065
    SAE J1939-1 SubNet 1; description and measuring....1067
    SE2203; description and measuring....1069
    SE2301; description and measuring....1071
    SE2303; description and measuring....1074
    SE2509; description and measuring....1077
    SE2603; description and measuring....1079
    SE2606; description and measuring....1081
    SE2701; description and measuring....1083
    SE2703; description and measuring....1085
    SE8701; description and measuring....1087
    SE8702; description and measuring....1089
    SE8705; description and measuring....1092
    SE8706; description and measuring....1095
    SE9105; description and measuring....1098
    SE9121; description and measuring....1101
    SE9122; description and measuring....1103
    SE9123; description and measuring....1105
    SE9124; description and measuring....1107
    SE9125; description and measuring....1109
    SE9126; description and measuring....1111
    SE9127; description and measuring....1114
    SE9128; description and measuring....1117
    SE9131; description and measuring....1120
    SE9132; description and measuring....1123
    SE9136; description and measuring....1125
    SE9141; description and measuring....1128
    SE9142; description and measuring....1130
    SE9191; description and measuring....1132
    SE9401; description and measuring....1134
    SE9726; description and measuring....1136
    SE9727; description and measuring....1139
    SE9729; description and measuring....1142
    SE9730; description and measuring....1145
    SE9732; description and measuring....1148
    SE9733; description and measuring....1151
    SE9734; description and measuring....1154
    SW3301; description and measuring....1157
    SW3802; description and measuring....1160
    SW3803; description and measuring....1163
    SW9161; description and measuring....1166
    SW9162; description and measuring....1168
  31 - BATTERY....1170
    Battery; storage....1171
    Battery; description....1175
    Battery; specifications....1179
    Battery condition; checking....1180
    Battery charging capacity; checking....1184
    Battery; charging....1186
    Batteries; replacing....1188
    Earth lead to battery; replacing....1191
  32 - ALTERNATOR; CHARGE REGULATOR....1194
    Charging; description....1195
    Alternator; specifications....1197
    Alternator; description....1199
    Alternator; replacing incl function checking....1203
    Alternator; testing....1207
  33 - STARTING SYSTEM....1211
    Starting operation....1212
    Starter motor; description....1214
    Starter motor; specifications....1217
    Starter motor; testing....1218
    Starter motor; replacing....1222
    Preheating; description....1225
    Preheating; specifications....1227
    Ignition switch; description and operation....1228
    Starter switch; testing....1231
  35 - LIGHTING....1234
    Work lights and extra lights; description....1235
    Work lights and extra lights; specifications....1238
    Work lighting headlamp assembly; replacing....1239
  36 - OTHER ELECTRICAL EQUIPMENT....1243
    Electric pedal control on X1 (on_off); replacing....1245
    Electric pedal control on X1 (proportional); replacing....1250
    Electric horn; specifications....1255
    Horn; replacing....1258
    Rotating beacon; specifications....1261
    Travel alarm; specifications....1264
    Travel alarm; replacing....1267
    Travel alarm; description....1270
    Windscreen wiper; description....1273
    Upper wiper motor; description....1276
    Upper wiper motor; specifications....1279
    Windscreen flusher pump; specifications....1282
    Window limit switch; description....1285
    Windscreen wiper front motor; replacing....1289
    Windscreen wiper switch; replacing....1294
    Windscreen flusher pump; replacing....1298
    Connectors; overview....1301
    Pre-heating relay; replacing....1312
    Control lockout lever switch; replacing....1315
    Ignition switch; replacing....1319
    Crimping tools....1322
    Dismantling tools....1334
    General purpose machine electronic control unit GPMECU; function description....1346
    Human machine interface control unit HMICU; function description....1348
    GPMECU1 non-programmed; replacing....1350
    GPMECU1 pre-programmed; replacing....1354
    mGPMECU non-programmed; replacing....1358
    mGPMECU pre-programmed; replacing....1361
    HMICU non-programmed; replacing....1364
    HMICU pre-programmed; replacing....1369
  37 - CABLE; FUSE; RELAY....1373
    Electrical symbols and designations....1375
    Explanation of wiring diagrams....1380
    Component designations....1384
    Component list Alternator; batteries; capacitors; electronic units; voltage outlet....1387
    Component list; fuses....1389
    Component list; Heating coils....1391
    Component list; lights....1392
    Component list; Miscellaneous....1393
    Component list; motors....1394
    Component list; relays....1395
    Component list; sensors....1396
    Component list; Solenoid valves....1398
    Component list; Switches....1400
    CCM; I_O list....1402
    E-ECU; I_O list....1406
    GPMECU1; I_O list....1409
    HMICU; I_O list....1412
    IC (Instrument Cluster); I_O list....1415
    Wiring diagram....1416
    Wiring diagram; electrical distribution box....1418
    Wiring diagram SCH01....1420
    Wiring diagram SCH02....1424
    Wiring diagram SCH03....1428
    Wiring diagram SCH04....1431
    Wiring diagram SCH05....1435
    Wiring diagram SCH06....1438
    Wiring diagram SCH07....1441
    Wiring diagram SCH08....1445
    Wiring diagram SCH09....1449
    Wiring diagram SCH10....1452
    Wiring diagram SCH11....1456
    Wiring diagram SCH12....1461
    Wiring diagram SCH13....1464
    Wiring diagram SCH14....1467
    Wiring diagram SCH15....1470
    Wiring diagram SCH16....1473
    Wiring diagram SCH17....1478
    Wiring diagram SCH18....1482
    Wiring diagram SCH19....1486
    Wiring diagram SCH20....1489
    Wiring diagram SCH21....1493
    Wiring diagram SCH22....1497
    Wire harness layout....1502
    Engine wire harness; replacing....1505
    Electrical battery disconnect switch; replacing....1515
    Electrical distribution box....1518
    Electrical distribution box; circuit board replacing....1520
    Fuse; description....1524
  38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....1528
    Instruments and controls; overview....1530
    Instruments and controls; front instrument panel....1532
    Instruments and controls; left instrument panel....1534
    Instruments and controls; right instrument panel....1536
    Instruments and controls; rear instrument panel....1538
    Fuel level sender; replacing_40-07....1540
    Fuel level sender; replacing....1542
    Control lockout lever switch; description....1545
    Control lockout lever switch; specifications....1548
    Engine temperature sensor; replacing....1552
    Engine oil pressure sensor; replacing....1554
    Hydraulic oil temperature sensor; replacing....1556
    Keypad; description_38-08....1559
    Keypad; description....1560
    Keypad; specification....1562
    Service mode....1563
    Engine system....1565
    Hydraulic system....1567
    Electrical system....1570
    Rear view camera; specifications....1574
    Rear view camera; replacing....1575
    Volvo Smart View....1578
    Volvo Smart View; specification....1582
    Volvo Smart View camera; replacing....1584
    Volvo Smart View; calibrating....1587
    Volvo Smart View accuracy; checking....1591
    Volvo Co-Pilot; description_{34-09}....1596
    Volvo Co-Pilot; description_{33-43}....1598
    Volvo Co-Pilot; component location_{33-11}....1603
    Volvo Co-Pilot; component location_{32-45}....1604
    Volvo Co-Pilot; replacing....1607
    USB tethering....1611
    Volvo Co-Pilot Android software; updating offline (USB)....1620
    Volvo Co-Pilot; software updating....1622
    Dig Assist; description....1625
    Dig Assist Information Center; description....1636
    Dig Assist; component location....1656
    Dig Assist; software update....1657
    Dig Assist connectors; overview....1658
    Dig Assist; tightening torques....1662
    Dig Assist IMU; teach-in....1666
    36703-3 Dig Assist; calibration; body IMU....1675
    36703-3 Dig Assist; calibration; linkage....1679
    36703-3 Dig Assist; calibration; GNSS....1688
    Dig Assist GNSS antenna; calibrating....1696
    36705-3 Dig Assist; configuration....1704
    Dig Assist Onboard Weighing system; calibrating....1712
    Dig Assist Onboard Weighing; tool weight; calibrating....1723
    Dig Assist accuracy; checking....1731
    Dig Assist IMU; checking....1740
    Dig Assist quick coupler; measuring....1752
    Dig Assist lift point; measuring....1759
    Smart Receiver; replacing....1765
    GNSS Antenna; replacing....1770
    Laser catcher; replacing....1774
    Dig Assist OBW pressure sensors; replacing....1777
  39 - MISCELLANEOUS....1781
    Radio; description_23-33....1782
    Radio; description_23-18....1784
    Radio; description....1786
    Radio with MP3; specifications....1788
    PSR; description....1789
    PSR; replacing....1793
4 - POWER TRANSMISSION....1796
  40 - GENERAL....1797
    Tightening torque; specifications ....1798
    Power transmission; description....1800
  43 - GEARBOX....1801
    Function description....1802
    Track gearbox; specifications....1804
    Track gearbox; description....1805
    Track gearbox; maintenance standard....1811
    Track unit; replacing....1814
    Track gearbox; replacing....1818
    Track gearbox cover; replacing....1822
    Track gearbox (removed); replacing floating seal....1825
    Track gearbox; disassembly....1830
    Track gearbox; assembly....1838
    Function description ....1849
    Swing gearbox; specifications....1852
    Swing gearbox; description....1853
    Swing gearbox; maintenance standard....1857
    Swing unit; replacing....1861
    Swing gearbox; replacing....1866
    Swing gearbox removed; seal replacing....1871
    Swing gearbox removed; replacing shaft....1875
    Swing gearbox; disassembly....1882
    Swing gearbox; assembly....1890
    Hydraulic pump coupling; description ....1901
    Pump coupling; replacing ....1903
    Pump gearbox flange; replacing ....1906
  44 - HYDROSTATIC DRIVE....1908
    Track motor; specifications....1910
    Track motor; description....1911
    Track motor; maintenance standard_{10-25}....1919
    Track motor; maintenance standard_{09-56}....1923
    Track motor; maintenance standard_{09-29}....1925
    Track motor; replacing....1928
    Track motor relief valve; replacing....1936
    Track motor; disassembly....1939
    Track motor; assembly....1946
    Swing motor; specifications....1961
    Swing motor; description....1962
    Swing motor; maintenance standard_{06-04}....1967
    Swing motor; maintenance standard_{05-34}....1971
    Swing motor; maintenance standard_{05-07}....1973
    Swing motor; maintenance standard_{04-40}....1975
    Swing motor; replacing....1983
    Swing motor relief valve; replacing....1988
    Swing motor removed; seal replacing....1990
    Swing motor; disassembly....1994
    Swing motor; assembly....2001
    Travel speed; description....2010
    Track motor air; bleeding....2013
    Track motor; flushing....2014
    Swing motor air; bleeding....2021
    Swing motor; flushing....2027
    Hydraulic pump coupling; description....2034
    Pump gearbox flange; replacing....2036
    Pump coupling; replacing....2038
    Tightening torque; specifications ....2041
    Center passage; specifications....2043
    Center passage; description....2045
    Center passage; replacing....2047
    Center passage; replacing seal kit....2051
    Center passage; disassembly....2057
    Center passage; assembly....2062
  49 - MISCELLANEOUS....2068
    Swing ring gear; specifications....2069
    Swing ring gear; description....2070
    Swing ring gear; replacing....2073
    Swing ring gear grease pipe; replacing....2077
    Swing ring gear inner seal; replacing....2080
    Swing ring gear outer seal; replacing....2085
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....2090
  70 - GENERAL....2091
    Undercarriage; tightening torque....2092
    Frame and track unit; specifications....2094
    Frame and track unit; description....2095
  71 - FRAME....2097
    Machine weight; specifications....2098
    Superstructure; removing....2100
    Superstructure; installing....2106
    Tightening torque; specifications....2111
    Counterweight; tightening torques....2113
    Counterweight; specifications....2115
    Counterweight; description....2116
    Counterweight; removing....2118
    Counterweight; installing....2122
  77 - WHEELS; TRACKS; TYRE; HUB; DRUM....2125
    Idler; description....2127
    Idler; measurement of wear....2129
    Front idler; removing....2132
    Front idler; installing....2135
    Front idler wheel; disassembling....2139
    Front idler wheel; assembling....2144
    Tools & equipment....2149
    Sprocket; replacing one....2155
    Track chain; description....2158
    Track link; dimension....2160
    Track; adjusting track sag....2161
    Track chain; measurement of wear....2164
    Track shoe; replacing one....2170
    Track links; replacing....2174
    Track shoes....2179
    Track chain assembly; removing....2180
    Track chain assembly; installing....2184
    Top roller; description....2189
    Top roller; measurement of wear....2192
    Top roller; replacing one....2195
    Bottom roller; description....2199
    Bottom roller; measurement of wear....2201
    Bottom roller; replacing one....2204
    Bottom roller; replacing seal....2208
    Track guards....2213
    Track guard; replacing one....2215
    Full track guard; replacing....2218
    Spring package; assembly dimension_09-15....2222
    Spring package; assembly dimension....2224
    Track recoil spring (tensioner) assembly; replacing....2226
    Spring package; disassembling....2230
    Spring package; assembling....2235
    Selection of track shoes....2239
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....2241
  80 - GENERAL....2242
    Tech Tool; operations ....2243
  81 - CAB; NAKED; CANOPY....2246
    Cab; weight....2247
    Cab; removing....2249
    Cab suspension; description....2257
  83 - DOORS; HATCH; COVER PLATE; (all)....2260
    Door; replacing....2261
    Cab door; changing door catch....2266
  84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....2273
    Rear-view mirror; replacing_{01-30}....2274
    Rear-view mirror; replacing_{01-04}....2276
    Windows; general....2278
    Windscreen; replacing....2282
    Side window; replacing....2297
    Rear window; replacing....2304
    Door window; replacing....2313
  85 - CAB INTERIOR; UPHOLSTERY....2317
    Driver's seat; description....2318
    Driver's seat; specifications....2324
    Seat; replacing....2329
    Seat cushion; replacing....2333
    Seat support; replacing....2340
    Longitudinal adjustment cable; replacing....2348
    Longitudinal suspension cable; replacing....2355
    Backrest; replacing....2360
    Seat heater; checking....2369
  87 - AIR CONDITIONING UNIT....2374
    HVAC system....2375
    Air conditioning unit; specifications....2380
    Air conditioning unit; description....2383
    Air conditioning unit; maintenance....2390
    CCM pre-programmed ECU; replacing....2394
    CCM non-programmed ECU; replacing....2400
    Air conditioning unit; refrigerant check and recharging....2406
    Cooler and Heater assembly; replacing....2415
    Air distribution; description_49-35....2423
    Air distribution; description....2425
    Cab filter; replacing....2428
    Heating system; description....2433
    Fan motor; replacing....2436
    Heater core; replacing....2441
    Air conditioning performance; checking....2448
    Compressor; replacing incl draining and filling....2455
    Receiver; replacing incl draining and filling....2460
    Condenser; replacing incl draining and filling....2465
    Evaporator; replacing incl draining and filling....2470
    Expansion valve; replacing incl draining and filling....2480
    Vent actuator; replacing....2490
    Mode (foot) actuator; replacing....2493
    Intake actuator; replacing....2496
    Air mix door actuator; replacing....2499
    Compressor; replacing magnetic clutch (compressor removed)....2503
    Auxiliary heater; specifications....2510
    Auxiliary heater; description....2513
    Auxiliary heater; principles....2517
    Troubleshooting....2521
  88 - INTERIOR EQUIPMENT....2532
    Instrument panel (left); replacing....2533
    Instrument panel (right); replacing....2538
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....2543
  90 - GENERAL....2544
    Hydraulic diagram; with option components - Image....2545
    Hydraulic diagram; standard - Image....2546
    Explanations to hydraulic diagram....2547
    Hydraulic diagram; standard....2559
    Hydraulic diagram; with option components....2562
    Hydraulic system; cleanliness when handling hydraulic components....2565
    Description; general....2570
    Hydraulic system; description....2571
    Recommended hydraulic oil; specifications....2573
    Hydraulic pressure; specifications....2578
    Hydraulic system; repair of hydraulic components in workshop....2579
    Hydraulic oil; storage and handling....2585
    Hydraulic components; storing and transporting....2590
    Tech Tool; operations....2595
  91 - WORKING HYDRAULIC; SERVO HYDRAULICS....2596
    Hydraulic system; work instructions....2601
    Hydraulic components; description....2606
    Hydraulic system; position of main components....2608
    Drain filter; description....2611
    Servo filter; description....2617
    Hydraulic oil tank; specifications....2623
    Hydraulic oil tank; description....2624
    Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump....2627
    Oil level gauge; replacing....2630
    Air breather; description....2632
    Breather; replacing....2635
    Shock reducing valve; description....2637
    Servo hydraulic block....2639
    Shuttle valve block; description....2642
    Check valve; description....2646
    Oil cooler line bypass valve (check valve); replacing....2648
    Hydraulic oil cooling system; specifications....2651
    Hydraulic cooling fan control; specifications....2653
    Hydraulic oil cooling system; description....2655
    Hydraulic oil cooler; description....2659
    Hydraulic oil cooler; replacing....2661
    Fan pump; description....2668
    Fan pump; parts inspection....2669
    Fan pump; disassembly....2671
    Fan pump; assembly....2673
    Oil cooler fan pump; replacing....2675
    Fan motor; description....2676
    Fan motor; disassembly....2682
    Fan motor; assembly....2689
    Fan motor; troubleshooting....2695
    Oil cooler fan motor; replacing....2697
    Proportional relief valve; specifications....2704
    Proportional relief valve; description....2705
    Hydraulic oil tank; tightening torques....2708
    Main control valve; port size and tightening torque....2709
    Main control valve; specifications....2710
    Hydraulic diagram; ports....2712
    Main control valve; description....2714
    Main control valve troubleshooting....2723
    Control valve; part inspection....2728
    General; precautions....2731
    Main relief valve; description....2734
    Main relief valve; adjustment....2736
    Main relief valve; disassembly....2739
    Pressure relief valve; troubleshooting....2742
    Main pressure relief valve; replacing....2747
    Port relief valve; description....2749
    Port relief valve pressure; checking and adjusting....2752
    2 stage port relief valve; description....2755
    2 stage port relief valve; adjustment....2761
    2 stage port relief valve; disassembly and assembly....2764
    Make up valve; description....2768
    Boom and arm holding valve (Boom-1; Arm-1); description....2771
    Boom and arm holding valve (Boom-1; Arm-1); disassembly....2775
    Boom boost check valve; disassembly....2779
    Cover assembly (for preventing Boom-1 spool rotation); disassembly....2781
    Arm regenerating valve; description....2784
    Arm parallel conflux changeover valve; disassembly....2787
    Check valve (for arm parallel conflux; slew priority); disassembly....2789
    Arm conflux check valve; disassembly....2791
    Main control valve adjustor; adjusting....2793
    Option confluence check....2795
    Slew priority valve; disassembly....2797
    Check valve (for straight travel changeover valve); disassembly....2799
    Center bypass valve; disassembly and assembly....2801
    Control valve; replacing....2803
    Tightening torques_08-16....2809
    Tightening torques_07-57....2813
    Line rupture valve (boom); specifications....2817
    Line rupture valve (boom); description....2818
    Line rupture valve pressure; checking and adjusting....2823
    Port relief valve pressure; adjustment (when installing or dismantling the line rupture valve)....2825
    Line rupture valve (boom); air bleeding....2828
    Boom cylinder; rupture valve; replacing....2830
    Disassembly and assembly; general....2834
    Line rupture valve (boom); disassembly....2837
    Line rupture valve (boom); assembly....2840
    Line rupture valve (boom); troubleshooting....2843
    Line rupture valve (arm); specifications....2847
    Line rupture valve (arm); description....2849
    Line rupture valve (arm); air bleeding....2854
    Dipper arm cylinder; rupture valve; replacing....2856
    Line rupture valve (arm); disassembly....2859
    Line rupture valve (arm); assembly....2862
    Line rupture valve (arm); troubleshooting....2865
    Tightening Torques....2868
    Hydraulic pump; specifications....2872
    Hydraulic pump; description....2873
    Hydraulic pump; maintenance standard; Specifications....2879
    Pump; troubleshooting....2884
    Pump; tools....2886
    Pump; disassembly....2889
    Pump; assembly....2898
    Pump; installation....2907
    Regulator; description....2909
    Regulator; maintenance....2914
    Regulator; disassembly....2916
    Regulator; assembly....2923
    Proportional solenoid valve; specifications....2929
    Current_pressure; specifications....2930
    Proportional solenoid valve; description....2931
    Proportional solenoid valve; measuring and adjustment....2934
    Proportional solenoid valve; troubleshooting....2939
    Hydraulic pump (removed); changing shaft seal....2941
    Hydraulic pump; replacing....2943
    Hydraulic pump regulator; replacing....2953
    Proportional solenoid valve (power shift); replacing....2955
    Servo pump; specifications....2957
    Servo pump; description....2959
    Gear pump; maintenance standard....2965
    Servo pump; parts inspection....2969
    Servo hydraulic pressure; adjustment....2972
    Servo pump; disassembly....2975
    Servo pump; assembly....2982
    Servo pump; replacing....2990
    Pressure accumulator; specifications....2994
    Pressure accumulator; description....2995
    Accumulator; replacing....2998
    Tightening torques....3000
    Remote control valve (Lever); specifications....3006
    Remote control valve (Lever); description....3007
    Remote control valve (lever); replacing....3021
    Remote control valve (Lever); disassembly....3033
    Remote control valve (Lever); assembly....3045
    Remote control valve (Lever); troubleshooting....3057
    Remote control valve (pedal); specifications....3061
    Remote control valve (pedal); description....3062
    Remote control valve (pedal); maintenance standard; Specifications....3069
    Remote control valve (pedal); replacing....3073
    Remote control valve (pedal); disassembly....3079
    Remote control valve (pedal); assembly....3090
    Remote control valve (pedal); troubleshooting....3103
    Solenoid valve; specifications_45-18....3107
    Solenoid valve; specifications....3108
    Solenoid valve; description....3109
    Solenoid valve; inspection....3112
    Solenoid valve; troubleshooting....3114
    Solenoid valve; disassembly and assembly....3119
    Solenoid valve; replacing....3122
    Boom float position; description....3125
  92 - MECHANICAL EQUIPMENT_ATTACHMENT....3129
    Bucket adapter maintenance guideline....3130
  97 - UNIT; DIGGING....3141
    Tightening torques....3143
    Function description....3151
    Digging unit; maintenance....3153
    Bushing general; replacing....3157
    Cylinder; description....3162
    Cylinder; disassembly and assembly....3167
    Cylinder; troubleshooting....3186
    Hydraulic cylinder; replacing....3191
    Boom; specifications....3198
    Boom; description....3199
    Boom; replacing....3202
    Boom cylinder; specifications....3219
    Boom cylinder; description....3221
    Boom cylinder; replacing_{35-45}....3223
    Boom cylinder; replacing_{35-17}....3232
    Lower boom cylinder bushing; replacing....3241
    Upper boom cylinder bushing; replacing....3247
    Dipper arm; specifications....3251
    Dipper arm; description....3252
    Dipper arm; replacing....3254
    Link; description....3267
    Dipper arm connecting rod; replacing....3270
    Connecting rod yoke; replacing....3278
    Dipper arm cylinder; specifications....3287
    Dipper arm cylinder; description....3289
    Dipper arm cylinder; replacing....3292
    Dipper arm cylinder bushing on boom; replacing....3302
    Dipper arm cylinder bushing on dipper arm; replacing....3308
    Bucket cylinder; specifications....3312
    Bucket cylinder; description....3314
    Bucket cylinder; replacing....3317
    Bucket cylinder bushing on dipper arm; replacing....3328
    Bucket cylinder bushing lever-link; replacing....3333
  99 - MISCELLANEOUS....3337
    Automatic lubrication system; description....3338
    Control units; software functions....3341

Volvo Construction EC480E HR, EC480E L, EC480E LD, EC480E LR Excavators Workshop Service Repair manual