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