Volvo EC210C N Excavator Service Repair Manual PDF

Volvo EC210C N Excavator Service Repair Manual PDF

Size: 124.93 MB
Language: English
Make: Volvo
Machine: Excavator
Document: Service Repair Manual, Electrical Diagram, Hydraulic Diagram
Model: Volvo EC210C N
Page: 1558 Pages

Detail Contents:
EC210C N
Repair

• 2 stage port relief valve, adjustment
  Accumulator, replacing
  Adjustable boom valve, disassembly
  Air cleaner primary filter, change
  Air cleaner primary filter, clean
  Air cleaner secondary filter, change
  Air conditioner main filter, change
  Air conditioner main filter, clean
  Air conditioning unit, maintenance
  Air mix door actuator, replacing
  Alternator, replacing incl function checking
  Antenna, replacing
  Arm parallel conflux check valve, disassembly and assembly
  Arm parallel conflux valve, disassembly and assembly
  Arm regenerating valve, disassembly
  Arrival Inspection, according to Inspection Program
  Batteries, replacing
  Battery condition, check
  Battery, charging
  Belts and belt tension, check, replace when needed.
  Boom 2 conflux shut-off valve, disassembly
  Boom and arm holding valve (Boom-1, Arm-1), disassembly
  Boom back pressure check valve, disassembly
  Boom cylinder, rupture valve, replacing
  Boom, installing
  Boom, removing
  Boom, replacing
  Bottom roller, assembly
  Bottom roller, disassembly
  Bottom roller, measurement of wear
  Bottom roller, replacing one
  Bottom roller, replacing seal
  Breather, replacing
  Bucket assembly, installing
  Bucket assembly, removing
  Bucket assembly, replacing
  Bucket cylinder, installing
  Bucket cylinder, removing
  Bucket cylinder, repacking in machine
  Bucket cylinder, replacing
  Bucket flow control valve, disassembly
  Bucket regenerating valve, disassembly
  Cab elevating cylinder, replacing
  Cab filter, replacing
  Cab, installing
  Cab, prefilter, clean
  Cab, prefilter, replace
  Cab, removing
  Cab; door, covers, hinges, joints and locks, lubricate
  Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope
  Carbon dioxide in fuel system, checking
  Center bypass valve, disassembly and assembly
  Center passage hose (center passage – motor), replacing
  Center passage hose (valve – center passage), replacing
  Center passage, assembly
  Center passage, disassembly
  Center passage, inspection and troubleshooting
  Center passage, replacing seal kit
  Center passage, replacing
  Charge air cooler connection (hose, tube), replacing
  Charge air cooler, replacing
  Coasting left and right swing
  Component locations
  Compressor, replacing incl draining and filling
  Condenser, replacing incl draining and filling
  Connecting rod yoke, installing
  Connecting rod yoke, removing
  Connecting rod yoke, replacing
  Control lockout lever switch, replacing
  Control types for X1 and X3 operation
  Coolant anti-freeze resistance, checking 2
  Coolant anti-freeze resistance, checking
  Coolant level, check
  Coolant, change
  Coolant, changing
  Cooler and Heater assembly, replacing
  Counterweight, installing 2
  Counterweight, installing
  Counterweight, removing
  Creeping of hydraulic cylinder
  Cylinder speed
  Delivery Inspection, according to Inspection Program
  Digging unit, maintenance
  Dipper arm connecting rod, installing
  Dipper arm connecting rod, removing
  Dipper arm connecting rod, replacing
  Dipper arm cylinder, installing
  Dipper arm cylinder, removing
  Dipper arm cylinder, repacking in machine
  Dipper arm cylinder, replacing
  Dipper arm cylinder, rupture valve, replacing
  Dipper arm, installing
  Dipper arm, removing
  Dipper arm, replacing
  Door window, replacing
  Earth lead to battery, replacing
  ECC (Electronic Climate Control), replacing
  E-ECU MID 128 non-Programd, replacing 2
  E-ECU MID 128 non-Programd, replacing
  E-ECU MID 128 pre-Programd, replacing 2
  E-ECU MID 128 pre-Programd, replacing
  Engine hood, replacing
  Engine mounting
  Engine oil and filter, changing
  Engine rotation speed sensor (camshaft), replacing
  Engine speed control switch, inspection
  Engine speed control switch, replacing
  Engine wire harness, replacing
  Engine, oil level, check
  Engine, tightening torques
  E-tools, NET 8940-00270 Replace tool for the swing ring gear
  E-tools, NET 8940-00300 Swing ring gear guide pin
  Evaporator, replacing incl draining and filling
  Exhaust pipe flexible tube, replacing
  Expansion tank, replacing
  Expansion valve, replacing incl draining and filling
  Fan belt and or alternator belt, replacing
  Fan belt and or alternator-, compressor belt, replacing all belts
  Fan motor, assembly 2
  Fan motor, assembly
  Fan motor, disassembly
  Fan motor, replacing
  Fan motor, tools
  Fan pump, assembly 2
  Fan pump, assembly
  Fan pump, disassembly
  Feed pump pressure, checking
  Feed pump, replacing
  Fire extinguisher, fault indication
  Flow control valve, disassembly and assembly
  Front idler, replacing one
  Fuel control valve (FCV), replacing
  Fuel filling pump, installing
  Fuel filling pump, removing
  Fuel filter extra (water separator element), check drain
  Fuel filter extra, replacing
  Fuel filter housing, replacing
  Fuel filter, change
  Fuel filter, checking
  Fuel filters, replacing
  Fuel pump, inspecting
  Fuel rail pressure, checking
  Fuel system, bleeding
  Fuel tank air ventilation filter, change
  Fuel tank sediment, drain
  General, precautions
  General, tools
  Heater core, replacing
  Horn, replacing
  Hydraulic oil drain filter, change
  Hydraulic oil level, check
  Hydraulic oil return filter, replacing
  Hydraulic oil servo filter, change
  Hydraulic oil suction strainer, clean
  Hydraulic oil tank breather filter, replacing
  Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
  Hydraulic oil, changing
  Hydraulic pump (removed), changing shaft seal
  Hydraulic pump regulator, replacing
  Hydraulic pump, maintenance standard, Specifications
  Hydraulic quickfit, adjustment
  Idler, assembly
  Idler, disassembly
  Idler, measurement of wear
  I-ECU MID 140 pre-Programd, replacing 2
  I-ECU MID 140 pre-Programd, replacing
  Injector, replacing one
  Instrument panel (left), replacing
  Instrument panel (right), replacing
  Intake actuator, replacing
  Line rupture valve (arm), disassembly
  Line rupture valve (boom), disassembly
  Load check valve – single, disassembly and assembly
  Machine view, waste handler
  Machine view
  Main pressure relief valve, replacing
  Main relief valve, adjustment
  Main relief valve, disassembly and assembly
  Main spool, disassembly and assembly
  Main switch, replacing
  Maintenance of Stored Machines, according to Inspection Program
  Maintenance service, according to display message
  Maintenance service, daily
  Maintenance service, every 50 hours
  Maintenance service, every 100 hours
  Maintenance service, every 250 hours
  Maintenance service, every 500 hours
  Maintenance service, every 1000 hours
  Maintenance service, every 2000 hours
  Maintenance service, every 4000 hours
  Maintenance service, every 6000 hours
  Maintenance service, general
  Maintenance
  Make up valve, disassembly
  MATRIS, reading, export reading
  Measuring condition
  Measuring of swing bearing clearance
  Mode (foot) actuator, replacing
  NET 8940-00200 Replace tool for the remote control valve joint
  NET 8940-00290 Track motor guide pin
  Oil cooler, replacing
  Oil level gauge, replacing
  Oil-bath air cleaner’s reservoir (optional equipment), clean, and oil, change
  Oil-bath air cleaner’s reservoir (optional equipment), filter insert, clean
  Oil-bath air cleaner’s reservoir (optional equipment), oil, check
  Operation numbers for additional work
  Port relief valve pressure, measuring and adjusting
  Port relief valve, disassembly and assembly
  Preheating coil, replacing
  Pre-heating relay, replacing
  Proportional solenoid valve (power shift), replacing
  Proportional solenoid valve, measuring and adjustment
  Pump coupling, installing
  Pump coupling, removing
  Pump gearbox coupling assembly, replacing
  Pump, assembly
  Pump, disassembly
  Pump, installation
  Pump, tools
  Quickfit, installing
  Quickfit, removing
  Radiator hose upper, replacing
  Radiator hoses lower, replacing
  Radiator outside hydraulic oil cooler outside, cleaning
  Radiator, replacing
  Rear window, replacing
  Rear-view mirror, replacing
  Receiver, replacing incl draining and filling
  Remote control valve (Lever), assembly
  Remote control valve (Lever), disassembly
  Remote control valve (Lever), maintenance standard, Specifications
  Remote control valve (pedal), assembly 2
  Remote control valve (pedal), disassembly
  Remote control valve (pedal), maintenance standard, Specifications
  Rotator valve, adjustment
  Seat support, replacing
  Seat, replacing
  Servo hydraulic pressure, adjustment
  Servo pump, parts inspection
  Servo pump, replacing
  Side window, replacing
  Silencer, replacing
  Slew gearbox, lubrication
  Slew motor, troubleshooting
  Solenoid valve, disassembly and assembly
  Solenoid valve, inspection
  Speaker, replacing
  Spring package, assembly
  Spring package, disassembly
  Sprocket, measurement of wear
  Sprocket, replacing one
  Starter motor lead to battery, replacing
  Starter motor, testing
  Starter relay, replacing
  Starter switch (engine start switch), replacing
  Straight traveling performance
  Swing bath grease, check
  Swing gearbox oil level, check
  Swing gearbox removed, replacing shaft
  Swing gearbox removed, seal replacing
  Swing gearbox, assembly 2
  Swing gearbox, assembly
  Swing gearbox, disassembly
  Swing gearbox, maintenance standard
  Swing gearbox, replacing
  Swing motor gearbox, changing oil
  Swing motor relief valve, replacing
  Swing motor removed, seal replacing
  Swing motor, assembly
  Swing motor, disassembly
  Swing motor, maintenance standard
  Swing motor, replacing brake piston seal
  Swing motor, replacing plate (brake)
  Swing motor, replacing
  Swing ring gear bearing, lubricate
  Swing ring gear grease pipe, replacing
  Swing ring gear outer seal, replacing 2
  Swing ring gear outer seal, replacing
  Swing speed
  Swing unit, replacing
  Test-run and check
  The machine, check for external damages, cracks and wear damages
  Thermostat, checking
  Tools & equipment
  Top roller, assembly
  Top roller, disassembly
  Top roller, measurement of wear
  Top roller, replacing one
  Track chain assembly, installing
  Track chain assembly, removing
  Track chain, measurement of wear
  Track chain, wear limit
  Track gearbox (removed), replacing floating seal
  Track gearbox cover, replacing
  Track gearbox oil level, check
  Track gearbox, assembly
  Track gearbox, disassembly
  Track gearbox, maintenance standard
  Track guard, replacing one 2
  Track guard, replacing one
  Track motor gearbox, changing oil
  Track motor relief valve, replacing
  Track motor, assembly
  Track motor, disassembly
  Track motor, replacing
  Track recoil spring (tensioner) assembly, replacing
  Track running speed
  Track shoe bolts, check
  Track shoe, replacing one
  Track tension condition, check
  Track unit, replacing
  Track, adjusting track sag
  Travel Speed
  Turbocharger, inspecting
  Turbocharger, replacing
  Valve clearance, check adjust
  Valves, adjusting
  VCADS Pro, logged errors, read off
  V-ECU MID 187 non-Programd, replacing 2
  V-ECU MID 187 non-Programd, replacing
  V-ECU MID 187 pre-Programd, replacing 2
  V-ECU MID 187 pre-Programd, replacing
  Vent actuator, replacing
  Warranty inspection 100 hours
  Warranty inspection 1000 hours
  Washer fluid level, check
  Water separator filter element, change
  Water separator housing, replacing
  W-ECU, MID142, changing non-Programd ECU
  W-ECU, MID142, changing pre-Programd ECU
  Windscreen flusher pump, replacing
  Windscreen wiper controller, replacing
  Windscreen wiper switch, replacing 2
  Windscreen wiper switch, replacing
  Windscreen, replacing
  Work lighting head lamp assy, replacing 2
  Work lighting head lamp assy, replacing
  X1 return filter (optional equipment), change

Safety

• CE-marking, EMC-directive
  Checklist after a fire or heat exposure
  Decontamination
  Environmental handling for the future
  Environmentally hazardous fluids
  Environmentally safe handling
  Fire prevention measures
  Health hazards with paint, plastics and rubber
  Safety concerns everybody!
  Safety rules when servicing
  Safety when handling oils and fuel
  Safety when handling the machine
  Safety when using lifting equipment
  Safety when working with air conditioning refrigerant
  Safety when working with batteries
  Safety when working with hydraulic systems
  Starting with booster batteries
  Waste handling
  Working in environmentally contaminated areas

Service Bulletins

• Air conditioning compressor improvement 2
  Air conditioning compressor improvement
  Attachment shims for clearance adjustment of pin joint
  Auxiliary heater
  Battery maintenance guideline for long term stock machines
  Biodegradable hydraulic oil
  Biodiesel fuel for Volvo CE
  Blower motor
  Bottom roller improvement
  Bucket cylinder protection improvement
  Cab door latch 2
  Cab door latch
  Cab update, C-series 2
  Cab update, C-series 3
  Cab update, C-series 4
  Cab update, C-series 5
  Cab update, C-series
  Cable harness connector, engine
  CD & MP3 player
  Charged air cooler pipe mounting bracket bolt loosening
  Check method on engine oil consumption
  Cigar lighter and ashtray change
  Coolant pump improvement
  Crankshaft and camshaft gear manufacturing improvements
  Cylinder liner, specifications
  D4 – D7 Alternator improvement
  D6 D7 Exhaust gas leakage into the cooling system
  D6E and D7E, high pressure pipe leakage
  DEF AdBlue AUS32 sampling, method
  Diesel fuels – quality and function
  Dipstick level gauge improvement for swing gearbox
  ECU, functional check
  Electric connector
  Electric horn improvement
  Electric horn
  Electrical distribution box
  Engine limp home switch wire harness
  Engine oil filter hose improvement
  Engine oil leakage
  Engine speed control switch improvement
  Engine starting in the manual mode
  Fuel cap improvement
  Fuel Level
  Fuel pump (Tier 3) manufacturing process improvement
  Fuel sampling, method
  Fuel tank crack
  Heat-resistant kit for RCV leakage
  Hose leakage
  Hour counter improvement
  Hydraulic hose assembly leakage handling
  Hydraulic oil
  Hydraulic system flushing method
  Hydraulic tank air breather
  Idler wheel and bushing improvement
  Idler yoke, improvement
  I-ECU, clock and rear view camera
  Improved Volvo quick-fit block
  Improvement of return check valve
  Injector wire harness for D4E-D6E-D7E
  Injector yoke bolt
  Injector yoke retention bolt loose
  Instrument ECU change
  Instrument ECU Improvement
  Internal modem change
  Leakage at engine oil pump gasket
  Line rupture valve hose, improvement
  Lower frame improvement
  Machine model
  Modification of CareTrack wire harness
  Muffler improvement
  New engine oil cooler
  New engine oil level sensor
  New fastener assortment
  New oil change interval for Volvo bio hydraulic oil
  New product
  New software
  New turbo charger for D6E-D7E
  Oil analyses
  Oil sampling, method
  Oil sampling, sampling points
  Operating hour parameter
  Pipe leakage
  Plastic shims for Boom Arm pin joints
  Poor straight travel operation
  Portable refillable O-ring kits
  Pressure sensor
  Receiver drier improvement
  Recoil spring grease valve
  Recoil spring package rod
  Recommendations for Oil Sampling Intervals
  Reporting of product misuse & near-miss report
  Reports
  Reversible fan, modes and setting
  Rotating beacon lamp, tightening torque
  Routines for reporting cracks on Boom and Arm
  Serial number location on machine components
  Sprocket improvement
  Swing ring gear seal
  Thermostat failure (D4, D5, D6 & D7)
  Tool box change
  Tool box improvement
  Travel gearbox floating seal improvement
  Travel motor 2
  Travel motor
  Turbo outlet gasket change
  Turbocharger
  Volvo Product incident accident report & Interview Form
  Washer check valve
  Washer pump improvement 2
  Washer pump improvement
  Waste handler strobe light
  Water separator drain valve
  Whistle noise during boom down
  X1 stop valve

Specifications

• Adjustable boom and cylinder, specifications
  Air conditioning unit, specifications
  Alternative fuels
  Alternator, specifications
  Audio remote controller, specifications 2
  Audio remote controller, specifications
  Auto Manual pump control switch, specifications
  Automatic lubrication system, specifications
  Battery, specifications
  Boom lifting cylinder, specifications
  Boom, specifications
  Bucket cylinder, specifications
  Cab, weight
  Circuit breaker, specification
  Control lockout lever switch, specifications
  Control pattern selector valve, specifications
  Coolant pump, thermostat, specifications
  Coolant with freezing and corrosion protection
  Cooling system, specifications
  Counterweight, specifications]
  Counterweight, tightening torques 2
  Counterweight, tightening torques
  Current pressure, specifications
  Diesel coolant heater (5kw), specifications
  Dipper arm cylinder, specifications
  Dipper arm, specifications
  Electric horn, specifications
  Electrical system, specifications
  Electronic climate control unit ECC, specification
  Elevating cylinder, specifications
  Emergency engine speed control switch, specifications
  Engine – Pump control, specification
  Engine control unit E-ECU, specifications
  Engine speed control switch, specifications
  Engine, specifications
  Engine, weights
  Flywheel, weight
  Frame and track unit, specifications 2
  Frame and track unit, specifications
  Fuel feed pump, specifications
  Fuel filler pump, specifications
  Fuel pressure, specifications
  Fuel system, tightening torques
  Fuel tank, specifications
  Fuse, specifications 2
  Fuse, specifications
  Hammer return filter, specifications
  Hour counter, specifications
  Hydraulic oil cooling system, specifications
  Hydraulic pump, specifications
  Hydraulic tank, specifications
  Keypad, specification
  Line rupture valve (arm), specifications
  Line rupture valve (boom), specifications
  Logic valve, specifications
  Lower wiper motor, specifications
  Lubrication system, specifications
  MA9109 Quickfit solenoid valve, specifications
  Machine weight, specifications
  Main control valve, specifications
  Measurement conversion tables
  Preheating, specifications
  Pressure accumulator, specifications
  Proportional solenoid valve, specifications 2
  Proportional solenoid valve, specifications
  Radio with CD and MP3 player, specifications
  Radio with tape or CD player, specifications
  Regulator, specifications
  Relay, specifications 2
  Relay, specifications
  Remote control valve (Lever), specifications
  Remote control valve (pedal), specifications
  Rotating beacon, specifications
  Rotator pump, specifications 2
  Rotator pump, specifications
  Servo pump, specifications
  Slew gearbox, specifications
  Slew ring gear, specifications
  Solenoid valve, specifications 2
  Solenoid valve, specifications
  Specifications
  Standard tightening torques
  Start switch, specifications
  Starter motor, specifications
  Swing motor, specifications
  Tightening torque, specifications 2
  Tightening torque, specifications
  Track gearbox, specifications
  Track motor, specifications
  Travel alarm, specifications
  Upper wiper motor, specifications
  Valve system specifications
  Vehicle control unit V-ECU, specifications
  Windscreen flusher pump, specifications
  Wiper controller, specifications
  Wireless control unit W-ECU, specification
  Work lights and extra lights, specifications

Wiring

• Adjustable boom (X2), hydraulic diagram
  Component designations
  Component list Control lights warning lights
  Component list Alternator, batteries, capacitors, electronic units, voltage outlet
  Component list, fuses
  Component list, Heating coils
  Component list, lights
  Component list, Miscellaneous
  Component list, motors
  Component list, relays
  Component list, sensors
  Component list, Solenoid valves
  Component list, Switches
  Control system diagram
  Electrical symbols and designations
  Explanation of wiring diagrams
  Explanations to hydraulic diagram
  Grounding points, frame connections
  Hydraulic diagram, arm in fig 1
  Hydraulic diagram, arm in
  Hydraulic diagram, arm out fig 1
  Hydraulic diagram, arm out
  Hydraulic diagram, boom lower fig 1
  Hydraulic diagram, boom lower
  Hydraulic diagram, boom raise fig 1
  Hydraulic diagram, boom raise
  Hydraulic diagram, bucket curl
  Hydraulic diagram, bucket dump
  Hydraulic diagram, control pattern selector valve
  Hydraulic diagram, elevating cab 1
  Hydraulic diagram, elevating cab
  Hydraulic diagram, ports
  Hydraulic diagram, slew (left)
  Hydraulic diagram, standard Image 1
  Hydraulic diagram, standard
  Hydraulic diagram, straight travel
  Hydraulic diagram, travel
  Hydraulic diagram, with option components image 1
  Hydraulic diagram, with option components
  Hydraulic diagram, X1 line
  Hydraulic quickfit
  Hydraulics diagram
  Rotator (X3 Line option), hydraulic circuits
  Waste handler, electrical circuit
  Waste handler, electrical circuit-2
  Waste handler, electrical circuit-3
  Wiring diagram SCH01
  Wiring diagram SCH02
  Wiring diagram SCH03 1
  Wiring diagram SCH03
  Wiring diagram SCH04
  Wiring diagram SCH07
  Wiring diagram SCH08
  Wiring diagram SCH08-1
  Wiring diagram SCH10
  Wiring diagram SCH11
  Wiring diagram SCH11-1
  Wiring diagram SCH12
  Wiring diagram SCH12-2
  Wiring diagram SCH12-3
  Wiring diagram SCH13
  Wiring diagram SCH14
  Wiring diagram SCH14-2
  Wiring diagram SCH15
  Wiring diagram SCH15-2
  Wiring diagram SCH16
  Wiring diagram SCH17
  Wiring diagram SCH18
  Wiring diagram SCH18-2
  Wiring diagram SCH20
  Wiring diagram SCH21
  Wiring diagram SCH22
  Wiring diagram SCH23
  Wiring diagram SCH24
  Wiring diagram SCH27
  Wiring diagram, electrical distribution box
  Wiring diagram
  Wiring harnesses

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