Volvo EC480E HR Excavator Service Repair Manual PDF

Volvo EC480E HR Excavator Service Repair Manual PDF

Size: 191.58 MB
Language: English
Make: Volvo
Machine: Excavator
Document: Service Repair Manual, Electrical Diagram, Hydraulic Diagram
Model: Volvo EC480E HR
Page: 4308 Pages

Detail Contents:
1. EC480E HR
Repair

• 2 stage port relief valve, adjustment
  Accumulator, replacing
  ACM (After treatment control module), replacing, non-Programd
  ACM (After treatment control module), replacing, pre-Programd
  Actuator, variable turbocharger, replacing
  AdBlue DEF hoses, replacing
  AdBlue DEF nozzle, replacing
  AdBlue DEF pump unit, components, replacing
  AdBlue DEF pump unit, replacing
  AdBlue DEF pump, replacing
  AdBlue DEF quality, checking
  AdBlue DEF tank, breather filter, replacing
  AdBlue DEF tank, replacing
  AdBlue DEF tank, tank armature, replacing
  AdBlue DEF, draining
  Additional counterweight, description
  Additional counterweight, installing
  Additional counterweight, removing
  Aftertreatment fuel dosing unit, replacing
  Aftertreatment fuel nozzle, cleaning
  Aftertreatment fuel nozzle, replacing
  Air conditioner main filter, cleaning
  Air conditioner main filter, replacing
  Air conditioning unit, maintenance
  Air conditioning unit, refrigerant check and recharging
  Air drier cartridge, replacing
  Air in fuel system, checking
  Air mix door actuator, replacing
  Alternator, replacing incl function check
  Antenna, replacing
  Backrest, replacing
  Base boom modular joint cylinder pin, replacing
  Base boom modular joint cylinder, replacing
  Batteries, replacing
  Battery, charging
  Battery, checking
  Boom cylinder protecting guard, installation
  Boom cylinder protecting guard, removal
  Bottom roller, measurement of wear
  Bottom roller, replacing one
  Bottom roller, replacing seal
  Breather, replacing
  Bucket cylinder bushing lever-link, replacing
  Bucket cylinder bushing on dipper arm, changing
  Bucket cylinder protecting guard, installation
  Bucket cylinder protecting guard, removal
  Bucket cylinder, replacing
  Cab door, covers, hinges, joints and locks, lubricating
  Cab filter, replacing
  Cab prefilter, cleaning
  Cab prefilter, replacing
  Cab, installing
  Cab, removing
  Camshaft setting, checking
  Camshaft, replacing
  Carbon dioxide in coolant system, checking
  Carbon dioxide in fuel system, check
  CareTrack antenna, replacing
  CareTrack backup battery, replacing
  CareTrack battery, replacing
  CCM, changing non-Programd ECU
  CCM, changing pre-Programd ECU
  Center passage, assembly
  Center passage, disassembly
  Center passage, replacing seal kit
  Center passage, replacing
  Coasting left and right swing
  Component locations engine
  Compression test
  Compressor, replacing magnetic clutch (compressor removed)
  Compressor, replacing
  Condenser, replacing incl draining and filling
  Connecting rod yoke, replacing
  Control lockout lever switch, replacing
  Control valve, replacing
  Coolant freezing point, checking
  Coolant, changing
  Coolant, checking anti-freeze resistance
  Counterweight, description
  Counterweight, fitting
  Counterweight, removing
  Crankcase ventilation separator, replacing
  Creeping of hydraulic cylinder
  Cylinder speed
  Cylinder, disassembly and assembly
  DC–DC converter, description
  Demolition control valve, replacing
  Demolition dipper arm cylinder, replacing
  Diesel particulate filter, check and clean
  Diesel particulate filter, checking and cleaning
  Digging unit, maintenance
  Dipper arm connecting rod, replacing
  Dipper arm cylinder bushing on boom, replacing
  Dipper arm cylinder bushing on dipper arm, replacing
  Dipper arm cylinder, replacing
  Dipper arm, replacing
  Door window, replacing
  Door, replacing
  Earth lead to battery, replacing
  ECM (Engine control module), replacing non-Programd
  ECM (Engine control module), replacing pre-Programd
  EGR cooler, cleaning
  EGR cooler, pressure test
  EGR cooler, replacing
  EGR pressure sensor, replacing
  EGR valve, replacing
  EGR venturi tube, cleaning
  EGR Venturi tube, replacing
  Electric pedal control on X1 (on off), replacing
  Electric pedal control on X1 (proportional), replacing
  Electrical battery disconnect switch, replacing
  Engine air cleaner primary filter, replacing
  Engine air cleaner secondary filter, replacing
  Engine belt condition, checking
  Engine belts, replacing
  Engine oil and filter, changing
  Engine oil pressure sensor, replacing
  Engine rotation speed sensor (camshaft), replacing
  Engine rotation speed sensor (crank shaft), replacing
  Engine temperature sensor, replacing
  Engine wire harness, replacing
  Engine, installing
  Engine, removing
  E-tools, NET 8940-00290 Swing motor guide pin
  Evaporator, replacing incl draining and filling
  Exhaust aftertreatment system fuel flow, checking
  Exhaust pipe, flexible tube, replacing
  Expansion valve, replacing incl draining and filling
  Extensible undercarriage cylinder, replacing
  Fan motor, assembly
  Fan motor, disassembly
  Fan motor, replacing
  Feed pump, checking feed pressure
  Front idler, installing
  Front idler, removing
  Front idler, replacing one
  Fuel filter, replacing
  Fuel level sender, replacing
  Fuel system, bleeding
  Fuel tank breather filter, replacing
  Full track guard, replacing
  General, precautions
  GPMECU1, changing non-Programd ECU
  GPMECU1, changing pre-Programd ECU
  Hammer hydraulic option, installing new
  Heater core, replacing
  High pressure air system, pressure, checking
  HMICU, changing non-Programd ECU
  HMICU, changing pre-Programd ECU
  Horn, replacing
  Hour meter, replacing’
  Hydraulic oil drain filter, replacing
  Hydraulic oil level, checking
  Hydraulic oil return filter, replacing
  Hydraulic oil servo filter, replacing
  Hydraulic oil suction strainer, cleaning
  Hydraulic oil tank breather filter, replacing
  Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
  Hydraulic oil temperature sensor, replacing
  Hydraulic oil, changing
  Hydraulic pump (removed), changing shaft seal
  Hydraulic pump, replacing
  Hydraulic quickfit, adjustment
  Hydraulic return filter on X1 option circuit, replacing
  Idler, assembly
  Idler, disassembly
  Idler, measurement of wear
  Ignition switch, replacing
  Injector sleeves, replacing
  Injectors, replacing all
  Inlet and exhaust system, component location
  Inlet throttle, replacing
  Instrument panel, replacing (left)
  Instrument panel, replacing (right)
  Intake actuator, replacing
  Intercooler, replacing
  Line rupture valve (arm), assembly
  Line rupture valve (arm), disassembly
  Line rupture valve (boom), air breathing
  Line rupture valve (boom), assembly
  Line rupture valve (boom), disassembly
  Line rupture valve (boom), troubleshooting’
  Longitudinal adjustment cable, replacing
  Longitudinal suspension cable, replacing
  Lower boom cylinder bushing, replacing
  Lubrication oil consumption, checking
  Lubrication oil pressure, checking with pressure gauge
  Lubrication, every 50 hours
  Machine view
  Main pressure relief valve, replacing
  Main relief valve, adjustment
  Maintenance service, every 10 hours
  Maintenance service, every 50 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 4500 hours
  Maintenance service, every 6000 hours
  Maintenance service, first 500 hours
  Maintenance service, general
  Maintenance
  MATRIS and Tech Tool, reading
  Measuring condition
  Measuring of swing bearing clearance
  Middle dipper arm cylinder, replacing
  Mode (foot) actuator, replacing
  Muffler, replacing
  NOx sensor, replacing
  Oil cooler fan motor, replacing
  Oil cooler line bypass valve (check valve), replacing
  Oil cooler, replacing
  Oil level gauge, replacing
  Oil level sensor, changing
  Oil-bath air cleaner reservoir filter insert, cleaning
  Oil-bath air cleaner reservoir oil, changing
  Oil-bath air cleaner reservoir oil, checking
  Port relief valve pressure, checking and adjusting
  Pre-heating relay, replacing
  Proportional solenoid valve (power shift), replacing
  Proportional solenoid valve, measuring and adjustment
  Pump gearbox coupling assembly, replacing
  Pump gearbox flange, replacing
  Pump regulator, replacing
  Pump, maintenance standard
  Quickfit, replacing 1
  Quickfit, replacing
  Radiator and hydraulic oil cooler, cleaning
  Radiator, replacing
  Radio, replacing
  Rear window, replacing
  Rear-view mirror, changing
  Receiver, replacing incl draining and filling
  Recoil spring cylinder seal kit, replacing
  Regulator, maintenance
  Remote control valve (Lever), assembly
  Remote control valve (Lever), disassembly
  Remote control valve (Lever), maintenance standard
  Remote control valve (lever), replacing
  Remote control valve (pedal), assembly
  Remote control valve (pedal), disassembly
  Remote control valve (pedal), maintenance standard
  Remote control valve (pedal), replacing
  Removable counterweight cylinder, description
  Removable counterweight cylinder, specifications
  Removable counterweight, installing
  Removable counterweight, removing
  Retractable track, installing
  Retractable track, removing
  Ring gear grease pipe, replacing
  Rocker arms, replacing
  Rotator valve, adjustment
  Rupture valve, replacing (boom cylinder)
  Rupture valve, replacing (dipper arm cylinder)
  SCR system, dosing test
  Seat cushion, replacing
  Seat heater, checking
  Seat support, replacing
  Seat, replacing
  Servo hydraulic pressure, adjustment
  Servo pump, assembly
  Servo pump, disassembly
  Servo pump, parts inspection
  Servo pump, replacing
  Side window, replacing
  Solenoid valve, disassembly and assembly
  Solenoid valve, inspection
  Solenoid valve, replacing
  Speaker, replacing
  Spring package, assembly
  Spring package, disassembly
  Sprocket, installation
  Sprocket, measurement of wear
  Sprocket, removal
  Sprocket, replacing one
  Sprocket, replacing one1 1
  Starter motor, replacing
  Starter motor, tests
  Straight traveling performance
  Superstructure, installing
  Superstructure, removing
  Support information
  Swing bath grease, checking
  Swing gearbox oil level, checking
  Swing gearbox oil, changing
  Swing gearbox removed, replacing seal
  Swing gearbox, assembly
  Swing gearbox, disassembly
  Swing gearbox, maintenance standard
  Swing gearbox, replacing
  Swing limitation sensor, adjusting
  Swing motor relief valve, replacing
  Swing motor removed, replacing seal
  Swing motor, assembly
  Swing motor, disassembly
  Swing motor, maintenance standard
  Swing motor, replacing
  Swing ring gear bearing, lubricating
  Swing ring gear inner seal, replacing
  Swing ring gear outer seal, replacing
  Swing ring gear, replacing
  Swing speed 1
  Swing speed
  Swing unit, replacing
  Test running and checking
  Tool box assembly, replacing
  Tools & equipment
  Top roller, measurement of wear
  Top roller, replacing one
  Total moment indicator (TMI), replacing
  Track chain assembly, installing
  Track chain assembly, removing
  Track chain, measurement of wear
  Track gearbox oil level, checking
  Track gearbox oil, changing
  Track gearbox, assembly 1
  Track gearbox, assembly
  Track gearbox, disassembly
  Track gearbox, disassembly1`
  Track gearbox, maintenance standard
  Track gearbox, replacing cover
  Track gearbox, replacing
  Track guard, replacing one
  Track link, dimension
  Track links, replacing
  Track motor relief valve, replacing
  Track motor, assembly 1
  Track motor, assembly
  Track motor, disassembly 1
  Track motor, disassembly
  Track motor, maintenance standard
  Track motor, replacing
  Track recoil spring (tensioner) assembly, replacing
  Track running speed
  Track shoe bolts, checking
  Track shoe, replacing one
  Track tension and condition, checking
  Track unit, replacing
  Track, adjusting track sag
  Travel Speed
  Turbocharger, replacing
  Unit injectors, adjusting pretension
  Upper boom cylinder bushing, replacing’
  Valves, adjusting 1
  Valves, adjusting
  Vent actuator, replacing
  Venturi tube, checking
  Voltage converter, replacing
  Water separator filter, replacing
  W-ECU, replacing, non-Programd
  W-ECU, replacing, pre-Programd
  Windscreen flusher pump, replacing
  Windscreen wiper front, replacing motor
  Windscreen wiper, replacing switch
  Windscreen, replacing
  Work lighting, replacing one head lamp assy

Descriptions

• 2 stage port relief valve, description
  2 stage port relief valve, disassembly and assembly
  3 way selector valve, description
  Air breather, description
  Air conditioning unit, description
  Air distribution, description
  Alternator, description
  Alternator, test
  Arm conflux check valve, disassembly
  Arm parallel conflux changeover valve, disassembly
  Arm regenerating valve, description
  Attachment quick coupler
  Auto Idle
  Automatic engine shut-down
  Automatic lubrication system, description
  Auxiliary heater, description
  Auxiliary heater, principles
  Auxiliary start
  Base boom cylinder, description
  Base boom modular joint cylinder, description
  Battery charging capacity, checking
  Battery, description
  Boom and arm holding valve (Boom-1, Arm-1), description
  Boom and arm holding valve (Boom-1, Arm-1), disassembly
  Boom boost check valve, disassembly
  Boom float position, description
  Boost control, description
  Bottom roller, description
  Bucket cylinder, description
  Cab suspension, description
  CareTrack W-ECU, description
  CareTrack with anti-theft
  Center bypass valve, disassembly and assembly
  Center passage, description
  Central lubrication system, description
  Change capacities
  Charging, description
  Check valve (for arm parallel conflux, slew priority), disassembly
  Check valve, description
  Connectors, overview
  Control lockout lever switch, description
  Control pattern selector valve, description
  Control units, software functions
  Control valve, part inspection
  Cooling fan control
  Cooling system, description
  Cover assembly (for preventing Boom-1 spool rotation), disassembly
  Crankcase ventilation, description
  Crusher cylinder, description
  Cylinder, description
  Cylinder, troubleshooting
  Demolition control valve, description
  Demolition dipper arm cylinder, description
  Demolition machine, description
  Digging unit, description
  Dipper arm cylinder, description
  Dipper arm, description
  Driver’s seat, description
  ECO mode, description
  EGR actuator, specification
  Electrical system, special instructions for servicing, electrical components, alternator and charging regulator
  Electrical system, special instructions for servicing, electrical components, batteries
  Electrical system, special instructions for servicing, electronic components
  Electrical system
  Electro hydraulic pump control, description
  Electronic control system, description
  Engine limp home switch, description
  Engine start
  Engine stops
  Engine system
  Engine, description
  Exhaust Aftertreatment System, component location
  Exhaust Aftertreatment System, description
  Exhaust gas recirculation (EGR), component location
  Exhaust Gas Recirculation (EGR), description
  Extensible undercarriage cylinder, description
  Fan motor, description
  Fan motor, troubleshooting
  Foreword additional Service manual Demolition machine
  Frame and track unit, description
  Fuel system, component location
  Fuel system, description
  Function description transm
  General purpose machine electronic control unit GPMECU, function description
  Grading and lifting control, description
  Hammer return filter, description
  Heating system, description
  Human machine interface control unit HMICU, function description
  HVAC system
  Hydraulic components, description
  Hydraulic cylinders, dieseling
  Hydraulic diagram, ports
  Hydraulic oil cooler, description
  Hydraulic oil cooling system, description
  Hydraulic oil tank, description
  Hydraulic pump coupling, description
  Hydraulic pump, description
  Hydraulic quickfit, description
  Hydraulic system, position of main components
  Hydraulic system
  Idler, description
  Ignition switch, description and operation
  Inlet and exhaust system, description
  Instruments and controls, front instrument panel
  Instruments and controls, left instrument panel
  Instruments and controls, overview
  Instruments and controls, rear instrument panel
  Instruments and controls, right instrument panel
  Intermittent wiper and washer
  Keypad, description
  Limp home
  Line rupture valve (arm), air breathing
  Line rupture valve (arm), description
  Line rupture valve (boom), description
  Line rupture valve pressure, checking and adjusting
  Link, description
  Lower wiper motor, description
  Lubrication system, component locations
  Lubrication system, description
  Machine view, demolition
  Main control valve troubleshooting
  Main control valve, description
  Main relief valve, description
  Main relief valve, disassembly
  Make up valve, description
  Middle dipper arm cylinder, description
  Mode selection, description
  MS.Internal.Documents
  Option confluence check
  Overload warning
  Overview
  Port relief valve pressure, adjustment (when installing or dismantling the line rupture valve)
  Port relief valve, description
  Power transmission, description
  Preheating, description
  Pressure accumulator, description
  Pressure relief valve, troubleshooting
  Product plates
  Proportional relief valve, description
  Proportional solenoid valve, description
  Pump, troubleshooting
  Quickfit system, operation
  Radio with MP3, description
  Radio, description
  Regeneration process, description
  Regulator, description
  Remote control valve (Lever), description
  Remote control valve (Lever), troubleshooting
  Remote control valve (pedal), description
  Remote control valve (pedal), troubleshooting
  Reversible cooling fan, description
  Rotating beacon, replacing
  Rotator (X3 Line option), description
  Seat belt
  Selection of track shoes
  Service mode
  Service positions
  Service
  Servo hydraulic block
  Servo pump, description
  Shock reducing valve, description
  Shuttle valve block, description
  Software parameters, description
  Solenoid valve, description
  Solenoid valve, troubleshooting
  Spring package, assembly dimension
  Starter switch, testing
  Starting operation
  Stop valve
  Straight travel pedal, description
  Swing gearbox, description
  Swing motor, description
  Swing ring gear inner seal, replacing
  Swing ring gear, description
  System voltage
  Tightening torque, specifications
  Top roller, description
  Total moment indicator (TMI), description
  Track chain, description
  Track gearbox, description
  Track guards
  Track motor, description
  Travel alarm, replacing
  Travel alarm
  Travel Speed
  Undercarriage, description
  Upper wiper motor, description
  Welding on the machine
  Window limit switch, description
  Windows, general
  Windscreen wiper, description
  X1 control, description
  X1 Line, description
  X3 control, description

Diagrams

• Explanations to hydraulic diagram
  Hydraulic diagram, demolition equipment 4
  Hydraulic diagram, demolition equipment
  Wiring diagram SCH01
  Wiring diagram SCH01-1
  Wiring diagram SCH02
  Wiring diagram SCH02-1
  Wiring diagram SCH03
  Wiring diagram SCH03-1
  Wiring diagram SCH04
  Wiring diagram SCH05
  Wiring diagram SCH05-1
  Wiring diagram SCH07
  Wiring diagram SCH08
  Wiring diagram SCH10′
  Wiring diagram SCH11
  Wiring diagram SCH12
  Wiring diagram SCH13
  Wiring diagram SCH14
  Wiring diagram SCH15
  Wiring diagram SCH16
  Wiring diagram SCH17
  Wiring diagram SCH17-1
  Wiring diagram SCH18
  Wiring diagram SCH20
  Wiring diagram SCH22
  Wiring diagram SCH30
  Wiring diagram SCH31
  Wiring diagram SCH32
  Wiring diagram SCH33

Service Bulletins

• CareTrack Telematics system
  CareTrack, new software version 2008w6
  Check method on engine oil consumption
  DEF AdBlue AUS32 sampling, method
  ECU, functional check
  Fuel sampling, method
  Hydraulic hose assembly leakage handling
  Hydraulic system flushing method
  Machine model
  Modification of CareTrack wire harness
  New product 1
  New product
  Oil sampling, method
  Oil sampling, sampling points
  Recommendations for Oil Sampling Intervals
  Reporting of product misuse & near-miss report
  Reports
  Routines for reporting cracks on Boom and Arm

Special tool catalog

• General
  Index
  Hooks
  1. Enviroment and Safety equipment
  2. Measuring equipment
  3. Tightening and Loosening tools
  4. Lifting equipment
  5. Pullers and Pressing equipment
  6. Drifts
  7. Guide pins and Guide sleeves
  8. Pliers
  9. Fixtures
  10. Tech Tool
  11. Spare parts

Specifications

• AdBlue DEF
  Air conditioning unit, specifications
  Alternator, specifications
  Automatic lubrication system, specifications
  Auxiliary heater, specifications
  Base boom cylinder, specifications
  Base boom modular joint cylinder, specifications
  Base boom, specifications
  Battery, specifications
  Boom cylinder protecting guard
  Bucket cylinder protecting guard torques
  Cab, weight
  Center passage, specifications
  Control lockout lever switch, specifications
  Control pattern selector valve, specifications
  Coolant with freezing and corrosion protection
  Coolant
  Cooling system, specifications
  Cooling system, tightening torques
  Counterweight, tightening torques
  Crusher cylinder, specifications
  DC–DC converter, specifications
  Demolition boom, specifications
  Demolition control valve, specifications
  Demolition dipper arm cylinder, specifications
  Demolition dipper arm line rupture valve, specifications
  Demolition dipper arm, specifications
  Digging boom, specifications
  Dipper arm cylinder, specifications
  Dipper arm, specifications
  Driver’s seat, specifications
  EGR system, tightening torques
  Electric horn, specifications
  Electrical system, specifications
  Engine – Pump control, specification
  Engine limp home switch, specifications
  Engine oil
  Engine, specification’
  Engine, tightening torques
  Extensible undercarriage cylinder, specifications
  Frame and track unit, specifications
  Fuel system, specifications
  Fuel
  Grease
  Hammer return filter, specifications
  Handrail, tightening torque
  High pressure water, specifications
  Hydraulic oil cooling system, specifications
  Hydraulic oil tank, specifications
  Hydraulic oil
  Hydraulic pump, specifications
  Ignition switch, specifications
  Inlet and exhaust system, specification
  Inlet and exhaust system, tightening torques
  Line rupture valve (arm), specifications
  Line rupture valve (boom), specifications
  Lower wiper motor, specifications
  Lubrication system, specifications
  Lubrication system, tightening torques
  Machine weight, specifications
  Main control valve, port size and tightening torque
  Main control valve, specifications
  Measurement conversion tables
  Middle dipper arm cylinder, specifications
  Middle dipper arm, specifications
  Preheating, specifications
  Proportional solenoid valve, specifications
  Radio with MP3, specifications
  Recommended lubricants
  Relay, specifications
  Remote control valve (Lever), specifications
  Remote control valve (Lever), tightening torque
  Remote control valve (pedal), specifications
  Rotating beacon, specifications
  Servo pump, specifications
  Solenoid valve for rotator
  Solenoid valve, specifications
  Standard tightening torques
  Starter motor, specifications
  Swing gearbox, specifications
  Swing motor, specifications
  Swing ring gear, specifications
  Tightening torque, fuel system
  Tightening torque, specifications frame
  Tightening torque, specifications side
  Tightening torque, specifications
  Tightening torques
  Track gearbox, specifications
  Track motor, specifications’
  Track shoes
  Travel alarm, specifications
  Undercarriage, description
  Undercarriage, tightening torque
  Upper wiper motor, specifications
  Valve system, specifications
  Windscreen flusher pump, specifications
  Work lights and extra lights, specifications
  X1 electronic proportional pedal, tightening torque

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