Volvo ECR235E L Excavator Workshop Service Repair Manual PDF Wiring Diagrams - MVLVCONECR235E.zip

A full-service repair guide, complete with electrical wiring diagrams, for the Volvo ECR235E L Excavator—packed with every technical detail needed to service, troubleshoot, fix, and rebuild the machine the way professional technicians do.

The Volvo Construction ECR235E L Excavator workshop service and repair manual covers:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:

Total Pages: 3,462 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

Volvo ECR235E L Excavators Service Repair Manual.pdf

MAIN SECTIONS

000 - Foreword.......2

000 - GENERAL.......3

00 - DESCRIPTION; COMPLETE MACHINE.......4

Machine view.......5

Product plates.......7

03 - SPECIFICATIONS.......9

Main dimensions.......10

Measurement conversion tables.......12

Specifications.......21

Tightening torque, specifications.......23

Tightening torques.......26

07 - STANDARD TIME.......35

Operation numbers for additional work.......36

08 - TOOL.......38

E-tools, NET 8940-00270 Replace tool for the swing ring gear.......39

Infrared Thermometer.......41

NET 8940-00190 Travel motor guide pin.......45

09 - MISCELLANEOUS.......46

Hydraulic cylinders, dieseling.......47

Service positions.......51

Welding on the machine.......54

001 - STANDARD PARTS, SERVICE.......57

16 - LUBRICANT; FUEL; OTHER FLUID.......58

AdBlue_DEF .......59

Alternative fuels.......65

Change capacities.......68

Coolant with freezing and corrosion protection.......69

Coolant.......73

Engine oil.......77

Fuel.......79

Grease.......82

Hydraulic oil.......86

Lubricants, service capacities and intervals.......90

Recommended lubricants.......92

17 - SERVICE.......95

AdBlue_DEF pump unit filter, replacing.......98

AdBlue_DEF tank breather filter, replacing.......101

Air conditioner compressor belt, checking.......102

Air conditioner main filter, cleaning.......104

Air conditioner main filter, replacing.......106

Arrival Inspection, according to Inspection Programme.......108

Battery, checking.......113

Bearings.......115

Cab door, covers, hinges, joints and locks, lubricating.......119

Cab prefilter, cleaning.......121

Cab prefilter, replacing.......123

CareTrack backup battery, replacing.......125

Cleaning prior to repair.......128

Coasting left and right swing.......132

Coolant freezing point, checking.......134

Coolant, changing.......137

Creeping of hydraulic cylinder.......139

Cylinder speed.......141

Delivery Inspection, according to Inspection Programme.......144

Diesel particulate filter, checking and cleaning.......148

Diesel particulate filter, regenerating.......152

Engine air cleaner primary filter, replacing.......154

Engine air cleaner secondary filter, replacing.......156

Engine oil and filter, changing.......158

Fan_alternator belt, checking.......161

Fuel filter, replacing.......163

Fuel tank breather filter, replacing.......165

Hoses and tubes.......168

Hydraulic oil drain filter, replacing.......172

Hydraulic oil level, checking.......173

Hydraulic oil return filter, replacing.......174

Hydraulic oil servo filter, replacing.......176

Hydraulic oil suction strainer, cleaning.......177

Hydraulic oil tank breather filter, replacing.......179

Hydraulic oil, changing.......181

Lubrication, every 50 hours.......183

MATRIS and Tech Tool, reading.......185

Maintenance of Stored Machines, according to Inspection Programme.......186

Maintenance service, every 10 hours.......190

Maintenance service, every 1000 hours.......191

Maintenance service, every 2000 hours.......193

Maintenance service, every 250 hours.......195

Maintenance service, every 4000 hours.......196

Maintenance service, every 4500 hours.......198

Maintenance service, every 50 hours.......199

Maintenance service, every 500 hours_{09-51-11}.......200

Maintenance service, every 500 hours_{09-51-22}.......202

Maintenance service, every 6000 hours_{09-49-29}.......204

Maintenance service, every 6000 hours_{09-49-41}.......206

Maintenance service, every 8000 hours_{09-49-01}.......207

Maintenance service, every 8000 hours_{09-49-12}.......208

Maintenance service, first 500 hours.......209

Measuring condition.......210

Measuring of swing bearing clearance.......213

Pressure testing.......216

Radiator and hydraulic oil cooler, cleaning.......220

Replacement parts.......222

Safety when servicing.......226

Service methods.......230

Service position.......234

Service.......237

Software update, checking.......240

Straight traveling performance.......244

Swing bath grease, checking.......246

Swing gearbox oil level, checking.......247

Swing gearbox oil, changing.......249

Swing ring gear bearing, lubricating.......251

Swing speed.......253

Tech Tool, operations.......254

Test running and checking.......256

Track gearbox oil, changing.......258

Track running speed.......260

Track shoe bolts, checking.......261

Track tension and condition, checking.......263

Travel Speed.......265

Valves, adjusting-[4718].......267

Water separator filter, replacing.......271

19 - GENERAL.......273

CE-marking, EMC-directive.......274

Cautions during operation.......278

Checklist after a fire or heat exposure.......285

Decontamination.......289

Environmental handling for the future.......293

Environmentally hazardous fluids.......297

Environmentally safe handling.......301

Fire prevention measures.......305

Health hazards with paint, plastics and rubber.......311

Move and operate machine safely.......316

Safety concerns everybody!.......319

Safety rules when servicing.......323

Safety when handling oils and fuel.......328

Safety when handling the machine.......332

Safety when using lifting equipment.......338

Safety when working with air conditioning refrigerant.......342

Safety when working with batteries.......347

Safety when working with hydraulic systems.......352

Starting with booster batteries.......356

Waste handling.......360

Working in environmentally contaminated areas.......364

002 - ENGINE WITH MOUNTING AND EQUIPMENT.......368

20 - GENERAL.......369

Component locations.......370

Engine belts, replacing.......372

Engine control module (ECM), replacing non-programmed.......375

Engine control module (ECM), replacing pre-programmed.......379

Engine, description.......381

Engine, reference values.......388

Tech Tool, operations_{09-26-36}.......391

Tech Tool, operations_{09-26-47}.......393

21 - ENGINE.......395

Crankcase ventilation, description.......396

Cylinder compression, testing.......400

Engine rotation speed sensor (camshaft), replacing.......404

Engine rotation speed sensor (crank shaft), replacing.......406

Engine, installing.......408

Engine, removing.......418

Engine, replacing_{09-23-30}.......429

Engine, replacing_{09-23-41}.......431

Engine, specifications.......434

Engine, tightening torques.......435

Valve cover, installing.......443

Valve cover, removing.......446

Valve mechanism, specifications.......449

Valves, adjusting.......450

22 - LUBRICATING SYSTEM.......454

Lubrication oil pressure, checking with pressure gauge.......455

Lubrication system, component locations.......458

Lubrication system, description.......460

Lubrication system, specifications.......465

Lubrication system, tightening torques.......467

23 - FUEL SYSTEM.......470

Carbon dioxide in fuel system, checking.......471

Feed pump pressure, checking.......477

Fuel control valve (FCV), replacing.......479

Fuel rail pressure sensor, replacing.......484

Fuel rail, replacing.......486

Fuel system, bleeding.......489

Fuel system, component location.......491

Fuel system, description.......493

Fuel system, specifications.......500

Fuel system, tightening torques.......502

High pressure fuel pipes, replacing.......508

High pressure fuel pump, replacing.......510

Injector sleeves, replacing.......513

Injectors, replacing.......523

Pressure relief valve (PRV), replacing.......528

Water separator, specifications.......531

25 - INLET & EXHAUST SYSTEM.......533

ACM (Aftertreatment control module) non-programmed, replacing.......535

ACM (Aftertreatment control module) pre-programmed, replacing-[0810].......538

ACM (Aftertreatment control module) pre-programmed, replacing.......540

AdBlue_DEF dosing injector, replacing.......542

AdBlue_DEF hoses, replacing.......545

AdBlue_DEF mixing tube, replacing.......549

AdBlue_DEF pump unit diagnostics, description.......553

AdBlue_DEF pump unit, filter, replacing.......557

AdBlue_DEF pump unit, flushing.......560

AdBlue_DEF pump unit, inlet nipple, replacing.......562

AdBlue_DEF pump unit, replacing.......565

AdBlue_DEF quality, checking.......568

AdBlue_DEF tank armature suction filter, replacing.......571

AdBlue_DEF tank armature, cleaning.......573

AdBlue_DEF tank armature, replacing.......576

AdBlue_DEF tank, cleaning.......581

AdBlue_DEF tank, replacing.......584

AdBlue_DEF, draining.......586

AdBlue_DEF.......589

Charge air cooler, replacing.......594

Coolant valve, replacing.......603

Crystallization of AdBlue_DEF, checking.......606

DOC (Diesel oxidation catalyst), replacing.......611

DPF (Diesel particulate filter), checking and cleaning.......615

Exhaust Aftertreatment System, component location.......619

Exhaust Aftertreatment System, description.......621

Exhaust pipe flexible tube, replacing.......635

Inlet and exhaust system, component location.......638

Inlet and exhaust system, description.......640

Inlet and exhaust system, specification.......646

Inlet and exhaust system, tightening torques.......648

Inlet throttle, replacing-[0747].......653

Inlet throttle, replacing.......655

Regeneration log, checking.......657

Regeneration process, description.......668

SCR (Selective catalytic reduction) dosing system, checking.......675

SCR (Selective catalytic reduction) muffler, replacing.......678

Turbocharger, replacing.......684

Wastegate, checking.......687

26 - COOLING SYSTEM.......689

Carbon dioxide in coolant system, checking.......690

Coolant pump, replacing.......696

Coolant with anti-freeze and corrosion protection, recommendation.......699

Cooling fan control.......702

Cooling fan rpm, specifications.......706

Cooling system pressure, checking.......707

Cooling system, description.......709

Cooling system, specifications.......713

Expansion tank, replacing.......715

Radiator, replacing.......718

Reversible cooling fan, description.......720

Thermostat, replacing.......723

27 - ENGINE CONTROL.......725

Engine - Pump control, specification.......726

29 - MISCELLANEOUS.......728

EGR actuator, replacing.......729

EGR cooler, replacing.......731

EGR reed valve, replacing.......735

EGR system, tightening torques.......738

EGR venturi tube, cleaning.......740

EGR venturi tube, replacing.......742

Exhaust Gas Recirculation (EGR), description.......745

Exhaust gas recirculation (EGR), component location.......751

003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.......753

30 - GENERAL.......754

AL3201, description and measuring.......760

Attachment quick coupler.......763

Auto Idle.......765

Automatic engine shut-down.......768

Auxiliary start.......771

BA3101, description and measuring.......775

BB1 Communication bus, description and measuring.......777

BB2 Communication bus, description and measuring.......780

Boom float position, description.......783

CU9901, description and measuring.......784

CareTrack with anti-theft.......786

Collection of basic data.......797

Conditions when checking.......801

ECO mode, description.......806

Electrical system, description.......808

Electrical system, special instructions for servicing, action when working on machine.......810

Electrical system, special instructions for servicing, electrical components, alternator and charging regulator.......813

Electrical system, special instructions for servicing, electrical components, batteries.......816

Electrical system, special instructions for servicing, electronic components.......820

Electrical system, special instructions for servicing, general.......823

Electrical system, specifications.......827

Electro hydraulic pump control, description.......830

Electronic control system, description.......835

Engine stops.......841

Error code information, general.......843

Error codes, build-up.......854

FX1005, description and measuring.......856

FX1006, description and measuring.......859

FX1007, description and measuring.......862

FX1008, description and measuring.......866

FX1054, description and measuring.......870

FX1074, description and measuring.......873

FX1079, description and measuring.......876

FX1116, description and measuring.......879

FX1117, description and measuring.......882

General fault diagnosis information.......885