Volvo EC240CL Excavator Workshop Repair Service Manual PDF Download - MVLVEC240CL.zip
Full service and repair documentation featuring Electrical Wiring Diagrams for the Volvo EC240CL Excavator, packed with every technical detail needed to service, troubleshoot, fix, and rebuild these machines the way professional technicians do.
The Volvo Construction EC240CL Excavator workshop service and repair manual contains:
* 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.
Volvo EC240CL Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,176 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
000 - Foreword....2
000 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Machine view, waste handler_{05-18-17}....5
Machine view, waste handler_{05-18-41}....7
Machine view_{06-10-39}....9
Machine view_{06-11-03}....11
Product plates....13
03 - SPECIFICATIONS....15
2-pump flow selector valve....19
Adjustable boom and cylinder, specifications....21
Adjustable boom selector valve....23
Air conditioning unit, specifications....25
Alternator, specifications ....28
Attachment quick coupler solenoid valve, specification....30
Audio remote controller, specifications_{04-08-11}....31
Audio remote controller, specifications_{04-08-25}....33
Auto_Manual pump control switch, specifications ....36
Automatic lubrication system, specifications....38
Battery, specifications ....41
Boom lifting cylinder, specifications....42
Boom, specifications....44
Bucket cylinder, specifications....45
Cab, weight....47
Center passage, tightening torques....49
Circuit breaker, specification ....52
Control lockout lever switch, specifications....54
Control pattern selector valve, specifications....56
Coolant pump, thermostat, specifications....58
Cooling fan motor, specifications....60
Cooling system, specifications....62
Counterweight, specifications_{02-24-16}....63
Counterweight, specifications_{02-24-30}....64
Counterweight, tightening torques-[2559]....65
Counterweight, tightening torques....67
Current_pressure, specifications....69
Diesel coolant heater (10kw), specifications....71
Dipper arm cylinder, specifications....73
Dipper arm, specifications....75
Electric horn, specifications ....76
Electrical system, specifications....78
Electronic climate control unit ECC, specification....80
Emergency engine speed control switch, specifications ....82
Engine - Pump control, specification....84
Engine control unit E-ECU, specifications ....86
Engine speed control switch, specifications....88
Engine, specifications....90
Engine, weights....91
Flywheel, weight....92
Frame and track unit, specifications....94
Fuel feed pump, specifications....95
Fuel filler pump, specifications....98
Fuel pressure, specifications....100
Fuel system, tightening torques....104
Fuel tank, specifications....108
Fuse, specifications ....109
Hammer return filter, specifications....111
Hour counter, specifications....112
Hydraulic oil cooling system, specifications....114
Hydraulic pressure, specifications....116
Hydraulic pump, specifications....117
Hydraulic tank, specifications....118
Keypad, specification....119
Line rupture valve (arm), specifications....122
Line rupture valve (boom), specifications....124
Lower wiper motor, specifications ....126
Lubrication system, specifications....128
Main control valve, specifications....131
Measurement conversion tables....133
Preheating, specifications ....142
Pressure accumulator, specifications....144
Proportional solenoid valve, specifications-[2034]....146
Proportional solenoid valve, specifications....149
Radio with CD and MP3 player, specifications....151
Radio with tape or CD player, specifications....154
Recommended hydraulic oil, specifications....157
Regulator, specifications....160
Relay, specifications_{04-10-04}....161
Relay, specifications_{04-10-18}....163
Remote control valve (Lever), specifications....165
Remote control valve (pedal), specifications....167
Rotating beacon, specifications ....169
Rotator pump, specifications....171
Servo hydraulic selector valve, specifications....172
Servo pump, specifications....174
Slew gearbox, specifications_{04-05-36}....176
Slew gearbox, specifications_{04-05-49}....177
Solenoid valve for rotator....178
Solenoid valve, specifications....179
Start switch, specifications ....180
Starter motor, specifications ....182
Swing motor, specifications....183
Tightening torque, specifications....184
Tightening torques....186
Track gearbox, specifications....195
Track motor, specifications_{04-04-47}....196
Track motor, specifications_{04-05-01}....198
Travel alarm, specifications ....200
Upper wiper motor, specifications ....202
Valve system specifications....204
Windscreen flusher pump, specifications ....205
Wiper controller, specifications ....207
Wireless control unit W-ECU, specification....209
Work lights and extra lights, specifications ....211
07 - STANDARD TIME....213
Operation numbers for additional work....214
08 - TOOL....216
E-tools, NET 8940-00300 Swing ring gear guide pin....217
E-tools, NET 8940-00330 Swing motor guide pin....219
NET 8940-00200 Replace tool for the remote control valve joint....221
NET 8940-00290 Track motor guide pin....223
09 - MISCELLANEOUS....225
Control units, changing....226
Hydraulic cylinders, dieseling....228
Service positions....232
Welding on the machine....235
001 - STANDARD PARTS, SERVICE....238
16 - LUBRICANT; FUEL; OTHER FLUID....239
Alternative fuels....240
Coolant with freezing and corrosion protection....243
Grease....247
Recommended lubricants....251
17 - SERVICE....254
Air cleaner primary filter, change....257
Air cleaner primary filter, clean....259
Air cleaner secondary filter, change....261
Air conditioner main filter, change....263
Air conditioner main filter, clean....267
Arrival Inspection, according to Inspection Programme....271
Battery condition, check....276
Bearings....279
Cab prefilter, cleaning....283
Cab prefilter, replacing....285
Cab; door, covers, hinges, joints and locks, lubricate....287
Cleaning prior to repair....289
Coasting left and right swing....293
Coolant anti-freeze resistance, checking ....295
Coolant level, check....299
Coolant, change....300
Creeping of hydraulic cylinder....303
Cylinder speed....305
Delivery Inspection, according to Inspection Programme....308
Engine oil and filter, changing....312
Engine, oil level, check....315
Fuel filter extra (water separator element), check_drain....317
Fuel filter, change....319
Fuel tank air ventilation filter, change....321
Fuel tank sediment, drain....323
Hoses and tubes....325
Hydraulic oil drain filter, change....329
Hydraulic oil level, check....330
Hydraulic oil return filter, replacing....332
Hydraulic oil servo filter, change....335
Hydraulic oil suction strainer, clean....337
Hydraulic oil tank breather filter, replacing....339
Hydraulic oil, changing....342
Hydraulic pressure, checking....344
Loose and loss of bolts, check....346
Lubrication, see lubrication chart....349
MATRIS, reading, export reading....351
Maintenance of Stored Machines, according to Inspection Programme....354
Maintenance service, daily....358
Maintenance service, every 1000 hours....359
Maintenance service, every 2000 hours....361
Maintenance service, every 250 hours....363
Maintenance service, every 4000 hours....365
Maintenance service, every 50 hours....367
Maintenance service, every 500 hours....368
Maintenance service, every 6000 hours....370
Measuring condition....372
Measuring of swing bearing clearance....374
Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change....377
Oil-bath air cleaner's reservoir (optional equipment), filter insert, clean....380
Oil-bath air cleaner's reservoir (optional equipment), oil, check....383
Pressure testing....385
Radiator outside_hydraulic oil cooler outside, cleaning....389
Replacement parts....392
Safety when servicing....396
Service methods....400
Service....404
Starting engine with booster cables ....406
Straight traveling performance....410
Swing bath grease, check....412
Swing gearbox oil level, check....413
Swing motor gearbox, changing oil....415
Swing ring gear bearing, lubricate_{01-24-32}....417
Swing ring gear bearing, lubricate_{01-24-54}....419
Swing speed....422
Test-run and check....423
The machine, check for external damages, cracks and wear damages....426
Track gearbox oil level, check....429
Track motor gearbox, changing oil....431
Track running speed_{01-07-44}....433
Track running speed_{01-08-05}....435
Track shoe bolts, check....437
Track tension_condition, check....440
Travel Speed....442
VCADS Pro, logged errors, read off....444
Valve clearance, check_adjust....447
Warranty inspection 100 hours....456
Warranty inspection 1000 hours....458
Warranty inspection....460
Washer fluid level, check....462
Water separator filter element, change....464
X1 return filter (optional equipment), change....466
19 - GENERAL....468
CE-marking, EMC-directive....469
Checklist after a fire or heat exposure....472
Decontamination....476
Environmental handling for the future....480
Environmentally hazardous fluids....484
Environmentally safe handling....488
Fire prevention measures....491
Health hazards with paint, plastics and rubber....497
Safety concerns everybody!....502
Safety rules when servicing....506
Safety when handling oils and fuel....510
Safety when handling the machine....514
Safety when handling the waste handler....521
Safety when using lifting equipment....523
Safety when working with air conditioning refrigerant....527
Safety when working with batteries....532
Safety when working with hydraulic systems....537
Starting with booster batteries....541
Waste handling....545
Working in environmentally contaminated areas....549
002 - ENGINE WITH MOUNTING AND EQUIPMENT....553
020 - GENERAL....554
Component locations....555
E-ECU MID 128 non-programmed, replacing....558
E-ECU MID 128 pre-programmed, replacing....561
Engine, description....564
Engine, identification....566
Engine, tightening torques....567
Engine, weights ....571
Fuel system, tightening torques ....572
021 - ENGINE....576
Basic check, Engine....577
Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope....579
Camshaft, description....585
Connecting rod, description....588
Crankshaft, description....591
Cylinder block, description....594
Cylinder head gasket, description....596
Cylinder head, description....598
Cylinder liner, description....600
Engine characteristic curve....602
Engine mounting....604
Engine timing gear, description....608
Engine, specifications....611
Engine, weights....612
Flywheel, weight....613
Internal Exhaust Gas Recirculation (IEGR), description....615
Oil level sensor, replacing....621
Oil sump, description....625
Piston cooling....627
Piston rings, description....629
Pistons, description....631
Troubleshooting....633
Valve system specifications....636
Valves, adjusting....637
Valves, description....647
Vibration damper, description....649
022 - LUBRICATING SYSTEM....652
Lubrication oil pressure, checking with pressure gauge....653
Lubrication system, description....656
Lubrication system, principle of operation....659
Lubrication system, specifications....663
Oil cooler, replacing....666
023 - FUEL SYSTEM....672
Carbon dioxide in fuel system, checking....673
Feed pump pressure, checking....676
Feed pump, replacing....679
Fuel control valve (FCV), description....682
Fuel control valve (FCV), replacing....684
Fuel feed pump, description....690
Fuel feed pump, specifications....693
Fuel filler pump, description....696
Fuel filler pump, specifications....699
Fuel filling pump, installing....701
Fuel filling pump, removing....703
Fuel filter extra, replacing....705
Fuel filter, checking....709
Fuel filters, replacing....712