Service manual Volvo EC260F NL5 Excavator | Updated 2025

(0) GENERAL
– (00) DESCRIPTION, COMPLETE MACHINE
— (000) General
— Machine view
— Product plates
– (03) SPECIFICATIONS
— (030) General
— Volvo standard tightening torques
— Measurement conversion tables
– (07) STANDARD TIME
— (070) General
— Operation numbers for additional work
– (08) TOOL
— (080) General
— NET 8940-00190 Travel motor guide pin
— E-tools, NET 8940-00290 Swing motor guide pin
— E-tools, NET 8940-00300 Swing ring gear guide pin
— NET 8940-00290 Track motor guide pin
— E-tools, NET 8940-00420 Replace tool for the swing ring gear
— E-tools, NET 8940-00340 Replace tool for the swing ring gear
— E-2016
— E-2036
— 88830540 User Instruction
— E-3003
– (09) MISCELLANEOUS
— (091) Service instruction; safety instruction
— Welding on the machine
— Hydraulic cylinders, dieseling
(1) STANDARD PARTS, SERVICE
– (16) LUBRICANT; FUEL; OTHER FLUID
— (160) General
— Recommended lubricants
— Grease
— Hydraulic oil
— Change intervals
— Lubricants and filling capacities
— Engine oil
— Engine oil filter, replacing
— Fuel
— Alternative fuels
— Air conditioner main filter, replacing
— AdBlue®/DEF
— Coolant
— Coolant with freezing and corrosion protection
— Purpose of fluid analysis
— Fluid analysis, tools
— Fluid analysis, sampling instructions
— Fluid analysis, submission process
— Now Mobile-App (CHAIN), installation
— Fluid analysis, sampling points
— Recommendations for fluid sampling intervals
— Engine oil, sampling
— Hydraulic oil, sampling
— Track gearbox oil, sampling
— Swing gearbox oil, sampling
— Fuel, sampling
— AdBlue®/DEF, sampling
— Coolant, sampling
– (17) SERVICE
— (170) General, common info about 171 – 179
— Bearings
— Replacement parts
— Safety when servicing
— Service
— Service methods
— Pressure testing
— Hoses and tubes
— Cleaning prior to repair
— Tech Tool, operations
— (171) Arrival inspections; delivery service
— Arrival Inspection, according to Inspection Programme
— Delivery Inspection, according to Inspection Programme
— Maintenance of Stored Machines, according to Inspection Programme
— (173) Maintenance
— Swing ring gear bearing, lubricate
— Maintenance service, first 500 hours
— 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 3000 hours
— Maintenance service, every 4000 hours
— Maintenance service, every 4500 hours
— Maintenance service, every 6000 hours
— Service position
— Lubrication, every 50 hours
— Test running and checking
— Engine belt condition, checking
— Valves, adjusting
— Engine oil and filter, changing
— Fuel filter, replacing
— Water separator filter, replacing
— Fuel tank breather filter, replacing
— Air drier cartridge, replacing
— Diesel particulate filter, replacing
— AdBlue®/DEF tank breather filter, replacing
— Engine air cleaner primary filter, replacing
— Engine air cleaner secondary filter, replacing
— Oil-bath air cleaner reservoir oil, checking
— Oil-bath air cleaner reservoir oil, changing
— Oil-bath air cleaner reservoir filter insert, cleaning
— Coolant, changing
— Coolant mixture, checking
— Radiator and hydraulic oil cooler, cleaning
— MATRIS and Tech Tool, reading
— Software update, checking
— Track gearbox oil level, checking
— Track gearbox oil, changing
— Swing gearbox oil level, checking
— Swing gearbox oil, changing
— Swing bath grease, checking
— Track shoe bolts, checking
— Track tension and condition, checking
— Cab door, covers, hinges, joints and locks, lubricating
— Air conditioner main filter, cleaning
— Air conditioner main filter, replacing
— Cab prefilter, cleaning
— Cab prefilter, replacing
— Hydraulic oil level, checking
— Hydraulic oil, changing
— Hydraulic oil suction strainer, cleaning
— Hydraulic oil drain filter, replacing
— Hydraulic oil servo filter, replacing
— Hydraulic oil return filter, replacing
— Hydraulic return filter on X1 option circuit, replacing
— Hydraulic oil tank breather filter, replacing
— Hydraulic accumulator, checking
– (19) GENERAL
— (191) Safety equipment, without own function group
— Service position
— Safety concerns everybody!
— CE-marking, EMC-directive
— Safety when handling the machine
— Safety rules when servicing
— Move and operate machine safely
— Welding and grinding work
— Fire prevention measures
— Checklist after a fire or heat exposure
— Safety when handling oils and fuel
— Safety when using lifting equipment
— Safety when working on hydraulic systems
— Safety when working with air conditioning refrigerant
— Starting with booster batteries
— Safety when working with batteries
— Environmental handling for the future
— Environmentally safe handling
— Environmentally hazardous fluids
— Health hazards with paint, plastics and rubber
— Working in environmentally contaminated areas
— Decontamination
— Waste handling
— Cautions during operation
— (198) Packing material, standard and transportation
— Measuring condition
— Creeping of hydraulic cylinder
— Swing speed
— Coasting left and right swing
— Measuring of swing bearing clearance
— Travel Speed
— Track running speed
— Straight traveling performance
(2) ENGINE WITH MOUNTING AND EQUIPMENT
– (20) GENERAL
— (200) General, engine installation and its function
— Engine, description
— Tech Tool, operations
— Engine control module (ECM), replacing pre-programmed
— Engine control module (ECM), replacing non-programmed
— Component locations
— Engine belts, replacing
– (21) ENGINE
— (210) General, common info about 211 – 218
— Engine, specifications
— Engine rotation speed sensor (crankshaft), replacing
— Engine rotation speed sensor (camshaft), replacing
— Camshaft and flywheel signals, checking with Tech Tool and oscilloscope
— Engine, removing
— Engine, installing
— Engine, tightening torques
— (212) Cylinder block with crankcase ventilation
— Crankcase ventilation, description
— (214) Valve mechanism
— Valve system, specification
— Rocker arms, replacing
— Valves, adjusting
— Valve cover, removing
— Valve cover, installing
— Rocker arm shaft, replacing
— (215) Engine transmission; camshaft
— Camshaft setting, checking
— Camshaft, replacing
— (216) Crank shaft; connecting rod; vibration damper; fly wheel
— Crankshaft front oil seal, replacing
— Crankshaft rear oil seal, replacing
— (217) Oil sump, dipstick incl.
— Oil sump, replacing
— Oil level sensor, replacing
– (22) LUBRICATING SYSTEM
— (220) General, common info about 221 – 224
— Lubrication system, description
— Lubrication system, specifications
— Lubrication oil consumption, checking
— Lubrication system, component locations
— Lubrication system, tightening torques
— (221) Oil pump; line
— Lubrication oil pressure, checking
— (223) Oil cooler
— Oil cooler, replacing
— Oil cooler, leakage check
– (23) FUEL SYSTEM
— (230) General (common info about 233 – 238)
— Fuel system, description
— Fuel system, specifications
— Fuel system, tightening torques
— Carbon dioxide in fuel system, checking
— Fuel system basics, checking
— Fuel system, component locations
— (233) Fuel pump; filter; strainer
— Feed pump pressure, checking
— Feed pump, replacing
— Fuel system, bleeding
— (234) Fuel tank; fuel filling pump
— Fuel tank, replacing
— (237) Injector; delivery pipe
— Injector fuel return flow, checking
— Injectors, replacing
— Fuel rail, replacing
— Fuel rail pressure and temperature sensor, replacing
— High pressure fuel pipes, replacing
— Fuel control valve (FCV), replacing
— Pressure relief valve (PRV), replacing
— Fuel pump unit, replacing
– (25) INLET SYSTEM; EXHAUST SYSTEM
— (250) General, common info about 251 – 258
— Inlet and exhaust system, description
— Inlet and exhaust system, specification
— Inlet and exhaust system, component locations
— Inlet and exhaust system, tightening torques
— (252) Silencer; exhaust pipe
— Exhaust pipe flexible tube, replacing
— (254) Catalytic converter; exhaust emission control equipment
— Exhaust aftertreatment system, description
— Exhaust aftertreatment system, component locations
— Regeneration process, description
— AdBlue®/DEF tank, replacing
— AdBlue®/DEF, draining
— AdBlue®/DEF quality, checking
— SCR (Selective catalytic reduction) dosing system, checking
— AdBlue®/DEF pump unit diagnostics, description
— Exhaust aftertreatment fuel system diagnostics, description
— Diesel particulate filter, replacing
— ACM (Aftertreatment control module) non-programmed, replacing
— ACM (Aftertreatment control module) pre-programmed, replacing
— Compressor, replacing
— NOx sensor, replacing
— NOx sensor after turbocharger, replacing
— Inlet throttle, replacing
— High pressure air system pressure, checking
— Exhaust aftertreatment system fuel flow, checking
— Muffler, replacing
— AdBlue®/DEF pump unit, replacing
— AdBlue®/DEF pump, replacing
— AdBlue®/DEF pump unit, components, replacing
— AdBlue®/DEF nozzle, replacing
— AdBlue®/DEF tank armature, replacing
— AdBlue®/DEF tank armature, cleaning
— AdBlue®/DEF tank armature suction filter, replacing
— Aftertreatment fuel nozzle, replacing
— Aftertreatment fuel nozzle, cleaning
— Aftertreatment fuel dosing unit, replacing
— AdBlue®/DEF hoses, replacing
— AdBlue®/DEF
— AdBlue®/DEF tank, cleaning
— (255) Turbo charger
— Turbocharger rotation speed sensor, replacing
— Turbocharger, inspecting
— Turbocharger, replacing
— (258) Charge air cooler with connections
— Charge air cooler, replacing
– (26) COOLING SYSTEM
— (260) General, common info about 261 – 269
— Cooling system, description
— Cooling system, specifications
— Carbon dioxide in coolant system, checking
— Cooling system, component locations
— Cooling system, tightening torques
— (261) Radiator, mounting and connections included
— Coolant, changing
— Radiator, replacing
— Expansion tank, replacing
— (262) Coolant pump; thermostat
— Coolant pump, replacing
— Thermostat, replacing
— (263) Fan; fan shroud; fan coupling
— Cooling fan, description
— Cooling fan control
— Reversible cooling fan, description
— Cooling fan rpm, specifications
– (27) ENGINE CONTROL
— (270) General, common info about 272 – 277
— Engine – Pump control, specification
– (29) Miscellaneous
— (293) EGR (Exhaust Gas Recirculation)
— EGR (Exhaust Gas Recirculation), description
— EGR (Exhaust Gas Recirculation), component locations
— EGR system, tightening torques
— EGR cooler, replacing
— EGR cooler pressure, testing
— EGR valve, replacing
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
– (30) GENERAL
— (300) Comprehensive info, electrical system
— Electrical system, special instructions for servicing, general
— Electrical system, special instructions for servicing, electronic components
— Electrical system, special instructions for servicing, electrical components, batteries
— Electrical system, special instructions for servicing, electrical components, alternator and charging regulator
— Electrical system, special instructions for servicing, action when working on machine
— Electrical system, description
— Electronic control system, description
— Communication with data buses
— Electrical system, specifications
— Tech Tool, operations
— (301) Software documents, complete vehicle
— Air compressor control, description
— Attachment link connect, description
— Audio mute control, description
— Automatic engine shut down, description
— Automatic hydraulic oil warm up, description
— Automatic lubrication system, description
— Battery and system voltage monitoring, description
— Boom down speed setting, description
— Boom float activation control, description
— Boom recovery (hybrid) system, description
— Camera control, description
— Climate control system, description
— Clock and date control, description
— Code lock control, description
— Cooling fan demand control, description
— Cooling fan control, description
— Crane mode, description
— Daily maintenance, description
— Delayed engine shutdown, description
— Display unit interface, description
— DPF regeneration control system, description
— Dust suppression system, description
— Intermittent wiper and washer, description
— Engine auto idle function, description
— Emergency stop system, description
— Engine preheating, description
— Engine system monitoring, description
— Engine power derating function, description
— EH-pump control interface, description
— EH-MCV control interface, description
— Fuel consumption, description
— Fuel filler pump control, description
— Fuel level, description
— X1 control, description
— X3 control, description
— Guarded supply control
— Hour meter, description
— Horn control
— High altitude control, description
— Hydraulic motion priority setting
— Hydraulic oil temperature monitoring, description
— Hydraulic response mode control, description
— Instrument pannel and display backlight control, description
— Joystick control system, description
— Machine information menu
— Magnet provision
— Mirror heating control, description
— Motion alarm control, description
— Noise test mode for cooling fan, description
— Overload warning
— Power Boost control, description
— Power management, description
— Removal CWT control, description
— Tech tool interface, description
— Travel speed control, description
— Seat belt
— Service reminder, description
— Software parameters, description
— Vehicle messages reset, description
— Volvo Active Control (VAC), description
— (302) Faulttracing
— General fault diagnosis information
— Troubleshooting strategy
— Collection of basic data
— Information display, check
— Error codes, build-up
— Conditions when checking
— Lead and connector checks
— Special tools for troubleshooting
— Tech Tool, operations
— AL3201, description and measuring
— AN3905, description and measuring
— BA3101, description and measuring
— BB1 Communication bus, description and measuring
— BB2 Communication bus, description and measuring
— CU3602, description and measuring
— CU3640, description and measuring
— CU8404, description and measuring
— CU9901, description and measuring
— CU9907, description and measuring
— CU9909, description and measuring
— CU9911, description and measuring
— Electrical battery disconnect switch (EBDS), description and measuring
— Electrical battery disconnect switch (EBDS) 2, description and measuring
— FX1005, description and measuring
— FX1006, description and measuring
— FX1007, description and measuring
— FX1008, description and measuring
— FX1065, description and measuring
— FX1066, description and measuring
— FX1079, description and measuring
— FX1116, description and measuring
— FX1117, description and measuring
— FX1130, description and measuring
— HE2501, description and measuring
— HE2511, description and measuring
— HE2512, description and measuring
— IM3812, description and measuring
— Instrument Cluster (IC), description and measuring
— MA2301-MA2306, description and measuring
— MA2517, description and measuring
— MA2602, description and measuring
— MA8701, description and measuring
— MA9109, description and measuring
— MA9125, description and measuring
— MA9206, description and measuring
— MA9614, description and measuring
— MA9716, description and measuring
— MA9982, description and measuring
— Machine net1, description and measuring
— Machine net2, description and measuring
— Machine net3, description and measuring
— MO2501, description and measuring
— MO2507, description and measuring
— MO2631, description and measuring
— MO2632, description and measuring
— MO2633, description and measuring
— MO3301, description and measuring
— MO8707, description and measuring
— PO3601, description and measuring
— Power supply ACM, description and measuring
— Power supply ALVA, description and measuring
— Power supply CCM, description and measuring
— Power supply Co-Pilot 2.0, description and measuring
— Power supply ECM, description and measuring
— Power supply MMCU, description and measuring
— Power supply GPMECU 1, description and measuring
— Power supply GPMECU 2, description and measuring
— Power supply GPMECU 3, description and measuring
— Power supply HDIC, description and measuring
— Power supply TGW, description and measuring
— PWM2602, description and measuring
— PWM9111, description and measuring
— PWM9112, description and measuring
— PWM9113, description and measuring
— PWM9114, description and measuring
— PWM9115, description and measuring
— PWM9116, description and measuring
— PWM9117, description and measuring
— PWM9118, description and measuring
— PWM9119, description and measuring
— PWM9120, description and measuring
— PWM9121, description and measuring
— PWM9122, description and measuring
— PWM9123, description and measuring
— PWM9124, description and measuring
— PWM9129, description and measuring
— PWM9141, description and measuring
— PWM9142, description and measuring
— PWM9143, description and measuring
— PWM9145, description and measuring
— PWM9146, description and measuring
— PWM9156, description and measuring
— PWM9165, description and measuring
— PWM9168, description and measuring
— PWM9169, description and measuring
— PWM9170, description and measuring
— PWM9175, description and measuring
— PMW9176, description and measuring
— PWM9724, description and measuring
— PWM9728, description and measuring
— PWM9730, description and measuring
— PWM9751, description and measuring
— PWM9752, description and measuring
— PWM9759, description and measuring
— PWM9761, description and measuring
— PWM9762, description and measuring
— PWM9763, description and measuring
— PWM9764, description and measuring
— PWM9765, description and measuring
— PWM9768, description and measuring
— PWM9777, description and measuring
— PWM9778, description and measuring
— RE2501, description and measuring
— RE3101, description and measuring
— RE3301, description and measuring
— RE3535, description and measuring
— RE3713, description and measuring
— SE2203, description and measuring
— SE2301, description and measuring
— SE2510, description and measuring
— SE2511, description and measuring
— SE2512, description and measuring
— SE2513, description and measuring
— SE2514, description and measuring
— SE2516, description and measuring
— SE2519, description and measuring
— SE2521, description and measuring
— SE2522, description and measuring
— SE2533, description and measuring
— SE2539, description and measuring
— SE2540, description and measuring
— SE2542, description and measuring
— SE2603, description and measuring
— SE2604, description and measuring
— SE2606, description and measuring
— SE2701, description and measuring
— SE2703, description and measuring
— SE4242, description and measuring
— SE8501, description and measuring
— SE8702, description and measuring
— SE8705, description and measuring
— SE8706, description and measuring
— SE8708, description and measuring
— SE8709, description and measuring
— SE9105, description and measuring
— SE9121, description and measuring
— SE9122, description and measuring
— SE9135, description and measuring
— SE9136, description and measuring
— SE9196, description and measuring
— SE9216, description and measuring
— SE9217, description and measuring
— SE9304, description and measuring
— SE9305, description and measuring
— SE9306, description and measuring
— SE9307, description and measuring
— SE9401, description and measuring
— SE9714, description and measuring
— SE9715, description and measuring
— SE9726, description and measuring
— SE9727, description and measuring
— SE9728, description and measuring
— SE9729, description and measuring
— SE9730, description and measuring
— SE9731, description and measuring
— SE9732, description and measuring
— SE9733, description and measuring
— SE9734, description and measuring
— SE9735, description and measuring
— SE9981, description and measuring
— SE9983, description and measuring
— SE9984, description and measuring
— SE9985, description and measuring
— SW3803, description and measuring
— SW4202, description and measuring
— SW4216, description and measuring
— SW9206, description and measuring
— Tiltrotator detection, description and measuring
— Telematics net, description and measuring
– (31) BATTERY; ENERGY STORAGE SYSTEM; MOUNTING PARTS
— (311) Battery
— Battery, storage
— Battery, description
— Battery, specifications
— Battery condition, checking
— Battery charging capacity, checking
— Starting with booster batteries
— Batteries, replacing
— Earth lead to battery, replacing
– (32) ALTERNATOR; CHARGING; ELECTRIC MOTOR; ELECTRIC DRIVES
— (320) General, common info about 321 – 322
— Charging, description
— (321) Alternator inclusive drive
— Alternator, specifications
— Alternator, description
— Alternator, replacing incl function checking
— Alternator, testing
– (33) STARTING SYSTEM
— (330) General, common info about 331 – 334
— Starting operation
— (331) Starter motor inclusive solenoid
— Starter motor, description
— Starter motor, specifications
— Starter motor, testing
— Starter motor, replacing
— (333) Electric air pre-heater, excluding element
— Preheating description
— Preheating, specifications
— (334) Starter lock
— Ignition switch, description and operation
— Start/stop button, replacing
— Start/stop button, specifications
– (35) LIGHTING
— (350) General, common info about 351 – 356
— Work lights and extra lights, specifications
— (354) Lighting, interior
— LED lighting in cab, replacing
— LED lighting in cab, specifications
— (356) Lighting, extra, including working lighting
— Work lighting headlamp assembly, replacing
– (36) OTHER ELECTRICAL EQUIPMENT
— (360) General, common info about 361 – 367
— Electric pedal control on X1 (on/off), replacing
— Electric pedal control on X1 (proportional), replacing
— (362) Audible warning from horn; mounting
— Electric horn, specifications
— Horn, replacing
— Rotating beacon, specifications
— Travel alarm, description
— Travel alarm, specifications
— Travel alarm, replacing
— (363) Cleaner
— Windscreen wiper, description
— Upper wiper motor, specifications
— Lower wiper motor, specifications
— Windscreen wiper front motor, replacing
— Window limit switch, description
— Windscreen flusher pump, replacing
— Windscreen flusher pump, specifications
— (364) Switch; connector
— Connectors, overview
— Crimping tools
— Dismantling tools
— Engine limp home switch, specifications
— Pre-heating relay, replacing
— Control lockout lever switch, description
— Control lockout lever switch, specifications
— Control lockout lever switch, replacing
— Emergency stop switch, replacing
— USB charger, replacing
— USB charger, specifications
— Wireless charger, replacing
— (366) Automatic control/blocking function, lacking a function group of its own
— People and obstacle detection (POD) control unit, description
— People and obstacle detection (POD) control unit, replacing
— GPMECU1 non-programmed, replacing
— GPMECU1 pre-programmed, replacing
— GPMECU2 non-programmed, replacing
— GPMECU2 pre-programmed, replacing
— GPMECU3 non-programmed, replacing
— GPMECU3 pre-programmed, replacing
— Machine Master Control Unit (MMCU) non-programmed, replacing
— Machine Master Control Unit (MMCU) pre-programmed, replacing
— Co-pilot 2.0 ECU non-programmed, replacing
— Co-pilot 2.0 ECU pre-programmed, replacing
— ALVA non-programmed, replacing
— ALVA pre-programmed, replacing
— (367) Electronic standard components
— Left hand control lever, replacing
— Right hand control lever, replacing
— Electric remote control pedal, replacing
— Electric travel straight pedal, replacing
— Radar, replacing
— Swing position sensor, replacing
– (37) CABLE; FUSE; RELAY
— (370) General, common info about 371 – 379
— Smart diagrams, description
— Smart diagrams, symbols and designations
— (371) Cable; battery disconnector
— Electrical battery disconnect switch, replacing
— (372) Electrical distribution box; fuse box; junction box
— Relays, specifications
— Electrical distribution box, circuit board replacing
– (38) INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM
— (380) General, common info about 383 – 387
— Instruments and controls, overview
— Instruments and controls, front instrument panel
— Instruments and controls, left instrument panel
— Instruments and controls, right instrument panel
— Instruments and controls, rear instrument panel
— (383) Speedometer; trip meter; hour counter
— Hour meter, description
— Hour meter, replacing
— (386) Sender, monitoring system
— Fuel level sender, replacing
— Engine temperature sensor, replacing
— Engine oil pressure sensor, replacing
— Hydraulic oil temperature sensor, replacing
— (387) Warning/information unit, display unit
— Jogwheel keypad, replacing
— Jogwheel keypad, specifications
— Key pad, replacing
— Keypad, specification
— Service mode
— Engine system
— Hydraulic system
— Electrical system
— Instrument cluster (display unit), replacing
— Volvo Smart View
— Volvo Smart View, specification
— Volvo Smart View camera, replacing
— Volvo Smart View, calibrating
— Volvo Smart View accuracy, checking
— Volvo Co-Pilot, description
— Volvo Co-Pilot, component location
— Volvo Co-Pilot, specifications
— Volvo Co-Pilot display, replacing
— Volvo Co-Pilot SIM card, installing
— USB tethering
— Volvo Co-Pilot Android software, updating online (OtA)
— Volvo Co-Pilot Android software, updating offline (USB)
— Volvo Co-Pilot, software updating
— Dig Assist, description
— Dig Assist 3D, description
— Dig Assist, advanced machine settings
— Dig Assist, advanced GNSS settings
— Information Center, description
— Information Center, Message History
— Information Center, Active sensor information
— Information Center, Dig Assist – Dig Assist data
— Information Center, Dig Assist – Connection Status
— Information Center, Hardware and software info
— Information Center, Positioning
— Dig Assist, troubleshooting
— Dig Assist GNSS positioning, basics
— Dig Assist RTK base station, troubleshooting
— Dig Assist NTRIP, troubleshooting
— 3D applications for Dig Assist, troubleshooting
— Dig Assist, component location
— Dig Assist connectors, overview
— Laser catcher, specifications
— Dig Assist, tightening torques
— Dig Assist IMU, teach-in
— 36703-3 Dig Assist, calibration, body IMU
— 36703-3 Dig Assist, calibration, linkage
— 36703-3 Dig Assist, calibration, GNSS
— Dig Assist GNSS antennas position, adjusting
— Dig Assist GNSS antenna, calibrating
— 36705-3 Dig Assist, configuration
— Dig Assist Onboard Weighing system, calibrating
— Dig Assist Onboard Weighing, tool weight, calibrating
— Dig Assist accuracy, checking
— Dig Assist tiltrotator accuracy, checking
— Dig Assist IMU, checking
— Dig Assist quick coupler, measuring
— Dig Assist lift point, measuring
— Smart Receiver, replacing
— GNSS Antenna, replacing
— Inertial measurement unit (IMU), replacing
— Laser catcher, replacing
— Dig Assist OBW pressure sensors, replacing
– (39) MISCELLANEOUS
— (393) Radio, with tape or CD player; voltage divider
— Radio, replacing
— Radio, specifications
— DC–DC converter, specifications
— DC/DC converter, replacing
— (395) Radio equipment for communication
— Antenna, replacing
— Speaker, replacing
— (398) Telematics systems
— TGW (Telematics Gateway), description
— TGW, non-programmed, replacing
— TGW, pre-programmed, replacing
(4) POWER TRANSMISSION
– (40) GENERAL
— (400) General, common info about 410 – 436
— Tightening torque, specifications
— Power transmission, description
– (43) GEARBOX,
— (431) Gearbox
— Function description
— Track gearbox, specifications
— Track gearbox, description
— Track gearbox, maintenance
— Track unit, replacing
— Track gearbox, replacing
— Track gearbox cover, replacing
— Track gearbox (removed), replacing floating seal
— Track gearbox, disassembling
— Track gearbox, assembling
— Swing gearbox, specifications
— Swing gearbox, description
— Swing gearbox, maintenance
— Swing unit, replacing
— Swing gearbox, replacing
— Swing gearbox, disassembling
— Swing gearbox, assembling
— Hydraulic pump coupling, description
— Pump gearbox coupling assembly, replacing
– (44) HYDROSTATIC DRIVE
— (441) Hydraulic motor incl. operating system.
— Track motor, specifications
— Track motor, description
— Track motor, maintenance
— Track motor, replacing
— Track motor relief valve, replacing
— Manual release of parking brake
— Travel speed, description
— Track motor, disassembling
— Track motor, assembling
— Hydraulic system, flushing
— Track motor air, bleeding
— Track motor, flushing
— Swing motor, specifications
— Swing motor, description
— Swing motor, maintenance
— Swing motor, replacing
— Swing motor relief valve, replacing
— Swing motor removed, seal replacing
— Swing motor, replacing brake piston seal
— Swing motor, replacing plate (brake)
— Swing motor, disassembling
— Swing motor, assembling
— Swing motor air, bleeding
— Swing motor, flushing
— Recovery motor, specifications
— Recovery motor, description
— Recovery motor, maintenance
— Recovery motor, replacing
— Recovery motor, disassembling
— Recovery motor, assembling
— (443) Centre passage; lines
— Center passage, tightening torques
— Center passage, specifications
— Center passage, description
— Center passage, maintenance
— Center passage, replacing
— Center passage, disassembling
— Center passage, assembling
– (49) MISCELLANEOUS
— (492) Swing system upper part
— Tightening torque, specifications
— Swing ring gear, specifications
— Swing ring gear, description
— Swing ring gear, replacing
— Swing ring gear grease pipe, replacing
— Swing ring gear inner seal, replacing
— Swing ring gear outer seal, replacing
— Swing ring gear grease, repacking
— Swing ring gear cover, removing
— Swing ring gear cover, installing
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
– (70) GENERAL
— (700) Comprehensive info about frame and track unit/wheels
— Undercarriage, tightening torque
— Frame and track unit, specifications
— Frame and track unit, description
– (71) FRAME
— (710) General, common info about 711 – 718
— Machine weight, specifications
— Superstructure, removing
— Superstructure, installing
— (715) Protection; belly plate; bumper
— Tightening torque, specifications
— Boom cylinder protection guard, removing
— Boom cylinder protection guard, installing
— Bucket cylinder protection guard, removing
— Bucket cylinder protection guard, installing
— (716) Counterweight
— Counterweight, tightening torques
— Counterweight, specifications
— Counterweight, replacing
— GNSS Antenna bracket, replacing
– (77) WHEELS; TRACKS; TYRE; HUB; DRUM
— (775) Crawler unit
— Selection of track shoes
— Front idler wear, measuring
— Front idler, replacing one
— Front idler wheel, disassembling
— Front idler wheel, assembling
— Sprocket wear, measuring tools
— Sprocket wear, measuring
— Sprocket, replacing one
— Track link, specifications
— Track chain, description
— Track chain wear, measuring
— Track shoe, replacing one
— Track links, replacing
— Track tension, adjusting
— Track chain assembly, removing
— Track chain assembly, installing
— Top roller, description
— Top roller wear, measuring
— Top roller, replacing one
— Top roller, disassembling
— Top roller, assembling
— Bottom roller, description
— Bottom roller wear, measuring
— Bottom roller, replacing one
— Bottom roller, replacing seal
— Bottom roller, disassembling
— Bottom roller, assembling
— Track guard, description
— Track guard, replacing one
— Spring package assembly, specifications
— Recoil spring cylinder seal kit, replacing
— Track recoil spring (tensioner) assembly, replacing
— Spring package, disassembling
— Spring package, assembling
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
– (80) GENERAL
— (800) Comprehensive info, machinery house and cab
— Tech Tool, operations
– (81) CAB, NAKED; CANOPY
— (810) General
— Cab, weight
— Cab, removing
— Cab, installing
— Cabin, tightening torques
— (818) Cab mounting
— Cab suspension, description
– (82) ENGINE HOOD; MUDGUARD; FOOT STEP
— (821) Engine hood with assembly parts
— Engine hood, replacing
– (83) DOORS; HATCH; COVER PLATE, (all)
— (831) Door, complete with catch, hinges (no glass)
— Door, replacing
— Cab door, changing door catch
– (84) TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
— (841) Outside trim parts, emblems, reflectors, rear view mirrors
— Rear-view mirror, replacing
— (843) Glass; sealing moulding
— Windows, general
— Windscreen, replacing
— Side window, replacing
— Rear window, replacing
— Door window, replacing
— Cab roof window, replacing
– (85) CAB INTERIOR/UPHOLSTERY
— (852) Driver’s seat, complete; instructor’s seat
— Operator’s seat, description
— Driver’s seat, specifications
— Seat, replacing
— Seat cushion, replacing
— Seat support, replacing
— Longitudinal adjustment cable, replacing
— Longitudinal suspension cable, replacing
— Backrest, replacing
— Seat heater, checking
– (86) PROTECTIVE EQUIPMENT, not specified in a special group
— (867) Protecting frame; protecting equipment for cab
— Falling object protection structure (FOPS), description
— FOPS (Falling object protection structure), removing
— Falling object guards (FOG), description
— Falling object guard (FOG), removing
— Falling object guard (FOG), installing
– (87) AIR CONDITIONING UNIT
— (870) General, common info about 872 – 877
— HVAC system
— Air conditioning unit, specifications
— Air conditioning unit, description
— Air-conditioning, component location
— Air conditioning unit, maintenance
— CCM pre-programmed ECU, replacing
— CCM non-programmed ECU, replacing
— Cooler and Heater assembly, replacing
— (872) Air distribution incl. air intake with filter
— Air distribution, description
— Cab filter, replacing
— (873) Heating unit
— Heating system, description
— Fan motor, replacing
— Heater core, replacing
— Water valve, replacing
— (874) Cooling unit
— Air conditioning unit, refrigerant check and recharging
— Air conditioning, tightening torques
— Air conditioning, checking performance
— Compressor, replacing incl draining and filling
— Receiver, replacing incl draining and filling
— Condenser, replacing incl draining and filling
— Evaporator, replacing incl draining and filling
— Expansion valve, replacing incl draining and filling
— Vent actuator, replacing
— Mode (foot) actuator, replacing
— Intake actuator, replacing
— Compressor, replacing magnetic clutch (compressor removed)
— Refrigerant, draining
— Refrigerant, filling incl vacuum pumping
— Air conditioning system, flushing
— (875) Auxiliary heater, diesel fuel operated
— Auxiliary heater, specifications
— Auxiliary heater, description
— Auxiliary heater, principles
— Troubleshooting
— Auxiliary heater, replacing
– (88) INTERIOR EQUIPMENT
— (881) Instrument panel/console; control panel/console/-pedestal
— Instrument panel (left), replacing
— Instrument panel (right), replacing
— Instrument console, removing
— Instrument console, installing
— (884) Seat belt; other restraining system
— Seat belt, replacing
– (89) MISCELLANEOUS
— (896) Tools; tool box
— Tool box assembly, replacing
(9) HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
– (90) GENERAL
— (900) General
— Explanations to hydraulic diagram
— Hydraulic components, cleanliness when handling
— Hydraulic diagram, standard
— Hydraulic diagram, with option components
— Description, general
— Hydraulic system, description
— Recommended hydraulic oil, specifications
— Hydraulic pressure, specifications
— Hydraulic system, repair of hydraulic components in workshop
— Hydraulic oil, storage and handling
— Hydraulic components, storing and transporting
— Tech Tool, operations
– (91) WORKING HYDRAULICS; SERVO HYDRAULICS
— (910) General, common info about 911 – 917
— Hydraulic system, work instructions
— Hydraulic components, description
— Hydraulic system, position of main components
— Drain filter, description
— (911) Tank; line; oil cooling; filter; breather; filling pump
— Hydraulic tank, specifications
— Hydraulic oil tank, description
— Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
— Oil level gauge, replacing
— Air breather, description
— Breather, replacing
— Servo hydraulic block
— Return check valve, description
— Oil cooler line bypass valve (check valve), replacing
— Hydraulic oil cooling system, specifications
— Hydraulic cooling fan control, specifications
— Hydraulic oil cooling system, description
— Hydraulic oil cooler, description
— Hydraulic oil cooler, replacing
— Hydraulic oil cooler fan pump, description
— Hydraulic oil cooler fan pump, parts inspecting
— Hydraulic oil cooler fan pump, disassembling
— Hydraulic oil cooler fan pump, assembling
— Oil cooler fan pump, replacing
— Hydraulic oil cooler fan motor, description
— Hydraulic oil cooler fan motor, disassembling
— Hydraulic oil cooler fan motor, assembling
— Hydraulic oil cooler fan motor, troubleshooting
— Oil cooler fan motor, replacing
— Proportional relief valve, specifications
— Proportional relief valve, description
— (912) Working hydraulics
— Main control valve, tightening torques
— Main control valve, specifications
— Hydraulic diagram, ports
— Main control valve, description
— Main control valve, troubleshooting
— Control valve, part inspection
— General, precautions
— Main spool, disassembly and assembly
— Main relief valve, description
— Main relief valve, adjusting
— Main relief valve, disassembly and assembly
— Pressure relief valve, troubleshooting
— Main pressure relief valve, replacing
— Port relief valve, description
— Port relief valve pressure, checking and adjusting
— Port relief valve, disassembling
— 2 stage port relief valve, description
— 2 stage port relief valve pressure, checking and adjusting
— 2 stage port relief valve, disassembly and assembly
— X1 Pre-set relief valve, description
— X1 Pre-set relief valve, adjusting
— X1 Pre-set relief valve, disassembling and assembling
— Make up valve, description
— Make up valve, disassembling
— Boom holding valve, description
— Boom holding valve, disassembling and assembling
— Boom regenerating valve, description
— Boom back pressure check valve, disassembly and assembly
— Arm holding valve, description
— Arm holding valve, disassembly and assembly
— Arm regenerating valve, description
— Arm regenerating valve, disassembly
— Arm parallel conflux valve, disassembly and assembly
— Arm parallel conflux check valve, disassembly and assembly
— Conflux check valve, description
— Conflux check valve, disassembly
— Main control valve adjustor, adjusting
— Creep flow control valve, description
— Creep flow control valve, disassembling and assembling
— Return check valve, description
— Return check valve, disassembly and assembly
— Boom float port relief valve, description
— Center bypass valve, description
— Escape swamp valve, description
— Load check valve – single, description
— Load check valve – double, description
— Load check valve – single, disassembly and assembly
— Proportional pressure reducing valve, description
— Proportional reducing valve, replacing
— Control valve, replacing
— Tightening torques
— Line rupture valve (boom), specifications
— Line rupture valve (boom), description
— Line rupture valve (boom), air bleeding
— Boom cylinder, rupture valve, replacing
— Line rupture valve (boom), disassembling
— Line rupture valve (boom), assembling
— Line rupture valve (boom), troubleshooting
— Line rupture valve (arm), specifications
— Line rupture valve (arm), description
— Line rupture valve (arm), air bleeding
— Dipper arm cylinder, rupture valve, replacing
— Line rupture valve (arm), disassembling
— Line rupture valve (arm), assembling
— Line rupture valve (arm), troubleshooting
— Disassembly and assembly, general
— Port relief valve pressure, adjustment (when installing or dismantling the line rupture valve)
— (913) Pump, working hydraulics
— Tightening torques
— Hydraulic pump, specifications
— Hydraulic pump, description
— Hydraulic pump, maintenance standard, Specifications
— Pump, troubleshooting
— Pump, tools
— Pump, disassembly
— Pump, assembly
— Pump, installation
— Regulator, description
— Regulator, disassembly and assembly
— Proportional solenoid valve, specifications
— Current/pressure, specifications
— Proportional solenoid valve, description
— Proportional solenoid valve, troubleshooting
— Hydraulic pump (removed), changing shaft seal
— Hydraulic pump, replacing
— Hydraulic pump regulator, replacing
— Proportional solenoid valve (power shift), replacing
— (914) Servo hydraulic system
— Servo pump, specifications
— Servo pump, description
— Gear pump, maintenance standard
— Servo pump, parts inspection
— Servo pressure, checking and adjusting
— Servo pump, troubleshooting
— Servo pump, disassembly
— Servo pump, assembly
— Servo pump, replacing
— Pressure accumulator, specifications
— Pressure accumulator, description
— Accumulator, replacing
— Solenoid valve, specifications
— Solenoid valve, description
— Solenoid valve , inspecting
— Solenoid valve, troubleshooting
— Solenoid valve, replacing
— (916) Other hydraulic equipment
— Tightening torques
— X1 Line, description
— Hammer and shear pedal valve (RCV), replacing
— Hammer return filter, specifications
— Hammer return filter, description
— Solenoid valve, specifications
— Solenoid valve, description
— 3 way selector valve, specifications
— 3 way selector valve, description
— Proportional solenoid valve, specifications
— Proportional solenoid valve, description
— Stop valve, description
— Tightening torques
— Adjustable boom, specifications
— Adjustable boom (1st boom), description
— Adjustable boom (2nd boom), description
— Adjustable boom cylinder, specifications
— Adjustable boom cylinder, description
— Adjustable boom valve, description
— Adjustable boom valve, disassembly
— Single pedal stopper position
— Solenoid valve for rotator
— Rotator pump, specifications
— Rotator pump, description
— Rotator pump, disassembly
— Rotator pump, assembly
— Rotator pump, parts inspection
— Rotator valve, adjustment
— Rotator (X3 Line option), description
— Tightening torque, specifications
— Main dimensions
— Specifications
— Tiltrotator control system, description
— Electrical control system, tiltrotator
— 91618-3 Tiltrotator calibration
— Hybrid hydraulic accumulator, specification
— Hybrid hydraulic system, description
— Hybrid hydraulic piston accumulator, description
— Hybrid hydraulic accumulator, charging and testing unit
— Hybrid hydraulic accumulator pressure, releasing
— Hybrid hydraulic accumulator, disassembling and assembling
— Hybrid accumulator, checking and adjusting
— Hybrid hydraulic oil pressure in accumulators, depressurizing
— Hybrid accumulator, replacing
— Hybrid boom recovery valve, replacing
– (92) MECHANICAL EQUIPMENT/ATTACHMENT
— (924) Attachment bracket, mechanical and hydraulic Quickfit
— Attachment quick coupler, description
— Attachment quick coupler, operation
— Attachment quick coupler, adjustment
— Attachment quick coupler solenoid valve, description
— Attachment quick coupler, replacing
– (97) UNIT, DIGGING
— (970) General, common info about 971 – 975
— Tightening torques
— Function description
— Digging unit, maintenance
— Bushing general, replacing
— Cylinder, description
— Cylinder, disassembly and assembly
— Cylinder, troubleshooting
— Hydraulic cylinder, replacing
— (974) Boom with links
— Boom, specifications
— Boom, description
— Boom, replacing
— Boom cylinder, specifications
— Boom cylinder, description
— Boom cylinder, replacing
— Lower boom cylinder bushing, replacing
— Upper boom cylinder bushing, replacing
— (975) Dipper arm with links
— Dipper arm, specifications
— Dipper arm, description
— Dipper arm, replacing
— Link, description
— Dipper arm connecting rod, replacing
— Connecting rod yoke, replacing
— Dipper arm cylinder, specifications
— Dipper arm cylinder, description
— Dipper arm cylinder, replacing
— Dipper arm cylinder bushing on boom, replacing
— Dipper arm cylinder bushing on dipper arm, replacing
— Bucket cylinder, specifications
— Bucket cylinder, description
— Bucket cylinder, replacing
— Bucket cylinder bushing on dipper arm, replacing
— Bucket cylinder bushing lever-link, replacing
– (99) MISCELLANEOUS
— (992) Fire protection; anti theft systems; anti vandalism system
— Fire Suppression System, tightening torques
— Fire suppression system, specification
— Fire suppression system, component location
— Fire suppression system, functional description
— Fire suppression system, component description
— Fire suppression system, actions when the squib (gas generator) has reached the date of expiration (5 years)
— Fire suppression system, actions when the components have reached the date of expiration (10 years)
— Fire suppression system, actions after manual activation
— Fire suppression system, actions after activation
— (993) Automatic lubricating system
— Overview
— Automatic lubrication system, specifications
— Automatic lubrication system, description
— Central lubrication system, description
— Control units, software functions
— Maintenance service, general
— Technical data
— Troubleshooting
— Bleeding air