Volvo EC480E HR Excavator Service Repair Manual

Volvo EC480E HR Excavator Service Repair Manual

Size: 191.58 MB
Format: PDF
Language: English
Machine:Excavator 
Document: Service Repair Manual, Electrical Wiring Diagram, Hydraulic Diagram
Machine Model: EC480E HR 
Pages: 4308 Pages

The Bookmarks of Volvo EC480E HR Excavator Service Repair Manual:
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
Time Guide Current generation
Time Guide Previous generation

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