Volvo FC2421C Forestry Carriers Service and Repair Manual
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Volvo FC2421C Forestry Carriers Service and Repair Manual
Size: 143.14 MB
Format: PDF
Language: English
Machine: Forestry Carriers
Document: Electrical and Hydraulic Diagrams, Service and Repair Manual
Machine Model: FC2421C
Pages: 5550 Pages
The Bookmarks of Volvo FC2421C Forestry Carriers Service and Repair Manual:
1 Volvo FC2421C
Description
Additional fuel tank system, description
Additional oil cooler, description
Adjustable boom cylinder, description
Air conditioning unit, description1
Air conditioning unit, description2
Air distribution, description
Alternator, description
Alternator, testing
Angle sensor, description
Arm holding valve, description
Arm regenerating valve, description
Audio remote controller, description1
Audio remote controller, description2
Auxiliary start
Basic check, Engine
Battery charging capacity, checking
Battery, description
Battery, storage
Bearings
Boom 2 conflux shut-off valve, description
Boom float position, description
Boom float position, hydraulic circuits
Boom holding valve, description
Boom lifting cylinder, description1
Boom lifting cylinder, description2
Boom regenerating valve, description
Boom, description
Bottom roller, description
Bucket cylinder, description
Bucket flow control valve, description
Bucket operation1
Bucket operation2
Bucket regenerating valve, description
Cab suspension, description
Camshaft, description
CareTrack system, description
Center bypass valve, description
Charge air cooler, description
Charging, description
Check valve, description
Checking and Adjusting procedure
Circuit breaker, description
Cleaning prior to repair
Communication with data buses
Conflux check valve, description
Connecting rod, description
Control levers, description
Control lockout lever switch, description
Control pattern selector valve, hydraulic circuits
Control units changing, precaution
Cooling system, description
Crankshaft, description
Cylinder block, description
Cylinder head gasket, description
Cylinder head, description
Cylinder, description
Cylinder, description1
Cylinder, troubleshooting
Data buses, function
DC–DC converter, description
Description, general
Diesel coolant heater (5kw), description
Diesel coolant heater (5kw), principles
Dipper arm cylinder, description
Dipper arm, description
Disassembly and assembly, general
Electric horn, description
Electrical distribution box1
Electrical distribution box2
Electrical distribution box3
Electrical system, description
Electrical system, special instructions for servicing, action when working on machine
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, general
Electronic climate control unit ECC, description
Electronic climate control unit ECC, specification
Electronic control system, description
Engine block heater, description
Engine characteristic curve
Engine control unit E-ECU, function description
Engine control unit E-ECU, specifications
Engine speed control switch, description
Engine timing gear, description
Engine, description
Engine, identification
Examples, hydraulic system
Examples, power transmission
Exhaust system, description
Fan motor, description
Fan motor, troubleshooting
Fan pump, description
Flow control valve, description
Fuel control valve (FCV), description
Fuel filler pump, description
Fuel system, description
Fuel tank, description
Fuse, description
Gull wing, description1
Gull wing, description2
Hammer and shear pedal valve (RCV), replacing
Hammer and shear selector and shuttle valve, description
Hammer and Shears (X1 Line option), description
Hammer return filter, description
Heating system, description
Hoses and tubes
Hour counter, description
HVAC system
Hydraulic circuits, ports
Hydraulic components, description
Hydraulic components, storing and transporting
Hydraulic cylinders, dieseling
Hydraulic diagram, schematic
Hydraulic oil cooling system, description
Hydraulic oil, description
Hydraulic oil, storage and handling
Hydraulic pump, description
Hydraulic quickfit, description
Hydraulic system, cleanliness when handling hydraulic components
Hydraulic system, description
Hydraulic system, repair of hydraulic components in workshop
Hydraulic system, work instructions
Hydraulic tank, description
Idler, description1
Idler, description2
Incline sensor, description
Injectors, description
Inlet system, description
Instructions for working with electronic fuel injection
Instrument control unit I-ECU, functional description
Instrument control unit I-ECU, specifications
Instruments and controls, front instrument panel
Instruments and controls, left instrument panel
Instruments and controls, overview
Instruments and controls, rear instrument panel1
Instruments and controls, rear instrument panel2
Instruments and controls, right instrument panel1
Instruments and controls, right instrument panel2
Levelling control unit, function description
Levelling display unit, description
Line rupture valve (arm), description
Line rupture valve (arm), troubleshooting
Line rupture valve (boom), description
Line rupture valve (boom), troubleshooting
Line rupture valve relief pressure, adjustment1
Line rupture valve relief pressure, adjustment2
Line rupture valve relief pressure, measurement
Link, description
Load check valve - double, description
Load check valve - single, description
Logic valve, description
Lower wiper motor, description
Lubrication system, description
Lubrication system, principle of operation
MA9109 Quickfit solenoid valve, description
Main control valve troubleshooting
Main control valve, description
Main relief valve, description
Make up valve, description
Oil sump, description
Overload warning device, description
Overload warning device, operation
Piston cooling
Piston rings, description
Pistons, description
Port relief valve pressure, adjustment (when installing or dismantling the line rupture valve)
Port relief valve, description
Pressure accumulator, description
Pressure relief valve, troubleshooting
Pressure testing
Product plates
Proportional relief valve, description
Proportional solenoid valve, description
Proportional solenoid valve, description1
Proportional solenoid valve, troubleshooting
Pump, troubleshooting
Radio with CD and MP3 player, description
Radio with tape or CD player, descriptions
Radio with tape player, description
Radio, description
Radio, replacing1
Radio, replacing2
Recommended lubricants
Regulator, description
Relay, description
Remote control valve (Lever), troubleshooting
Remote control valve (pedal), description
Remote control valve (pedal), replacing
Remote control valve (pedal), troubleshooting
Replacement parts
Rotator (X3 Line option), description
Rotator pump, description
Safety when servicing
Selection of track shoes1
Selection of track shoes2
Service connection and programming connection1
Service connection and programming connection2
Service methods
Service positions
Service
Servo hydraulic block
Servo pump, description
Shuttle valve block, description
Solenoid valve, description
Solenoid valve, description1
Solenoid valve, troubleshooting
Standard of the setting pressure
Starter motor, description
Starter motor, replacing
Starter switch, testing1
Starter switch, testing2
Starting engine with booster cables
Starting operation
Stop valve
Swing gearbox, description1
Swing gearbox, description2
Top roller, description
Track chain, description1
Track chain, description2
Track gearbox, description
Track gearbox, troubleshooting
Track guards
Travel alarm, description
Travel alarm, replacing
Troubleshooting (5kw)
Troubleshooting Engine
Troubleshooting, diagnosing procedure
Turbocharger, description
Undercarriage, description1
Undercarriage, description2
Upper wiper motor, description
Valves, description
Vehicle control unit V-ECU, functional description
Vibration damper, description
Voltage converter, replacing
Welding on the machine
Window limit switch, description
Windows, general
Windscreen wiper, description
Wiper controller, description
Wireless control unit W-ECU, specification
Diagrams
Component designations
Component list Alternator, batteries, capacitors, electronic units, voltage outlet
Component list Control lights warning lights
Component list, fuses
Component list, Heating coils
Component list, lights
Component list, Miscellaneous
Component list, motors
Component list, relays
Component list, sensors
Component list, Solenoid valves
Component list, Switches
Control system diagram1
Control system diagram2
Electrical symbols and designations
Explanation of wiring diagrams
Explanations to hydraulic diagram
Grounding points, frame connections
Hydraulic diagram, double acting1 Figure 1
Hydraulic diagram, double acting1
Hydraulic diagram, double acting2 Figure 1
Hydraulic diagram, double acting2 Figure 2
Hydraulic diagram, double acting2
Hydraulic diagram, level system Figure 1
Hydraulic diagram, level system Figure 2
Hydraulic diagram, level system
Hydraulic diagram, single acting1 Figure 1
Hydraulic diagram, single acting1
Hydraulic diagram, single acting2 Figure 1
Hydraulic diagram, single acting2 Figure 2
Hydraulic diagram, single acting2
Wiring diagram SCH01-1
Wiring diagram SCH01-2
Wiring diagram SCH02
Wiring diagram SCH03-1
Wiring diagram SCH03-2
Wiring diagram SCH04
Wiring diagram SCH07
Wiring diagram SCH08
Wiring diagram SCH10
Wiring diagram SCH11-1
Wiring diagram SCH11-2
Wiring diagram SCH12-1
Wiring diagram SCH12-2
Wiring diagram SCH12-3
Wiring diagram SCH12-4
Wiring diagram SCH13
Wiring diagram SCH14-1
Wiring diagram SCH14-2
Wiring diagram SCH15
Wiring diagram SCH16-1
Wiring diagram SCH16-2
Wiring diagram SCH17
Wiring diagram SCH21
Wiring diagram SCH22
Wiring diagram SCH23
Wiring diagram SCH24-1
Wiring diagram SCH24-2
Wiring diagram SCH26
Wiring diagram
Wiring harnesses1
Wiring harnesses2
Repair
2 stage port relief valve, adjustment
Accumulator, replacing
Air conditioning unit, maintenance
Air mix door actuator, replacing
Alternator, replacing incl function checking
Antenna, replacing
Arm holding valve, disassembly and assembly
Arm parallel conflux check valve, disassembly and assembly
Arm parallel conflux valve, disassembly and assembly
Arm regenerating valve, disassembly
Batteries, replacing
Battery, charging
Boom 2 conflux shut-off valve, disassembly
Boom and arm holding valve (Boom-1, Arm-1), disassembly
Boom back pressure check valve, disassembly
Boom cylinder, repacking in machine
Boom cylinder, rupture valve, replacing
Boom, installing
Boom, removing
Boom, replacing
Bottom roller, assembly
Bottom roller, disassembly
Bottom roller, measurement of wear1
Bottom roller, measurement of wear2
Bottom roller, replacing one
Breather, replacing
Bucket assembly, installing
Bucket assembly, removing
Bucket assembly, replacing
Bucket cylinder, installing
Bucket cylinder, removing
Bucket cylinder, repacking in machine
Bucket cylinder, replacing
Bucket flow control valve, disassembly
Bucket regenerating valve, disassembly
Cab filter, replacing
Carbon dioxide in fuel system, checking
Center bypass valve, disassembly and assembly
Center passage hose (center passage – motor), replacing
Center passage hose (valve – center passage), replacing
Center passage, assembly
Center passage, disassembly
Center passage, inspection and troubleshooting
Center passage, replacing seal kit
Center passage, replacing
Charge air cooler connection (hose, tube), replacing
Charge air cooler, replacing
Coasting left and right swing
Component locations
Compressor, replacing incl draining and filling
Condenser, replacing incl draining and filling
Connecting rod yoke, installing
Connecting rod yoke, removing
Connecting rod yoke, replacing
Control lockout lever switch, replacing
Control types for X1 and X3 operation
Coolant anti-freeze resistance, checking
Coolant anti-freeze resistance, checking1
Coolant, changing
Cooler and Heater assembly, replacing
Counterweight, installing1
Counterweight, installing2
Counterweight, removing1
Counterweight, removing2
Creeping of hydraulic cylinder
Cylinder speed
Digging unit, maintenance
Dipper arm connecting rod, installing
Dipper arm connecting rod, removing
Dipper arm connecting rod, replacing
Dipper arm cylinder, installing
Dipper arm cylinder, removing
Dipper arm cylinder, repacking in machine
Dipper arm cylinder, replacing
Dipper arm cylinder, rupture valve, replacing
Dipper arm, installing
Dipper arm, removing
Dipper arm, replacing
Door window, replacing
E-3002, Spanner wrench
Earth lead to battery, replacing
ECC (Electronic Climate Control), replacing
E-ECU MID 128 non-programmed, replacing
E-ECU MID 128 pre-programmed, replacing
Engine mounting
Engine oil and filter, changing1
Engine oil and filter, changing2
Engine speed control switch, inspection
Engine speed control switch, replacing
Engine, tightening torques
E-tools, NET 8940-00270 Replace tool for the swing ring gear
E-tools, NET 8940-00300 Swing ring gear guide pin
Evaporator, replacing incl draining and filling
Exhaust pipe flexible tube, replacing
Expansion tank, replacing
Expansion valve, replacing incl draining and filling
Fan belt and or alternator belt, replacing
Fan belt and or alternator-, compressor belt, replacing all belts
Fan motor, assembly
Fan motor, disassembly
Fan motor, replacing
Fan motor, tools
Fan pump, assembly1
Fan pump, assembly2
Fan pump, disassembly1
Fan pump, disassembly2
Fan pump, parts inspection
Feed pump, replacing
Flow control valve, disassembly and assembly
Fuel control valve (FCV), replacing
Fuel filling pump, installing
Fuel filling pump, removing
Fuel filter extra, replacing
Fuel filter housing, replacing
Fuel filters, replacing
Fuel rail pressure, checking
Fuel system, bleeding
General, precautions
General, tools
Gull wing cylinder, replacing
Gull wing power pack, replacing
Heater core, replacing
Horn, replacing
Hydraulic oil return filter, replacing
Hydraulic oil tank breather filter, replacing
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic oil, changing
Hydraulic pump (removed), changing shaft seal
Hydraulic pump regulator, replacing
Hydraulic pump, maintenance standard, Specifications
Hydraulic quickfit, adjustment
Idler, assembly
Idler, disassembly
Idler, measurement of wear
Idler, tools for disassembly and assembly
I-ECU MID 140 non-programmed, replacing
I-ECU MID 140 pre-programmed, replacing
Injector, replacing one
Instrument panel (left), replacing
Instrument panel (right), replacing
Intake actuator, replacing
Line rupture valve (arm), disassembly
Line rupture valve (boom), disassembly
Load check valve – single, disassembly and assembly
Machine view, forestry
Main pressure relief valve, replacing
Main relief valve, adjustment
Main relief valve, disassembly and assembly
Main spool, disassembly and assembly
Main switch, replacing
Maintenance service, according to display message
Maintenance service, daily
Maintenance service, every 50 hours
Maintenance service, every 100 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 6000 hours
Make up valve, disassembly
Measuring condition
Measuring of swing bearing clearance
Mode (foot) actuator, replacing
NET 8940-00200 Replace tool for the remote control valve joint
NET 8940-00290 Track motor guide pin
Oil level gauge, replacing
Operation numbers for additional work
Port relief valve pressure, measuring and adjusting
Port relief valve, disassembly and assembly
Preheating coil, replacing
Pre-heating relay, replacing
Proportional solenoid valve (power shift), replacing
Proportional solenoid valve, measuring and adjustment
Pump, assembly
Pump, disassembly
Pump, tools
Quickfit, installing
Quickfit, removing
Radiator hose upper, replacing
Radiator hoses lower, replacing
Radiator, replacing
Rear window, replacing
Rear-view mirror, replacing
Receiver, replacing incl draining and filling
Remote control valve (Lever), assembly
Remote control valve (Lever), disassembly
Remote control valve (Lever), maintenance standard, Specifications
Remote control valve (pedal), assembly
Remote control valve (pedal), disassembly
Remote control valve (pedal), maintenance standard, Specifications
Rotator valve, adjustment
Seat support, replacing
Seat, replacing
Servo hydraulic pressure, adjustment
Servo pump, parts inspection
Servo pump, replacing
Side window, replacing
Silencer, replacing
Slew gearbox, lubrication
Slew motor, troubleshooting
Solenoid valve, disassembly and assembly
Solenoid valve, inspection
Speaker, replacing
Spring package, assembly
Spring package, disassembly
Sprocket, measurement of wear
Starter motor lead to battery, replacing
Starter motor, testing
Starter relay, replacing
Starter switch (engine start switch), replacing
Straight traveling performance
Superstructure, installing
Superstructure, removing
Swing gearbox removed, replacing shaft
Swing gearbox removed, seal replacing
Swing gearbox, assembly
Swing gearbox, assembly1
Swing gearbox, disassembly
Swing gearbox, maintenance standard
Swing gearbox, replacing
Swing motor gearbox, changing oil
Swing motor relief valve, replacing
Swing motor removed, seal replacing
Swing motor, assembly
Swing motor, disassembly
Swing motor, maintenance standard
Swing motor, replacing brake piston seal
Swing motor, replacing plate (brake)
Swing motor, replacing
Swing ring gear cover, installing
Swing ring gear cover, removing
Swing ring gear grease pipe, replacing
Swing ring gear outer seal, replacing
Swing speed
Swing unit, replacing
Thermostat, checking
Tools & equipment
Top roller, assembly
Top roller, disassembly
Top roller, measurement of wear
Top roller, replacing one
Track chain assembly, installing
Track chain assembly, removing
Track chain, measurement of wear
Track chain, wear limit
Track gearbox, assembly
Track gearbox, disassembly1
Track gearbox, disassembly2
Track gearbox, installation1
Track gearbox, installation2
Track gearbox, maintenance standard
Track gearbox, precautions for operation1
Track gearbox, precautions for operation2
Track gearbox, removal
Track guard, replacing one
Track links, replacing
Track motor gearbox, changing oil
Track motor relief valve, replacing
Track motor, assembly
Track motor, disassembly
Track recoil spring (tensioner) assembly, replacing
Track running speed
Track shoe, replacing one
Track, adjusting track sag
Travel Speed
Turbocharger, inspecting
Turbocharger, replacing
Valves, adjusting
V-ECU MID 187 non-programmed, replacing
V-ECU MID 187 pre-programmed, replacing
Vent actuator, replacing
Water separator housing, replacing
W-ECU, MID142, changing non-programmed ECU
W-ECU, MID142, changing pre-programmed ECU
Windscreen flusher pump, replacing
Windscreen wiper controller, replacing
Windscreen wiper switch, replacing
Windscreen wiper switch, replacing1
Windscreen, replacing
Work lighting head lamp assy, replacing
Safety
CE-marking, EMC-directive
Checklist after a fire or heat exposure
Decontamination
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Fire prevention measures
Health hazards with paint, plastics and rubber
Safety concerns everybody!
Safety regulations, forestry
Safety rules when servicing
Safety when handling oils and fuel
Safety when handling the machine
Safety when using lifting equipment
Safety when working with air conditioning refrigerant
Safety when working with batteries
Safety when working with hydraulic systems
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
Service Bulletins
Air conditioning compressor improvement
Auxiliary heater
Battery maintenance guideline for long term stock machines
Biodegradable hydraulic oil
Biodiesel fuel for Volvo CE
Blower motor
Cab door latch
Cab door latch1
Camshaft, hardening process update
CareTrack, new software version 2008w6
CD & MP3 player
Check method on engine oil consumption
Cigar lighter and ashtray change
Crankshaft and camshaft gear manufacturing improvements
Cylinder liner, specifications
D4 – D7 Alternator improvement
D6 D7 Exhaust gas leakage into the cooling system
D6E Camshaft, insufficient hardening
D6E Cylinder liner broken
DEF AdBlue AUS32 sampling, method
Diesel fuels - quality and function
Dipstick level gauge improvement for swing gearbox
ECU, functional check
Electric connector
Electric horn improvement
Electric horn
Engine limp home switch wire harness
Engine oil filter hose improvement
Engine oil leakage
Engine speed control switch improvement
Expansion tank
Fuel cap improvement
Fuel pump (Tier 3) manufacturing process improvement
Fuel pump (Tier 3) manufacturing process improvement1
Fuel regulator
Fuel sampling, method
Heat-resistant kit for RCV leakage
Hour counter improvement
Hydraulic hose assembly leakage handling
Hydraulic system flushing method
Hydraulic tank air breather
Improvement of return check valve
Injector yoke bolt
Injector yoke retention bolt loose
Instrument ECU change
Instrument ECU Improvement
Leakage at engine oil pump gasket
Line rupture valve hose, improvement
Lubrication point change on swing bearing
Machine model
MCV block leakage
Modification of CareTrack wire harness
New engine oil cooler
New engine oil level sensor
New fan bracket with profile washer
New fastener assortment
New oil change interval for Volvo bio hydraulic oil
New product
New software for anti-theft and cold starting improvement
New software for W-ECU1
New software release
New software, V-ECU
New software
New software1
New software2
New TechTool VCADS Pro interface
New turbo charger for D6E D7E
Oil analyses
Oil sampling, method
Oil sampling, sampling points
Plastic shims for Boom Arm pin joints
Poor gradability in unit having heavy attachment
Poor straight travel operation
Portable refillable O-ring kits
Pressure sensor
Recoil spring change
Recoil spring grease valve
Recoil spring package rod
Recommendations for Oil Sampling Intervals
Reporting of product misuse & near-miss report
Reports
Routines for reporting cracks on Boom and Arm
Serial number location on machine components
Sprocket improvement
Swing ring gear seal improvement
Swing ring gear seal
Thermostat failure (D4, D5, D6 & D7)
Travel motor
Travel motor1
Turbo outlet gasket change
Volvo Product incident accident report & Interview Form
Water separator drain valve
Whistle noise during boom down
X1 stop valve
Special Tools, Misc
Inspection Programme, Arrival Inspection
Special tool Manual
Special Tools Recommendations
Time Guide Currrent generation
Time Guide Old generation
Time Guide Previous generation
Specifications
Adapter stick, specifications
Additional fuel tank, specifications
Additional oil cooler, specifications
Air conditioning unit, specifications
Air conditioning unit, specifications1
Air conditioning unit, specifications2
Alternative fuels
Alternator, specifications
Angle sensor, specifications1
Angle sensor, specifications2
Audio remote controller, specifications1
Audio remote controller, specifications2
Auto Manual pump control switch, specifications
Battery, specifications
Boom lifting cylinder, specifications1
Boom lifting cylinder, specifications2
Boom, specifications
Bucket cylinder, specifications
Cab riser, specifications
Cab, weight
Circuit breaker, specification
Control lockout lever switch, specifications
Coolant pump, thermostat, specifications
Coolant with freezing and corrosion protection
Cooling system, specifications
Counterweight, specifications1
Counterweight, specifications2
Current pressure, specifications
Diesel coolant heater (5kw), specifications
Dipper arm cylinder, specifications
Electric horn, specifications
Electrical system, specifications
Electronic climate control unit ECC, specification
Emergency engine speed control switch, specifications
Engine - Pump control, specification
Engine control unit E-ECU, specifications
Engine speed control switch, specifications
Engine, specifications
Engine, weights
Flywheel, weight
Frame and track unit, specifications
Fuel filler pump, specifications
Fuel pressure, specifications
Fuel system, tightening torques
Fuel tank, specifications
Fuse, specifications1
Fuse, specifications2
Fuse, specifications3
Fuse, specifications4
Gull wing cylinder, specifications
Gull wing power pack, specifications
Hour counter, specifications
Hydraulic oil cooling system, specifications
Hydraulic pressure, specifications
Hydraulic pump, specifications
Hydraulic tank, specifications
Incline sensor, specifications
Keypad, specification
Leveler structure, tightening torque
Levelling control unit, specifications
Levelling display unit, specifications
Line rupture valve (arm), specifications
Line rupture valve (boom), specifications
Logic valve, specifications
Lower wiper motor, specifications
MA9109 Quickfit solenoid valve, specifications
Main control valve, specifications
Manual control box, specifications
Measurement conversion tables
Preheating, specifications
Pressure accumulator, specifications
Proportional solenoid valve, specifications
Protector cab, specifications
Radio with CD and MP3 player, specifications
Radio with tape or CD player, specifications
Recommended hydraulic oil, specifications
Regulator, specifications
Relay, specifications1
Relay, specifications2
Remote control valve (Lever), specifications
Remote control valve (pedal), specifications
Rotating beacon, specifications
Rotational connector, specifications
Rotator pump, specifications
Rotator valve, specifications
Servo hydraulic selector valve, specifications
Servo pump, specifications
Slew gearbox, specifications
Slew ring gear, specifications
Solenoid valve, specifications
Solenoid valve, specifications1
Standard tightening torques
Start switch, specifications
Starter motor, specifications
Swing motor, specifications
Track gearbox, specifications
Track motor, specifications
Travel alarm, specifications
Upper wiper motor, specifications
Valve system specifications
Vehicle control unit V-ECU, specifications
Windscreen flusher pump, specifications
Wiper controller, specifications
Wireless control unit W-ECU, specification
Work lights and extra lights, specifications