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Service Information Document Title: Function Group: Safety concerns everybody! 191



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Safety concerns everybody! Always follow the instructions in the machine's Operator's Manual. The Operator's Manual shall always be easily accessible in the cab. Volvo designs and manufactures machines with a high level of safety as well as effectiveness. All this work may be wasted if anyone who is about to perform service on any of our machines does not read the safety instructions, or does not follow them, e.g., does not replace guards, climbs on slippery machine parts instead of using a ladder, grabs a hold of hoses instead of handles or uses the wrong tools for the job. Always use the intended and adapted genuine Volvo spare parts for the machine in question to maintain safe and efficient function. Machines seldom cause accidents, instead people often do. A safety-conscious person and a well-maintained machine make for a safe, effective and profitable combination. Those who do not follow the safety instructions and observe the warnings in this manual must make sure that their work method is safe. Otherwise, there is a great risk of accidents, perhaps even accidents that result in fatalities.



WARNING WARNING SYMBOL This symbol appears at various points throughout the manual together with a warning text. It means "Warning, stay alert! Your safety is involved!". Get to know the capacity and limits of your machine!



Service Information Document Title: CE-marking, EMC-directive



Function Group: 191



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



CE-marking, EMC-directive CE-marking



Figure 1



(Declaration of conformity, only applies to machines marketed within the EU/EEA). This machine is CE-marked. This means that, when delivered, the machine meets the applicable "Essential Health and Safety Requirements" specified in EU's so-called Machine Safety Directive, 2006/42/EC. The person making any changes that affect machine safety is also responsible for the same. As proof that the requirements are fulfilled the machine is supplied with an EU Declaration of Conformity, issued by Volvo CE for every individual machine. This EU declaration also covers attachments manufactured by Volvo CE. The documentation is a valuable document that should be stored in a safe place and retained for at least ten years. The documentation shall always accompany the machine when it is sold. If the machine is used for other purposes or with other attachments than described in this manual, safety must be maintained at all times and in each individual case. The person carrying out such action is also responsible for the action which, in some cases, may require a new CE-marking and the issue of a new EU Declaration of Conformity. EU EMC Directive The electronic equipment of the machine may in some cases cause interference with other electronic equipment, or the equipment may be adversely affected by external electromagnetic interference, which may constitute safety risks. The EU EMC directive on "Electromagnetic conformity" provides a general description of what demands can be made on the machine from a safety perspective, where permitted limits have been determined and given according to international standards. A machine or device which meets the requirements should be CE-marked. Our machines have been specifically tested for electromagnetic interference. The CE marking of the machine and the declaration of conformity also cover the EMC directive. If other electronic equipment is fitted to this machine, the equipment must be CE-marked and tested on the machine with regard to electromagnetic interference. EU's noise directive Within the EU there is a noise directive stating that a machine may not have noise values that exceed a certain level. The values are indicated on a plate on the outside of the machine. Each machine is also delivered with a noise certificate where Volvo CE assures that the machine fulfills the governing legal requirements. It is important that this certificate accompanies the machine when it is sold. It is also important that no modifications are made to the machine's noise-damping components in order to fulfill the limit values.



Service Information Document Title: Function Group: Safety when handling the 191 machine



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Safety when handling the machine Volvo Construction Equipment is only responsible if:      



the machine has been used correctly and has been maintained according to instructions in Service Manuals and the Operator's Manual. prescribed service and prescribed inspections have been performed at the stated intervals. the lubricant recommendations in the manual have been followed. no safety seals have been opened by unauthorized persons. all modifications and repairs have been performed as prescribed by Volvo. only Volvo genuine spare parts/accessories or attachments that meet Volvo's requirements have been used.



Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating the machine. It is important that the operator reads and follows the instructions in the machine's Operator's Manual. An untrained operator may cause serious injuries and fatalities. Never operate a excavators for which there is no Operator's Manual available. Learn to understand the warning plates, symbols and operating instructions for the machine before you start operating. A few simple safety rules General 



Repair malfunctions or defects that affect safety as soon as possible.



      



Figure 1 Always maintain a three point contact with the steps and handrails Always use a hard hat, safety glasses, gloves, protective work shoes and other protective items as required by the work situation. Avoid standing in front of or behind the machine when the engine is running. Always use a rubber window scraper or brush with a long handle when cleaning the outside of the windows in order to avoid unnecessary climbing on the machine. When servicing the machine, for example when changing light bulbs, a ladder may be needed. Make sure that stepping surfaces, handles, service areas and anti-slip surfaces are free from oil, diesel, dirt and ice and that they are changed if they are damaged or missing. Check at regular intervals that all anti-slip surfaces are securely fastened. If not, fasten or replace as required. Always face the machine and use the steps and handrails when entering or leaving the machine. Use two hands and one foot, or two feet and one hand. Do not jump!



Before operating 



Read the Operator's Manual before you operate the machine! Follow the operating instructions and perform actions according to the instructions in the manual before operating. A few important rules are given below:



 



Figure 2 Read the operator's manual before you operate the machine Perform a control light test before starting the engine by turning the ignition key to position I, see Operator's Manual. Perform all recommended safety checks as outlined in the Operator's Manual.



WARNING Never operate the machine if you are tired or under the influence of alcohol, medicine or other drugs. 



     



Before starting the engine indoors, make sure that the extraction capacity of the ventilation system is sufficient. The machine is equipped with a diesel engine and the exhausts may be hazardous to your health. Make sure that ventilation is sufficient, and avoid running the engine indoors for longer than necessary where ventilation is insufficient. Read all plates and instructions on the machine and in the Operator's Manual before operating or servicing the machine. Each of these instructions contains important information about safety, handling and service. Use the seat belt during all operation. Always sit in the operator's seat when starting the engine. The machine must be fully operational before it is put into work, that is, all malfunctions that may cause an accident must be repaired. Do not operate the machine for long periods without ventilation or with a completely closed cab without running the cab fan (risk of lack of oxygen). Only step and stand on surfaces with slip-protected treads and hold on to the available handles and handrails.



Seat belt 



If the seat belt needs to be washed: Use a mild soap solution when washing and allow the belt to dry while it is fully pulled out, before rolling it up. Make sure that the belt is fitted correctly.



Figure 3 Use the seat belt during all operation A. B. C.   



Strap lap type (2 inches) Strap lap type (3 inches) Retractable type (2 inches)



Change the belt immediately if it is worn, damaged or if the machine has been involved in an accident where the belt had to take some strain. Never make changes to the belt or its mounts. Keep the belt rolled up when not in use.



Control lockout system Move the control lockout lever down to lock the hydraulic system securely. Unless the control lockout lever is on the “Locked” position (B), operating levers can be operated by careless touch, which could cause serious injury.



Figure 4 Control lockout lever 1



Control lockout lever



2



Left control lever



3



Left control console



A



Unlocked position



B



Locked position



Unlocked position (A)  



The control lockout lever is in “Unlocked” position (A) for working and travelling operations. When the control lockout lever is in this position the engine can not be started.



Locked position (B)   



The control lockout lever is used to lock-out the attachment, slew and travel unit. Place this lever on the left control console to “Locked” position (B) to lock out the hydraulic control levers and pedals. When the control lockout lever is in this position the engine can be started.



NOTE! In manual control mode, the engine can be started using the ignition switch even if the control lockout lever is in the unlocked (up) position. Place the control lockout lever in locked position to lock the hydraulics before starting the engine, otherwise the control levers can be activated inadvertently, which could cause serious injury.



Figure 5 Automatic/manual pump control switch 1. 2.



Manual control Automatic control



Theft protection system The machine can be equipped with theft protection in the form of a code lock (See Operator's Manual) which prevents start of the machine without the correct four-digit code. Do not forget the code. It can only be programmed and changed via VCADS Pro. If you forget the code, contact your dealer.



Service Information Document Title: Function Group: Safety rules when servicing 191



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Safety rules when servicing This section covers general safety rules when checking and servicing. Other rules, information and warning texts are given in the Operator's Manual. CE-marking This machine is CE-marked. This means that, when delivered, the machine meets the applicable "Essential Health and Safety Requirements", which are given in the EU Machine Safety Directive. If changes are made that affect the safety of the machine, the person making the changes is responsible for the same. Before you begin any service work: Service work done incorrectly is dangerous. Make sure that you have sufficient knowledge, correct information, the right tools and the correct equipment to perform the service in a correct manner. Repair or replace damaged tools and defective equipment. Park the machine on a level surface and prepare it for service by placing it in the service position according to figure: NOTE! No work may be done on the machine until you have the correct skills and knowledge of the machine to do the work. General 



Machine working in a environmentally contaminated area, See 191 Working in environmentally contaminated areas.See also 191 Checklist after a fire or heat exposure.







If someone is to take over the job that you have started, make sure that this person is informed about what part of the work has been completed and what remains to be done. When high-pressure washing the machine, do not aim the water jet directly at anti-slip surfaces or decals that are glued on.







WARNING Only walk or step on the machine's prepared stepping surfaces, see operator's manual.







Figure 1 Do not step on engine covers Never wear loose fitting clothing, for example, a scarf or jewelry, that can get caught and cause injury when working on the machine.



   







Figure 2 Protective equipment Always use a hard hat, safety glasses, gloves, protective work shoes and other protective items as required by the work situation. Always stop the engine when servicing the machine unless instructions on plates or in this manual state otherwise. Turn off the engine before opening engine covers, radiator casing, etc. Make sure that no tools or other objects that can cause damage are forgotten in the machine. Pay attention when removing or installing the tracks of track type machines. When removing the track pin, the track separates suddenly, so never let anyone stand at either end of the track. Always blocks both ends of the track to prevent any sudden uncontrolled movement.



Figure 3 Pay attention when removing or installing the tracks Pay attention when removing or installing the master pin of the track using a press, the master pin may pop out suddenly, so never let anyone stand at either end of the master pin.



Figure 4 Pay attention when removing or installing the master pin



Service Information Document Title: Fire prevention measures



Function Group: 191



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Fire prevention measures General 







 



There is always a risk of fire. Find out which type of fire extinguisher to use, where it is located and how to use it. The fire extinguisher in the machine should be located according to the figure or in an external box that can be locked. Fire-fighting equipment installed in or on the machine must be maintained in working order. Such equipment should be regarded as a complement to the operator's own efforts in case of a fire. The equipment should not be considered as a replacement of the operator's own fire fighting efforts. Fire extinguishers mounted on the machine or used when working on the machine must fulfil certain requirements. See the Operator's Manual. At the slightest sign of fire, if the situation allows it and keeping in mind your own safety, take the following action:     



   



drive the machine away from the danger area. stop the engine by turning the ignition key to the "0" position. leave the cab. turn off the battery disconnect switch. start fighting the fire and call the fire department if necessary.



Figure 2 Smoking and open flames are absolutely forbidden when filling fuel or any time diesel fuel is in contact with the open air. Smoking or open flames are absolutely forbidden close to the machine when filling fuel or at any time the fuel system is in contact with the open air. Diesel fuel is flammable and must not be used for cleaning. Use an approved solvent instead. Remember that certain solvents can cause skin rashes and are usually flammable. Avoid inhaling solvent vapour. Engine starting aids are flammable. Store such items in cool and adequately ventilated areas. Remember that such aids must not be used in combination with electric preheating of induction air.



Cleanliness 



Cleanliness is a decisive factor for operational reliability of the machine's systems. Therefore, keep the servicing area clean. Oil or water make floors and steps slippery and are also dangerous in combination with electrical systems or tools. Oily clothes or clothes drenched in grease constitute a serious fire hazard.



NOTICE If a high-pressure washer is used when cleaning, work carefully since damage may be caused to electrical components and insulation of the electrical cabling even at relatively moderate water pressure and temperature. Protect electrical cabling in a suitable manner. 



Keep the machine especially clean when operating in environments with fire hazards, such as saw mills, garbage dumps, etc. In such environments, suitable equipment to reduce the risk of accumulation of material and spontaneous combustion should be fitted (for example muffler guard, radiator screen, heavy-duty cyclone precleaner, etc.).



Electrical system 



Check electrical cables with regard to chafing damage and make sure that they cannot be damaged in such a way. This applies particularly to unfused electrical cables, which are red. For example, electrical cables between:    



 



Batteries Battery–starter motor Alternator–starter motor Cable to engine preheating coil.



When unfused cables have been disconnected, it is important to check that they are re-connected and clamped in such a way that they cannot be exposed to chafing. Unfused cables must not rest against oil and fuel hoses. When fitting any optional equipment, make sure that all cables (circuits) are connected across a fuse and routed and clamped so that there is no risk of chafing.



Welding and grinding 







Welding and grinding on the machine may only be performed on well-cleaned areas and not in places filled with combustible fluids, e.g., tanks, hydraulic pipes. Work with extra care when welding and grinding near flammable objects. Never weld on a painted surface without first removing the paint. Welding on a painted surface generates, in addition to health-hazardous vapours, technically inferior welds which may lead to future failures, with subsequent accidents. Use personal protective equipment and, where possible, air extraction shall be used to handle gases from welding and grinding.



Actions after a fire: See 191 Checklist after a fire or heat exposure.



Service Information Document Title: Function Group: Health hazards with paint, 191 plastics and rubber



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Health hazards with paint, plastics and rubber Work on painted surfaces Never weld or cut with a torch on painted surfaces. All paint decomposes when heated and generates a vast number of different substances that may be irritating and, in case of repeated exposure, be very hazardous to health The following safety actions shall be followed: 



Remove the paint by sandblasting at least 100 mm (3.93 inch) around the welding or cutting point (use breathing mask). If the paint cannot be removed by sandblasting, then remove the paint in another way, e.g., with paint solvent/ remover. NOTE! When using paint remover/solvent, use air extraction, breathing protection and protective work gloves.







Grinding machines with high-speed grinding discs also heat the paint and may only be used if there is an air extractor on the grinder. Use breathing protection as well.



Rubber and plastics



WARNING When heated, rubber and plastics can give off substances that are hazardous to personal health and the environment. The following safety instructions shall be followed:    



Do not weld or cut with a torch near polymer materials (plastics and rubber) without first protecting them from the heat. Never burn polymer materials when scrapping them. Be careful when handling machines that have been exposed to fire or other intense heat. See also 191 Checklist after a fire or heat exposure. Always use gloves, protective safety glasses and breathing protection.



Fluor rubber



WARNING Risk of serious corrosive injuries! Certain seals designed to withstand high operating temperatures (e.g., in engines, transmissions, axles, brakes, hydraulic motors and pumps) may be made of fluor rubber which, when heated to high temperatures, generate hydrogen fluoride and hydrofluoric acid. Hydrofluoric acid is highly acidic and corrosive. It cannot be rinsed or washed off the skin and causes very severe burn and corrosive injuries that take a very long time to heal. As a rule, injures tissue must be removed surgically. Hydrofluoric acid may remain on machine parts for a very long time (several years) after a fire. NOTE! In case of contact with hydrofluoric acid, it may take several hours before any symptoms appear. If swelling, redness or burning sensations appear and contact with heated fluor rubber is suspected to be the cause, seek immediate medical attention. If a machine or a component for a machine has been exposed to fire or other intense heat it shall be handled by specially trained personnel.



For all handling of machines after a fire, use heavy-duty gloves made of neoprene rubber and effective safety goggles.



WARNING Burning of painted parts, plastic or rubber parts constitutes a health hazard. See 191 Environmentally safe handling. Decontamination The area around a heated part that is suspected to be made of fluor rubber shall be decontaminated by thorough and ample washing with lime water (a solution or suspension of calcium hydroxide, that is, slaked lime) in water. After completing the decontamination work, wash the gloves in the lime water and then discard them. If the machine has been exposed to a fire or other intense heat, the safety actions in the following checklist shall be followed unconditionally at all times: 191 Checklist after a fire or heat exposure. Asbestos information The components in Volvo CE's machines are free from asbestos, that is why it is important to use genuine Volvo spare parts.



Service Information Document Title: Function Group: Checklist after a fire or heat 191 exposure



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Checklist after a fire or heat exposure 



As a precaution, seal rings (O-rings or axle/shaft seals) should always be handled as if they were made of fluor rubber, See also section “Fluor rubber”.



WARNING Avoid splashing when washing a machine damaged by fire. For this reason, never use high-pressure washing equipment. 











Never touch burned components or parts with your bare hands when there is a risk that you may be exposed to contact with melted polymers. First, wash thoroughly with plenty of lime water (a solution or a suspension of calcium hydroxide, i.e. slaked lime). Use thick, protective gloves made of rubber and wear goggles that are certain to protect your eyes. Seek medical attention if your skin may have come in contact with burnt fluor rubber. The skin should be treated with Hydrofluoric Acid Burn Jelly or similar. Symptoms may not appear until several hours after contact with burnt fluor rubber. Discard protective gloves, rags and other items that may have come into contact with burnt fluor rubber.



Service Information Document Title: Function Group: Safety when using lifting 191 equipment



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Safety when using lifting equipment WARNING Risk of crushing injuries



Figure 1 Do not overload lifting or support equipment. 



  



All lifting devices, e.g., slings, straps, ratchet blocks, etc., must meet governing national regulations for lifting devices. We will not accept any responsibility if other lifting devices, tools or work methods are used, other than those described in this publication. Make sure that the ground surface is flat and has sufficient strength to support the expected load for lifting device with load. When lifting or supporting machine parts, use equipment with a lifting capacity that at least equals the weight of the part in question. Use the lifting eyes or lifting points that are located on certain machine components.



Service Information Document Title: Function Group: Safety when handling oils 191 and fuel



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Safety when handling oils and fuel  











When changing oil in engine, hydraulic system: Keep in mind that the oil may be hot and can cause scalding or burn injuries. Engine, hydraulic and transmission oils as well as diesel fuel have a corrosive effect on mucous membranes, for example, in eyes and throat and on skin. Therefore, take special care to keep such oils away from these sensitive body parts. When emptying/draining oils or fuel, steps must be taken to avoid unnecessary spills. In places where a container for collecting the liquid cannot be used, use a pump or connect a hose to ensure safe handling. Oil released or spilled on the ground will harm the environment and could also cause a fire. Waste oils/fluids shall always be taken care of by a company authorized for this work. See 191 Environmentally safe handling. Remember the fire hazard!



Service Information Document Title: Function Group: Safety when working with 191 batteries



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Safety when working with batteries WARNING Risk of serious corrosive injuries! Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine. In addition, batteries give off hydrogen gas when they are loaded (supplying electricity) or being charged. Together with the oxygen in the air, hydrogen gas forms a very explosive mixture. This combination, corrosive acid and explosive gas, means a high risk of accidents during all work with batteries used in vehicles. Therefore, it is very important that you take great care and follow the rules below when you are working with batteries. Follow these instructions when charging batteries:        



Batteries give off explosive gases. Never smoke near batteries. Begin by disconnecting the ground lead when removing a battery. In order to reduce the risk of sparks that can cause fire, always connect the ground lead last when fitting a battery. Never tilt a battery to any great extent in any direction. Battery electrolyte may leak out. Do not connect a discharged battery in series with a fully charged battery. The current surge can cause the batteries to explode. Do not allow metal objects (such as tools, rings, wristwatches) to come in contact with battery terminals. Risk of fire and personal injury. Always cover the top of the battery with a rag or other non-conducting material when you work close to the batteries. Always refit the terminal caps on the batteries. Batteries contain substances hazardous to health and the environment. Therefore, discarded batteries be handled according to governing local/national regulations. See 191 Environmentally safe handling.



Charging batteries Explosion hazard When a battery is being charged, an explosive mixture of oxygen and hydrogen is formed. A short circuit, open flame or spark near the battery can cause a powerful explosion. Always turn off the charging current before disconnecting the charging clamps. Ventilate well, especially if the battery is charged in a confined space. Corrosive sulphuric acid The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin must be removed immediately. Wash with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention.



Figure 2 Corrosive acid



Service Information Document Title: Starting with batteries



Function Group: booster 191



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Starting with booster batteries When starting with booster batteries, the following must be observed: Check that the booster batteries or other power source have the same voltage as the standard batteries.



WARNING Batteries may explode due to the current surge if a fully-charged battery is connected to a completely discharged or frozen battery. Personal injuries may be sustained. Follow these steps: 1. 2. 3. 4. 5. 6. 7. 8. 9.



Turn OFF the battery disconnect switch. Remove the protections from the battery pole studs. Check that the booster batteries or other power source have the same voltage as the standard batteries. Do not disconnect the cables to the standard batteries! Connect (+) on the booster battery to (+) on the battery nearest the starter motor. Connect the other start cable from (-) on the booster battery to the machine chassis, such as on the frame member close to the starter motor. Start the engine with the ignition key in the cab. Once the engine has started, remove the start cable between the chassis and the booster battery negative terminal (-). Then remove the start cable between the positive terminals (+). Refit the terminal caps on the battery terminals.



Service Information Document Title: Function Group: Safety when working with 191 air conditioning refrigerant



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Safety when working with air conditioning refrigerant General Special competence is required for service work and more involved work which requires opening of the air conditioning system. Many countries also require special training and official authority approval. Find out about governing regulations for your country and follow them! Refrigerant R134a is used in the air conditioning unit, See also Section 8. The type of refrigerant and the amount to be filled are shown on the type plate. NOTE! R134a adds to the greenhouse effect and should never be intentionally released into the open air. Personal protective equipment



Figure 1 Protective goggles and gloves should be worn when there is a risk of contact with refrigerant. When there is a risk of skin contact with refrigerant, use: Tight-fitting protective goggles and protective gloves, and protect other bare skin (risk of frostbite). Risks



WARNING The gases have no smell and may cause serious damage to the lungs already at low concentrations. Refrigerant R134a may, if incorrectly handled, cause serious personal injuries as well as damage to the environment. Therefore, great care must be taken in all work with air conditioning units! The rules given below may be a great help to avoid injuries to all who come into contact with refrigerants.



WARNING Risk of frostbite! Wear protective work gloves.  



In liquid form the refrigerant may cause: Frostbite. When in the form of a gas and at low concentration, the gas may: Have some effect, especially on the nervous system.



 







When in the form of a gas and at high concentration it may: Have an anaesthetic effect. The air conditioning unit is pressurized and the refrigerant can unintentionally leak out. Never disconnect hoses or remove the filler plug on the compressor. If you suspect a leak, certified and trained personnel at a licensed workshop should be contacted for troubleshooting and repair. The refrigerant gas is heavier than air and will sink to the floor. Therefore, make sure that any escaped gas is ventilated before work is started in any low-lying areas.



Smoking, welding or other open flames are not allowed in a workplace where work with refrigerant is in progress. The refrigerant gas will then burn and form a toxic gas which is very dangerous to inhale. The gases formed when heating the refrigerant have a pungent smell at high concentrations. The symptoms may appear several hours (perhaps up to 24 hours) after exposure to the gases. Action in case of accidents Inhalation If escape of gas is suspected, leave the area, try to find fresh air and move affected persons out of the danger area. Small amounts of vapour from refrigerant R134a may have some effect especially on the nervous system. In large amounts, the gas may have an anaesthetic effect. In serious cases, seek immediate medical attention. Skin contact In case of frostbite, flush with lukewarm water for a long time. If a large amount of liquid refrigerant comes into contact with unprotected skin, the injured area should be carefully warmed with lukewarm water or warm clothes. Seek medical attention immediately if symptoms persist. Splash in eyes Flush with warm water until the irritation ceases. Seek immediate medical attention.



Service Information Document Title: Function Group: Safety when working with 191 hydraulic systems



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Safety when working with hydraulic systems The hydraulic systems in our excavators operate at very high pressure. In order to avoid serious personal injuries it is very important that the systems are maintained in the right way, and that all persons who come into contact with the machines are very careful in their work and are very attentive to any defects. Those who follow the simple rules below have laid a good foundation for avoiding accidents. General   



Never adjust a pressure limiting valve to a higher pressure than that recommended by the manufacturer. A hydraulic hose that swells, e.g., at a connection, shows that it is about to rupture. Replace the hose as soon as possible! Pay attention to leaks from hydraulic hoses and connection. Repair the leak before the part ruptures! Discarded pressure accumulators shall be punctured before they are scrapped to avoid the risk of explosion.



WARNING If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious personal injuries.



Service Information Document Title: Function Group: Environmental handling for 191 the future



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Environmental handling for the future The world stands before gigantic challenges on environmental matters where clean water, climate change, and use of chemicals are some of the most important issues. Volvo has an important function in meeting these challenges and contributing to a more ecologically sustainable development. Quality, safety and environment are Volvo core values and have for a long time been integral parts of our company and our products. Volvo Construction Equipment works with continuous improvement of the machine's environmental performance. An important factor to retain the machine's performance is the service offered by the workshops. This service manual contains recommendations, warning texts, etc. to facilitate your work for the environment.



Service Information Document Title: Environmentally handling



Function Group: safe 191



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Environmentally safe handling Always choose an environmentally friendly alternative where one is available, e.g., biodegradable oils. Always follow national and local environmental regulations. All waste shall be brought to a waste handling company, approved by the authorities. Oils and fluids Oils and fluids, e.g., coolant, that are not reused shall be collected in tight-sealing containers and left for destruction. Oils could be used as energy after proper treatment by authorized party. Filters Oil and fuel filters shall be drained and put into sealed containers before they are left for destruction. Refrigerant R134a Refrigerant R134a contains substances that affect the greenhouse effect and may never be released into the open air. Shall be recycled according to instructions in separate component manual for the air conditioning. Batteries



WARNING Risk of serious corrosive injuries!



Figure 1 Corrosive acid Batteries contain environmentally hazardous substances and corrosive acid. Shall be left for recycling. Chemicals Chemicals, paints, glue, cleaning agents, etc. shall be left for recycling and destruction. Rubber and plastics Rubber materials and plastics may not be burned. Shall be left for recycling. Tires shall be handled according to special rules. Electronics Electrical and electronic waste, e.g., circuit boards and bulbs, shall be left for recycling. They must not be thrown away into normal waste bin.



Crystalline silica (quartz) dust Because crystalline silica is a basis component of sand and granite, many activities at construction sites produce dust containing crystalline silica. Trenching, sawing and boring of material containing crystalline silica can produce dust containing crystalline silica. If dust which contains crystalline silica is present there are guidelines which should be followed. 1. 2. 3. 4. 5. 6.



7. 8. 9. 10.



Be aware of the health effects of crystalline silica and that smoking adds to the damage. Be aware of and follows OSHA (or other) guidelines for exposure to airborne crystalline silica. Know the work operations where exposure to crystalline silica may occur. Participate in air monitoring or training programs offered by the employer. Be aware of and use optional equipment controls such as water sprays, local exhaust ventilation, and enclosed cabs with positive pressure air conditioning. Where respirators are required, wear a respirator approved for protection against crystalline silica-containing dust. Do not alter the respirator in any way. Workers who use tight-fitting respirators cannot have beards/mustaches which interfere with the respirator seal to the face. If possible, change into disposable or washable work clothes at the work site ; shower and change into clean clothing before leaving the work site. Do not eat, drink use tobacco products, or apply cosmetics in areas where there is dust containing crystalline silica. Store food, drink and personal belongings away from the work area. Wash hands and face before eating, drinking, smoking, or applying cosmetics after leaving the exposure area.



Service Information Document Title: Function Group: Environmentally hazardous 191 fluids



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Environmentally hazardous fluids Pay attention to leakage of fuel, oils and other fluids from the machine that may contaminate the environment. Take appropriate actions to seal the leak immediately and decontaminate contaminated ground as soon as possible.See 191 Decontamination. Oils and fuels When emptying/draining oils and fuels, take appropriate actions so that unnecessary spills are avoided. In places where containers for draining cannot be used, use a pump or hose for safe handling. Air conditioning Refrigerant R134a contains substances that affect the greenhouse effect and may never be released into the open air. Service personnel who work with refrigerants must know the laws/rules that apply in the local country but also international rules. Special training is recommended for all service work on the air conditioning. Many countries require certification from an authority for such work.



Service Information Document Title: Working environmentally contaminated areas



Function Group: in 191



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Working in environmentally contaminated areas Machines that are used in environmentally contaminated and/or health-hazardous areas shall be specially equipped for operation in such an environment. Used cab and engine air filters from machines working in environments with asbestos or other hazardous dust shall be put into tight-sealing plastic bags that the new filters come in, then leave the used filters for destruction.



Service Information Document Title: Decontamination



Function Group: 191



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Decontamination Start decontamination as soon as possible. Certain substances spread quickly in the environment. Decontamination after leaks/spills Use suitable absorbing materials to collect leaking oil or fuel, e.g., absorbent mats. Prevent leaking oil/fuel from draining into rain water/storm water drains. Contaminated soils and ground materials must be removed and collected in suitable containers. Collected soils and absorbent materials shall be left for destruction. Decontamination after accident If possible, seal leaks from the machine. Isolate the leakage area using banks drain booms. Add absorbent materials, e.g., absorbent sand or bark cuttings. Stop leaking fluids so that they do not drain into rain water/storm water drains or ditches. Collect the absorbent materials and the top layer of soil, put it into sealed containers for transport to destruction. Decontamination after fire First of all, put out the fire. Decontaminate in the same way as after an accident. NOTE! Pay attention and be aware that certain 191 Health hazards with paint, plastics and rubber. See also 191 Checklist after a fire or heat exposure.



substances



may



be



poisonous



after



a



fire.



See



Service Information Document Title: Waste handling



Function Group: 191



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Waste handling Contribute to careful use of natural resources by following the steps below when handling waste. If possible, deposit the waste for recycling. REUSE of products is the best from an environmental aspect. MATERIAL RECYCLING for use in new products is a good environmental alternative. ENERGY RECOVERY by burning combustible materials is a good alternative when recycling is not possible. DESTRUCTION is used for hazardous waste. Destruction is performed in special facilities. DEPOSITION is the worst from an environmental aspect and should be avoided as much as possible. STORAGE is a temporary measure until a suitable recycling method has been developed.



Thank you for your purchase. Have a nice day.



file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/7/14 8:48:31]



Service Information Document Title: Product plates



Function Group: 000



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Product plates Please refer to the figure below to locate the product plate, engine plate, cab plate and attachment plates. Always use the Product Identification Number (PIN) provided on the vehicle and/or engine plates for troubleshooting purposes and/or when ordering spare parts. Product plate This plate with Product Identification Number, PIN, for the complete machine indicates the model designation, serial number and when applicable, machine weight, engine power, manufacturing year and CE approval. The plate is positioned on the right side of the upper frame. Engine The engine type designation, part and serial numbers are stamped on the top of valve cover. Attachment quick coupler This nameplate is attached on the outside of the bracket and indicates the part number and weight. Bucket This nameplate is attached on the top of the bucket and indicates the bucket model order number, serial number, bucket part number, rated capacity, weight, cutting width, tooth part number, and adapter part number. Cab The nameplate is attached on the inside of the cab and indicates the product number, serial number, model type, and weight.



Service Information Document Title: Component locations



Function Group: 000



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Component locations



Figure 1



1



Dipper arm cylinder



14



Main pump



2



Boom



15



Track motor and gearbox



3



Boom cylinder



16



Hydraulic tank



4



Operator cab



17



Fuel tank



5



Hydraulic oil cooler



18



Upper roller



6



Swing motor and gearbox



19



Turning joint



7



Air cleaner



20



Bottom roller



8



Main control valve



21



Idler



9



Radiator and Charged air cooler



22



Bucket



10



Engine



23



Link



11



Rear hood



24



Bucket cylinder



Date: 2014/7/14



12



DPF and burner



25



Dipper arm



13



Counterweight



26



Swing ring gear



Service Information Document Title: Machine view, demolition



Function Group: 000



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Machine view, demolition Demolition standard The demolition machine is based on a standard machine. This demolition machine is composed of HD Side door reinforce, Swing ring gear protection cover, Upper frame side protection plate reinforce, Upper under cover reinforce, Boom cylinder protection plate and Bucket cylinder protection plate, Working and maintenance lamps, Top protection round pipe on rear and RH side.



Figure 1 Machine view, demolition standard A. B. C. D. E. F. G.



– Bucket cylinder protecting guard Boom cylinder protecting guard Swing ring gear cover Side impact protection (bolt tightening torque: 262 ±27 Nm, 26.7 ±2.8 kgf m, 193 ±27 lbf ft) Auxiliary hood, right side door Auxiliary hood, left side door



Service Information Document Title: Function Group: Measurement conversion 030 tables



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Measurement conversion tables Length Unit



cm



m



km



in



ft



yd



mile



cm



1



0.01



0.00001



0.3937



0.03281



0.01094



0.000006



m



100



1



0.001



39.37



3.2808



1.0936



0.00062



km



100000



1000



1



39370.7



3280.8



1093.6



0.62137



in



2.54



0.0254



0.000025



1



0.08333



0.02777



0.000015



ft



30.48



0.3048



0.000304



12



1



0.3333



0.000189



yd



91.44



0.9144



0.000914



36



3



1



0.000568



mile



160930



1609.3



1.6093



63360



5280



1760



1



1 mm = 0.1 cm, 1 mm = 0.001 m Area Unit



cm2



m2



km2



a



ft2



yd2



in2



cm2



1



0.0001



-



0.000001



0.001076



0.000012



0.155000



m2



10000



1



0.000001



0.01



10.764



1.1958



1550.000



km2



-



1000000



1



10000



1076400



1195800



-



a



0.01



100



0.0001



1



1076.4



119.58



-



ft2



-



0.092903



-



0.000929



1



0.1111



144.000



yd2



-



0.83613



-



0.008361



9



1



1296.00



in2



6.4516



0.000645



-



-



0.006943



0.000771



1



1 ha = 100 a, 1 mile2 = 259 ha = 2.59 km2 Volume Unit



cm3 = cc



m3



Liter



in3



ft3



yd3



cm3 = m liter



1



0.000001



0.001



0.061024



0.000035



0.000001



m3



1000000



1



1000



61024



35.315



1.30796



Liter



1000



0.001



1



61.024



0.035315



0.001308



in3



16.387



0.000016



0.01638



1



0.000578



0.000021



ft3



28316.8



0.028317



28.317



1728



1



0.03704



yd3



764529.8



0.76453



764.53



46656



27



1



1 gal(US) = 3785.41 cm3 = 231 in3 = 0.83267 gal(US) Weight Unit



g



kg



t



oz



lb



g



1



0.001



0.000001



0.03527



0.0022



kg



1000



1



0.001



35.273



2.20459



t



1000000



1000



1



35273



2204.59



oz



28.3495



0.02835



0.000028



1



0.0625



lb



453.592



0.45359



0.000454



16



1



1 tonne(metric) = 1.1023 ton(US) = 0.9842 ton(UK) Pressure Unit



kgf/cm2



bar



Pa=N/m2



kPa



lbf/in2



lbf/ft2



kgf/cm2



1



0.98067



98066.5



98.0665



14.2233



2048.16



bar



1.01972



1



100000



100



14.5037



2088.6



Pa=N/m2



0.00001



0.001



1



0.001



0.00015



0.02086



kPa



0.01020



0.01



1000



1



0.14504



20.886



lbf/in2



0.07032



0.0689



6894.76



6.89476



1



144



lbf/ft2



0.00047



0.00047



47.88028



0.04788



0.00694



1



1 kgf/cm2 = 735.56 Torr(mmHg) = 0.96784 atm Approximate conversions SI



Conversion



Non-SI



Conversion



SI



Unit



Factor



Unit



Factor



Unit



newton meter (N·m)



x 10.2



= kgf·cm



x 0.8664



= (lbf·in)



newton meter (N·m)



x 0.74



= lb·ft



x 1.36



= N·m



newton meter (N·m)



x 0.102



= kgf·m



x 7.22



= (lbf·ft)



kilopascal (kPa)



x 4.0



= in. H2O



x 0.249



= kPa



kilopascal (kPa)



x 0.30



= in. Hg



x 3.38



= kPa



kilopascal (kPa)



x 0.145



= psi



x 6.89



= kPa



(bar)



x 14.5



= psi



x 0.069



= (bar)



(kgf/cm2)



x 14.22



= psi



x 0.070



= (kgf/cm2 )



(newton/mm2 )



x 145.04



= psi



x 0.069



= (bar)



megapascal (MPa)



x 145



= psi



x 0.00689



= MPa



kilowatt (kW)



x 1.36



= PS (cv)



x 0.736



= kW



kilowatt (kW)



x 1.34



= HP



x 0.746



= kW



kilowatt (kW)



x 0.948



= Btu/s



x 1.055



= kW



watt (W)



x 0.74



= ft·lb/s



x 1.36



=W



kilojoule (kJ)



x 0.948



= Btu



x 1.055



= kJ



joule (J)



x 0.239



= calorie



x 4.19



=J



meter per sec2 (m/s2 )



x 3.28



= ft/s2



x 0.305



= m/s2



meter per sec (m/s)



x 3.28



= ft/s



x 0.305



= m/s



kilometer per hour (km/h)



x 0.62



= mph



x 1.61



= km/h



Torque



Pressure (Pa = N/m2 )



Power (W = J/s)



Energy (J = N·m)



Velocity and Acceleration



Horse power/torque BHP x 5252 rpm = TQ (lb·ft)



TQ x rpm 5252 = B.H.P.



Temperature °C = (°F - 32) /1.8 Flow Rate



°F = (°C x 1.8) + 32



liter/min (dm3/min) Note: ( ) non-si unit



x 0.264



= US gal/min x 3.785



= liter/min



Service Information Document Title: Specification, capacities



Function Group: filling 030



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Specification, filling capacities Oils and other liquids



Change capacities



Engine oil, including filter



55 litres (14.5 US gal.)



Coolant



60 litres (16 US gal.)



Hydraulic tank



270 litres (71 US gal.)



Hydraulic system, total



525 litres (139 US gal.)



Swing gearbox (each)



6 litres (1.6 US gal.)



Track gearbox (each)



8 litres (2.1 US gal.)



Fuel tank



685 litres (181 US gal.)



Swing ring gear



45 litres (11.8 US gal.)



Oil bath precleaner



8.5 litres (2.25 US gal.)



Air pump oil



0.045 litres (0.012 US gal.)



Date: 2014/7/14



Service Information Document Title: Tightening specifications



Function Group: torque, 030



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Tightening torque, specifications Center passage NOTE! Center passage, sectional view. See 4431 Center passage, description.



Center passage mounting screws tightening torque. See 400 Tightening torque, specifications.



Figure 1 Center passage port Center passage port, specifications Port



Port size



Rated pressure, MPa (kgf cm2) (psi) (bar)



Flow rate, Litres/min (gal)



Application



A



1-1/4 Flange



35.3 (360) (5120) (353)



360 (95)



Travel



B



1-1/4 Flange



35.3 (360) (5120) (353)



360 (95)



C



1-1/4 Flange



35.3 (360) (5120) (353)



360 (95)



D



1-1/4 Flange



35.3 (360) (5120) (353)



360 (95)



E



9/16-18 UNF-2B



3.9 (40) (569) (39)



5 (1.3)



Speed control



F



1-1/16-12 UNF-2B



0.49 (5) (71.1) (4.9)



45 (11.9)



Drain motor



Tightening torque, specifications Item



Tightening torque, Nm (kgf m) (lbf ft)



PT1/4 Plug



392.3 ±3.92 (40 ±0.4) (288.8 ±2.9)



PT1 Plug



490.3 ±49.0 (50 ±5) (361 ±36.1)



G. Hose (GDr) track motor



119.6 ±11.8 (12.2 ±1.2) (88.1 ±8.7)



F. Hose (FPi) track motor



25.5 ±2.9 (2.6 ±0.3) (18.8 ±2.2)



15. Plug



47.1 ±4.9 (4.8 ±0.5) (34.7 ±3.6)



H. Nipple



47.1 ±4.9 (4.8 ±0.5) (34.7 ±3.6)



I-1. Tee nipples nipple I-2. Straight nipple



119.6 ±11.8 (12.2 ±1.2) (88.1 ±8.7) 189.3 ±18.6 (19.3 ±1.9) (139.4 ±13.7)



J. Flange



175.5 ±17.7 (17.9 ±1.8) (129.2 ±13.0)



K. Nipple



189.3 ±18.6 (19.3 ±1.9) (139.4 ±13.7)



Service Information Document Title: Tightening specifications



Function Group: torque, 030



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Tightening torque, specifications Swing ring gear cover, Demolition standard



Figure 1 Swing ring gear cover Tightening torque No.



Items



Weight: kg (lbs)



Tightening torque, Nm (kgf m) (lbf ft)



1



Swing ring gear cover-front



32.1 (70.8)



–



2



Swing ring gear cover-left and right



32.5 (71.6)



–



3



Swing ring gear cover-rear



32.2 (71)



–



4



Mounting screws



8 EA



1727 ±173 (176 ±18) (1271 ±127)



5



Swing ring gear cover-grease port



6 (13)



–



6



Mounting screws



2 EA



64 ±6.9 (6.5 ±0.7) (47 ±5.1)



NOTE! Mounting screws. Apply Loctite #277 or equivalent locking fluid.



Service Information Document Title: Service positions



Function Group: 091



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Service positions Park the machine on a horizontal and firm surface. The suitable position is indicated in the description for the various service jobs. Before beginning any work on the machine.   



Turn off the engine and remove the ignition key. Depressurize all pressurized lines and pressure vessels carefully so that high pressure is released without risk. Allow the machine to cool down.



Figure 1 Service position A



Figure 2 Service position B



Figure 3 Service position C



Figure 4 Service position D



Figure 5 Service position E



Figure 6 Service position F



Service Information Document Title: Welding on the machine



Function Group: 091



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Welding on the machine NOTICE During electric welding on the machine or attachments connected to the machine, components such as bearings and electric units may be damaged if the ground cable is connected incorrectly. The following actions should be taken before starting electric welding to eliminate these risks: 1. 2.



Turn off the electric power using the battery disconnector. Disconnect the batteries. NOTE! Both the plus and minus terminal.



3.



Disconnect the following electronic units: – Vehicle electronic control unit (V-ECU) – Engine electronic control unit (E-ECU) – Instrument electronic control unit (I-ECU) – Electronic climate control unit (ECC) – Wiper control unit (CU3601) Connect the welding unit's ground connection as close as possible to the welding point, and make sure that the current does not pass across a bearing.



4.



If welding is necessary on the boom or dipper arm, the following basic rules should be followed: 1. 2. 3. 4.



Welding beads should be laid down in the longitudinal direction. If possible, weld in the middle of the metal section and never closer than 80 mm to an edge. Do not weld near the welded connections of the cylinder mounting eyes. Minimum distance from eye's weld to weld for weld lug = 100 mm. Do not weld close to where a metal plate has been bent.



Service Information Document Title: Hydraulic dieseling



Function Group: cylinders, 091



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Hydraulic cylinders, dieseling If air enters the hydraulic cylinders during work on the hydraulic system, this can lead to spontaneous ignition, an effect known as dieseling. This occurs if a favourable mixture of air and hydraulic oil is compressed when the piston approaches its end position in the cylinder. A sufficiently high temperature can be reached for the mixture to spontaneously ignite.



NOTICE The dieseling effect may result in burnt piston seals and bushings. In order to prevent dieseling, the lines for the hydraulic cylinders must be bled after work is completed, as follows:  







Operate the digging equipment several times with no load and full cylinder strokes. Position the dipper arm and bucket cylinders so that any air collects at the cylinder's outlet side, that is, it should be the highest point. The piston should be at the opposite end of the cylinder. Wait approx. 1 minute from the time that the cylinder has reached its position before running the piston towards the outlet side. Repeat 3 to 5 times. The boom cylinders, which cannot be pointed downward, must be run in and out approx. 5 times without bucket load.



NOTICE If the cylinders are pressurized either through lifting of the machine or lifting of a load in the bucket, without first performing the mentioned bleeding movements, the seals will likely be damaged. If a cylinder is to be pressure-tested after a repair, the piston rod should be run in and out a few times before increasing the pressure to testing pressure.



Service Information Document Title: Control units, changing



Function Group: 091



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Control units, changing Before changing electronic control unit Volvo CE product specialist should be consulted. NOTE! Before changing a control unit, customer parameters must be read out so that they can be programmed again.



Thank you for your purchase. Have a nice day.



file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/7/14 8:52:15]



Service Information Document Title: Recommended lubricants



Function Group: 160



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Recommended lubricants The Volvo lubricants have been specially developed to fulfil the demanding operating conditions, in which Volvo excavators are used in. The oils have been tested according to Volvo excavator specifications and therefore meet the high requirements for safety and quality. Other mineral oils can be used if they conform to our viscosity recommendations and meet our quality requirements. The approval of Volvo is required, if any other oil base quality (for example biologically degradable oil) is to be used. System



Oil grade



Recommended viscosity at varying ambient temperature °C °F



Engine



-30 -22



-20 -4



-10 +14



Engine oil see page 160 Engine oil.



0 +32



+10 +50



+20 +68



+30 +86



+40 +104



SAE 10W/30 SAE 15W/40 SAE 10W/40 SAE 5W/30 SAE 5W/40 SAE 30 SAE 40



Engine_Air pump



Volvo compressor oil (P/N: 85108974)



Track gearbox



Gear oil (with EP** additive) API GL4 or GL5



*SAE 90



Swing gearbox



Gear oil (with EP** additive) API GL4 or GL5



*SAE 90



SAE 140 SAE 140



Swing ring gear Grease (Bath and Ball) Hydraulic system



Multi purpose EP** grease NLGI 2



Hydraulic oil (Anti-wear hydraulic oil with high viscosity index 160 or more)



ISO VG32 HV



Bio oil (based synthetic ester)***



Bio oil VG32



ISO VG46 HV ISO VG68 HV



on



Bio oil VG46



Long life hydraulic oil



ISO VG32 ISO VG46 ISO VG68



Pin and bushing



Grease (Multi purpose EP** grease NLGI 2)



Fuel



Diesel fuel



*ISO-L-XBCFB2 ASTM D975 No.1 *ASTM D975 No. 2



Cooling system



Volvo Coolant VCS



Air conditioner Refrigerant system



Volvo Coolant VCS should be used only, see page 160 Coolant. HFC R134a



+50 +122



°C °F



-30 -22



-20 -4



-10 +14



0 +32



+10 +50



+20 +68



+30 +86



+40 +50 +104 +122



* : Installed at factory. EP** : Extreme Pressure *** : If the machine is filled with Volvo Biodegradable hydraulic oil this oil must also be used when filing and changing. The mineral oil content in bio oil should not exceed 2%. if changing from mineral oil to bio oil. contact a workshop authorised by Volvo. NOTE! When starting the engine in an ambient temperature of lower than 0°C, be sure to use engine oil of SAE 5W-30, SAE 10W-30 and SAE 15W-40, even though the ambient temperature goes up to 10°C more or less in the day time. NOTE! The fuel should at least meet the legal requirement, and national and international standards for marketed fuels, for example : EN590 (with nationally adapted temperature requirements), ASTM D975 No 1-D and No 2-D, JIS KK 2204. NOTE! The content of Volvo coolant must not be less than 40% of the total mixture.



Service Information Document Title: Specification, capacities



Function Group: filling 160



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Specification, filling capacities Oils and other liquids



Change capacities



Engine oil, including filter



55 litres (14.5 US gal.)



Coolant



60 litres (16 US gal.)



Hydraulic tank



270 litres (71 US gal.)



Hydraulic system, total



525 litres (139 US gal.)



Swing gearbox (each)



6 litres (1.6 US gal.)



Track gearbox (each)



8 litres (2.1 US gal.)



Fuel tank



685 litres (181 US gal.)



Swing ring gear



45 litres (11.8 US gal.)



Oil bath precleaner



8.5 litres (2.25 US gal.)



Air pump oil



0.045 litres (0.012 US gal.)



Date: 2014/7/14



Service Information Document Title: Engine oil



Function Group: 160



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Engine oil An engine oil of quality class VDS-4 is mandatory for Tier4i/StageⅢB machines, due to its low content of substances that would otherwise clog the diesel particulate filter. The table below shows the oil drain interval valid for the engine. Sulphur content in the fuel, ppm (10000 ppm = 1%) Oil grade



< 15



15 - 500



Oil changing interval Volvo Ultra Diesel 500 hours Engine Oil, VDS-4 or other VDS-4 approved engine oil



Not applicable



ACEA: E9 API: CJ-4



Not applicable



 



250 hours



ACEA: European Automobile Manufacturers Association API: American Petroleum Institute



500 - 3000



3000 - 5000



> 5000



Service Information Document Title: Fuel



Function Group: 160



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Fuel Quality requirements The fuel should at least meet the legal requirements, and national and international standards for marketed fuels, for example: EN590 (with nationally adapted temperature requirements), ASTM D 975 No. 1D and 2D, JIS KK 2204. Fuel specification varies according to the working temperature. Please contact authorized Volvo dear.



Sulphur content According to current USA legal requirement, the sulphur content in the diesel fuel must not exceed 0.0015 percent (15 ppm) by weight. According to current EU legal requirements, the sulphur content in the diesel fuel must not exceed 0.001 percent (10 ppm) by weight. See page Service and maintenance, Engine, Engine oil, changing.



Bio-diesel fuel Vegetable oils and / or esters, also called “bio-diesel”, (e.g. rape-seed methyl ester RME fuel), which are offered on certain markets both as pure products and as mixed into the diesel fuel. Volvo Construction Equipment accepts a maximum intermix of 7% bio-diesel fuel in the diesel fuel, ready mixed from the oil companies. A higher intermix than 7% of bio-diesel fuel may cause:        



Increased emission by nitrogen oxide, (thereby not meeting legal requirements) Shorter service life of engine and injection system Increased fuel consumption Altered engine output Shortening the engine oil change interval to a half Shortened service life of rubber materials in the fuel system Less good cold handling properties of the fuel Limit storage time for the fuel, which may cause clogging up of the fuel system if the machine is laid up for longer periods



Warranty condition The warranty does not cover damage caused be an intermix of more than 7% of bio-diesel fuel.



Service Information Document Title: Function Group: Coolant with freezing and 160 corrosion protection



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Coolant with freezing and corrosion protection Anti-freeze Check the anti-freeze every 2000 hours. At delivery, the cooling system is filled with a mixture of 50% water and 50% Volvo Construction Equipment concentrated coolant with freezing protection down to -35 °C (-31 °F). If there's a risk that the ambient temperature drops below this temperature, the freezing protection should be adjusted, see below. Corrosion protection Volvo Construction Equipment concentrated coolant contains active corrosion protection additives to protect engine and radiator. These additives have a limited service life. Therefore, change the coolant every 6000 hours. NOTE! Volvo Construction Equipment concentrated coolant may not be mixed with other brands of coolant or additives. Mixing could have negative effects. The content of concentrated coolant with anti-freeze protection may not be below 40%. 40% provides protection against freezing down to -25 °C (-13 °F). 50% provides protection against freezing down to -35 °C (-31 °F).



Service Information Document Title: Service



Function Group: 170



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Service For the machine to operate safely and at the lowest possible cost, it must receive thorough and complete maintenance. Intervals for maintenance and lubrication refer to normal operating and environmental conditions. Maintenance work is described in the Operator's manual and the manual "Service and maintenance" as well as the Service program. Service program The checking boxes in the service program show what type of service should be done for intervals from every 10 hours up to and incl. 4000 hours. The service intervals from and incl. 4500 hours only contain the additional service points that are to be done at each interval. The additional service points that are to be done at the first 500 hours are presented in the same way. Time Guide The Time Guide for service intervals for every 10 hours up to and incl. 4000 hours shows time for the total service. Intervals from and incl. 4500 hours only show time for the additional service points. Example, 4500 hour interval: Do all maintenance according to the standard interval every 500 hours and also do the extra interval 4500 hours. Follow the same example at the first 500 hours.



Service Information Document Title: Replacement parts



Function Group: 170



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Replacement parts For reference when ordering replacement parts or making service inquires, record the model and serial numbers of your machine. They are stamped on the serial number plate positioned under the boom on the superstructure frame.



Service Information Document Title: Service methods



Function Group: 170



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Service methods Appropriate service methods and proper repair procedures are essential for safe, reliable operation of the machines and safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will assure reliability. There are many variations in procedures, techniques, tools and parts for servicing machines, as well as work skills. This manual cannot possibly anticipate all such variations and provide advice or cautions for each one. Accordingly, anyone who intends to depart from the instructions in this manual must first consider personal safety and then machine integrity. NOTE! Volvo CE recommends the use of environmentally sound waste storage and disposal practises. Never drain fluids on the ground or into a sewer or catch basin. Use suitable collection containers, then store and/or dispose of waste products in an approved and safe manner. Check and obey all federal, state and/or local regulations regarding waste storage, disposal and recycling.



Service Information Document Title: Bearings



Function Group: 170



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Bearings Removal Bearings should never be removed unless absolutely necessary. Always use the recommended puller to reduce the risk of bearing or related component damage. When bearings or bushing are removed, check that the bearings is free from discoloration, nicks, scuffing and signs of overheating. If in doubt, replace the bearing or bushing. Cleaning Bearings acceptable for service should be cleaned in a suitable solvent and immersed in a clean lubricating oil until needed. Installation Be sure bearings are installed with care during servicing, maintenance and repair. All bearings on this machine are installed as a press fit. When possible, always install the bearing into the rotating part first. Use the proper tools or a press when installing a bearing or bushing. In the absence of the proper tools or a press, cool the bearings and/or heat casing to assist in the installation.



Service Information Document Title: Hoses and tubes



Function Group: 170



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Hoses and tubes Inspection If the hose end connections are damaged, always replace hoses and tubes. Damaged, dented, crushed or leaking hose fittings restrict oil flow and the operation of the parts being served. Be sure hoses are in good condition. If in doubt, replace them. Replace hoses if the following occur:    



chafed outer cover concealed corrosion of wire reinforcement ballooning (replace immediately!) kinked, crushed, stretched or deformed.



Installation When installing a new hose, loosely connect each end and take the designed position before tightening the connection. Hoses must be tightened using two wrenches. One is used to tighten the swivel nut, the other to ensure the hose flexible part is not twisted. Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing. If a hose is replaced on a moving part, be sure it does not foul by moving the part through its complete range of travel. Be sure any hose which has been installed is not kinked, twisted or exposed to any sharp edges. Free moving, unsupported hoses must never touch each other or related work surfaces. This causes chafing, reducing hose life.



Service Information Document Title: Pressure testing



Function Group: 170



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Pressure testing 1. 2. 3.



Prior to pressure testing, be sure all hoses are in good condition and all fittings are tight. Use a pressure gauge with a range that is high enough to measure the specified pressure. Comply with the correct procedure to prevent damage to the system or the equipment and to eliminate the possibility of injury.



Service Information Document Title: Cleaning prior to repair



Function Group: 170



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Cleaning prior to repair Clean the exterior of all parts before repairing. Dirt and abrasive dust reduce the efficient work life of the part and lead to costly replacement. Use cleaning fluids and solvents which are suitable for cleaning parts and do not risk the safety of the user. Certain types of fluids damage rubber parts and/or cause skin irritation. The following precautions must be observed to insure hydraulic cleanliness: 1. 2. 3. 4. 5. 6.



Flush hose and tube assemblies with a solvent compatible with hose assemblies. Blow out excess solvent with shop air. Cap hydraulic fittings and protect threads until installation. Cap hoses and tube assemblies until installation. Flush hydraulic reservoir, fuel tank and chain case housings with a suitable solvent to remove any foreign debris. Protect system components from airborne contaminants. Plug all cylinder, valve, reservoir, tank and pump openings until installation. Use clean, filtered motor oil when filling the system. See 160 Recommended lubricants



Service Information Document Title: VCADS Pro, Operations



Function Group: 170



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



VCADS Pro, Operations The following VCADS Pro operations are available for function group 1. Operations used when changing or working on components are mandatory. Tests Operation



Application



17012-3 Error codes



Used when there is a suspicion of fault and/or at abnormal values/ readings.



17034-3 Vehicle information, test



Read out vehicle information



Programming Operation



Application



17030-3 Parameter, programming



When changing parameters.



17055-3 Central systems, updating, replace When replacing ECU by conversion kit. control unit 17056-3 Central systems, updating, change When replacing software by conversion kit. software



Service Information Document Title: Function Group: Maintenance service, first 173 500 hours



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Maintenance service, first 500 hours Op nbr 173-040 1. 173 Hydraulic oil servo filter, change 2. 173 Hydraulic oil return filter, changing 3. 173 Hydraulic oil drain filter, change 4. 173 Swing motor gearbox, changing oil 5. 173 Track gearbox oil, change 6. 173 Service history (included in the respective Operator's manual), fill in.



Date: 2014/7/14



Service Information Document Title: Maintenance service, daily



Function Group: 173



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Maintenance service, daily Op nbr 173-002 1. 173 Test-run and check 2. 173 The machine, check for external damages, cracks and wear damages 3. 173 Track shoe bolts, check



Date: 2014/7/14



Service Information Document Title: Function Group: Maintenance service, every 173 50 hours



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Maintenance service, every 50 hours Op nbr 173-004 The service points where "optional equipment" is stated are not included in the accounted time for the interval. 1. 173 Test-run and check 2. 173 The machine, check for external damages, cracks and wear damages 3. 173 Washer fluid level, check 4. 173 Engine, oil level, check 5. 173 Coolant level, check 6. 173 Hydraulic oil level, check 7. 173 Water separator, check/drain 8. 173 Fuel tank sediment, drain 9. 173 Lubrication, see lubrication chart 10. 173 Track shoe bolts, check 11. 173 Oil-bath air cleaner's reservoir (optional equipment), oil, check



Service Information Document Title: Function Group: Maintenance service, every 173 250 hours



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Maintenance service, every 250 hours Op nbr 173-007 The service points where "optional equipment" is stated are not included in the accounted time for the interval. 1. 173 Test-run and check 2. 173 The machine, check for external damages, cracks and wear damages 3. 173 Washer fluid level, check 4. 173 Engine, oil level, check 5. 173 Coolant level, check 6. 173 Hydraulic oil level, check 7. 173 Water separator, check/drain 8. 173 Fuel tank sediment, drain 9. 173 Air cleaner primary filter, clean 10. 173 Battery condition, check 11. 173 Cab, prefilter, clean 12. 173 Lubrication, see lubrication chart 13. 173 Swing gearbox oil level, check 14. 173 Swing ring gear bearing, lubricate 15. 173 Track shoe bolts, check 16. 173 Track tension/condition, check 17. 173 Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change



Service Information Document Title: Function Group: Maintenance service, every 173 500 hours



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Maintenance service, every 500 hours Op nbr 173-010 The service points where "optional equipment" is stated are not included in the accounted time for the interval. 1. 173 Test-run and check 2. 173 The machine, check for external damages, cracks and wear damages 3. 173 Washer fluid level, check 4. 173 Engine, oil level, check 5. 173 Coolant level, check 6. 173 Hydraulic oil level, check 7. 173 Engine, oil and filter, change. 8. 173 Fuel filter, change 9. 173 Water separator filter element, change 10. 173 Fuel tank sediment, drain 11. 173 Air cleaner primary filter, clean 12. 173 Battery condition, check 13. 173 Radiator outside, cleaning 14. 173 Hydraulic oil cooler outside, cleaning 15. 173 Air conditioner main filter, clean 16. 173 Cab, prefilter, clean 17. 173 Lubrication, see lubrication chart 18. 173 Swing gearbox oil level, check 19. 173 Swing ring gear bearing, lubricate 20. 173 Track shoe bolts, check 21. 173 Track tension/condition, check 22. 173 Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change



23. 173 X1 return filter (optional equipment), change 24. 173 Service history (included in the respective Operator's manual), fill in.



Service Information Document Title: Function Group: Maintenance service, every 173 1000 hours



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Maintenance service, every 1000 hours Op nbr 173-012 The service points where "optional equipment" is stated are not included in the accounted time for the interval. 1. 173 Test-run and check 2. 173 MATRIS, reading, export reading 3. 173 VCADS Pro, logged errors, read off 4. 173 The machine, check for external damages, cracks and wear damages 5. 173 Washer fluid level, check 6. 173 Engine, oil level, check 7. 173 Coolant level, check 8. 173 Hydraulic oil level, check 9. 173 Engine, oil and filter, change. 10. 173 Fuel filter, change 11. 173 Water separator filter element, change 12. 173 Fuel tank sediment, drain 13. 173 Hydraulic oil servo filter, change 14. 173 Air cleaner primary filter, clean 15. 173 Battery condition, check 16. 173 Belts and belt tension, check, replace when needed. 17. 173 Radiator outside, cleaning 18. 173 Hydraulic oil cooler outside, cleaning 19. 173 Hydraulic oil drain filter, change 20. 173 Air conditioner main filter, clean 21. 173 Cab, prefilter, clean 22. 173 Lubrication, see lubrication chart



23. 173 Swing motor gearbox, changing oil 24. 173 Swing ring gear bearing, lubricate 25. 173 Swing bath grease, check 26. 173 Cab; door, covers, hinges, joints and locks, lubricate 27. 173 Track shoe bolts, check 28. 173 Track tension/condition, check 29. 173 Track gearbox oil level, check 30. 173 Loose and loss of bolts, check 31. 173 Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change 32. 173 X1 return filter (optional equipment), change 33. 173 Service history (included in the respective Operator's manual), fill in.



Service Information Document Title: Function Group: Maintenance service, every 173 2000 hours



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Maintenance service, every 2000 hours Op nbr 173-014 The service points where "optional equipment" is stated are not included in the accounted time for the interval. 1. 173 Test-run and check 2. 173 MATRIS, reading, export reading 3. 173 VCADS Pro, logged errors, read off 4. 173 The machine, check for external damages, cracks and wear damages 5. 173 Washer fluid level, check 6. 173 Engine, oil level, check 7. 173 Coolant level, check 8. 173 Hydraulic oil level, check 9. 173 Engine, oil and filter, change. 10. 173 Fuel filter, change 11. 173 Water separator filter element, change 12. 173 Fuel tank sediment, drain 13. 173 Fuel tank air ventilation filter, change 14. 173 Hydraulic oil servo filter, change 15. 173 Air cleaner primary filter, change 16. 173 Battery condition, check 17. 173 Belts and belt tension, check, replace when needed. 18. 173 Radiator outside, cleaning 19. 173 Hydraulic oil cooler outside, cleaning 20. 173 Hydraulic oil return filter, changing 21. 173 Hydraulic oil drain filter, change 22. 173 Hydraulic oil suction strainer, clean



23. 173 Hydraulic tank breather filter, change 24. 173 Hydraulic system, changing oil 25. 173 Coolant's freezing point, check 26. 173 Air dryer cartridge, change 27. 173 Venturi tube, check 28. 173 Air conditioner main filter, change 29. 173 Cab, prefilter, replace 30. 173 Lubrication, see lubrication chart 31. 173 Swing motor gearbox, changing oil 32. 173 Swing ring gear bearing, lubricate 33. 173 Swing bath grease, check 34. 173 Cab; door, covers, hinges, joints and locks, lubricate 35. 173 Track shoe bolts, check 36. 173 Track tension/condition, check 37. 173 Track gearbox oil, change 38. 173 Loose and loss of bolts, check 39. 173 Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change 40. 173 Oil-bath air cleaner's reservoir (optional equipment), filter insert, clean 41. 173 X1 return filter (optional equipment), change 42. 173 Service history (included in the respective Operator's manual), fill in.



Service Information Document Title: Function Group: Maintenance service, every 173 4000 hours



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Maintenance service, every 4000 hours Op nbr 173-018 The service points where "optional equipment" is stated are not included in the accounted time for the interval. 1. 173 Test-run and check 2. 173 MATRIS, reading, export reading 3. 173 VCADS Pro, logged errors, read off 4. 173 The machine, check for external damages, cracks and wear damages 5. 173 Washer fluid level, check 6. 173 Engine, oil level, check 7. 173 Coolant level, check 8. 173 Hydraulic oil level, check 9. 173 Engine, oil and filter, change. 10. 173 Fuel filter, change 11. 173 Water separator filter element, change 12. 173 Fuel tank sediment, drain 13. 173 Fuel tank air ventilation filter, change 14. 173 Hydraulic oil servo filter, change 15. 173 Air cleaner primary filter, change 16. 173 Air cleaner secondary filter, change 17. 173 Battery condition, check 18. 173 Belts and belt tension, check, replace when needed. 19. 173 Radiator outside, cleaning 20. 173 Hydraulic oil cooler outside, cleaning 21. 173 Hydraulic oil return filter, changing 22. 173 Hydraulic oil drain filter, change



23. 173 Hydraulic oil suction strainer, clean 24. 173 Hydraulic tank breather filter, change 25. 173 Hydraulic system, changing oil 26. 173 Valve clearance, check/adjust 27. 173 Coolant's freezing point, check 28. 173 Air dryer cartridge, change 29. 173 Venturi tube, check 30. 173 Air conditioner main filter, change 31. 173 Cab, prefilter, replace 32. 173 Lubrication, see lubrication chart 33. 173 Swing motor gearbox, changing oil 34. 173 Swing ring gear bearing, lubricate 35. 173 Swing bath grease, check 36. 173 Cab; door, covers, hinges, joints and locks, lubricate 37. 173 Track shoe bolts, check 38. 173 Track tension/condition, check 39. 173 Track gearbox oil, change 40. 173 Loose and loss of bolts, check 41. 173 Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change 42. 173 Oil-bath air cleaner's reservoir (optional equipment), filter insert, clean 43. 173 X1 return filter (optional equipment), change 44. 173 Service history (included in the respective Operator's manual), fill in.



Service Information Document Title: Function Group: Maintenance service, every 173 4500 hours



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Maintenance service, every 4500 hours This interval only contains the methods that supplement the relevant standard interval. See example in Foreword,. 170 Service Op nbr 173-019 1. 173 Diesel particulate filter, check and clean 2. 173 Air pump oil level, check 3. 173 Spark plugs, replacing 4. 173 Service history (included in the respective Operator's manual), fill in.



Service Information Document Title: Function Group: Maintenance service, every 173 6000 hours



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Maintenance service, every 6000 hours This interval only contains the methods that supplement the relevant standard interval. See example in Foreword, 170 Service. Op nbr 173-022 1. 173 Coolant, change 2. 173 Service history (included in the respective Operator's manual), fill in.



Service Information Document Title: Function Group: Maintenance service, every 173 8000 hours



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Maintenance service, every 8000 hours This interval only contains the methods that supplement the relevant standard interval. See example in Foreword, 170 Service. Op nbr 173-024 1. 173 Spark plug cable, replacing 2. 173 Service history (included in the respective Operator's manual), fill in.



Service Information Document Title: Function Group: Maintenance service, every 173 12000 hours



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Maintenance service, every 12000 hours This interval only contains the methods that supplement the relevant standard interval. See example in Foreword, 170 Service. Op nbr 173-028 1. 173 Air pump oil, change 2. 173 Service history (included in the respective Operator's manual), fill in.



Service Information Document Title: Test-run and check



Function Group: 173



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Test-run and check Op nbr This is part of other procedure 1. Start and stop function (including preheating function) 2. Instruments 3. Lighting 4. Direction indicators 5. Hazard flasher 6. Wipers 7. Washers 8. Horn 9. Rear view mirror 10. Decal/Plates and reflectors 11. Warning system 12. Tanks, hoses and pipes, check for leaks, clamping and scuffing 13. Climate control systems, check function 14. Access routes for maintenance



Date: 2014/7/14



Service Information Document Title: Function Group: MATRIS, reading, export 173 reading



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MATRIS, reading, export reading Op nbr This is part of other procedure Matris read-off is performed to follow up the machine's history



1. Figure 1 Service equipment connection, location behind the seat to the right 1.



Cover



Pull out the cover from the service socket. 2. Connect the Matris equipment to service socket and check the machine history. 3. Export the machine information.



Date: 2014/7/14



Service Information Document Title: Function Group: VCADS Pro, logged errors, 173 read off



Information Type: Service Information



Profile: EXC, EC480D L [GB]



VCADS Pro, logged errors, read off Op nbr This is part of other procedure



1. Figure 1 Service equipment connection, location behind the seat to the right 1.



Cover



Pull out the cover from the service socket. 2. Connect the VCADS Pro-computer to service socket and read out logged errors.



Date: 2014/7/14



Service Information Document Title: Function Group: The machine, check for 173 external damages, cracks and wear damages



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



The machine, check for external damages, cracks and wear damages Op nbr This is part of other procedure. 1. Check the superstructure, undercarriage and attachment are free from external damages, crack and wear damages.



Service Information Document Title: Washer fluid level, check



Function Group: 173



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Washer fluid level, check Op nbr This is part of other procedure. 1. Open the side door on the left side of the machine. 2. Check the washer fluid level and add washer fluid as needed.



Figure 1



Date: 2014/7/14



Service Information Document Title: Engine, oil level, check



Function Group: 173



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Engine, oil level, check Op nbr This is part of other procedure. 1. Open the engine hood. 2. Pull out the dipstick and wipe it with a clean cloth.



Figure 1



1. 2.



Dipstick Engine oil filler port



3. Push it in and pull it out again. 4. Check the oil level and refill to proper oil through the filler port if the oil level is low.



Date: 2014/7/14



Service Information Document Title: Coolant level, check



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Coolant level, check Op nbr This is part of other procedure. 1. Open the engine hood of the machine. 2. Inspect the coolant level in the expansion tank. The level should be between the MAX and MIN marks on the expansion tank.



Figure 1 Checking, coolant level NOTE! The coolant level should be checked after the engine has been run until warm and then cooled down.



Service Information Document Title: Hydraulic oil level, check



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Hydraulic oil level, check Op nbr This is part of other procedure. 1. Park the machine on the firm and level ground. 2. Place the machine in service position C. See 091 Service positions. 3. Move the control lockout lever down to lock the system securely and stop the engine. 4. Open the side door on the right side of the machine and check the oil level in the sight gauge.



Figure 1 NOTE! If the level is between lower limit line and upper limit line of the gauge, the level is correct. NOTE! If the level is low, open the cover on the tank and add hydraulic oil.



Service Information Document Title: Function Group: Engine, changing oil and 173 filter



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Engine, changing oil and filter Op nbr 173-059 88830167 Oil filter wrench



Draining



NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. NOTE! Drain the oil when the engine is warm.



WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. 1. Start the engine and warm it for two minutes. 2. Loosen the screws and open the under cover.



Figure 1



3. Open the oil drain valve cap and install the engine oil drain hose and then allow the oil to drain from the engine into a suitable collection container.



Figure 2



1. 2.



Oil drain valve cap Engine oil drain hose



4. Change the oil filter using a filter wrench (tool part no.: 88830167), fill the new oil filter with engine oil. Clean the filter housing base. Make sure all of the old filter gasket is removed. NOTE! Apply a light coat of the engine oil to the gasket of the new filter. Screw the filter in place until the gasket just touches the sealing surface. Tighten another 1/2 turn by hand. NOTE! Dispose of waste oil and used oil filters in an environmentally safe manner.



Figure 3



1. 2.



Oil filter Bypass filter



Filling 5. Fill the engine oil through the engine oil filling port



Figure 4



1. 2.



Dipstick gauge Engine oil filling port cap



NOTE! Engine Oil capacity: see 160 Specification, filling capacities. 6. Warm up the engine and check that there is no oil leakage. 7. Check the oil level on the dipstick. 8. Install the under cover.



Service Information Document Title: Fuel filter, change



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Fuel filter, change This is part of other procedure Op nbr 9996672 Oil filter wrench



A reduction in engine power can be caused by a clogged fuel filter. If the filter becomes clogged quickly, check fuel for contamination and clean fuel tank if necessary. 1. Loosen the fuel filter with a 9996672 Oil filter wrench, and remove.



Figure 1 Removal, filter 1. 2.



Fuel filter Filter wrench (Tool part no: 9996672)



2. Clean the sealing surface of the filter head. 3. Lightly oil the rubber seal of the new filter, or moisten with diesel fuel. 4. Screw on the filter by hand until the seal makes contact, then tighten another half turn. 5. Perform the air bleeding operation. See 233 Fuel system, bleeding



Service Information Document Title: Water separator element, change



Function Group: filter 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Water separator filter element, change Op nbr 9996672 Oil filter wrench 11666167 Disassembly tool



This is part of other procedure. NOTE! A reduction in engine power can be caused by a clogged fuel filter. if the filter becomes clogged quickly, check fuel for contamination and clean fuel tank if necessary. 1. Disconnect the wire harness connector.



Figure 1



1.



Wire harness connector



2. Loosen the drain valve to drain the sediment from the water separator bowl.



Figure 2



3. Loosen the fuel separator bowl with a 11666167 Disassembly tool, and remove. 4. Loosen the fuel separator filter with a 9996672 Oil filter wrench, and remove. 5. Clean the sealing surface of the filter head. 6. Lightly oil the rubber seal of the new filter, or moisten with diesel fuel. 7. Screw on the filter by hand until the seal makes contact, then tighten another half turn. 8. Screw on the filter bowl by hand until the seal makes contact, then tighten another half turn. 9. Perform air bleeding operation. See 233 Fuel system, bleeding.



Service Information Document Title: Fuel tank sediment, drain



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Fuel tank sediment, drain Op nbr This is part of other procedure. 1. Swing machine to the right about 45°~60°. 2. Open the drain valve and allow the water and sediment to drain into a suitable container. NOTE! The fuel tank drain valve is located underneath the fuel tank.



Figure 1 NOTE! Dispose of drained fluids according to local regulations.



Service Information Document Title: Function Group: Fuel tank air ventilation 173 filter, change



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Fuel tank air ventilation filter, change Op nbr This is part of other procedure. 1. Remove the screws and the fuel tank air ventilation filter cap.



Figure 1



1. 2.



Screw Fuel tank ventilation filter cap



2. Remove the clamping screw and the fuel tank air ventilation filter.



Figure 2



1. 2.



Clamping screw Fuel tank ventilation filter



Date: 2014/7/14



3. Install a new fuel tank air ventilation filter with a rubber connector.



Figure 3



1. 2.



Fuel tank ventilation filter Rubber connector



4. Install the clamping screw and the fuel tank air ventilation filter cap.



Service Information Document Title: Function Group: Hydraulic oil servo filter, 173 change



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Hydraulic oil servo filter, change Op nbr This is part of other procedure NOTE! Replace the element for the servo hydraulic filter after the first 500 hours and then every 1000 hours. 1. Open the side door on the left side of the machine. 2. Place a container under the filter. Remove the filter bowl.



Figure 1



3. Replace the inner element of the servo hydraulic filter. 4. Reinstall the filter bowl.



Service Information Document Title: Function Group: Air cleaner primary filter, 173 clean



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Air cleaner primary filter, clean Op nbr This is part of other procedure. 1. Open the side door on the left side of the machine. 2. Open the air cleaner cover. 3. Pull out the air cleaner primary filter and carefully tap the end of the filter against a soft and clean surface.



Figure 1



4. Clean the filter using clean and dry compressed air with a max. pressure of 500 kPa (5 bar) (73 psi). NOTE! If there is the smallest hole, scratch, crack or other damage, the filter must be replace with a new one. 5. Install the primary filter and the cover. 6. Close the side door.



Service Information Document Title: Function Group: Air cleaner primary filter, 173 change



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Air cleaner primary filter, change Op nbr This is part of other procedure. NOTE! Replace the primary filter after cleaning 5 times maximum, or at least once every year. 1. Open the side door on the left side of the machine. 2. Open the air cleaner cover. 3. Remove the air cleaner primary filter and clean the filter housing.



Figure 1



4. Install a new primary filter 5. Close the air cleaner cover and the side door.



Date: 2014/7/14



Service Information Document Title: Function Group: Air cleaner secondary filter, 173 change



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Air cleaner secondary filter, change Op nbr This is part of other procedure. NOTE! Replace the secondary air filter every 3rd primary filter replacement, or at least every 2 years. 1. Open the side door on the left side of the machine. 2. Open the air cleaner cover. 3. Remove the air cleaner primary filter.



Figure 1



4. Remove the air cleaner secondary filter and clean the filter housing



Figure 2



5. Install a new secondary filter and the primary filter 6. Close the air cleaner cover and the side door.



Date: 2014/7/14



Service Information Document Title: Battery condition, check



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Battery condition, check Op nbr This is part of other procedure.



WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately. Wash the affected area with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention. 1. Open the cover for the battery disconnect switch on the right side of the machine.



Figure 1



2. Ensure the battery disconnect switch is at off position.



Figure 2



3. Open the cover of the battery box on the right side of the machine.



Figure 3



4. Remove the toolbox bracket.



Figure 4



1.



Toolbox bracket



5. Remove the battery cover.



Figure 5



1.



Battery cover



6. Remove the battery cap. The electrolyte level should stand approximately 10 mm (0.4 in) above the cell plates.



Figure 6



1.



Battery cap



7. Top up with distilled water when required. 8. Operate the machine after toping up, so that the water is mixed in with the battery electrolyte. This is more important in cold weather. 9. Check that cable terminals and pole studs are clean, tight, and coated with petroleum jelly or similar product.



Service Information Document Title: Function Group: Belts and belt tension, 173 check, replace when needed.



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Belts and belt tension, check, replace when needed. This is part of other procedure. Op nbr 1. Open the engine hood. 2. Inspect tension, cracks, wear or damage of the belts. 263 Fan belt and/or alternator-, compressor belt, replacing all belts.



Figure 1



1. 2. 3. 4.



Fan belt Air pump belt Alternator/compressor belt Tensioner



3. Close the engine hood.



If



damaged



replace



the



belts.



See



Service Information Document Title: Radiator outside, cleaning



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Radiator outside, cleaning Op nbr This is part of other procedure.



WARNING Compressed air. Never direct to bare skin. Use protective equipment. 1. Open the left side door of the machine. 2. Remove the wing-nuts and the 2 radiator screens.



Figure 1 Removal, radiator screen 3. Clean the radiator and the charge air cooler outside with compressed air flow or steam.



Figure 2 Cleaning, radiator and charge air cooler outside NOTE! If there is a large amount of contamination on the fins, apply detergent, thoroughly clean and rinse with tap water.



Service Information Document Title: Hydraulic oil outside, cleaning



Function Group: cooler 173



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Hydraulic oil cooler outside, cleaning Op nbr This is part of other procedure.



WARNING Compressed air. Never direct to bare skin. Use protective equipment. 1. Open the left side door of the machine. 2. Remove the two screws of the cover.



Figure 1



1.



Screw



3. Remove the screws and the cover.



Figure 2



Date: 2014/7/14



1. 2.



Screw Cover



4. Remove the wing-nuts and the screen in front of the hydraulic oil cooler.



Figure 3



1. 2.



Wing-nut Screen



5. Clean the hydraulic oil cooler with compressed air flow or steam.



Figure 4 Cleaning, hydraulic oil cooler outside



Service Information Document Title: Function Group: Hydraulic oil tank, return 173 oil filter change



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Hydraulic oil tank, return oil filter change Op nbr 173-076 NOTE! When using the hydraulic hammer, refer to the table below for changing the return filter. Frequency of hammer use



Change interval



50%



every 1000 hours



100%



every 500 hours



NOTE! Filling hydraulic oil or other system service requires great cleanliness. Even the smallest particles can damage the system or cause system failure. Clean the filling area before filling the hydraulic oil tank with new oil. 1. Release the residual pressure in the hydraulic oil tank from the breather. 2. Remove the screws and the cover.



Figure 1



1. 2.



Screw Cover



3. Remove the spring, valve, strainer and the filter element.



Figure 2



1. 2. 3. 4.



Filter element Strainer Valve Spring



4. Install a new filter element, strainer, valve and spring.



Figure 3



A.



Blank area



NOTE! Make sure blank area (A) of the filter faces toward lower direction when installing. 5. Install the cover. NOTE! Use only a new O-ring if replacing it.



Service Information Document Title: Function Group: Hydraulic oil drain filter, 173 change



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Hydraulic oil drain filter, change This is part of other procedure Op nbr 88830167 Oil filter wrench



NOTE! Replace the cartridge for the drain filter after first 500 hours and then every 1000 hours. 1. Place a container under the drain filter, and turn the filter counterclockwise to remove it.



Figure 1



2. Fill the new filter with oil, thinly coat O-ring with oil. 3. Install the new filter.



CAUTION Take care of filters, oils and liquids in an environmentally safe way.



CAUTION Take care of filters, oils and liquids in an environmentally safe way.



Service Information Document Title: Hydraulic oil strainer, clean



Function Group: suction 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Hydraulic oil suction strainer, clean Op nbr This is part of other procedure. NOTE! Clean every 2000 hours and replace it if necessary. 1. Release the residual pressure in the hydraulic oil tank from the breather. 2. Remove the cover.



Figure 1



3. Take out the suction strainer. Clean it with non-flammable solvent and dry with compressed air.



Figure 2



4. Install the suction strainer. NOTE! If the suction strainer has any damage (even minor damage), it must be replaced with a new one. NOTE!



Use only a new O-ring if replacing it. 5. Install the cover.



Service Information Document Title: Function Group: Hydraulic oil tank, 173 changing breather filter



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Hydraulic oil tank, changing breather filter Op nbr 173-077 1. Release the residual pressure in the hydraulic oil tank from the breather. 2. Align the locking hole to a horizontal using a (-) screwdriver and remove the breather cap.



Figure 1



1. 2.



(-) screwdriver Breather cap



3. Remove the snap ring, valve and the breather filter element.



Figure 2



1. 2.



Snap ring Breather



1. 2. 3. 4.



Snap ring Breather valve Breather filter Spring



4. Install new breather filter, the valve and snap ring. 5. Push and rotate filter cover, and then align the locking hole to a vertical direction to lock the cover using a (-) screwdriver.



Service Information Document Title: Hydraulic oil changing oil



Function Group: tank, 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Hydraulic oil tank, changing oil Op nbr 173-073



NOTICE Use the same hydraulic oil that is already in the system. The hydraulic system may be damaged if different brands of hydraulic oil are mixed. NOTE! Refer to the table below for changing the hydraulic oil. Hydraulic oil



Change interval



Mineral oil



every 2000 hours



Bio oil



every 5000 hours



Long life hydraulic oil



every 5000 hours



NOTE! When using the hydraulic hammer, refer to the table below for changing the hydraulic oil. Frequency of hammer use



Change interval



50%



every 1000 hours



100%



every 600 hours



NOTE! Filling hydraulic oil and system service requires great cleanliness. Even the smallest particles can damage the system or cause system failure. Clean the filling area before filling the hydraulic oil tank with new oil. 1. Release the residual pressure in the hydraulic oil tank from the breather.



Figure 1



2. Place the machine in the service position C. See 091 Service positions. 3. Install the oil drain hose. Drain the oil into a suitable sized container.



Figure 2



1.



Oil drain hose



NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. 4. Refill the hydraulic tank, pour the oil through the filling port on the cover.



Figure 3 NOTE! Refill capacity: see 160 Specification, filling capacities. 5. Push down the breather to release the residual pressure again. 6. Check the oil level. See 173 Hydraulic oil level, check. 7. Perform a test run procedure to check for any leaks. 8. Remove the oil drain hose and close the cover on the bottom.



Service Information Document Title: Valves, adjusting



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Valves, adjusting Op nbr 214-012 9993590 Gear wheel



Feeler gauge



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work. 1. Open the engine hood. 2. Remove the screws on the expansion tank bracket.



Figure 1



1.



Screw



3. Loosen the screws on the bracket and move the coolant expansion tank to the MCV side.



Figure 2



1.



Screw



4. Remove the screws and the crankcase ventilation tube.



Figure 3



1. 2.



Screw Ventilation hose



5. Remove the mounting screws and the valve cover.



Figure 4



6. Remove the engine room under cover.



Figure 5



1.



Engine room under cover



7. Remove the screws and the protection cover.



Figure 6



1. 2.



Screw Protection cover



8. Remove the protective cover on the flywheel housing.



Figure 7



9. Install a rotating tool, extension bar and a ratchet handle.



Figure 8



1. 2. 3.



Ratchet Rotating tool Extension bar 9993590 Gear wheel



NOTE! The rotation tool should be turned counterclockwise. 10. Turn the engine until the nearest dash marking on the camshaft is between the marks on the bearing cap. The number matches the cylinder for which the inlet and exhaust valves are in correct position for adjusting.



Figure 9



1. 2.



Inlet valves Exhaust valves



NOTE! Cylinder 1 is closest to the marked end of the camshaft. 11. Loosen the lock nut at the 214 Valve system, specification.



respective



rocker



arm



Tighten the lock nut according to 214 Valve system, specification.



and



adjust



the



clearance



according



to



Figure 10



12. Turn the engine and adjust the rest of the valves in the same way. 13. Install the valve cover and crankcase ventilation tube, see 214 Valve system, specification 14. Close the engine hood. 15. Restore the machine to operating condition.



Service Information Document Title: Water separator, drain



Function Group: check/ 173



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Water separator, check/drain Op nbr This is part of other procedure. 1. Open the side door on the right side of the machine. 2. Check for water and the sediment in the water separator bowl.



Figure 1



1. 2.



Water separator bowl Water drain valve



3. Open the water drain valve and drain off the water and sediment if needed 4. Perform air bleeding operation. See 233 Fuel system, bleeding. 5. Close the side door on the right side of the machine.



Date: 2014/7/14



Service Information Document Title: Coolant, checking freeze resistance



Function Group: anti- 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Coolant, checking anti-freeze resistance Op nbr 261-002 88890105 Refractometer



WARNING Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant may rush out and cause severe burns. 1. Check the freezing protection with 88890105 Refractometer. Open the cover on the refractometer and place a few drops of the coolant on the glass surface. Close the cover and read off the value against strong light source. Read off the value on the ethylene scale. The coolant should be taken from the filling point on the expansion tank.



Figure 1



2. The machine is delivered with a coolant mixture for optimal cooling and corrosion characteristics. That is why the same coolant mixture shall be filled, regardless of ambient temperature conditions. See 160 Coolant and 160 Coolant with freezing and corrosion protection.



Figure 2 NOTE! Volvo Construction Equipment concentrated coolant with anti-freeze must not be mixed with other brands of anti-freeze or additives as this type of mixture could have negative effects.



Service Information Document Title: Coolant, change



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Coolant, change This is part of other procedure Op nbr



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work.



WARNING Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling system.



Draining coolant 1. Open the engine hood and slowly remove the cap from the expansion tank.



Figure 1



1.



Expansion tank cap



2. Open the left side cover. 3. Connect a extension hose to the drain hose installed the machine.



Figure 2 NOTE! Prepare a suitable container. 4. Loosen the drain valve handle and drain off the coolant.



Figure 3



1.



Drain valve



NOTE! The cooling system is not protected from freezing after draining. There may still be pockets of water in the system. NOTE! Handle and take care of waste oil/fluids in an environmentally safe manner. NOTE! The Volvo Construction Equipment Group’s concentrated coolant with anti-freeze must not be mixed with other brands of anti-freeze or additives as this type of mixture could have negative effects. NOTE! Anti-freeze must always be used, see Section 1, Coolant with freezing and corrosion protection, Section S.



Refilling coolant into drained cooling system 5. Refill coolant through the expansion tank. NOTE! Refill capacity: see 160 Specification, filling capacities. NOTE! Fill coolant to 2/3 of the expansion tank volume. 6. Start and run the engine to operating temperature and top up with coolant so that the cooling system is



completely filled with coolant and is free of air. 7. Check the coolant level after the engine has been run to operating temperature and then cooled down. NOTE! Never fill or top up the cooling system with cold coolant when the engine is warm. This can cause cracking of the engine block and the cylinder head.



Service Information Document Title: Air dryer cartridge, change



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Air dryer cartridge, change Op nbr This is part of other procedure 1. Open the under cover. 2. Release the pressure in the air compressed system by pushing up a valve on the air tank.



Figure 1



1. 2. 3.



Air tank Release valve Under cover



3. Open the side door on the right side of the machine. 4. Remove the screws and the thrust collar.



Figure 2



1. 2.



Screw Thrust collar



5. Remove the cartridge with the housing from the valve unit. 6. Turn the cartridge counter clock-wise until a open mark on the filter makes contact with a hole on the housing.



Figure 3



1. 2. 3. 4.



“Open” mark Hole Cartridge Housing



7. Turn the cartridge upside down and take out the filter cartridge



Figure 4



8. Assemble a new cartridge and turn it clock-wise for locking up to the housing. 9. Install the cartridge to the valve unit and then install the thrust collar and the screws. 10. Close the side door. 11. Install the engine room under cover



Service Information Document Title: Air pump oil level, check



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Air pump oil level, check Op nbr This is part of other procedure 1. Open the engine hood. 2. Pull out the dipstick from the air pump oil filling port and wipe it with a clean cloth.



Figure 1



1. 2.



Air pump Oil filling port & dipstick gauge



3. Push it in and pull it out again. 4. Check the oil level and refill to proper oil through the filling port If the oil level is low.



Figure 2



5. Close the engine hood.



Service Information Document Title: Air pump oil, change



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Air pump oil, change Op nbr This is part of other procedure



NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. 1. Open the engine hood. 2. Remove the screws on the air pump oil filling port.



Figure 1



1. 2.



Air pump Oil filling port & dipstick gauge



3. Open the engine room under covers. 4. Open the oil drain port and allow the oil to drain into a suitable collection container.



Figure 2



1.



Oil drain port



5. Close the oil drain port 6. Fill the oil through the oil filling port. NOTE! See 160 Recommended lubricants for oil specification. 7. Check the oil level using the oil level gauge and refill if necessary.



Figure 3



8. Close the engine hood. 9. Install the engine room under covers.



Service Information Document Title: Spark plug, replacing



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Spark plug, replacing Op nbr 254-046 88830188 Measuring tool



DANGER Risk of electrocution. Contact with live parts will cause death or serious injury. Never touch live electrical parts. Carefully follow procedures to de-energize the machine.



WARNING Risk of burns as well as damage to the spark plug cables when removing them before the parts have cooled down. 1. Park the machine in service position B, see 091 Service positions. 2. Switch off the battery disconnect switch. 3. Remove the DPF hood. 4. Disconnect the spark plug cables from the DPF burner.



Figure 1



1. 2. 3. 4.



ASU (After treatment support unit) Clip Spark plug cable DPF burner



5. Remove the spark plugs. Install the 254 Exhaust aftertreatment system, tightening torques.



new



spark



plugs.



Tightening



torque,



see



6. Remove the hose from the nozzle. Remove the nozzle from the burner.



Figure 2



1.



Nozzle



7. Check the gap between the spark plugs' electrodes. Use a flashlight. If the go-side cannot pass, or if the stop-side can, the gap between the spark plugs must be adjusted. NOTE! The tool must be inserted at a slight angle from below.



Figure 3



8.



1.



88830188 Measuring tool



1.



If the spark plug gap is not correct, continue to tighten one spark plug to maximum torque 35 Nm (26 lb ft) and check the gap again. If the gap is still not correct, tighten the second spark plug to 35 Nm (26 lb ft) and check the gap again. If the gap is still not correct, remove both spark plugs, switch their positions, and torque-tighten them to 30 Nm (22 lb ft) and check the gap again.



2. 3.



9. Install the nozzle using a new washer. Tightening torque: 20 Nm (14.8 lb ft). Connect the hose. 10. Restore the machine.



Service Information Document Title: Function Group: EGR Venturi tube, checking 173



Information Type: Service Information



Profile: EXC, EC480D L [GB]



EGR Venturi tube, checking Op nbr 293-003 1. Place the machine in service position 1, see 191 Service position. 2. Remove the connector for the sensor.



Figure 1



1. 2.



Push up the lock lug. Push the lock lug and remove the connector.



3. Remove the tube clamps. Remove the venturi tube (3 screws). 4. Remove the pressure sensor.



Date: 2014/7/14



Figure 2



5. Remove the bracket and the plastic washer.



Figure 3



6. Clean the venturi tube using a small part washer or a soft brush. Clean the tube and bracket channels with e.g. a cable tie. 7. Install news seals on the bracket and on the venturi tube. Install the pressure sensor bracket and plastic washer. Install new O-rings and fit the pressure sensor. 8. Install new seals on the venturi tube and inlet pipe. Install the venturi tube as follows: 1. 2. 3. 4.



Install the upper clamp. Install the lower clamp. Tighten the upper mounting screws. Tighten the lower screw.



Connect the pressure sensor. 9. Restore the machine



Service Information Document Title: Function Group: Air conditioner main filter, 173 clean



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Air conditioner main filter, clean Op nbr This is part of other procedure. 1. Move the operator's seat to the front position, and fold the backrest forward. Remove the floor mat and the cover.



Figure 1 Air conditioner filter, floor mat and cover 2. Disconnect wire harness of the air conditioner actuator. Remove the duct and the upper cover of the air conditioner.



Figure 2 Removal, wire harness, duct and cover NOTE! Refer to the method written at the top of the cover when disassembling the cover.



3. Take out the filter and clean with compressed air with a maximum pressure of 0.2 Mpa (30 psi).



Figure 3 Cleaning, air conditioner filter 4. Restore the machine to the operating condition. NOTE! Pay attention not to damage the parts. NOTE! If the air conditioner filter is clogged, the air flow will be reduced as well as the cooling and heating capacity. Therefore, clean it periodically.



Service Information Document Title: Function Group: Air conditioner main filter, 173 change



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Air conditioner main filter, change Op nbr This is part of other procedure. 1. Move the operator's seat to the front position, and fold the backrest forward. Remove the floor mat and the cover.



Figure 1 Air conditioner filter, floor mat and cover 2. Disconnect wire harness of the air conditioner actuator. Remove the duct and the upper cover of the air conditioner.



Figure 2 Removal, wire harness, duct and cover NOTE! Refer to the method written at the top of the cover when disassembling the cover.



3. Replace the filter with a new one.



Figure 3 Replacement, air conditioner filter 4. Restore the machine to the operating condition. NOTE! Pay attention not to damage the parts. NOTE! If the air conditioner filter is clogged, the air flow will be reduced as well as the cooling and heating capacity. Therefore, clean it periodically.



Service Information Document Title: Cab, prefilter, clean



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Cab, prefilter, clean This is part of other procedure Op nbr 1. Turn the screws counterclockwise using a L wrench (6 mm).



Figure 1



2. Pull the cover out towards rear side and lift up the filter.



Figure 2



3. Clean the prefilter with compressed air with a maximum pressure of 0.2 Mpa (30 psi). NOTE! If the filter is clogged, the air flow will be reduced as well as the cooling and heating capacity. Therefore, clean it periodically.



Service Information Document Title: Cab, prefilter, replace



Function Group: 173



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Cab, prefilter, replace This is part of other procedure Op nbr 1. Turn the screws counterclockwise using a L wrench (6 mm).



Figure 1



2. Pull the cover out towards rear side and lift up the filter.



Figure 2



3. Install a new filter.



Date: 2014/7/14



Service Information Document Title: Function Group: Lubrication, see lubrication 173 chart



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Lubrication, see lubrication chart Op nbr This is part of other procedure 1. Lubricate the attachment (boom, dipper arm, bucket). Follow care and lubrication charts in the Operator's Service and maintenance, Lubrication and service chart, Lubrication and service chart Service and maintenance, Greasing, Excavator unit, greasing.



Manual,



see and



Service Information Document Title: Function Group: Swing gearbox oil level, 173 check



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Swing gearbox oil level, check Op nbr This is part of other procedure. 1. Pull out the oil dipstick gauge and wipe it with a clean cloth. Insert the oil dipstick gauge and pull it out again.



Figure 1



2. Check the oil level and add if needed. NOTE! Wait about 5 minutes for checking the correct level after filling oil.



Service Information Document Title: Swing motor changing oil



Function Group: gearbox, 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Swing motor gearbox, changing oil Op nbr 173-079



NOTICE Drain the gear oil while it is still warm to flush out any contaminants.



NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. 1. Park the machine in the service position C, see 091 Service positions. 2. Remove the under cover.



Figure 1



3. Open the oil drain valve cap and install the drain hose.



Figure 2



1.



Oil drain hose



2.



Oil drain valve cap



4. Open oil drain valve cocks and drain the oil into a suitable container.



Figure 3



1.



Oil drain valve cock



5. After completely draining, close the oil drain cock and open the oil filling pipe cap. 6. Fill the oil through the oil filling pipes using a gear oil filling pump. Refill capacity: see 160 Specification, filling capacities. NOTE! Pay attention to loosen the oil level gauge when filling the gear oil.



Figure 4



1.



Oil filling pipe



7. Check the oil level using the oil level gauge and refill if necessary. 8. Remove the oil drain hose and install the oil drain valve cap. 9. Install the under cover and tighten to specification.



Service Information Document Title: Swing bath grease, check



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Swing bath grease, check Op nbr This is part of other procedure. 1. Remove the cover. 2. Check the grease level.



Figure 1 NOTE! If the grease is contaminated or discolored with water, change the grease (Quantity: 45 Litres (11.8 US gal))



Service Information Document Title: Function Group: Cab; door, covers, hinges, 173 joints and locks, lubricate



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Cab; door, covers, hinges, joints and locks, lubricate Op nbr This is part of other procedure 1. Lubricate the door hinges with grease.



Figure 1 Grease points cab door



Date: 2014/7/14



Service Information Document Title: Track shoe bolts, check



Function Group: 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Track shoe bolts, check Op nbr This is part of other procedure. 1. Place the machine in the service position F, See 091 Service positions.



Figure 1



2. Slew the superstructure to the side, and raise the track using boom down operation. Slowly turn the track in forward and reverse direction several times. Check for missing or loose or damaged shoe screws and shoes. 3. If track shoe bolts (A) are loose, the track shoes are likely to be damaged.



Figure 2



4. Check for looseness. Replace with new bolts and nuts, tighten the bolts to specified torque if needed. NOTE! Tightening torque : see 700 Undercarriage, tightening torque.



NOTE! Tighten the bolts in the order as shown in the figure.



Figure 3



5. After tightening, check whether the nut and the shoe are in full contact with the mating surfaces of the link.



Service Information Document Title: Function Group: Track tension/condition, 173 check



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Track tension/condition, check Op nbr This is part of other procedure 1. Place the machine in the service position F, See 091 Service positions.



Figure 1



2. Slowly turn the track in forward and reverse direction several times. Check for missing or loose or damaged shoe screws and shoes. Stop the track while moving in the reverse direction. 3. Measure track slack at the center of track frame between track shoe and track roller mounting surface.



Figure 2



4. Adjust the track tension according to the soil characteristics. Recommended track tension is as below. Track sag according to soil condition, unit: mm (in) Working condition



Clearance (A), unit: mm (in)



General soil



320 ~ 340 (12.6 ~ 13.4)



Rocky ground



300 ~ 320 (11.8 ~ 12.6)



Moderate soil like gravel sand, snow, etc.



340 ~ 360 (13.4 ~ 14.2)



Service Information Document Title: Function Group: Track gearbox oil level, 173 check



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Track gearbox oil level, check Op nbr This is part of other procedure. 1. Park the machine on the firm and level ground. 2. Rotate the gearbox as shown in the figure. Remove the plug of level check port and check if there is oil outflow.



Figure 1



1. 2.



Drain port Filling port or level check port



3. If the oil is about to overflow from the hole, the level is correct. 4. If the oil level is low, top up the oil to the correct level through the oil filling port. 5. Install the plugs.



Date: 2014/7/14



Service Information Document Title: Track motor changing oil



Function Group: gearbox, 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Track motor gearbox, changing oil Op nbr 173-101



NOTICE Drain the gear oil while it is still warm to flush out any contaminants.



NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. 1. Park the machine in the service position C, see 091 Service positions. Rotate the gearbox until the drain plug is located at bottom side. 2. Remove the 2 plugs on the cover and drain the oil into a suitable container.



Figure 1 Removal, plugs 1. 2.



Drain port Filling port or oil level check port



3. After completely draining, install the drain plug and tighten to specification. 4. Fill the oil through the filling port until oil exits. NOTE! Oil capacity: See 160 Specification, filling capacities. 5. Install the plug.



Service Information Document Title: Diesel particulate check and clean



Function Group: filter, 173



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Diesel particulate filter, check and clean Op nbr 254-001 VCADS Pro VCADS Pro Service Tool



NOTE! If the flexible tube is to be reused, mark the tube by drawing a line between the clamps. 1. Park the machine in service position B, see 091 Service positions. 2. Remove the DPF hood. 3. Disconnect the sensors.



Figure 1



1. 2.



DPF outlet temperature sensor DPF differential pressure sensor



4. Remove screws and put aside the wire harness.



Date: 2014/7/14



Figure 2



1.



Screw



5. Remove the clamp and then remove the outlet module with a tale pipe from the DPF.



Figure 3



1. 2. 3. 4.



Bracket Clamp Outlet module Tale pipe



6. Remove the bracket and the clamp.



Figure 4



1. 2. 3. 4.



Bracket Screw DPF Clamp



7. Remove the cover from the old filter and install it to a new filter. 8. Clean the filter and covers from remains of old gaskets and soot. The filter must be cleaned by Volvo according to Volvo Core handling instructions. 9. Clean the contact surfaces of the new clamps, filter and catalyst with a cleaning agent. Place a new gasket on the flange of the catalyst Install a new filter NOTE!



Hammer lightly with a plastic hammer on 254 Exhaust aftertreatment system, tightening torques.



the



clamp



and



torque-tighten



it



according



to



NOTE! Use only new gaskets and V-clamps when installing. NOTE! Pay attention to the flow direction mark on the filter when installing. 10. Restore the machine to operating condition. See 252 Exhaust pipe, flexible tube, replacing for exhaust tube installing. 11. To reset the soot load and ash load, run VCADS PRO operation “VCADS Pro, 25460-3, Reset soot and ash load”. NOTE! Keep the sensor wire harness routing when installing.



Service Information Document Title: Function Group: Spark plug cable, replacing 173



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Spark plug cable, replacing Op nbr 254-048



DANGER Risk of electrocution. Contact with live parts will cause death or serious injury. Never touch live electrical parts. 1. Park the machine in service position B, see 091 Service positions. 2. Remove the DPF hood. 3. Remove the screw and the clip on the cables.



Figure 1



1.



Screw



4. Pull out and remove the cables from both the DPF burner and the ASU and then replace them with new one.



Figure 2



1. 2. 3. 4.



ASU (After treatment support unit) Clip Spark plug cable DPF burner



NOTE! Cables must be firmly connected to the DPF buner and the ASU, check the connection after installing. 5. Install the screw and the clip. 6. Install the DPF hood.



Service Information Document Title: Function Group: Loose and loss of bolts, 173 check



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Loose and loss of bolts, check This is part of other procedure Op nbr 1. Check loose and loss of the engine mounting bolts visually. 2. Check loose and loss of the cap mounting bolts visually. 3. Check loose and loss of bolts of the hydraulic pump, motor, main control valve, etc.



Date: 2014/7/14



Service Information Document Title: Function Group: Oil-bath air cleaner's 173 reservoir (optional equipment), oil, check



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Oil-bath air cleaner's reservoir (optional equipment), oil, check This is part of other procedure Op nbr 1. Check the oil level of the pre-cleaner oil bath. Oil level is marked on inner oil cap.



Figure 1



2. If the oil has become sludgy or viscous, or if there are sediment deposits on the underside of the filter insert, then the oil must be changed and the reservoir and lower filter insert cleaned. Top up with the same viscosity as in the engine. NOTE! Volume : 8.5 litres (2.2 US gal)



Service Information Document Title: Function Group: Oil-bath air cleaner's 173 reservoir (optional equipment), clean, and oil, change



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change Op nbr This is part of other procedure



1. Figure 1 Reservoir If the oil has become sludgy or viscous, or if there are sediment deposits on the underside of the filter insert, then the oil must be changed and the reservoir and lower filter insert cleaned. Top up with the same viscosity as in the engine. Fill in accordance with the specifications, see 160 Recommended lubricants, but not higher. Avoid petrol when cleaning, as remaining petrol could cause an overspeeding in the engine during subsequent starting.



Service Information Document Title: Function Group: Oil-bath air cleaner's 173 reservoir (optional equipment), filter insert, clean



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Oil-bath air cleaner's reservoir (optional equipment), filter insert, clean Op nbr This is part of other procedure.



1. Figure 1 Filter insert If the lower filter insert has any sediment deposits or dry spots, then the upper filter insert must also be removed and rinsed. Avoid petrol when cleaning, as petrol remaining in the insert could cause an overspeeding in the engine during subsequent starting.



Service Information Document Title: Function Group: X1 return filter (optional 173 equipment), change



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



X1 return filter (optional equipment), change Op nbr This is part of other procedure. NOTE! Change the X1 return filter every 200 hours based on hammer operating hours.



When using the hydraulic hammer continuously, change the return element in hydraulic tank every 500 hours and draining/ filling the hydraulic oil every 600 hours. Hydraulic oil return filter, change interval Frequency of hammer use



Change interval



50%



every 1000 hours



100%



every 500 hours



Hydraulic oil, change interval Frequency of hammer use



Change interval



50%



every 1000 hours



100%



every 600 hours



1. Remove the filter cover. 2. Replace the filter element.



Figure 1



3. Install the filter cover.



Service Information Document Title: Function Group: Service history (included in 173 the respective Operator's manual), fill in.



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Service history (included in the respective Operator's manual), fill in. This is part of other procedure Op nbr 1. Fill in Service journal that is included in the Operator's Manual.



Service Information Document Title: Function Group: Swing ring gear bearing, 173 lubricate



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Swing ring gear bearing, lubricate Op nbr This is part of other procedure. 1. Clean the grease nipples. 2. Apply grease to the slew ring gear bearing until grease can be seen oozing from the slew bearing seals.



Figure 1 NOTE! Take care not to supply an excessive mount of grease. 3. After greasing, clean off the overflow grease completely.



Service Information Document Title: Measuring condition



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Measuring condition The purpose of this chapter is to explain how to evaluate the various performances of Volvo Construction Equipment hydraulic excavators. The tolerances shown are for new machines. For a machine already in use, certain allowance is permitted according to field conditions. Unless otherwise specified, measurements should be performed under the following conditions:   



Engine speed: high rpm, “P” mode (North America: "H" mode) Hydraulic oil temperature: 50 ±5 °C (122 ±9 °F) Site: Firm, level ground



Service Information Document Title: Cylinder speed



Function Group:



Profile: EXC, EC480D L [GB]



Cylinder speed Preparation Boom cylinder  



Arm cylinder is fully retracted. Bucket cylinder is fully extended.



Figure 1 Measuring condition, boom cylinder A. B.



Raise Lower



Arm cylinder 



Bucket cylinder is fully extended.



Figure 2 Measuring condition, arm cylinder A. B. Bucket cylinder



Roll out Roll in



Information Type: Service Information



Date: 2014/7/14



Figure 3 Measuring condition, bucket cylinder A. B.



Roll out Roll in



Measurement   



Operate the control lever at full stroke. Measure the time, by stop watch, for the cylinder to fully stroke (exclude the cushioned stroke). Measure 3 times to take average value.



Cylinder speed, unit: sec Operation



Standard



Allowable value



Remarks



Raise



3.3 ± 0.3



3.9



From the ground to full extension.



Lower



2.8 ± 0.3



3.4



From full extension to the ground.



Arm



Roll in



4.1 ± 0.4



4.7



From full retraction to full extension.



Roll out



3.1 ± 0.3



3.7



From full extension to full retraction.



Bucket



Roll in



3.5 ± 0.4



4.1



From full retraction to full extension.



Roll out



2.5 ± 0.3



3.1



From full extension to full retraction.



Boom



Service Information Document Title: Creeping of cylinder



Function Group: hydraulic



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Creeping of hydraulic cylinder Preparation



Figure 1 Measuring condition, creeping  



With a full load in the bucket, set the front–end digging unit as shown above. Load applied : see the Lifting capacity on Operator's manual.



Measurement    



Stop the engine. Wipe the oil off the cylinder rod(3), and mark the measuring start point(A) with tape(1). Measure the amount of creep (a or b) on the cylinder rod over a 5 minute period. After measuring, remove the tape and clean carefully.



Figure 2 Measuring, creeping 1



Tape



4



Start position



2



Cylinder gland



5



Retraction = A - a)



3



Cylinder rod



6



Extension (H = b - A)



Creeping value, unit: mm (in) / 5 minutes Standard



Allowable value



Maximum limit



Boom cylinder



Less than 10 (0.4)



15 (0.6)



20 (0.8)



Arm cylinder



Less than 10 (0.4)



15 (0.6)



20 (0.8)



Bucket cylinder



Less than 40 (1.6)



50 (2.0)



70 (2.8)



Service Information Document Title: Swing speed



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Swing speed Preparation  



Arm cylinder is fully retracted. Bucket cylinder is fully extended.



Figure 1 Measuring condition, slew speed Measurement   



Operate the slew control lever at full stroke. Measure the time for the superstructure to make 3 full turns at constant speed. (Exclude first full turn) Measure right and left alternately.



Slew speed, unit: sec / 3 rev Standard



Allowable value



Maximum limit



20.7 ± 1.3



22.8



23.9



Service Information Document Title: Coasting left and swing



Function Group: right



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Coasting left and right swing Preparation     



Full load in bucket. Arm cylinder is fully retracted. Bucket cylinder is fully extended. Mark (A) the slew bearing out race and directly below mark (B) the undercarriage. Slew the superstructure so that the arm and boom are 180 degrees.



Figure 1 Measurement condition, coasting slew Measurement   



Operate the slew control lever at full stroke and slew 180°. When the marks (A, B) align, return the lever to neutral position. Measure the distance between the mark (A) on the slew bearing and the mark (B) on the undercarriage.



Wear limits, unit: mm (in)



Amount of coasting (D)



Standard



Allowable value



Maximum limit



Less than 1970 (77.6)



2180 (86)



2248 (88.5)



Figure 2 Amount of coasting A



Mark position (slew bearing)



C



Slew stop position



E



Slew start



B



Mark position (undercarriage)



D



Amount of coasting



F



180° slew



Service Information Document Title: Measuring of bearing clearance



Function Group:



Information Type: Service Information



swing



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Measuring of swing bearing clearance Slew bearing clearance Clearance of bearing in axial direction



Tightening torque



Removed condition Installed condition Outer screw



Standard



0.05 ~ 0.2 mm (0.002 ~ 0.008 in)



Allowable clearance



0.4 mm (0.016 in)



Standard



0.2 ~ 1.7 mm (0.008 ~ 0.067 in)



Allowable clearance



3 mm (0.12 in)



kgf m (lbf ft)



176.1 ± 17.1 (1271 ± 123)



Inner screw Measurement



Figure 1 Measurement, bearing clearance (removed) 1



Inner race



4



Lift



2



Dial gauge



5



Outer race



3



Magnet base



NOTE! Prior to proceeding ensure that the mounting screws are properly tightened. Removed condition    



Put the slew gear on a flat surface and then set 3 magnetic bases on the outer race at 120° intervals. Set 3 dial gauges on the inner race. Lifting the outer race vertically, axial clearance is the movement between bearing races. Read the values of dial gauges.



Installed condition Clean the outer race of slew gear and the underside of undercarriage. The slew gear wear is not uniform over the entire circumference. To obtain the exact play, it is necessary to take two measurements and pivot the superstructure by 90°. 1st measurement 



Position superstructure on center line of undercarriage.



    



Bear the bucket on the ground until the tracks are partially lifted off the ground. Place the magnetic base. Adjust the dial gauge to zero at the underside of undercarriage and outer race of slew gear. Gently lower the excavator onto the ground and raise the bucket to the level of the cab floor with arm extended. Read the values shown by the needle on the dial gauge. Bear the bucket on the ground once again to check that the dial gauge pointer properly returns zero.



2nd measurement  



Position superstructure at 90° in relation to first measurement. Measure the clearance according to the method shown at 1st measurement.



Figure 2 Measurement, bearing clearance (installed) 1



Outer race



3



Inner race



2



Superstructure



4



Undercarriage



Allowable clearance Measure the clearance twice in each position and record it in the table below. Clearance recording format Clearance read superstructure



at



1st



position



of Clearance read superstructure



at



2nd



position



of



A (1st measurement) B (2nd measurement) Total



A+B



A+B



Average clearance



Total / 2



Total / 2



If there is a large difference between measurements A and B, there is likely a mistake, therefore, repeat the measurement several times. NOTE! The most important factor of slew gear failure is concerned with the axial clearance. Therefore, lubricate the bearing and slew gear teeth periodically.



Service Information Document Title: Travel Speed



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Travel Speed Preparation



Figure 1 Measurement condition, travel speed Measurement



Figure 2 Measurement, travel speed 1. 2. 3.



Preliminary distance 3 ~ 5 m (10 ~ 16.5 ft) Test run 20 m (66 ft) Preliminary distance 3 ~ 5 m (10 ~ 16.5 ft)



Allowable limits, unit: sec / 20 m (66 ft) Travel time Standard



Allowable value



Maximum limit



1 speed



23.2 ±2



26.1



28.7



2 speed



13.8 ±2



16.8



17.8



Service Information Document Title: Track running speed



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Track running speed Preparation



Figure 1 Measurement condition, track running speed  



Mark any one of the track shoes on the side on which this test is performed. Jack up the track to be tested.



Measurement   



Accelerate the engine to maximum speed. Measure the time for the track to make three full turns. (Exclude the first full turn) Apply this test to both tracks, forward and reverse.



Allowable limit, track running speed, unit: sec / 3 rev Running time 1 speed



Left



Standard



Allowable value



Maximum limit



39.1 ± 3



43.1



54.1



23.3 ± 3



27.3



29.3



Right 2 speed



Left Right



Service Information Document Title: Straight performance



Function Group: traveling



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Straight traveling performance Preparation



Figure 1 Measurement condition, straight traveling performance  



Extend the arm cylinder/bucket cylinder fully. Fix the digging units in the traveling posture.



Measurement    



Simultaneously operate both travel levers at full stroke. Measure the distance between the trace of the machine and line (A). Repeat it three times and give an average value. slew the superstructure 180° and measure in reverse travel.



Allowable limit, straight traveling performance, unit: mm (inch)



Deviation distance : A



Figure 2 Straight traveling performance



Standard



Allowable value



Maximum limit



Less than 200 (7.9)



240 (9.4)



300 (11.8)



Service Information Document Title: Starting engine booster cables



Function Group: with



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Starting engine with booster cables Before connecting the booster cables check the following:      



Size of booster cable and clip should be suitable for the battery capacity. Check cables and clips for breaks, corroded surfaces, etc. Make sure cables and clips are firmly secured. Keep the starting switch in “OFF” position, (both machines). The battery of the running engine must be the same capacity as that of the engine to be boost started. When starting from another machine do not allow the machines to touch.



Connect the booster cables in the following manner :



Figure 1 Connection, booster cables 1. 2. 3. 4.



Connect clip (1) of booster cable (A) to the battery positive (+) terminal of the machine to be boost started. Connect clip (2) to the battery positive (+) terminal of the engine which is running. Connect clip (3) of booster cable (B) to the battery negative (–) terminal of the engine which is running. Connect clip (4) to the upper structure of the machine to be boost started.



NOTICE Make sure the clips are firmly connected to battery terminals. Start the engine with the fully charged battery, then crank the engine being boost started.



When connecting the cables, do not allow the positive (+) and negative (–) terminals to make contact.



NOTICE Make sure that the booster cable connections are correct. Connect the booster cable to the engine block as far as possible from the battery. After the engine has started, the booster cables must be disconnected in the reverse order. Starting engine 1. 2. 3.



Turn the key switch to “START” position and start the engine. Cranking time maximum 30 seconds, wait minimum 2 minutes between cranking attempts. After the engine has started, the booster cables must be disconnected in the reverse order.



Disconnect the cables as follows :



Figure 2 Disconnection, booster cables 1. 2. 3. 4.



Disconnect clip (1) of booster cable (B) from the upper structure. Disconnect clip (2) from the battery negative (–) terminal of the running engine. Disconnect clip (3) of booster cable (A) from the battery positive (+) terminal of the running engine. Disconnect clip (4) from the battery positive (+) terminal of the machine which was boost started.



Thank you for your purchase. Have a nice day.



file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/7/14 9:06:54]



Service Information Document Title: Engine, description



Function Group: 200



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Engine, description Engines D11H, D13H, and D16H are straight six-cylinder, four-stroke, direct-injected diesel engines. They are equipped with a single variable geometry turbocharger (VGT) and feature cooled external exhaust gas recirculation (EGR). They have charge-air cooling with mechanically actuated electronically controlled unit injectors, controlled by the EMS-system. The engines have a one-piece cylinder head with four valves per cylinder and a single overhead camshaft. Rear-mounted timing gear results in a shorter engine and lighter drivetrain installation. The engine brake for articulated haulers, VEB7, does not have the additional Exhaust Pressure Governor, EPG. Sufficient exhaust back-pressure will be controlled via the VGT. For more information, see:       



220 Lubrication system, description 230 Fuel system, description 250 Inlet and exhaust system, description 254 Exhaust Aftertreatment System, description 255 Turbocharger, description 260 Cooling system, description 293 Exhaust Gas Recirculation (EGR), description



For Articulated Haulers: 



253 Auxiliary brake (engine braking), description



The cylinders are numbered in sequence, starting farthest from the flywheel. Ignition order: 1-5-3-6-2-4. The engine's rotational direction is counter-clockwise, seen from the flywheel. Engine identification



Figure 1 Identification plates, D13H Identification plate 1 A label located on the valve cover showing the engine's component ID-number, serial number, manufacturing site, engine part number, and engine build date, as well as their bar codes. Manufacturing sites: A = Skövde, Sweden E = Curitiba, Brazil F = Flen, Sweden L = Lyon, France Identification plate 2 The engine's serial number, part number, and manufacturing site are stamped into the engine's cylinder block. Identification plate 3 The hardware component number of the Engine Control Unit (ECU) is located on a label on the back of the ECU. Identification plate 4 The certification label is located on the valve cover as well as the machine's frame. Automatic Engine Shutdown This is a function used to automatically shut down the engine after idling for a certain time. The operator is informed and has the opportunity to cancel the function within one minute, either by increasing the engine speed, shifting gear, or by activating the hand throttle. Engine protection The ECU contains functionality designed to protect the engine from damage during extreme operating conditions or from further damage when an essential engine component fails. There are several proactive functions, and different applications have different functions activated. The ones that can be activated are: 



High coolant temperature



              



High intake manifold air pressure High intake manifold air temperature High oil temperature Low oil pressure Low coolant level High temperature of cooled EGR exhausts after the EGR-cooler High crankcase pressure Variable Geometry Turbo valve and position error High temperature of Smart Remote Actuator High compressor charge-air temperature (calculated) High soot load High differential pressure across Diesel Particulate Filter (DPF) High exhaust temperature High ECU temperature High DPF temperature



Various protective actions such as warning lights, engine torque reduction, engine speed limitation, and vehicle speed limitation may be taken when the above functions reach dangerous levels that may damage the engine. In order to always allow the operator to move a machine away from an unsafe situation, there is a delay of at least 30 seconds before the protective actions (such as forced idle and forced shutdown) are activated after a Key-ON. If the engine has been forced to shutdown or forced to idle due to an active engine protection function, the operator can obtain a 30 second delay by powering down the EMS with a Key-OFF for 7 seconds and then a Key-ON (the EMS is powered down by the Vehicle-ECU (V-ECU) after the ignition key has been in its OFF position for approx. 7 seconds). In addition to the above protective functions, other software functions could request engine protection, such as:      



High Altitude (ensures that high compressor charge-air temperature is never reached) Turbo OverSpeed Low Coolant Temp Crank Sensor Failure Gear Ratio Regeneration



Warning lights There are two levels for warning lights, an amber caution light and a red stop light.  



The amber light indicates a warning situation The red light indicates that the vehicle must be stopped.



Engine torque limitation The engine torque can be limited by the engine protection function. Engine torque limitation is active until the parameter has reached a safe level or until the EMS is powered down. Forced Idle The engine can be forced to idle speed by the engine protection function. Forced idle is active until conditions triggering the problem are back within normal working range or the EMS is powered down. Engine Shutdown The engine can be forced to shut down after conditions have reached levels that may cause engine failure and the machine speed is below a specified value. Machine Speed and Engine Speed Limits The engine protection function can limit the speed of the vehicle and/or the engine's rpm. Levels of engine protection Available proactive functions depend not only on the application but also on what level of protection has been activated for the specific machine. Two levels of engine protection are offered, the standard level is Basic protection and the optional level Extended protection. The general difference between basic and extended engine protection is that no active actions such as forced idle and forced shutdown will be taken in basic engine protection (with the exception of crankcase pressure that can cause shutdown in either setup). Warnings will be given to the operator regardless of engine protection level. Parameters  



(FAU) Automatic engine shut off (FAV) Automatic engine shut off, time



      



(JVL) Injector cylinder 1, calibration E3 Glitch Trim (JVM) Injector cylinder 2, calibration E3 Glitch Trim (JVN) Injector cylinder 3, calibration E3 Glitch Trim (JVO) Injector cylinder 4, calibration E3 Glitch Trim (JVP) Injector cylinder 5, calibration E3 Glitch Trim (JVQ) Injector cylinder 6, calibration E3 Glitch Trim (YA) Idle speed, setting



Supplementary information 



200 Component locations



Function check 



17030-3 Parameter, programming



Diagnostics Detailed information about the following relevant warnings and error codes is available under the diagnostics tab. Component



Control unit



Message ID



EF2112 (ART) PID404 (EXC, WLO)



MID128



PID404



EF2117 (ART) PPID55 (WLO, EXC)



MID128



PPID55



EF2127 (ART) PPID89 (EXC, WLO)



MID128



PPID89



EF2515 (ART) PSID28 (WLO, EXC)



MID128



PSID28



EF2525 (ART) PID173 (EXC) SE2510 (WLO)



MID128



PID173



SE2202 FX1006 (WLO)



MID128



PID175



SE2507 FX1007 (WLO)



MID128



PID105



MO2501



MID128



SID27



PPID326 (WLO, EXC)



MID128



PPID326



SE2203



MID128



PID100



SE2509



MID128



PID153



SE2516



MID128



PID412



SE2519



MID128



PID81



SE2603



MID128



PID111



SE2606



MID128



PID110



Service Information Document Title: VCADS Pro, Operations



Function Group: 200



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



VCADS Pro, Operations The following VCADS Pro operations are available for function group 2. Operations used when changing or working on components are mandatory. Tests Operation



Application



20046-3 Read out engine information



The operation is used to read out the engine emission and engine certificate information when requested by the customer or other interested parties.



21006-3 Cylinder compression, test



Used when there is a suspicion of fault and/or at abnormal values/ readings. This test indicates if there is any deviation in compression in any cylinder in relation to the other cylinders. As a first check this operation is both easy and fast to perform instead of a real compression test.



23016-3 Cylinder balancing, test



Used when there is a suspicion of fault and/or at abnormal values/ readings This test indicates whether any of the injectors deviates too much in the fuel injection so that the engine characteristics are damaged.



23017-3 Feed pressure, inspection



Used when there is a suspicion of fault and/or at abnormal values/ readings.



23712-3 Injectors shut off, manual



Used when there is a suspicion of fault and/or at abnormal values/ readings.



25410-3 Air pump exhaust aftertreatment, test



Used when there is a suspicion of fault and/or at abnormal values/ readings.



25411-3 Burner exhaust aftertreatment, test



Used when there is a suspicion of fault and/or at abnormal values/ readings.



25412-3 Components ASU, test



With this sub-test, the functions of the atomiser air valve, the main air valve, the fuel shut-off valve and the fuel pump are checked.



25433-3 Fuel bleeding



system



exhaust



aftertreatment, Used when there is a problem with the tension on the spring in the fuel pressure regulator in the atomization.



25434-3 Atomization unit, fuel pressure, adjust



Used when there is a problem with the tension on the spring in the fuel pressure regulator in the atomization.



25436-3 Atomization unit, air pressure, adjust



Used when there is a problem with the tension on the spring in the fuel pressure regulator in the atomization.



25456-3 Exhaust aftertreatment diagnostics



Used when there is a suspicion of fault and/or at abnormal values/ readings.



25457-3 Diesel Regeneration



Particulate



Filter



Service Used when the soot load is over 1.7. See 254 Exhaust Aftertreatment System, description Before starting service regeneration check the differential pressure over the diesel particle filter so that it is within stated value according to the service information. This is to make sure that the DPF won’t get damaged by the service regeneration. After the service regeneration and when the exhaust temperature has stabilized to a normal level check the differential pressure over the DPF again so that it is within stated value according to the service information. This is to determine that the filter has been



regenerated correctly and that it is not clogged with ash. 25460-3 Reset soot and ash load



When the diesel particulate filter has been changed, the soot load and the ash load must be reset. The reset is needed to indicate to the system that the filter has been cleaned. The soot load and ash load must only be reset if a clean filter has been installed.



25537-3 Variable geometry turbo function test



Used when there is a suspicion of fault and/or at abnormal values/ readings.



27502-3 Engine speed control, test



Used when there is a suspicion of fault and/or at abnormal values/ readings.



28407-3 Sensor values, monitoring



Used when there is a suspicion of fault and/or at abnormal values/ readings.



28420-3 Flywheel and camshaft signal, test



Used when there is suspicious of faulty signals or faulty connected sensor.



29332-3 Exhaust gas circulation, function test



Used when there is a suspicion of fault and/or at abnormal values/ readings.



Calibrations Operation



Application



25536-3 Variable geometry turbo, calibration When changing actuator. See 255 Actuator, variable turbocharger, replacing Programming Operation



Application



25801-3 MID 233 Control unit, programming When changing ACM or 254 ACM, replacing, non-programmed



only



reprogramming.



See



When changing ECU or only reprogramming. 200 E-ECU, MID 128, changing non-programmed ECU.



See



25802-3 MID 233 Control unit, campaign 28423-3 MID 128 ECU, programming 28422-3 MID 128 ECU, campaign



Service Information Document Title: Engine, identification



Function Group: 200



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Engine, identification Identification plate 1 A decal with the software's ID-number, the engine's serial number and assembly plant is located on the valve cover to ensure installation of correct ECU on the engine in production. On the back of the ECU, there is a decal indicating its hardware number. Identification plate 2 Engine designation, serial number, part number and assembly plant are stamped in one field on the engine block's left front edge. Assembly plants: A = Skövde, Sweden E = Curitiba, Brazil F = Flen, Sweden L = Lyon, France Identification plate 3 The engine control unit (ECU) has its component number on a plate on the back. Identification plate 4 The certification decal is located on the valve cover as well as on the left side of the machine's front frame.



Figure 1



Service Information Document Title: Component locations



Function Group: 200



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component locations



Figure 1 Engine, front side 1



Flywheel housing



7



Engine oil filter



2



P.T.O (Power Take Off) port



8



Oil pan



3



Valve cover



9



EGR cooler



4



Turbocharger



10



Starter motor



5



Turbocharger actuator



11



TDC mark checking port



6



Venturi pipe



Figure 2 Engine, back side 12



Fan pulley



20



Crankcase ventilation separator



13



Pre-heating coil



21



Oil level sensor



14



Engine oil filling port



22



Alternator



15



Dipstick gauge



23



Air conditioner compressor



16



Crankcase ventilation tube



24



Air pump



17



Air compressor



25



Air pump belt



18



Fuel feed pump



26



Alternator/Compressor belt



19



E-ECU



27



Fan belt



Service Information Document Title: Function Group: E-ECU, MID 128, changing 200 non-programmed ECU



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



E-ECU, MID 128, changing non-programmed ECU Op nbr 200-068 1. Park the machine in the service position A, see 091 Service positions. 2. Connect the VCADS Pro computer to the machine, and perform operation '28423-3 MID 128 control unit, programming'. 3. When VCADS Pro 'MID 128 ECU, programming' window appears, follow the instructions for replacing E-ECU. 4. Turn OFF battery disconnect switch. 5. Remove the engine hood rear cover screws.



Figure 1



1.



Screws



6. Remove the bracket.



Figure 2



1.



Bracket



2.



CNEI connector



7. Disconnect the CNEI connector. 8. Remove the air hose.



Figure 3



9. Remove screws from wire harness clamps, and disconnect the wiring harness connectors from E-ECU.



Figure 4



1.



Screws



10. Remove screws fixing the fuel pipe and E-ECU.



Figure 5



1.



Screw



2. 3.



Pipe Screw



Put the fuel pipe away. 11. Remove 4 screws fixing the E-ECU and replace the E-ECU.



12. Install fuel pipe and screws. Connect wire harness connectors to the E-ECU, and install wire harness clamp screws. 13. Install the air hose and bracket. 14. Install the engine hood rear cover, and the screws. 15. After replacing E-ECU, press OK button of VCADS Pro operation '28423-3 MID 128 control unit, programming'. Now VCADS Pro starts the programming of software and parameters to the new E-ECU. 16. Start the machine and check that no error messages appear.



Service Information Document Title: Function Group: E-ECU, MID 128, changing 200 pre-programmed ECU



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



E-ECU, MID 128, changing pre-programmed ECU Op nbr 200-070 1. Park the machine in the service position A, see 091 Service positions. 2. Connect VCADS Pro computer to the machine, and perform operation '17030-2 Parameter, programming'. 3. Use the function 'save all parameters to job card'. 4. Turn OFF battery disconnect switch. 5. Remove the engine hood rear cover screws.



Figure 1



1.



Screws



6. Remove the bracket.



Figure 2



1. 2.



Bracket CNEI connector



7. Disconnect the CNEI connector. 8. Remove the air hose.



Figure 3



1.



Hose



9. Remove screws from wire harness clamps, and disconnect the wire harness connectors from E-ECU.



Figure 4



1.



Screw



10. Remove screws fixing the fuel pipe and E-ECU. Put the fuel pipe away.



Figure 5



1. 2. 3.



Screw Pipe Screw



11. Remove 4 screws fixing the E-ECU and replace the E-ECU.



12. Install the fuel pipe, and screws. Connect wire harness connectors to the E-ECU, and install wire harness clamp screws. 13. Install the air hose and bracket. 14. Install the engine hood rear cover, and the screws. 15. Connect VCADS Pro computer to the machine, and perform operation 17030-2 Parameter, programming'. Now the customer parameters are changed according to the job card saved at step 3. 16. Start the machine and check that no error messages appear.



Service Information Document Title: Engine characteristic curve



Function Group: 210



Profile: EXC, EC480D L [GB]



Engine characteristic curve Engine characteristic curve



Figure 1 Engine characteristic curve, SAE J1349 Gross power



Information Type: Service Information



Date: 2014/7/14



Service Information Document Title: Engine, removing



Function Group: 210



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Engine, removing Op nbr 210-070



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work.



WARNING Removal of residual pressure from the circuit must be done prior to any maintenance. NOTE! Cable ties and clamps that secure hoses and electrical wiring must be removed and then replaced when installing components. NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container. 1. Place the machine in the service position B. See091 Service positions 2. Turn off the battery disconnect switch. 3. Drain the coolant in a collection container. See 261 Coolant, changing. 4. Open the engine hood and remove the bracket from the cowl frame.



Figure 1



1.



Bracket



5. Remove the DPF hood, radiator hood and the rear cover



Figure 2



1. 2. 3. 4.



DPF hood Engine hood Engine room rear cover Radiator hood



6. Remove the engine room cowl frame with the engine hood using a lifting device. 7. Disconnect the wire harness connector and the hoses.



Figure 3



1. 2.



Wire harness connector Hose



8. Remove the expansion tank with the bracket. 9. Remove the clamps and then remove the charge air cooler tube and the radiator hoses.



Figure 4



1. 2. 3.



Charge air cooler upper tube Radiator upper hose Radiator breathing hose



10. Remove the engine room under covers.



Figure 5



1.



Engine room under cover



11. Release the pressure in the air compressed system by pushing up a valve on the air tank.



Figure 6



1.



Release valve



2.



Air tank



12. Disconnect the radiator under hose and remove the charge air cooler under tube.



Figure 7



1. 2.



Radiator under hose Charge air cooler under tube



13. Remove the screws and separate the shroud from the radiator assembly. Move the shroud to the engine side.



Figure 8



1. 2.



Shroud Radiator assembly



14. Remove the main pump. See 913 Hydraulic pump, replacing 15. Remove pump room covers.



Figure 9



1.



Pump room cover



16. Disconnect the hoses, remove the mounting screws and the engine PTO pump. NOTE! Plug the P.T.O (Power take off) hole to protect from foreign substances.



Figure 10



1. 2. 3.



Hose Screw Engine PTO pump



17. Disconnect the fuel line hoses (4 pcs). NOTE! Ports must be plugged after disassembling hoses.



Figure 11



1.



Hose



18. Disconnect the hose connected to the air cooler and the compressor head.



Figure 12



1. 2. 3. 4. 5.



Compressor head Air cooler Hose Hose Hose



19. Disconnect hoses connected to the air pump.



Figure 13



1. 2.



Air pump Hose



20. Disconnect the wire-harness connector on the inlet air sensor.



Figure 14



1. 2.



Inlet air temperature/pressure sensor Connector



21. Remove the clamps and the air inlet hose.



Figure 15



1.



Turbocharger air inlet hose



22. Remove the foot step.



Figure 16



23. Remove the clamps and the exhaust flexible tube.



Figure 17



1.



Exhaust flexible tube



NOTE! Leave the markings on the tube before removing to remember the direction of flow direction. 24. Remove the air conditioner compressor belt and disconnect the wire harness.



WARNING Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage.



Figure 18



1. 2. 3.



Air conditioner compressor Alternator/compressor belt Wire harness



25. Remove the compressor and lay it down on the frame. 26. Disconnect the cab heater hose on the engine block.



Figure 19



1.



Cab heater hose



27. Disconnect the engine oil remote hoses.



Figure 20



1.



Engine oil remote hose



28. Disconnect the starter motor wire harness.



Figure 21



1.



Starter motor wire harness



29. Remove the connectors from the fuel filter and the water separator.



Figure 22



1.



Connector



30. Remove the cover and the clamps and then disconnect the main wire harnesses.



Figure 23



1. 2. 3.



Cover Clamp Wire harness



31. Remove the four mounting screws.



Figure 24



32. Lift the engine just a little using a lifting device, and after confirming safety around, lift it up and out slowly to the work stand.



Figure 25



Service Information Document Title: Cylinder head, description



Function Group: 211



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Cylinder head, description



Figure 1



The cylinder head is a one-piece cast iron design, which is a prerequisite for stable bearing positions for the overhead camshaft. The camshaft is carried in seven horizontally split bearing brackets with replaceable bearings shells. For the rear bearing bracket, the bearing shell is also designed as thrust bearing. The coolant thermostat's housing is machined directly into the cylinder head and is located at the front on the right side (A).



Each cylinder has separate inlet channels on one side of the cylinder head and separate exhaust channels on the other side, so-called ''crossflow'' (B). The fuel channel for the unit injectors is drilled longitudinally through the cylinder head, and has a machined ring-shaped groove around each unit injector (C). At the front there is a plug (D) that leads to the channel for measuring the rocker arm mechanism's oil pressure. The channel (E) for lubricating the camshaft and rocker arms is drilled centrally in the cylinder head's left side.



Figure 2



The unit injectors are located vertically in the centre of the cylinder between the four valves and are held in place by a yoke (B). The injector's lower part is separated from the cooling jacket with a copper sleeve, which is flared at the bottom and sealed with an O-ring at the upper part. The ring-shaped space around each injector is sealed with two O-rings. For maximal cooling, the coolant space in the cylinder head is provided with a horizontal wall that forces the coolant past the lower and hottest parts of the cylinder head. The valve mechanism has double inlet and exhaust valves. The exhaust valves have double valve springs (A) while the inlet valves have single springs (C). The inlet valves are linked in pairs with so-called 'floating valve yoke', that transfer the rocker arm's movement against the camshaft to the valve pairs, while the exhaust valves are linked with guided yokes. The valves are of a new type with three grooves and matching valve collets for inlet and exhaust valves. The design of the valve collet enables the valve to rotate in its valve seat. For improved heat tolerance and heat dissipation, there is more material in the exhaust valves' valve discs and the diameter is slightly smaller than for the inlet valves. Valve guides and valve seats are made of alloyed cast iron and hardened steel, respectively, and are replaceable. All valves have oil seals for the valve stems (D). The valve stem seals on the engine are of a new type with double sealing surfaces.



Service Information Document Title: Function Group: Crankcase ventilation, 212 description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Crankcase ventilation, description



Figure 1 Crankcase ventilation 1. 2. 3.



Oil separator Crankcase pressure sensor (SE2509) Diesel engine



Since some of the combustion products enter the crankcase after passing by the pistons and piston rings (blow-by), the crankcase must be ventilated. The purpose of the crankcase ventilation is to balance the pressure in the crankcase in order to avoid damage to engine components and also partly to prevent oil mist formation and oil leakage to the ground. The crankcase ventilation consists of an external oil separator and two oil traps; one on the upper timing gear casing and one in the valve cover. Oil traps



Figure 2 Oil traps 1. 2. 3. 4. 5. 6.



Cast channel External pipe to oil separator Oil trap in valve cover Oil trap in upper timing gear casing Crankcase connection Drain holes



In the timing gear casing the oil trap is shaped like a labyrinth with the crankcase connection directly opposite the centre of the adjustable transfer gear, where the rotation of the gear creates a relatively oil-free space. The valve cover’s inside has a cast channel with three drain holes. Oil separator



Figure 3 Oil separator 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.



Separator Inlet Diaphragm Outlet Pressure regulator Lubrication oil connection Return to oil pan for oil and soot particles Turbine Rotating disc for particle separation Drive shaft



After passing through the oil traps, the crankcase gas is led to the inlet at the top of the separator and enter the separator from above directly over of the rotating discs. Oil from the engine lubrication system drives a turbine via an oil channel to drive the separator. The turbine is connected to a drive shaft with a number of discs that are rotating during normal engine operation. On the side of the separator is a pressure regulator with a diaphragm, which closes the oil flow to the turbine if the pressure falls too low. Oil and heavier particles are thrown centrifugally towards the periphery and are led from to the oil sump together with the oil which drives the turbine. The gas, reduced from oil mist and soot, is then released into the ambient air. Parameters 



There are no parameters for this function.



Summary The crankcase gas is ventilated via two oil traps and an oil separator. The gas is led trough the oil traps for oil separation. The oil is led to the oil sump and the separated gas is led to an oil separator that functions as a centrifuge. Oil and heavier particles are thrown towards the periphery and then led to the oil sump and the clean gas is led to the ambient air. Complementary information  



200 Engine, description 200 Component locations



Diagnostics Detailed information about relevant warnings and error codes below is available under the diagnostics tab. Component



Control unit



Message ID



SE2509



MID128



PID153



Service Information Document Title: Valves, adjusting



Function Group: 214



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Valves, adjusting Op nbr 214-012 9993590 Gear wheel



Feeler gauge



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work. 1. Open the engine hood. 2. Remove the screws on the expansion tank bracket.



Figure 1



1.



Screw



3. Loosen the screws on the bracket and move the coolant expansion tank to the MCV side.



Figure 2



1.



Screw



4. Remove the screws and the crankcase ventilation tube.



Figure 3



1. 2.



Screw Ventilation hose



5. Remove the mounting screws and the valve cover.



Figure 4



6. Remove the engine room under cover.



Figure 5



1.



Engine room under cover



7. Remove the screws and the protection cover.



Figure 6



1. 2.



Screw Protection cover



8. Remove the protective cover on the flywheel housing.



Figure 7



9. Install a rotating tool, extension bar and a ratchet handle.



Figure 8



1. 2. 3.



Ratchet Rotating tool Extension bar 9993590 Gear wheel



NOTE! The rotation tool should be turned counterclockwise. 10. Turn the engine until the nearest dash marking on the camshaft is between the marks on the bearing cap. The number matches the cylinder for which the inlet and exhaust valves are in correct position for adjusting.



Figure 9



1. 2.



Inlet valves Exhaust valves



NOTE! Cylinder 1 is closest to the marked end of the camshaft. 11. Loosen the lock nut at the 214 Valve system, specification.



respective



rocker



arm



Tighten the lock nut according to 214 Valve system, specification.



and



adjust



the



clearance



according



to



Figure 10



12. Turn the engine and adjust the rest of the valves in the same way. 13. Install the valve cover and crankcase ventilation tube, see 214 Valve system, specification 14. Close the engine hood. 15. Restore the machine to operating condition.



Service Information Document Title: Function Group: Crank mechanism, 216 description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Crank mechanism, description



Figure 1



A. B. C.



Leading edge Middle centre bearing Trailing edge — engine timing gear



1. 2. 3. 4. 5. 6. 7. 8.



Bearing shells Thrust bearing Front teflon seal Rear teflon seal Gear Bolt, flywheel Bolt, crankshaft gear O-ring



The crankshaft is drop-forged and has induction-hardened bearing surfaces. The crankshaft is carried in seven main bearings with replaceable bearing shells. In the middle main bearing there is also the thrust bearing which is made up of four washers



shaped like half-moons. At the leading edge the seal is made up of a teflon seal against the front crankshaft flange. At the trailing edge there is also a teflon seal that seals against a machined surface on crankshaft gear. The gear is fixed to the crankshaft with a guide pin and two bolts. In the rear crankshaft flange there is a groove for the O-ring that seals between the flange and the gear.



Figure 2



1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.



Main bearing journal Lubrication channel, main bearing pin Lubrication channel, big-end bearing pin Damper housing Cast iron ring Bushes Flywheel Gear M16 bolts Guide pin Starter ring gear Groove for speed sensor



Lubrication of the crankshaft takes place via separate channels in the cylinder block to each main bearing. The main bearing pins have drilled lubrication channels and from each main bearing pin, except the middle one, there is a drilled channel to the nearest big-end bearing pin. The vibration damper is of hydraulic type and is bolted directly on the crankshaft's front flange. In the damper housing there is an oscillating mass in the form of a cast iron ring that can rotate freely on the bushings. The space between the damper housing and oscillating mass is filled with silicone oil of high viscosity. When the crankshaft rotates, torsional stresses are generated in the crankshaft by the pistons' power strokes. The viscous silicone oil evens out the movement between the



crankshaft's pulsating rotation and the oscillating mass' smooth rotation, thus reducing the vibrations. The flywheel and the gear located in-between are bolted on the crankshaft's rear flange with 14 M16-bolts. The flywheel is fitted to the crankshaft with a guide pin in the same position as the gear. On the outside there are machined grooves for the engine's speed sensor, speed sensor, flywheel, SE2701. The starter ring gear is shrink-fit on the flywheel and can be replaced. Supplementary information See also: 



482 PTO (Power Take Off), description



Diagnostics Detailed information about relevant warnings and the error codes below are found under the diagnostics section. Component



Control unit



Message ID



SE2701



MID128



SID22



Service Information Document Title: Oil level sensor, changing



Function Group: 217



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Oil level sensor, changing Op nbr 217-005



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work. NOTE! Cable ties and clamps that secure hoses and electrical wiring must be removed and then replaced when installing. 1. Place the machine in the service position B. See 091 Service positions 2. Turn the battery disconnect switch to off position. 3. Remove the engine room under covers.



Figure 1



1.



Engine room under cover



4. Disconnect wire harness connector and clamps.



Figure 2



1. 2. 3.



Oil pan Clamp Wire harness connector



5. Remove the oil level sensor and replace it with a new one.



Figure 3



1.



Oil level sensor



6. Restore the machine to operating condition. 7. Set the ignition switch to “ON” position and check the oil level on the I-ECU.



Figure 4



8. Install the engine room under covers.



Service Information Document Title: Lubrication description



Function Group: system, 220



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Lubrication system, description The engine is pressure-lubricated by a gear-pump that is driven by the engine's crankshaft. The pump transports oil from the oil sump and up through channels, pipes, and hoses to lubrication points and to the piston cooling system. Seven valves are located inside the cylinder block, pump, and oil filter housing. The valves regulate the oil flow in the system. The oil from the lubrication system passes through an oil cooler where the oil is cooled by the engine's coolant. It also passes through two full-flow filters and one by-pass filter to filter out foreign particles. The oil for the lubrication system is separate from the oil in the burner's air pump for the Exhaust Aftertreatment system (only on machines equipped with Diesel Particulate Filter — H-model engines). For information about other systems that affect the lubrication system:   



212 Crankcase ventilation, description 260 Cooling system, description 293 Exhaust Gas Recirculation (EGR), description (only H-model engines)



Figure 1



Red — before filter Orange — after filter 1. 2. 3.



Oil level and temperature sensor (SE2205,SE2202/FX1006) Strainer Pipe



4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. A. B. C.



D. E. F. G.



Oil pump Main lubrication channel, cylinder block Oil separator, crankcase ventilation (only H-model engines) Air compressor Connection housing EGR valve (only H-model engines) Turbocharger Oil cooler Piston cooling nozzles Pressure pipe Filter housing Full-flow filters By-pass filter Reduction valve — maintains the oil pressure at correct level. Safety valve — protects the oil pump, filter, and oil cooler against excessive pressure when the oil's viscosity is high. Oil thermostat valve — regulates the oil temperature to the optimal value. The thermostat is open when the engine temperature is low, ensuring that the oil circulates through the engine without being cooled. As the oil temperature increases, the thermostat gradually closes the conenction straight into the engine and the oil is forced through the oil cooler. Control valve for piston cooling — regulates the oil flow to the piston cooling channel. Opening valve for piston cooling — connects the piston cooling circuit when the oil pressure has increased to the preset opening pressure. Overflow valve for filters — opens and lets oil pass through, by-passing the oil filter if it becomes clogged. Overflow valve for full-flow filter (located in remote oil filter housing) — opens and lets oil pass through, bypassing the oil filter if it becomes clogged.



Oil is drawn up through the strainer via a pipe from the oil sump to the oil pump. The oil pump forces the oil via the pressure pipe into the cylinder block galleries and channels. Then the oil passes through the filter housing and the oil cooler if the thermostat has opened. After being filtered through both full-flow filters, the oil passes through a connection pipe to the main lubrication channel in the cylinder block for distribution to all of the engine's lubrication points and to the oil separator (only H-model engines). The valve mechanism is lubricated via a drilled channel up to the connection housing. The air compressor and the turbo are lubricated via external hoses with oil that has been filtered by the full-flow filter. The EGR valve is operated, lubricated, and cooled by oil from the full-flow filter (only H-model engines). The filtered oil from the by-pass filter is mixed with the rest of the oil in the oil sump. The piston cooling oil is fed into the piston cooling channel in the cylinder block. From here, the oil is sprayed on the underside of the pistons from the nozzles. The piston cooling valves are plugged in the oil filter housing and are not replaceable. The reduction valve is integrated in the oil pump and cannot be replaced as a separate part. The oil temperature sensor (SE2202/FX1006) and the oil level sensor (SE2205/FX1006) are located in the oil sump, except on engine D13 where the oil pressure sensor is located in the main lubrication channel in the engine block on the cold side. Oil pump and cooler



Figure 2



The oil pump is a gear-pump and is bolted to the rear main bearing cap with four bolts. It is driven by a gear (1) directly from the crankshaft's gear. The pump has a helical gear, and its shafts are mounted in bearings set into the pump housing. The reduction valve (2) is located inside the oil pump and regulates the lubrication oil pressure.



Figure 3



The suction system is in two parts and consists of a pipe (1) with the strainer in the sump and a pipe (2). The pipe is bolted to the ladder frame. The pipe is sealed at each end and is available in two lengths, depending on engine type. The pressure pipe (3) is secured and sealed against the cylinder block. The oil cooler (4) is located in the cylinder block cooling jacket on the right side. The oil cooler is bolted directly to the oil cooler's cover (5) and is completely surrounded with coolant due to the flow plate (6). Oil passes from the rear to the front and the coolant passes in the opposite direction. The amount of oil that passes through the cooler is regulated by the oil pump and the oil thermostat. Oil filter housing The purpose of the oil filter housing is to filter, distribute, and regulate the engine oil. The oil valve housing is mounted to the side of the engine. The remote oil filter housing has two full-flow filters and one by-pass filter and is placed separately from the valve housing in order to provide best possible serviceability. The sensor for the lubrication oil pressure is located in the oil filter housing. Piston cooling system



Figure 4



The illustration shows the oil flow for the piston cooling system when the valve (E) has opened and the valve (F) balances the oil flow to the piston cooling channel. The piston cooling nozzle is aimed so that the oil jet hits the inlet hole to the piston cooling chamber. Summary The lubrication system supplies oil to lubrication points and the piston cooling system. A gear-pump is used to pump the oil. The oil is filtered through two full-flow filters and one by-pass filter, and is cooled through an oil cooler that is connected to the cooling system. Seven valves regulate the system. Parameters 



(ACN) Engine oil, change interval



Supplementary information  



200 VCADS Pro, Operations 301 Software parameters, description



Function check 



VCADS test: 28407-3 Sensor values, monitoring



Diagnostics Detailed information about the following relevant warnings and error codes is available under the diagnostics tab. Component



Control unit



Message ID



SE2202 FX1006 (WLO)



MID128



PID175



SE2203



MID128



PID100



SE2205 FX1006 (WLO)



MID128



PID98



Service Information Document Title: Fuel system, description



Function Group: 230



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Fuel system, description The fuel system has two sides; a suction side and a pressure side. The fuel cools the electronic engine control unit via a circuit on the suction side. Then the fuel is filtered by the prefilter. Fuel for the exhaust aftertreatment system is taken from the suction side. On the pressure side, the fuel is filtered by the main filter and then injected into the cylinders by unit injectors. One injector per cylinder. For information about other systems that affect the fuel system: 



254 Exhaust Aftertreatment System, description



Figure 1 Fuel system Pink



Low pressure



Red



Fuel feed pressure



White



Bleed channel



Dashed black



Wiring



1. 2. 3. 4. 5. 6. 7. 8.



Fuel feed pump Fuel tank Fuel injector no. 1 (MA2301) Fuel injector no. 2 (MA2302) Fuel injector no. 3 (MA2303) Fuel injector no. 4 (MA2304) Fuel injector no. 5 (MA2305) Fuel injector no. 6 (MA2306)



9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.



Overflow valve Bleed valve Electronic engine control unit (E-ECU) Fuel feed sensor (SE2301) Prefilter Water trap Water-in-fuel sensor (SE2302) Main filter Fuel filter housing Fuel system interface Fuel for aftertreatment system — only machines equipped with Diesel Particulate Filter



The fuel is drawn by the fuel feed pump through a strainer in the tank to the fuel filter housing where it passes through a non-return valve and through the prefilter with a water trap. By way of the fuel system's interface it then flows through the cooling circuit, which cools the electronic engine control unit (E-ECU). After the cooling circuit, the fuel is mixed with the return fuel from the cylinder head. The return fuel from the cylinder head's fuel rail flows via the overflow valve and on to the fuel feed pump. Then the fuel feed pump sends pressurized fuel through the fuel system's interface to the fuel filter housing and through the main filter. Via the fuel system's interface, the fuel then flows up to the fuel rail in the cylinder head. This rail supplies each unit injector with fuel by way of a ring-shaped channel around each injector in the cylinder head. The overflow valve controls the fuel feed pressure to the injectors. The fuel from the bleed valve on the cylinder head's fuel rail is led via the fuel system's interface back to the fuel tank. Unit injectors



Figure 2



A. B. C.



Pump section Actuator section Injection section



1. 2. 3.



Yoke Sleeve Connector for solenoids



Fuel injection takes place with unit injectors, one for each cylinder, at high pressure. The high injector pressure is created mechanically via the overhead camshaft and rocker arms. The fuel amount and injection timing are controlled electronically by the E-ECU. The unit injectors are of type E3 with two solenoid valves for more precise injection.



The injector is placed in the middle of the cylinder and is held in place by a yoke. The injection section is separated from the coolant by a sleeve. The overflow valve on the cylinder head controls the pressure in the low pressure system, which supplies fuel to the unit injectors and cools them at the same time. The overflow valve has a built-in bleed valve for the fuel system. Fuel filter



Figure 3



1. 2. 3. 4. 5. 6. 7. 8. 9. 10.



Filter housing Fuel feed sensor (SE2301) Pressure checking point, fuel pressure Hand pump Prefilter Water-in-fuel sensor (SE2302/FX1005) Water drain valve Water trap Main filter Bleed valve



Prefilter The prefilter filters the fuel before it passes through the feed pump. Inside the prefilter there is a water trap and a non-return valve. The non-return valve prevents the fuel from running back to the tank when the engine is off, or when pumping by hand. There is a level sensor in the water trap that is monitored by the E-ECU. A message will be shown to the operator when it is time to drain the system. Draining is performed manually by opening the water drain valve. Main filter The main filter filters the fuel after it has passed through the fuel feed pump. The fuel feed sensor in the fuel filter housing measures the feed pressure after the fuel filter. The fuel filter housing also has a built-in bleed valve. The fuel system is vented automatically when the engine starts. Any air in the system flows, together with a small amount of fuel, back to the tank through a pipe. Fuel pump



Figure 4 Fuel feed pump 1. 2.



Safety valve Non-return valve



The fuel pump is of the gear type and is driven mechanically by the engine's timing gear. There are two valves in the fuel feed pump. The safety valve allows the fuel to flow back to the suction side when the pressure becomes too high, e.g., when the fuel filter is clogged. The non-return valve opens when the manual fuel pump is used, so that it is easier to pump the fuel by hand. The hand pump is used to pump fuel into the system if the system has been drained, and a non-return valve prevents fuel from running back to the tank when the engine is off. Parameters There are no parameters for this function. Supplementary information  



200 VCADS Pro, Operations 230 Fuel system, components



Function check  



23016-3 Cylinder balancing, test 23017-3 Feed pressure, inspection



Diagnostics Detailed information about the following relevant warnings and error codes is available under the diagnostics tab. Component



Control unit



Message ID



MA2301



MID128



SID1



MA2302



MID128



SID2



MA2303



MID128



SID3



MA2304



MID128



SID4



MA2305



MID128



SID5



MA2306



MID128



SID6



SE2301



MID128



PID94



SE2302/FX1005



MID128



PID97



SE2303



MID187



PID96



Service Information Document Title: Function Group: Carbon monoxide in fuel 230 system, check



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Carbon monoxide in fuel system, check Carbon monoxide in fuel tank, check with carbon monoxide tester Op nbr 230-001 9808038 Leak detector



1. Run the engine until it is warm. 2. Dismantle 9808038 Leak detector. Lubricate the O-rings with silicone grease or clean vaseline. 3. Fill both chambers with reaction fluid up to the indicated line. 4. Cover the inlet hole at the same time as the carbon monoxide tester is assembled so that no fluid is pressed out. NOTE! The carbon monoxide tester and its fluids may not be exposed to cigarette smoke, exhausts, or similar. Conduct the test on a machine that is not recently refuelled. 5. Rev up the engine several times. 6. Turn off the engine and open the tank cap. Place 9808038 Leak detector over the tank opening and pump 3–5 times on the rubber bulb to suck in air from the tank. Wait 10–15 seconds to see if the reaction fluid reacts. NOTE! Fuel may not be sucked into the carbon monoxide tester. If the reaction fluid in 9808038 Leak detector changes colour, this indicates that there is carbon monoxide in the tank. Very small quantities of carbon monoxide are often present in the machine's systems, that is why the measurement should be repeated if the first measurement generates a reaction. 7. Suck fresh air into 9808038 Leak detector by pumping a few times on the bulb. Pump until the reaction fluid has returned to its original colour. 8. Ventilate the air above the filler hole to the tank and repeat the test. NOTE! Do not blow with exhaled air as it contain carbon dioxide. 9. Reinstall the tank cap.



Service Information Document Title: Fuel feed description



Function Group: pump, 233



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Fuel feed pump, description The feed pump is of the gear type and is driven from the engine timing gears. The capacity is adapted to provide correct pressure and flow to all unit injectors. A fairly high pressure is required to provide reliable filling of the unit injectors.



Figure 1 Fuel feed pump, location



Figure 2 Fuel feed pump 1. Pump housing 2. Safety valve A non-return valve is also fitted in the pump housing cover The flow must be sufficiently great in order to even out any temperature differences of the fuel in the fuel duct in the cylinder head.



Service Information Document Title: Fuel system, bleeding



Function Group: 233



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Fuel system, bleeding Op nbr 233-001 1. Place the machine in the service position B. See 091 Service positions 2. Turn off the main electric power with the battery disconnect switch. 3. Turn the priming pump counterclockwise to unlock the plunger. Pump approximately 200 to 300 strokes until a heavy resistance can be felt. Push the plunger down and turn clockwise to lock into position. Then bleed the fuel system.



Figure 1



1.



Priming pump on filter head.



NOTE! Air bleeding may not be performed using the starter motor. 4. Turn on the electric power, start the engine and let it idle at low idle speed for a few minutes. If the engine is difficult to start, bleed again with the priming pump. NOTE! The priming pump must not be used when the engine is running.



Service Information Document Title: Fuel tank, description



Function Group: 234



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Fuel tank, description The fuel tank acts as a reservoir for supplying fuel to the engine. It is mounted towards right side of the upper frame. Refer to 030 Fuel tank, specifications for the fuel tank filling capacity.



Figure 1



1. 2. 3. 4. 5.



Fuel level sensor cover Strainer Fuel tank air ventilation filter Fuel tank Fuel level gauge



Service Information Document Title: Fuel filling removing



Function Group: pump, 234



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Fuel filling pump, removing Op nbr 234-041 1. Place the machine in the service position C. See 091 Service positions 2. Remove the under cover



Figure 1



3. Disconnect the wire harness connector.



Figure 2



1. 2. 3. 4.



Hose (fuel tank line) Hose (suction line) Fuel filling pump Wire harness connection



4. Disconnect the hoses from the fuel filling pump. 5. Remove the mounting screws and the fuel filling pump from the machine.



Date: 2014/7/14



Service Information Document Title: Function Group: Fuel filling pump, installing 234



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Fuel filling pump, installing Op nbr 234-042 1. Place the machine in the service position C. See 091 Service positions 2. Install a new fuel feed pump with the mounting screws.



Figure 1



1. 2. 3. 4.



Hose (fuel tank line) Hose (suction line) Fuel filling pump Wire harness connection



3. Connect the hoses. 4. Connect the wire harness connector to the fuel feed pump. 5. Check the fuel filler pump. 6. Install the cover.



Figure 2



Date: 2014/7/14



Service Information Document Title: Unit injectors, description



Function Group: 237



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Unit injectors, description The engine has six unit injectors, one for each cylinder. The unit injector is a combination of injection pump and injector, and it can operate at considerably higher pressure than an ordinary injector. The unit injector is vertical and located centrally between the four valves. The pressure force to the unit injector is transferred via a rocker arm from a cam on the overhead camshaft. The injection time, pressure and fuel quantity to be sprayed in are determined by the engine's control unit (E-ECU), which provides signals to the two electromagnetically controlled fuel valves in the unit injector's valve housing. The lower part of the unit injector is placed in a copper sleeve against the bottom of the cylinder head, like an ordinary injector. The intermediate section of the unit injector, where the inlet and outlet holes for the fuel are located, is located in the cylinder head's fuel channel. The unit injector takes fuel directly from the fuel channel. The top section of the unit injector, with thrust spring and valve housing, is located above the cylinder head. The unit injector consists of three main parts: 1. 2. 3.



Pump part, which contains cylinder and piston, corresponding to the pump element in an injection pump. Valve housing, with two electromagnetically controlled fuel valves. Injector part, with nozzle sleeve, nozzle needle, and spring.



Figure 1 Unit injector 1. 2.



Pump part Valve part



3.



Injector part



Injector valves By means of the injector it is possible to control the injection time, fuel quantity and also injection pressure with two separate valves activated by the solenoids. Spill valve (SV)function is to build up the fuel pressure in the injector's high-pressure channel. As long as the valve is open the fuel leaks from the pump chamber back to the cylinder head's fuel channel. When the valve closes there is a pressure build-up in the injector which enables injection into the engine's combustion chamber. Needle Control Valve (NCV)controls the pressure in a counter-pressure chamber above the nozzle needle. As long as the valve is closed there is a pressure build-up that prevents the nozzle needle from opening. When the valve opens the nozzle needle is allowed to open, and injection takes place. In this way the opening pressure can be controlled steplessly between 300 bar and 2000 bar. Unit injectors, tolerance classification The unit injectors are manufactured with tolerance classification. Each unit injector is marked with a code (1) on top of the electric connection. When replacing one or more of the unit injectors, the new codes must be programmed for the cylinder where a unit injector has been replaced. This is done through parameter programming using the service tool VCADS Pro.



Figure 2 Tolerance classification, unit injectors 1.



Position, code



Service Information Document Title: Function Group: Inlet and exhaust system, 250 description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Inlet and exhaust system, description The engine takes in clean air through the inlet system and the fuel comes from a separate fuel system. Included in the inlet and exhaust system there are subsystems such as exhaust aftertreatment, turbocharger (VGT) and exhaust gas recirculation system. For information about the subsystems, see    



254 Exhaust Aftertreatment System, description 255 Turbocharger, description 293 Exhaust Gas Recirculation (EGR), description 212 Crankcase ventilation, description



Figure 1 Inlet and exhaust system Red = exhaust gas



Blue = inlet air Brown = crankcase air Dashed black = wiring 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.



Diesel engine Pre heater EGR mixing chamber Charge air cooler Air filter Compressor Air dryer Air tank Turbo charger (VGT) EGR Venturi tube EGR cooler EGR valve Crank case ventilation Charge air temperature and pressure sensor (FX1007; SE2507, SE2508) Ambient air temperature and pressure sensor (FX1008; SE2501, SE2502)



E-ECU = Engine-Electronic Control Unit Inlet and exhaust manifold



Figure 2



1. 2.



Exhaust manifold Inlet manifold



Each cylinder has a separate inlet channel on one side of the cylinder head, and a separate exhaust channel on the other. The inlet manifold is a one piece open box design. ART applications has rear entry inlet manifold, while EXC and WLO have front entry, due to different installations. The exhaust manifold is manufactured in three sections covering two exhaust ports each. Between the cylinder head and the manifold flanges graphite-coated gaskets are used to prevent exhaust leakage. The exhaust manifold joints are of sliding type with sleeve seals. Air filter



Figure 3 Air filter It is important that the air taken into the engine is free from pollutants. The air filter insert consists of a folded filter paper which is protected by a mesh. The air is forced to flow in the intended path through the inlet. Starter element



Figure 4 Starter element Its purpose is to heat the air in the inlet manifold before the engine is started. This heated air helps the engine start easier and reduces white smoke in cold starts. The starter element is electrically heated and consists of two or three heater coils through which the air flows. Charge air cooler The charge air cooler is an air to air cooler and reduces the air temperature by approximately 100°C (212°F) and is raising engine power output by about 10%. Torque is increasing and fuel consumption drops. Turbocharging raises the temperature of the air entering the engine. If the air is cooled when exiting the turbocharger, its volume is reduced so more air (oxygen) can be pressed into the cylinders. This makes it possible to feed more fuel and produce more engine power. The service life of the engine increases since there is less thermal stress on the engine. Parameters 



There are no parameters for this function.



Complementary information 



250 Inlet and exhaust system, component location



Diagnostics Detailed information about relevant warnings and error codes below is available under the diagnostics tab. Component



Control unit



Message ID



HE2501



MID128



SID70



RE2501



MID128



PID45



SE2507



MID128



PID105



SE2508



MID128



PID102



FX1008 (SE2501)



MID128



PID172



FX1008 (SE2502)



MID128



PID107



Boost air system



MID128



PSID98



Service Information Document Title: Function Group: Inlet and exhaust system, 250 component location



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Inlet and exhaust system, component location



Figure 1



1. 2. 3. 4. 5. 6. 7. 8. 9. 10.



Exhaust manifold Sensor Pre-cleaner Air cleaner Inlet hose Turbocharger actuator VGT turbocharger Exhaust flexible tube Muffler (DPF and burner) Tale pipe



Date: 2014/7/14



Service Information Document Title: Function Group: Exhaust pipe, flexible tube, 252 replacing



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Exhaust pipe, flexible tube, replacing Op nbr 252-021 NOTE! If the flexible tube is to be reused, mark the tube by drawing a line between the clamps. 1. Park the machine in service position B, see 091 Service positions. 2. Open the engine hood. 3. Remove the foot step.



Figure 1



4. Remove the clamps.



Figure 2



1.



Clamp



5. Remove the flexible tube.



Date: 2014/7/14



6. Install the new gaskets on the flanges.



Figure 3



1. 2.



Exhaust flexible tube Gasket



7. Install a new flexible tube. 8. Install the upper end of the flexible tube. 9. Install and tighten the new upper clamps. Tightening torque, see 250 Inlet and exhaust system, tightening torques. NOTE!  



Make sure there are no tensions on the flexible tube. Make sure the clamps are placed right in the flange coupling.



10. Control from two directions that the flexible tube is straight and not bent.



Figure 4



11. If the tube is bent, loosen the clamps to the DPF and adjust the DPF until the tube is straight. 12. Make sure that the markings on the flexible tube is lined and the flow direction is as marked arrow on the label.



Figure 5



1. 2.



Lined markings Marked flow direction



Service Information Document Title: Function Group: Exhaust Aftertreatment 254 System, component location



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Exhaust Aftertreatment System, component location



Figure 1



1. 2. 3. 4. 5. 6. 7. 8. 9.



Aftertreatment control module (ACM) Compressed air cooler Muffler (DPF and burner) Atomization unit Purge tank Air filter Compressor Air tank Air pump



For more information about the components, see 254 Exhaust Aftertreatment System, description.



Service Information Document Title: Function Group: Exhaust Aftertreatment 254 System, description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Exhaust Aftertreatment System, description The engine features an exhaust aftertreatment system (EATS) in the form of a diesel particulate filter (DPF) to meet the the legal limit for particles. The DPF is continuously loaded with soot from the engine exhausts and needs to be regenerated periodically. The regeneration process involves the use of additional fuel and air added to the exhausts, which are ignited and combusted in the burner (to increase the internal temperature of the DPF), to burn off the trapped soot. When the soot has been burned off, the DPF is clean from soot and will regain its full soot trapping capacity. Systems that also reduce NO and particles from the exhausts, and will affect the exhaust aftertreatment system, are:    



255 Turbocharger, description 293 Exhaust Gas Recirculation (EGR), description 250 Inlet and exhaust system, description 230 Fuel system, description



Figure 1 Exhaust aftertreatment system during regeneration Green



Fuel



Blue



Air



Red



Exhausts



Black dashed



Wiring



ACM



Aftertreatment control module



E-ECU



Engine electronic control unit



1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.



Muffler Aftertreatment support unit (ASU) Atomization module Fuel pump Shut-off valve (MA2507) Ignition coil (IG2501) Main fuel filter Fuel prefilter Air cleaner Burner air pump (MA2506) Diesel engine Compressor Air dryer Regeneration air tank Air tank Priority valve (only ART) Turbocharger (Variable Geometry Turbine, VGT) Non-return valve Exhaust temp. sensor (SE2510) Flame temp. sensor (SE2529) DPF inlet temp. sensor (SE2521) Differential pressure sensor (SE2519) DPF outlet temp. sensor (SE2522) Nozzle pressure sensor (SE2527) Fuel pressure sensor (SE2528) Fuel pump (MO2504) Master air solenoid valve (PWM2504, FX1032) Atomization air solenoid valve (PWM2505, FX1032) Fuel injector solenoid valve (MA2514)



Regeneration The engine electronic control unit (E-ECU) and the aftertreatment control module (ACM) calculate together when regeneration is needed. This is done by the so-called "soot model", which uses fuel consumption, elapsed time, engine operating conditions, and the differential pressure sensor's signal (measuring differential pressure across the muffler) as input signals for the calculation. When the exhausts enter the DPF, they passes through a porous ceramic substrate which traps and removes the soot (particles) from the exhausts and allows the filtered exhausts to exit the unit. During DPF regeneration, the exhaust temperature is increased to 600-700°C (1112–1292°F) in order to burn the soot trapped in the DPF. Aftertreatment support unit (ASU)



Figure 2 Aftertreatment support unit 1. 2. 3. 4.



Atomization module Nozzle pressure sensor (SE2527) Fuel pressure sensor (SE2528) WLO, EXC: Connector FX1032 (for PWM2504, PWM2505, MA2514) ART: Connector (for PWM2504, PWM2505, MA2514)



5. 6.



Ignition coil Fuel pump with electric motor (MO2504)



The purpose of the atomization unit is to mix air and fuel into an atomized fuel/air spray, which is injected into the burner through the burner's nozzle during regeneration. The internal parts, such as atomization module, shut-off valve, fuel pump, and ignition coil, are controlled by the ACM. Atomization module The module has two inlets with filter, one for air and one for fuel. High pressure air is supplied into the atomization module from the compressor. The fuel pump delivers fuel to the atomization module. Excess fuel from the fuel regulator is returned from the atomization module to the fuel pump's inlet. Fuel is injected by a PWM-controlled fuel injector into the high pressure air flow. The pressurized air is used to reduce droplet size of the injected fuel (=atomize the fuel) to mix with the air flow. Then this air/fuel mixture is injected through a nozzle into the burner's combustion chamber and is ignited by the ignition system. If the nozzle pressure decreases, the exhaust temperature will become too high and an error code will be generated. If the fuel pressure becomes too low, the fuel injector (MA2514) will close to prevent the air from draining the fuel system. During normal engine operation, a small air flow is used to purge the nozzle and prevent clogging. Burner and wall flow DPF



Figure 3 Muffler 1. 2. 3.



Burner section DPF section Outlet section



Wall flow means that 100% of the exhausts are forced through the walls of the filter, where soot and ash is trapped and collected. During engine operation, soot and ash accumulate in the DPF wall flow substrate. The soot comes primarily from the combustion of fuel and is burned off during regeneration of the filter. The ash comes primarily from the engine oil and engine wear. Ash is not combustible and therefore it will not be burned off during regeneration. The complete muffler consists of a three main parts; the burner section with integrated inlet, the DPF section containing the substrate, and the outlet section. Combustion air system The air pump supplies combustion air to the burner section, and the air is needed to maintain stable combustion in the burner. The air pump will only operate during regeneration. The non-return valve lets air from the air pump pass through to the burner during regeneration. When regeneration is inactive, the non-return valve prevents exhausts from flowing back to the air pump and out to the atmosphere. The nonreturn valve is a mechanical spring-loaded valve that opens automatically when the air pump is running. Ignition system



Figure 4 Burner with igniters and sensors 1. 2. 3. 4.



Exhaust temperature sensor Igniters Air/fuel mixture nozzle Flame temperature sensor



The air/fuel mixture is sprayed into the burner. The ignition system ignites the air/fuel mixture. The ignition system consists of the ignition coil, two ignition wires, and two igniters. The igniters pulse to provide a steady spark, an arc, which bridges the gap between the ends of the two electrodes. Parameters There are no parameters for this function. Summary The exhaust aftertreatment system (EATS) is in the form of a diesel particulate filter (DPF) to be able to trap particles. The DPF is continuously loaded with soot from the engine exhausts and needs to be regenerated periodically. The soot comes primarily from the combustion of fuel and is burned off during regeneration of the DPF. The ash comes primarily from the engine oil and engine wear. Ash is not burned off during regeneration. A fuel/air mixture is injected into the burner. The mixture is ignited by the spark generated across the igniters. The resulting flame heats the particulate filter to the temperature necessary to burn off the soot. To maintain stable combustion, combustion air is also added. The regeneration process is self-monitoring using the muffler’s four temperature sensors and the differential pressure sensor. Supplementary information   



254 Exhaust Aftertreatment System, component location 254 Regeneration process, description 254 Exhaust aftertreatment system, specifications



Function check  



25410-3 Air pump exhaust aftertreatment, test 25411-3 Burner exhaust aftertreatment, test



Diagnostics Detailed information about the following relevant warnings and error codes is available under the diagnostics tab. Component/Display message



Control unit



Message ID



IG2501



MID128



PSID110



MA2506



MID128



PSID122



MA2507 EF 2505 (ART)



MID128



PPID328



MID128



PPID329



MA2514



MID128



PPID329



MID128



PSID108



MO2504



MID128



PSID111



PWM2504 FX1032



MID128



PSID58



PWM2505 FX1032



MID128



PSID59



SE2510 EF2525 (ART)



MID128



PID173



SE2519



MID128



PID81



SE2521



MID128



PPID387



SE2522



MID128



PPID436



SE2527



MID128



PPID277



SE2528



MID128



PPID437



SE2529



MID128



PPID440



MID128 EF2111 (ART) MID128 PSID232 (EXC, WLO)



MID128



PSID232



MID128 EF2132 (ART) MID128 PSID229 (EXC, WLO)



MID128



PSID229



MID128 EF2501 (ART) MID128 PSID77 (EXC, WLO)



MID128



PSID77



MID128 EF2503 (ART) MID128 PSID113 (EXC, WLO)



MID128



PSID113



MID128 EF2506 (ART) MID128 PSID22 (EXC, WLO)



MID128



PSID22



MID128 EF2507 (ART) MID128 PSID49 (EXC, WLO)



MID128



PSID49



MID128 EF2508 (ART) MID128 PSID113 (EXC, WLO)



MID128



PSID113



MID128 EF2510 (ART) MID128 PPID337 (EXC, WLO)



MID128



PPID337



MID128 EF2511 (ART) MID128 PSID108 (EXC, WLO)



MID128



PSID108



MID128 EF2512 (ART) MID128 PSID28 (EXC, WLO) MID128 PPID326 (EXC, WLO)



MID128



PSID28



MID128



PPID326



MID128 EF2526 (ART) MID128 PSID114 (EXC, WLO)



MID128



PSID114



MID128 EF2528 (ART) MID128 PSID127 (EXC, WLO)



MID128



PSID127



Service Information Document Title: Regeneration description



Function Group: process, 254



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Regeneration process, description 1. Wait state The software waits for a signal from the E-ECU to start the regeneration process. The E-ECU will start the regeneration process via the ACM when all parameters are correct and no error messages and error codes are generated from following actuators :       



Fuel pump Fuel shut-off valve Fuel injector Master air valve Atomization air valve Combustion air valve Igniters



2. Active diagnose state The software runs an active test of the components (see 1. Wait state). In case the EATS' fuel pressure falls too low, priming of the EATS fuel system will be requested. Priming will end as soon as the fuel pressure is higher than the pre-set minimum fuel pressure or when the air pressure is higher than the pre-set minimum nozzle pressure. If both priming time and number of tries have been exceeded, the priming has failed and sets the burner in error state until restart. 3. Igniters' cleaning state The igniters and master air valve are activated to clean the igniters from soot. 4. Preparation state This state is just to allow a couple of seconds of delay time for the actuators to get into position prior to start of fuel injection and ignition. Everything is activated except for the fuel injector. The flame temperature sensor's value is checked. If this temperature is too high, the process is returned to 1 wait state. 5. Ignition state This state handles the time limit for flame detection. The goal is to achieve reliable combustion while limiting the amount of unburned hydrocarbon emissions. The fuel rate is optimized for ignition. A noticeable increase in flame temperature is expected during the first few seconds following ignition. The exhaust temperature is also an indication of a flame, so therefore the software monitors both flame temperature and DPF inlet temperature sensors. If the result exceeds the limit value for minimum temperature increase, then the flame is considered lit. 6. Warm-up state The system attempts to achieve a steady state for the flame before making any attempt to increase the temperature in the system. The burner operates until the temperature demand is reached. If the flame temp. is detected as being too high, the process goes to state 9 Cool Down State. If the flame is lost or exhaust or DPF temperature is too high the process goes to state 11, Error state. 7. Ramp-up state The rate of the temperature increase is limited to avoid rapid thermal changes. The final regeneration temperature is predetermined. The software provides closed loop control of the DPF temperature. The DPF temperature is controlled by adjusting the fuel flow to the burner in relation to the difference between the temperature measured at the DPF inlet and the target temperature. The calculated fuel flow is finally converted to a PWM-signal, with which the fuel injector's actuator is driven. 8. Regeneration state The software attempts to maintain the DPF inlet temperature at the target regeneration temperature. The software continues in this state until the required soot combustion time has elapsed. 9. Cool-down state



The target temperature is determined as a function of exhaust temperature, such that a ramp-down of temperature is achieved. The cool-down state is given a fixed amount of time. The added combustion air helps to cool the system and to clean the igniters. 10. Shut-down state The igniters are activated, so that any fuel residue will be ignited. To cool down the nozzle, the injector is shut off but atomization air and ignition remain activated for a predefined time. 11. Error state The system shall go to error state if any malfunction condition is encountered which requires the system to cancel any state that is associated with an active burner (state 2-9). A transfer to error state will also take place if the flame is lost, ignition fails, or in case of malfunction detection during active diagnostics. In case of a major malfunction, a transfer to wait state will take place if the malfunction "recovers". 12. Power down state The system stays in the power down state for a predefined time. For limit values and limits, see 254 Exhaust aftertreatment system, specifications.



Service Information Document Title: Perform a regeneration



Function Group: service 254



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Perform a service regeneration Op nbr 254-020 NOTE! Before a service regeneration is performed, the DPF differential pressure test MUST be performed to measure back-pressure through the DPF. If the differential pressure is too high, a DPF regeneration MUST NOT be performed because the filter is filled over capacity with soot or ash. The filter must be replaced. If a regeneration is performed, the filter is at risk of cracking which ruins core value. 1. Operate engine until engine coolant temperature (ECT) reaches at least 82°C (180°F). 2. Start VCADS Pro and run 25456-3 Exhaust aftertreatment diagnostics. 3. Monitor the DPF differential pressure for maximum value while operating the engine (vehicle stationary) at maximum RPM for 30 seconds. 4. Compare the results with specifications. See 254 Exhaust aftertreatment system, specifications  



If the differential pressure is greater than the specification the DPF has to be replaced according to 254 Diesel particulate filter, check and clean If the differential pressure is below the specification, start 25457-3 Diesel Particulate Filter Service Regeneration in VCADS Pro.



5. Idle engine until exhaust gas temperature (EGT) is below 300°C (572°F). 6. Run 25456-3 Exhaust aftertreatment diagnostics. 7. Monitor the DPF differential pressure for maximum value while operating the engine (vehicle stationary) at maximum RPM for 30 seconds. 8. Compare the results with specifications. See 254 Exhaust aftertreatment system, specifications 



If the differential pressure is greater than the specification the DPF has to be replaced according to 254 Diesel particulate filter, check and clean.



NOTE! It is necessary to repeat the DPF differential pressure test after the service DPF regeneration has completed and after the EGT has stabilized at normal levels. This test will reveal a filter that is clogged with ash, or otherwise damaged with a restriction level that is too high.



Service Information Document Title: Diesel particulate check and clean



Function Group: filter, 254



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Diesel particulate filter, check and clean Op nbr 254-001 VCADS Pro VCADS Pro Service Tool



NOTE! If the flexible tube is to be reused, mark the tube by drawing a line between the clamps. 1. Park the machine in service position B, see 091 Service positions. 2. Remove the DPF hood. 3. Disconnect the sensors.



Figure 1



1. 2.



DPF outlet temperature sensor DPF differential pressure sensor



4. Remove screws and put aside the wire harness.



Date: 2014/7/14



Figure 2



1.



Screw



5. Remove the clamp and then remove the outlet module with a tale pipe from the DPF.



Figure 3



1. 2. 3. 4.



Bracket Clamp Outlet module Tale pipe



6. Remove the bracket and the clamp.



Figure 4



1. 2. 3. 4.



Bracket Screw DPF Clamp



7. Remove the cover from the old filter and install it to a new filter. 8. Clean the filter and covers from remains of old gaskets and soot. The filter must be cleaned by Volvo according to Volvo Core handling instructions. 9. Clean the contact surfaces of the new clamps, filter and catalyst with a cleaning agent. Place a new gasket on the flange of the catalyst Install a new filter NOTE!



Hammer lightly with a plastic hammer on 254 Exhaust aftertreatment system, tightening torques.



the



clamp



and



torque-tighten



it



according



to



NOTE! Use only new gaskets and V-clamps when installing. NOTE! Pay attention to the flow direction mark on the filter when installing. 10. Restore the machine to operating condition. See 252 Exhaust pipe, flexible tube, replacing for exhaust tube installing. 11. To reset the soot load and ash load, run VCADS PRO operation “VCADS Pro, 25460-3, Reset soot and ash load”. NOTE! Keep the sensor wire harness routing when installing.



Service Information Document Title: ACM, replacing, programmed



Function Group: pre- 254



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



ACM, replacing, pre-programmed Op nbr 254-023 VCADS Pro VCADS Pro Service Tool 88890180 Interface 88890027 Cable



1. Park the machine in the service position A, see 091 Service positions. 2. Turn OFF the battery disconnect switch. 3. Connect VCADS Pro computer to the machine, and perform the operation '17030-3 Parameter, programming'. 4. Use the function 'save all parameters to job card'. 5. Disconnect the wiring harness connector from ACM and remove a screw fixing the clamp.



Figure 1



1. 2.



Connector Screw



NOTE! Pull up the locking device to disconnect the connector. 6. Remove 4 screws fixing the ACM.



7. Install new ACM, and tighten 4 screws fixing the ACM. 8. Connect the wiring harness connectors to the ACM and tighten a screw fixing the clamp. 9. Connect VCADS Pro computer to the machine, and perform the operation 17030-3 Parameter, programming'. Now



the customer parameters are changed according to the job card saved at step 2. 10. Perform a service regeneration to secure the actual soot level in the DPF, see 254 Perform a service regeneration. 11. Start the machine and check that no error message appear.



Service Information Document Title: ACM, replacing, programmed



Function Group: non- 254



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



ACM, replacing, non-programmed Op nbr 254-022 VCADS Pro VCADS Pro Service Tool 88890180 Interface 88890027 Cable



1. Park the machine in the service position A, see 091 Service positions. 2. Turn OFF the battery disconnect switch. 3. Download software to VCADS Pro computer for target machine. 4. Connect the VCADS Pro computer to the machine, and perform the operation '25801-3 MID 233 control unit, programming'. 5. When VCADS Pro 'MID 233 ACM, programming' window appears, follow the instructions for replacing ACM. 6. Disconnect the wiring harness connectors from ACM and remove a screw fixing the clamp.



Figure 1



1. 2.



Connector Screw



NOTE! Pull up the locking device to disconnect the connector. 7. Remove 4 screws fixing the ACM. 8. Install new ACM, and tighten 4 screws. 9. Connect the wiring harness connectors to the ACM and tighten a screw fixing the clamp.



10. After replacing ACM, press OK button of VCADS Pro operation '25801-3 MID 233 control unit, programming'. Now VCADS Pro starts the programming of software and parameters to the new ACM. 11. Perform a service regeneration to secure the actual soot level in the DPF, see 254 Perform a service regeneration. 12. Start the machine and check that no error message appear.



Service Information Document Title: Spark plug, checking



Function Group: 254



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Spark plug, checking Op nbr 254-047 88830188 Measuring tool



DANGER Risk of electrocution. Contact with live parts will cause death or serious injury. Never touch live electrical parts. Carefully follow procedures to de-energize the machine. 1. Place the machine in service position B, see, 091 Service positions. 2. Turn OFF the battery disconnection switch. 3. Remove the DPF hood.



WARNING



4.



Risk of burns as well as damage to the spark plug cables when removing them before the parts have cooled down. Remove the hose clamp and disconnect the air hose from the DPF. Disconnect the ground braid. Disconnect the spark plug cables and the ground cables from the DPF. Disconnect the fuel hose from the ASU. Mark the position for the hood's stop block and remove it. Disconnect the ground cable. To avoid breaking the sensor, remove the cable ties that hold the sensor cable. 5. Remove spark plug caps and fuel nozzle from the burner.



Figure 1



1.



Fuel nozzle



2.



Spark plug cap



6. Check the clearance between the electrodes. Use a flashlight. If the go-side cannot pass, or if the stop-side can, the spark plugs must be replaced. NOTE! The tool must be inserted at a slight angle from below.



Figure 2



7.



1.



88830188 Measuring tool



1.



If the spark plug gap is not correct, continue to tighten one spark plug to maximum torque 35 Nm (26 lb ft) and check the gap again. If the gap is still not correct, tighten the second spark plug to 35 Nm (26 lb ft) and check the gap again. If the gap is still not correct, remove both spark plugs, switch their positions, and torque-tighten them to 30 Nm (22 lb ft) and check the gap again.



2. 3.



8. Install the nozzle using a new washer. Tightening torque: 20 Nm (14.8 lb ft). Connect the hose. 9. Restore the machine to operating condition.



Service Information Document Title: Spark plug, replacing



Function Group: 254



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Spark plug, replacing Op nbr 254-046 88830188 Measuring tool



DANGER Risk of electrocution. Contact with live parts will cause death or serious injury. Never touch live electrical parts. Carefully follow procedures to de-energize the machine.



WARNING Risk of burns as well as damage to the spark plug cables when removing them before the parts have cooled down. 1. Park the machine in service position B, see 091 Service positions. 2. Switch off the battery disconnect switch. 3. Remove the DPF hood. 4. Disconnect the spark plug cables from the DPF burner.



Figure 1



1. 2. 3. 4.



ASU (After treatment support unit) Clip Spark plug cable DPF burner



5. Remove the spark plugs. Install the 254 Exhaust aftertreatment system, tightening torques.



new



spark



plugs.



Tightening



torque,



see



6. Remove the hose from the nozzle. Remove the nozzle from the burner.



Figure 2



1.



Nozzle



7. Check the gap between the spark plugs' electrodes. Use a flashlight. If the go-side cannot pass, or if the stop-side can, the gap between the spark plugs must be adjusted. NOTE! The tool must be inserted at a slight angle from below.



Figure 3



8.



1.



88830188 Measuring tool



1.



If the spark plug gap is not correct, continue to tighten one spark plug to maximum torque 35 Nm (26 lb ft) and check the gap again. If the gap is still not correct, tighten the second spark plug to 35 Nm (26 lb ft) and check the gap again. If the gap is still not correct, remove both spark plugs, switch their positions, and torque-tighten them to 30 Nm (22 lb ft) and check the gap again.



2. 3.



9. Install the nozzle using a new washer. Tightening torque: 20 Nm (14.8 lb ft). Connect the hose. 10. Restore the machine.



Service Information Document Title: Function Group: Spark plug cable, replacing 254



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Spark plug cable, replacing Op nbr 254-048



DANGER Risk of electrocution. Contact with live parts will cause death or serious injury. Never touch live electrical parts. 1. Park the machine in service position B, see 091 Service positions. 2. Remove the DPF hood. 3. Remove the screw and the clip on the cables.



Figure 1



1.



Screw



4. Pull out and remove the cables from both the DPF burner and the ASU and then replace them with new one.



Figure 2



1. 2. 3. 4.



ASU (After treatment support unit) Clip Spark plug cable DPF burner



NOTE! Cables must be firmly connected to the DPF buner and the ASU, check the connection after installing. 5. Install the screw and the clip. 6. Install the DPF hood.



Service Information Document Title: Turbocharger, description



Function Group: 255



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Turbocharger, description The turbocharger is driven by the exhausts. The exhaust flow causes the turbine rotor in the turbine housing to rotate. When the compressor rotor turns, air is drawn (sucked) from the air cleaner. The air is compressed and forced into the engine cylinders via the charge-air cooler, where the air is cooled. A turbocharger with variable geometry (VGT) is used to quickly regulate the charge-air pressure and drive the EGR. The extent of turbocharger function can be varied by the speed of the gases entering into the turbine. This is controlled by the engine electronic control unit via an electrically operated actuator on the turbocharger. On Articulated Haulers, VGT is also used as an auxiliary engine brake. For information about the systems that affect the VGT, see   



293 Exhaust Gas Recirculation (EGR), description 250 Inlet and exhaust system, description



For Articulated Haulers, see also 



253 Auxiliary brake (engine braking), description



Figure 1



Red = exhausts Blue = inlet air Dashed black = wiring 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.



Basic engine Variable geometry turbine, VGT Air filter Charge-air cooler Mixing chamber Coolant temperature, sensor (SE2606) EGR temperature, sensor (SE2516) EGR differential pressure, sensor (SE2515) Charge-air temperature and boost pressure, sensor (SE2507 and SE2508) Turbine speed, sensor (SE2514) Electric actuator (MO2501) EGR solenoid valve (PWM2503)



E-ECU = Engine electronic control unit



The turbocharger has a set of vanes and an adjustable nozzle ring, which means that the boost pressure can be varied independent of engine speed. The engine electronic control unit regulates the nozzle ring via the actuator that regulates the nozzle's sector shaft to the requested position. The nozzle ring is controlled based on engine load, the EGR-valve, and the quantity of recirculated exhausts in the inlet pipe. The air inlet is divided into two areas - inner and outer - connected by a circular opening. This turbocharger design ensures efficiency at both low and high rotation speeds. The nozzle ring maintains sufficient back-pressure in the exhaust manifold for correct operation of the EGR-system. A certain amount of back-pressure is required to force the exhausts into the pressurized inlet air by the EGR mixing chamber. Also, the sliding nozzle ring controls the exhausts' back-pressure for enhanced braking. By fully closing the nozzle mechanism, the turbocharger works as an exhaust brake. The possibility of adjusting the inlet manifold's pressure ensures that an optimal amount of recirculated exhausts can be obtained throughout the entire engine speed range.



Figure 2 VGT A. B. C.



Exhausts Air inlet Charge-air outlet



1. 2. 3. 4. 5.



Electric actuator Speed sensor (SE2514) Compressor rotor Sliding nozzle ring and vanes Turbine rotor



Nozzle ring fully open     



Engine at idle or zero throttle Maximum turbine throat area Minimum boost pressure Minimum turbine speed Minimum exhaust manifold pressure



    



Engine cruise mode or part throttle load Reducing turbine throat area Increasing exhaust manifold pressure Increasing turbine speed Increasing turbo boost



Nozzle ring partly open



Nozzle ring fully closed    



Minimum turbine throat area Maximum boost pressure Maximum turbine speed Maximum exhaust manifold pressure



Actuator



Figure 3



1. 2. 3.



Electric motor (MO2501) Gear sector Lever



The actuator consists of an electric motor that is connected to gears and gear sector that moves the lever. The lever is connected to the nozzle ring. The nozzle ring is fully open in its neutral position. The actuator "knows" its own position, load, temperature, and history. It memorizes its end-positions and range when first calibrated together with the turbo. The actuator is connected to the engine control unit with a connector. Lubrication is obtained with engine oil directly from the partial-flow filter (fine filter). The turbocharger and the actuator are cooled by the engine coolant. Parameters There are no parameters for this function. Summary The turbocharger with a variable geometry turbine is essential to the EGR-system. The turbocharger has an adjustable nozzle ring that is adjusted by the engine control unit via an actuator. With an adjustable nozzle ring, it is possible to adjust the boost pressure regardless of engine speed. Supplementary information 



Turbocharger, component description



Function check 



VCADS Pro, 25537-3 - Variable geometry turbo function test



Diagnostics Detailed information about the following relevant warnings and error codes is available under the diagnostics tab. Component



Control unit



Message ID



FX1007 (SE2507, SE2508)



MID128



PID102



MID128



PID105



PWM2503



MID128



SID146



MO2501



MID128



PSID27



SE2514



MID128



PID103



SE2515



MID128



PID411



SE2516



MID128



PID412



SE2606



MID128



PID110



ART: EF2127 WLO: No component designation EXC: No component designation



MID128



PPID89



New servinfo



Service Information Document Title: Preheating coil, replacing



Function Group: 256



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Preheating coil, replacing Op nbr 256-006



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work. 1. Open the cover for the battery disconnect switch on the right side of the machine.



Figure 1



2. Ensure the battery disconnect switch is at OFF position.



Figure 2



3. Open the engine hood. 4. Remove the charge air cooler pipe clamp.



Figure 3



1. 2. 3.



Charge air cooler pipe Clamp Preheating coil



5. Remove the wire harness connectors.



Figure 4



1.



Wire harness connector



6. Remove the mounting screws and pre-heater coil. NOTE! Check the pre-heater coil gaskets (both side) and replace them if necessary.



Figure 5



1.



Pre-heater coil mounting screw



7. Install a new pre-heater coil. 8. Connect the wire harness connectors. 9. Install the intercooler hose clamp. 10. Close the engine hood.



Service Information Document Title: Function Group: Air cleaner, cleaning filter 256 element



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Air cleaner, cleaning filter element Op nbr 256-001 1. Open the side door on the left side of the machine. 2. Open the air cleaner cover. 3. Pull out the air cleaner primary filter and carefully tap the end of the filter against a soft and clean surface.



Figure 1



4. Clean the filter using clean and dry compressed air with a max. pressure of 500 kPa (5 bar) (73 psi). NOTE! If there is the smallest hole, scratch, crack or other damage, the filter must be replace with a new one. 5. Install the primary filter and the cover. 6. Close the side door.



Service Information Document Title: Function Group: Air cleaner, primary filter 256 replacing



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Air cleaner, primary filter replacing Op nbr 256-003 NOTE! Replace the primary filter after cleaning 5 times maximum, or at least once every year. 1. Open the side door on the left side of the machine. 2. Open the air cleaner cover. 3. Remove the air cleaner primary filter and clean the filter housing.



Figure 1



4. Install a new primary filter 5. Close the air cleaner cover and the side door.



Date: 2014/7/14



Service Information Document Title: Function Group: Air cleaner, secondary filter 256 replacing



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Air cleaner, secondary filter replacing Op nbr 256-004 NOTE! Replace the secondary air filter every 3rd primary filter replacement, or at least every 2 years. 1. Open the side door on the left side of the machine. 2. Open the air cleaner cover. 3. Remove the air cleaner primary filter.



Figure 1



4. Remove the air cleaner secondary filter and clean the filter housing



Figure 2



5. Install a new secondary filter and the primary filter 6. Close the air cleaner cover and the side door.



Date: 2014/7/14



Service Information Document Title: Intercooler, replacing



Function Group: 258



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Intercooler, replacing Op nbr 258-002



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work.



WARNING The parts are heavy. Take appropriate safety precautions. 1. Park the machine in service position B, see 091 Service positions. 2. Open the left side door of the machine. 3. Remove the wing-nuts and the 2 radiator screens.



Figure 1



4. Open the engine hood. 5. Remove the radiator hood.



Figure 2



6. Drain off coolant, See 261 Coolant, changing. 7. Remove the clamps and 3 hoses.



Figure 3



1. 2. 3.



Charge air cooler upper hose Radiator upper hose Radiator breathing hose



8. Remove the radiator under cover.



Figure 4



9. Remove the clamps and hoses.



Figure 5



1.



Charge air cooler under hose



2.



Radiator under hose



10. Remove the screws and separate the shroud from the radiator assembly. Move the shroud to the engine side.



Figure 6



1. 2.



Shroud Radiator assembly



11. Remove the support stays.



Figure 7



1.



Support stay



12. Remove the radiator mounting screws.



Figure 8



1.



Screw



13. Install the eye-bolts on the radiator bracket and remove radiator assembly slowly using a lifting device.



Figure 9



14. Remove the support bracket mounting screws on the bottom side.



Figure 10



1.



Screw



15. Move the radiator assembly to a work bench safely. 16. Remove the screws and the plate with the weather strip.



Figure 11



1. 2. 3.



Weather strip Plate Screws



17. Remove the screws and the top support brackets.



Figure 12



18. Remove the support bars.



Figure 13



1.



Support bar



19. Remove the screws and the bracket from the charge air cooler top side.



Figure 14



20. Install eye-bolts into the holes.



Remove the charge air cooler using a lifting device and install a new one.



Figure 15



21. For assembling, reverse disassembly procedure. NOTE! Do not reuse O-rings and gaskets. 22. Refill coolant through the expansion tank.



NOTICE Never fill a hot engine with cold coolant, as this may cause the cylinder block or the cylinder head to crack. Failure to change coolant will cause clogging of the cooling system and the risk of engine damage.



NOTICE Volvo Coolant VCS must never be mixed with any other coolant or corrosion protection to avoid damage to the engine. NOTE! Cooling system refill volume is approximately 60 litres (16 US gal). NOTE! Fill coolant to 2/3 of the expansion tank volume. NOTE! Anti-freeze must always be used, see Section 1, Coolant with freezing and corrosion protection, Section S. 23. After completion of the work, start the engine and check for leaks. 24. Run the engine to operating temperature and top up with coolant so that the cooling system is completely filled with coolant and is free of air. NOTE! Check the coolant level after the engine has been run to operating temperature and then cooled down.



Service Information Document Title: Function Group: Cooling system, description 260



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Cooling system, description The cooling system is a pressurized closed system. It uses a belt-driven pump to pump the coolant throughout the system. The coolant transfers heat from parts and oils that need cooling, both inside the engine as well as outside. The coolant is cooled in the radiator by an air flow generated by a cooling fan. A thermostat regulates the coolants path. When the engine is cold it by-passes the radiator to conserve heat instead of removing it. An expansion tank is used to handle the expansion of the coolant. It has a pressure relief valve integrated in the cap. Coolant is refilled via the refill nipple. For information about other systems that affect the cooling system:   



220 Lubrication system, description 255 Turbocharger, description 293 Exhaust Gas Recirculation (EGR), description (only H-model engines — for machines equipped with Diesel Particulate Filter)



Figure 1 Cooling system 1. 2.



Coolant pump Oil cooler



3. 4. 5. 6. 7. 8. 9. 10. 11. 12.



EGR cooler (only H-model engines) VGT turbo (only H-model engines) Turbo actuator (only H-model engines) Holes — cylinder liner, lower cooling jacket Hole — cylinder liner, upper cooling jacket Channel to cylinder head Thermostat By-pass pipe Air compressor Coolant temperature sensor (SE2606)



Coolant is pumped by the coolant pump up through the oil cooler, which is bolted to the oil cooler's cover. Then some of the coolant is forced into the EGR cooler, VGT turbo, and the turbo actuator (only H-model engines). The rest of the coolant is pumped to the cylinder liner's lower cooling jacket via the holes, while most of the coolant continues through hole to the cylinder liner's upper jacket. From there the coolant flows to the cylinder head via channels. The cylinder head has a horizontal dividing wall which forces the coolant past the hottest areas for efficient heat transfer. Then the coolant flows through the thermostat, which returns the coolant to the coolant pump via the radiator or the bypass pipe. The route taken by the coolant depends on the coolant temperature. The air compressor, transmission, and other equipment are connected via external pipes and hoses, with the return leading to the pump's suction side. Coolant pump



Figure 2



1. 2. 3. 4. 5. 6. 7. 8.



Aluminium casing Plastic impeller Shaft seal Bearing Belt pulley Ventilation space Ventilation space, opening Pump rear



The coolant pump has a casing which holds the impeller, shaft seal, and bearing. The shaft bearing is a permanently



lubricated combination bearing. Between the shaft seal and the bearing there is a ventilated space which opens behind the belt pulley. The pump is driven by the outer belt via a belt pulley. The rear of the pump is bolted to the cylinder block and has channels for coolant distribution. Thermostat



Figure 3



Closed thermostat (cold engine)



Figure 4



Open thermostat (warm engine) The coolant circulation thermostat is of piston type and has a temperature-sensitive body which regulates opening and closing. The thermostat begins to open when the coolant temperature reaches a level that indicates that the engine is warm and the coolant needs to transport heat away from the engine. Parameters 



There are no parameters for this function.



Supplementary information  



200 VCADS Pro, Operations 263 Cooling fan, description







Thermostat, specifications



Function check 



28407-3 Sensor values, monitoring



Diagnostics Detailed information about the following relevant warnings and error codes is available under the diagnostics tab. Component



Control unit



Message ID



SE2603



MID128



PID111



SE2606



MID128



PID110



Service Information Document Title: Carbon monoxide coolant system, check



Function Group: in 260



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Carbon monoxide in coolant system, check Op nbr 260-001 9808038 Leak detector



1. Check the coolant level according to the machine's operator's manual. 2. Warm up the engine, and let the engine run during the entire test. 3. Dismantle 9808038 Leak detector. Lubricate the O-rings with silicone grease or clean vaseline. 4. Fill both chambers with reaction fluid up to the marked line. 5. Cover the inlet hole at the same time as the carbon monoxide detector is assembled so that no fluid is pressed out. NOTE! The carbon monoxide detector and its fluids must not be exposed to cigarette smoke, exhausts, or similar.



WARNING Open the radiator cap carefully if the engine is warm. High pressure in the radiator may cause hot coolant to jet out. 6. Open the radiator cap. 7. Install 9808038 Leak detector over the opening on the expansion tank and pump 3–5 times with the rubber bulb to suck in air from the tank. Wait 10–15 seconds to see if the reaction fluid changes colour. NOTE! Coolant may not be sucked in to the carbon monoxide detector. If the reaction fluid changes colour, it means that there is carbon monoxide in the cooling system. Often there are very small quantities in the machine's systems, and that is why the measurement should be repeated if the first measurement produces a reaction. 8. Suck fresh air in to 9808038 Leak detector by pumping a few times on the rubber bulb. Pump until the reaction fluid has returned to its original colour. 9. Ventilate the air above the expansion tank. NOTE! Do not blow by exhaling since exhaled air contains carbon dioxide. Repeat the test. Carbon monoxide in the coolant indicates that exhausts are forced into the cooling system. This may be due to leakage by a unit injector's copper sleeve, leaking cylinder head gasket, or cracks in the cylinder head. These defects may also cause low compression. To determine if compression is low, perform a compression test with VCADS Pro.



10. Reinstall the radiator cap. Stop the engine.



Service Information Document Title: Radiator, description



Function Group: 261



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Radiator, description The cooling unit cells and tanks are made of aluminium. The hydraulic oil cooler and the charge air cooler are installed to the radiator frame. Air is drawn into the engine compartment passing through the radiator, the oil cooler and the charge air cooler as the fan rotates.



Figure 1



1. 2. 3. 4. 5. 6. 7. 8. 9.



Charge air outlet Bar Charge air cooler Charge air inlet Radiator breathing port Coolant outlet Radiator Coolant inlet Radiator drain plug



Service Information Document Title: Coolant, checking freeze resistance



Function Group: anti- 261



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Coolant, checking anti-freeze resistance Op nbr 261-002 88890105 Refractometer



WARNING Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant may rush out and cause severe burns. 1. Check the freezing protection with 88890105 Refractometer. Open the cover on the refractometer and place a few drops of the coolant on the glass surface. Close the cover and read off the value against strong light source. Read off the value on the ethylene scale. The coolant should be taken from the filling point on the expansion tank.



Figure 1



2. The machine is delivered with a coolant mixture for optimal cooling and corrosion characteristics. That is why the same coolant mixture shall be filled, regardless of ambient temperature conditions. See 160 Coolant and 160 Coolant with freezing and corrosion protection.



Figure 2 NOTE! Volvo Construction Equipment concentrated coolant with anti-freeze must not be mixed with other brands of anti-freeze or additives as this type of mixture could have negative effects.



Service Information Document Title: Coolant, changing



Function Group: 261



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Coolant, changing Op nbr 261-004



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work.



WARNING Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling system. 1. Place the machine in the service position B. See 091 Service positions



Draining coolant 2. Open the engine hood and slowly remove the cap from the expansion tank.



Figure 1



1.



Expansion tank cap



3. Open the side cover. 4. Connect the extension hose to the drain hose installed the machine.



Figure 2



1. 2.



Extension hose Coolant drain hose



NOTE! Prepare a suitable container. 5. Loosen the drain valve handle and drain off the coolant.



Figure 3



1.



Coolant drain valve



NOTE! The cooling system is not protected from freezing after draining. There may still be pockets of water in the system. NOTE! Handle and take care of waste oil/fluids in an environmentally safe manner. NOTE! The Volvo Construction Equipment Group’s concentrated coolant with anti-freeze must not be mixed with other brands of anti-freeze or additives as this type of mixture could have negative effects. NOTE! Anti-freeze must always be used, see Section 1, Coolant with freezing and corrosion protection, Section S.



Refilling coolant into drained cooling system 6. Refill coolant through the expansion tank. NOTE! Cooling system change refill volume is approximately 60 liters (16 US gal).



NOTE! Fill coolant to 2/3 of the expansion tank volume. 7. Start and run the engine to operating temperature and top up with coolant so that the cooling system is completely filled with coolant and is free of air. 8. Check the coolant level after the engine has been run to operating temperature and then cooled down. NOTE! Never fill or top up the cooling system with cold coolant when the engine is warm. This can cause cracking of the engine block and the cylinder head.



Service Information Document Title: Radiator, replacing



Function Group: 261



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Radiator, replacing Op nbr 261-008



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work.



WARNING The parts are heavy. Take appropriate safety precautions. 1. Place the machine in the service position B. See 091 Service positions 2. Remove the intercooler (charge air cooler) assembly. See 258 Intercooler, replacing. 3. Remove the screws and the support brackets.



Figure 1



1. 2.



Support bracket (left) Support bracket (right)



4. Remove the radiator core and install a new one.



Figure 2



5. For assembling, reverse disassembly procedure. NOTE! Do not reuse O-rings and gaskets. 6. Refill coolant through the expansion tank.



NOTICE Never fill a hot engine with cold coolant, as this may cause the cylinder block or the cylinder head to crack. Failure to change coolant will cause clogging of the cooling system and the risk of engine damage.



NOTICE Volvo Coolant VCS must never be mixed with any other coolant or corrosion protection to avoid damage to the engine. NOTE! Cooling system refill volume is approximately 60 litres (16 US gal). NOTE! Fill coolant to 2/3 of the expansion tank volume. NOTE! Anti-freeze must always be used, see Section 1, Coolant with freezing and corrosion protection, Section S. 7. After completion of the work, start the engine and check for leaks. 8. Run the engine to operating temperature and top up with coolant so that the cooling system is completely filled with coolant and is free of air. NOTE! Check the coolant level after the engine has been run to operating temperature and then cooled down.



Service Information Document Title: Radiator hose replacing



Function Group: upper, 261



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Radiator hose upper, replacing Op nbr 261-012



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work. 1. Place the machine in the service position B. See091 Service positions. 2. Open the engine hood. 3. Drain off coolant, See 261 Coolant, changing. Close the drain valve after draining the coolant in about 4 minutes. 4. Open the side door on the right side of the machine. 5. Remove the clamps and replace a radiator upper with a new one.



Figure 1



1.



Radiator upper hose



6. Refill coolant through the expansion tank.



NOTICE Never fill a hot engine with cold coolant, as this may cause the cylinder block or the cylinder head to crack. Failure to change coolant will cause clogging of the cooling system and the risk of engine damage.



NOTICE Volvo Coolant VCS must never be mixed with any other coolant or corrosion protection to avoid damage to the engine. NOTE! Cooling system refill volume is approximately 60 litres (16 US gal).



NOTE! Fill coolant to 2/3 of the expansion tank volume. NOTE! Anti-freeze must always be used, see Section 1, Coolant with freezing and corrosion protection, Section S. 7. After completion of the work, start the engine and check for leaks. 8. Run the engine to operating temperature and top up with coolant so that the cooling system is completely filled with coolant and is free of air. NOTE! Check the coolant level after the engine has been run to operating temperature and then cooled down. 9. Close the engine hood.



Service Information Document Title: Radiator hoses replacing



Function Group: lower, 261



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Radiator hoses lower, replacing Op nbr 261-014



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work.



WARNING Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling system. 1. Place the machine in the service position B. See 091 Service positions 2. Drain off the coolant, See 261 Coolant, changing. 3. Remove the radiator under cover.



Figure 1



4. Open engine room under cover (1).



Figure 2



5. Remove the clamps and the radiator lower hose.



Figure 3



1. 2.



Clamp Radiator lower hose (engine side)



Figure 4



1. 2.



Clamp Radiator lower hose (radiator side)



6. Install a new lower hose. 7. Refill coolant through the expansion tank.



NOTICE Never fill a hot engine with cold coolant, as this may cause the cylinder block or the cylinder head to crack. Failure to change coolant will cause clogging of the cooling system and the risk of engine damage.



NOTICE Volvo Coolant VCS must never be mixed with any other coolant or corrosion protection to avoid damage to the engine. NOTE! Cooling system refill volume is approximately 60 litres (16 US gal).



NOTE! Fill coolant to 2/3 of the expansion tank volume. NOTE! Anti-freeze must always be used, see Section 1, Coolant with freezing and corrosion protection, Section S. 8. After completion of the work, start the engine and check for leaks. 9. Run the engine to operating temperature and top up with coolant so that the cooling system is completely filled with coolant and is free of air. NOTE! Check the coolant level after the engine has been run to operating temperature and then cooled down. 10. Install under covers.



Service Information Document Title: Expansion tank, replacing



Function Group: 261



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Expansion tank, replacing Op nbr 261-018



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work. 1. Open the engine hood. 2. Drain off coolant, See 261 Coolant, changing. Close the drain valve after draining the coolant in about 4 minutes. 3. Disconnect the wire harness connector and the hoses.



Figure 1



1. 2.



Wire harness connector Hose



4. Remove the mounting screws and the expansion tank.



Figure 2



1. 2.



Screw Expansion tank



5. Install the new expansion tank. 6. Refill coolant through the expansion tank.



NOTICE Never fill a hot engine with cold coolant, as this may cause the cylinder block or the cylinder head to crack. Failure to change coolant will cause clogging of the cooling system and the risk of engine damage.



NOTICE Volvo Coolant VCS must never be mixed with any other coolant or corrosion protection to avoid damage to the engine. NOTE! Cooling system refill volume is approximately 60 litres (16 US gal). NOTE! Fill coolant to 2/3 of the expansion tank volume. NOTE! Anti-freeze must always be used, see Section 1, Coolant with freezing and corrosion protection, Section S. 7. After completion of the work, start the engine and check for leaks. 8. Run the engine to operating temperature and top up with coolant so that the cooling system is completely filled with coolant and is free of air. NOTE! Check the coolant level after the engine has been run to operating temperature and then cooled down.



Service Information Document Title: Thermostat, replacing



Function Group: 262



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Thermostat, replacing Op nbr 262-098



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work. 1. Open the engine hood. 2. Drain off coolant, See 261 Coolant, changing. Close the drain valve after draining the coolant in about 4 minutes. 3. Remove the clamp and disconnect the radiator upper hose from the engine.



Figure 1



1.



Radiator upper hose



4. Remove the mounting screws and the thermostat housing.



Figure 2



1. 2.



Screw Thermostat housing



5. Remove the thermostat with the gasket. 6. Install a new thermostat with a new gasket.



Figure 3



1. 2.



Thermostat housing Thermostat



NOTE! Use only new gaskets and copper washer when installing. 7. For assembling, reverse disassembly procedure. 8. Refill coolant through the expansion tank.



NOTICE Never fill a hot engine with cold coolant, as this may cause the cylinder block or the cylinder head to crack. Failure to change coolant will cause clogging of the cooling system and the risk of engine damage.



NOTICE Volvo Coolant VCS must never be mixed with any other coolant or corrosion protection to avoid damage to the engine. NOTE! Cooling system refill volume is approximately 60 litres (16 US gal). NOTE! Fill coolant to 2/3 of the expansion tank volume. NOTE! Anti-freeze must always be used, see Section 1, Coolant with freezing and corrosion protection, Section S. 9. After completion of the work, start the engine and check for leaks. 10. Run the engine to operating temperature and top up with coolant so that the cooling system is completely filled with coolant and is free of air. NOTE! Check the coolant level after the engine has been run to operating temperature and then cooled down. 11. Close the engine hood.



Service Information Document Title: Thermostat, check



Function Group: 262



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Thermostat, check 1.



Place the thermostat in a container filled with water.



Figure 1 Thermostat inspection 1. 2. 2.



Thermometer Thermostat



Heat it while measuring the water temperature, and see that the thermostat is actuated at the temperature of following table. Concerning the operating temperature, see 262 Coolant pump, thermostat, specifications. NOTE! Valve opening temperature is scribed on the flange.



Figure 2 Thermostat inspection 1. 2. 3.



Thermometer Thermostat Tester probes



3.



Place the thermostat in a container filled with antifreeze or oil. Heat it while measuring the fluid temperature. NOTE! The switch is normal if the multi-meter shows continuity when the fluid temperature is 107 ~ 113 °C (225 ~ 235 °F).



Service Information Document Title: Function Group: Fan belt and/or alternator 263 belt, replacing



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Fan belt and/or alternator belt, replacing Op nbr 263-012



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work.



WARNING Checking or replacing the belt may lead to contact with rotating parts. Stop the engine before checking the belt tension or replacing the belt. 1. Open the engine hood. 2. Turn the belt tensioner clockwise using a socket handle, remove the belt and then install a new belt. NOTE! The belt adjuster tension is very strong. Therefore pay attention to prevent injury after removing belt.



Figure 1



1. 2.



Tensioner Alternator/compressor belt



3. Close the engine hood.



Service Information Document Title: Function Group: Fan belt and/or alternator-, 263 compressor belt, replacing all belts



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Fan belt and/or alternator-, compressor belt, replacing all belts Op nbr 263-022



WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work.



WARNING Checking or replacing the belt may lead to contact with rotating parts. Stop the engine before checking the belt tension or replacing the belt.



Figure 1



1. 2. 3. 4.



Fan belt Air pump belt Alternator/compressor belt Tensioner 1. Open the engine hood. 2. Turn the belt tensioner clockwise using a socket handle and replace a alternator/compressor belt. NOTE! The belt adjuster tension is very strong. Therefore pay attention to prevent injury after removing belt.



Figure 2



1. 2.



Tensioner Alternator/compressor belt



3. Open the radiator under cover.



Figure 3



4. Turn the belt tensioner clockwise using a socket handle and replace a new fan belt. NOTE! The belt adjuster tension is very strong. Therefore pay attention to prevent injury after removing belt.



Figure 4



1. 2.



Fan belt Tensioner



5. Turn the belt tensioner clockwise using a socket handle and replace a new air pump belt. NOTE! The belt adjuster tension is very strong. Therefore pay attention to prevent injury after removing belt.



Figure 5



1. 2.



Air pump belt Tensioner



6. Install the engine room under cover and close the engine hood.



Service Information Document Title: Function Group: Exhaust Gas Recirculation 293 (EGR), description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Exhaust Gas Recirculation (EGR), description The system is called cooled EGR, and its purpose is to reduce nitrogen oxide (NOx) content in the exhausts. From the EGRvalve on the exhaust manifold, some of the exhausts are led to the EGR-cooler and then via the venturi tube and mixing chamber into the inlet manifold. The exhausts are oxygen-deficient, and when mixed with the inlet air, they will lower the combustion temperature and thereby reduce generation of NOx. Other systems that affect the EGR-system is the Variable Geometry Turbine (VGT), as well as the inlet and exhaust system. For more information, see  



255 Turbocharger, description 250 Inlet and exhaust system, description



Figure 1



Red = exhausts Blue = inlet air Dashed black = wiring



1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.



Basic engine EGR-valve EGR-cooler Venturi tube Mixing chamber VGT Coolant temperature, sensor (SE2606) EGR temperature, sensor (SE2516) EGR differential pressure, sensor (SE2515) Charge-air temperature and boost pressure, sensor (SE2507 and SE2508) EGR solenoid valve (PWM2503)



E-ECU = Engine Electronic Control Unit EGR-valve



Figure 2



Brown = engine oil Red = exhausts 1.



Solenoid



The engine uses a pressure-balanced poppet valve to regulate the amount of recirculated exhausts. The EGR-valve is controlled by the engine control unit using oil pressure from the engine lubrication system, and it supplies the EGR-system with exhausts from the exhaust manifold. The pressurized oil is regulated by the engine control unit via a solenoid valve. EGR-cooler



Figure 3



The EGR-cooler, which is cooled by the engine coolant, consists of a number of pipes with flanges that cool the recirculated exhausts before they enter the mixing chamber. The flanges increase the turbulence in the exhaust flow, which improves cooling performance at the same time as it reduces accumulation of unwanted particles in the cooler. Venturi tube



Figure 4



The venturi tube is a tube with differing inner diameter where the differential pressure of the cooled exhausts is measured. There is one pressure outlet from the big diameter and one pressure outlet from the small diameter. These two outlets lead to the differential pressure sensor. The engine control unit receives information about the measured differential pressure and converts this to exhaust recirculation flow. The EGR temperature sensor is located in the connecting pipe after the venturi tube. The sensor provides the engine control unit with information about the temperature of the recirculated exhausts. Mixing chamber The cooled recirculated exhausts and the intake air, which has been cooled in the charge-air cooler, meet in the mixing chamber. From here the mixture flows through the inlet pipe into the combustion chamber. The boost pressure sensor measures the pressure in the inlet manifold. The engine control unit collects information from the sensors and regulates the EGR-valve and turbocharger nozzle to create optimal EGR flow. The engine control unit cannot provide total control of the emission system without feedback from the many sensors in the exhaust aftertreatment system. This includes monitoring of the turbocharger, EGR-system, engine coolant, engine position, and the DPF muffler. Ambient air temperature and turbine rotor speed sensor are also required. Parameters There are no parameters for this function. Summary Some of the exhausts are recirculated via the EGR-valve and to the EGR-cooler. Then the exhausts flow through the venturi tube where the differential pressure is measured. The cooled exhausts are then mixed with intake air in the mixing chamber, to be led to the inlet manifold. There are several sensors involved and the engine control unit collects the information and then regulates the EGR-valve and turbocharger nozzle to create the correct EGR flow.



Supplementary information 



293 Exhaust gas recirculation (EGR), component location



Function check VCADS Pro, 29332-3 - Exhaust Gas Recirculation, function test Diagnostics Detailed information about the following relevant warnings and error codes is available under the diagnostics tab. Component



Control unit



Message ID



FX1007 Only WLO



MID128



PID102



MID128



PID105



PWM2503



MID128



SID146



SE2507



MID128



PID105



SE2508



MID128



PID102



SE2514



MID128



PID103



SE2515



MID128



PID411



SE2516



MID128



PID412



SE2606



MID128



PID110



Service Information Document Title: Function Group: EGR Venturi tube, checking 293



Information Type: Service Information



Profile: EXC, EC480D L [GB]



EGR Venturi tube, checking Op nbr 293-003 1. Place the machine in service position 1, see 191 Service position. 2. Remove the connector for the sensor.



Figure 1



1. 2.



Push up the lock lug. Push the lock lug and remove the connector.



3. Remove the tube clamps. Remove the venturi tube (3 screws). 4. Remove the pressure sensor.



Date: 2014/7/14



Figure 2



5. Remove the bracket and the plastic washer.



Figure 3



6. Clean the venturi tube using a small part washer or a soft brush. Clean the tube and bracket channels with e.g. a cable tie. 7. Install news seals on the bracket and on the venturi tube. Install the pressure sensor bracket and plastic washer. Install new O-rings and fit the pressure sensor. 8. Install new seals on the venturi tube and inlet pipe. Install the venturi tube as follows: 1. 2. 3. 4.



Install the upper clamp. Install the lower clamp. Tighten the upper mounting screws. Tighten the lower screw.



Connect the pressure sensor. 9. Restore the machine



Thank you for your purchase. Have a nice day.



file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/7/14 16:25:17]



Service Information Document Title: VCADS Pro, Operations



Function Group: 300



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



VCADS Pro, Operations The following VCADS Pro operations are available for function group 3. Operations used when changing or working on components are mandatory. Tests Operation



Application



30101-3 Sensor values Vehicle control unit Used when there is a suspicion of fault and/or at abnormal values/readings. (VECU, MID187), check 30902-3 Keypad status, test



Used when there is a suspicion of fault and/or at abnormal values/readings.



36003-3 Switches, control levers, test



Used when there is a suspicion of fault and/or at abnormal values/readings.



36401-3 Switches, test



Used when there is a suspicion of fault and/or at abnormal values/readings.



37173-3 Data oscilloscope



links,



fault



tracing with Used when there is a suspicion of fault and/or at abnormal values/readings.



38674-3 Pressure switches, test



Used when there is a suspicion of fault and/or at abnormal values/readings.



39796-3 MID 142 Control unit, reset



Used when it is transferred to another machine.



39797-3 Care Track status, check



Used when there is a suspicion of fault and/or at abnormal values/readings.



Calibrations Operation



Application



–



–



Programming Operation



Application



36646-3 MID 187 ECU, programming



When changing V-ECU or only reprogramming. 366 V-ECU, MID 187, changing non-programmed ECU



See



When changing I-ECU or only reprogramming. 300 I-ECU, MID 140, changing non-programmed ECU



See



39736-3 MID 142 Control unit, programming When changing W-ECU or only reprogramming. 398 W-ECU, MID142, changing non-programmed ECU



See



36648-3 MID 187 ECU, campaign 38145-3 MID 140 ECU, programming 38104-3 MID 140 ECU, campaign



39738-3 MID 142 Control unit, campaign



Service Information Document Title: Function Group: I-ECU, MID 140, changing 300 non-programmed ECU



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



I-ECU, MID 140, changing non-programmed ECU Op nbr 300-072 1. Park the machine in the service position A, see 091 Service positions. 2. Download the program for target machine. 3. Connect VCADS Pro computer to the machine, and perform operation '38145-3 MID 140 control unit, programming'. 4. When VCADS pro 'MID 140 ECU, programming' window appears, follow the instructions for replacing I-ECU. 5. Turn OFF battery disconnect switch. 6. Open the windscreen. 7. Remove the screws of plastic cover and disconnect the wire harness from the cab wire harness. 8. Remove the screws fixing I-ECU to the cab.



Figure 1 I-ECU, changing 1. 2.



Screw Wire harness



9. Install a new I-ECU to the cab with screws and connect wire harness. 10. Install the plastic cover with screws and close the windscreen. 11. After replacing the I-ECU, press OK button of VCADS Pro operation '38145–3 MID 140 control unit, programming'. Now VCADs Pro starts the programming of software and parameters to the new I-ECU.



12. Start the machine and check that no error messages appear.



Service Information Document Title: Function Group: I-ECU, MID 140, changing 300 pre-programmed ECU



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



I-ECU, MID 140, changing pre-programmed ECU Op nbr 300-074 1. Park the machine in the service position A, see 091 Service positions. 2. Connect VCADS Pro computer to the machine, and perform operation '17030-3 Parameter, programming'. 3. Use the function 'save all parameters to job card'. 4. Turn OFF battery disconnect switch. 5. Open the windscreen. 6. Remove the screws of plastic cover and disconnect the wire harness from the cab wire harness. 7. Remove the screws of fixing I-ECU to the cab.



Figure 1 I-ECU, changing 1. 2.



Screw Wire harness



8. Install a new I-ECU to the cab with screws and connect wire harness. 9. Install the plastic cover with screws and close the windscreen. 10. Connect VCADS Pro computer to the machine, and perform operation 17030-3 Parameter, programming'. Now the customer parameters are changed according to the job card saved at step 3. 11. Start the machine and check that no error messages appear.



Service Information Document Title: Electrical description



Function Group: system,



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Electrical system, description This section of the service manual describes the design and construction of the electrical system and all included components. This section also contains functional descriptions, troubleshooting and method instructions for servicing. The electrical system consists, in part, of electrical and electro-mechanical components such as batteries, switches, solenoid valves, fuses and relays. The electrical system also consists of a computer-based control system that monitors and controls machine functions. In order to access certain settings in the information system, special service instruments are required; VCADS Pro. User instruction for VCADS Pro is available in a separate user’s manual.



WARNING For all servicing of the electrical system, the general instructions must be strictly followed.



Service Information Document Title: Function Group: Electrical system, special instructions for servicing, general



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Electrical system, special instructions for servicing, general WARNING No changes may be made to the electrical system without prior approval from Volvo. Changes may affect machine functions and can result in risks for personal injury or machine damage.



WARNING Carelessness when working with the electrical system may result in risks of serious personal injuries as well as machine damage.



When working on the electrical system, the following instructions as well as instructions in respective section must be followed carefully.



Also read instructions in Section Safety and in the Operator's Manual.



WARNING Always remove watches, rings, bracelets and other metallic objects from the body before starting to work on the electrical system.



Figure 1



WARNING Never boost-start the machine by connecting directly to the starter motor. This may result in uncontrolled machine movements. When using another machine to boost-start, it must not touch the machine that is being started. Never test if a cable/connection is supplied with electric power by producing "spark". This may permanently damaged electrical/electronic components.



Service Information Document Title: Function Group: Electrical system, special instructions for servicing, electrical components, batteries



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Electrical system, special components, batteries



instructions



for



servicing,



electrical



WARNING During rapid charging of batteries, always remove the cell caps. During charging, an explosive mixture of oxygen and hydrogen is formed. A short-circuit, open flame or spark near the battery can cause a powerful explosion. Always turn off the charging current before disconnecting the charging clamps. Ventilate well, especially if the battery is being charged in a confined area.



The battery electrolyte contains corrosive sulphuric acid. Remove spilled electrolyte from the skin immediately. Wash with soap and plenty of water. If electrolyte has splashed into the eyes or on any other sensitive body part, rinse immediately with plenty of water and contact a physician immediately.



WARNING The batteries could explode due to the current surge if a fully charged battery is connected to a completely discharged battery. Since the batteries contain sulphuric acid, this could result in personal injuries.



WARNING Never charge a frozen battery. Explosion hazard! 



Never disconnect the main electric current or disconnect battery cables when the engine is running.



Figure 1 



The battery's minus connection must always be disconnected before removing or installing components and connections in the electrical system. NOTE! Incorrect handling may cause damage to, for example, control unit/ECU which results in downtime.



Figure 2   



Fully charged batteries must be used when checking the electrical system. If the batteries are not fully charged, charge them or replace with new batteries. During battery charging, the battery terminal cables must always be disconnected from the battery. When changing batteries connected in series, the batteries should have the same capacity (for example, 150 Ah). The batteries should be of the same age (equally good). The reason for this is that the charging current required to give the battery a certain charge varies with the age of the battery.







Only batteries may be used as assistant starting devices. An auxiliary starter unit and/or batteries connected in series to assist when starting may result in high (excess) voltage and can seriously damage electronic/electric components.



Service Information Document Title: Function Group: Electrical system, special instructions for servicing, electrical components, alternator and charging regulator



Information Type: Service Information



Date: 2014/7/14



Electrical system, special instructions for components, alternator and charging regulator



servicing,



Profile: EXC, EC480D L [GB]











electrical



Before any alternator or regulator tests are performed, the batteries and electrical cabling must be checked for insulation, loose connections and corrosion. Check the alternator belts. All eventual defects according to the above must be corrected before starting any electrical testing. Check the alternator belt and, if needed, make any necessary adjustment/repairs before troubleshooting.



NOTICE Always connect cabling in a safe manner and make sure that cables are free from rust/dirt. A disconnected cable may cause damage to both alternator and charging regulator.



NOTICE Never disconnect the alternator connections when the engine is running. This may damage both alternator and charging regulator.



NOTICE Make sure that the alternator plus connection is not connected to the frame. This will damage the alternator, and may also damage the regulator.



Service Information Document Title: Function Group: Electrical system, special instructions for servicing, electronic components



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Electrical system, components 



special



instructions



for



servicing,



electronic



If a connector on any of the data buses has been damaged, the bus must be replaced. Note that the two cables included in each data bus are paired and twisted in order to protect them from electrical interference. Cabling must only be repaired by trained personnel. As an alternative, the entire cable harness can be completely replaced.



NOTE! Electronic equipment is sensitive and may easily be damaged by electro-magnetic fields and/or by static electricity from tools or the human body. Therefore, always follow the instructions below when performing work involving electronic components.



The following instructions must be followed in order to meet the requirements for electro-magnetic compatibility (EMC).       



Connections to an electronic component must never be disconnected when the unit is supplied with electric power, this may damage the electronics. Discharge any static electricity in tools before servicing the electrical system by touching the tool to a metallic machine part that is connected to the frame. Never touch the connector pins on electronic units. Avoid touching circuit boards when servicing the electrical system. If this is necessary – only hold the circuit board by the edges. Never touch individual electronic components. Make sure that ground cables are securely connected when replacing units. Never replace paired, twisted cabling with paired, non-twisted cabling.



Service Information Document Title: Function Group: Electrical system, special instructions for servicing, action when working on machine



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



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



For electric welding on the machine, the battery cables must be disconnected and the connectors must be unplugged from the control units. During blasting work on the machine, work very carefully to prevent damage to electrical cabling and components. Never aim the water jet directly at electrical components when using a high-pressure washer. This is especially important when using a combination of warm water and degreasing agents. Before drilling or making any other holes in the machine, all electrical components in the area must be located with great accuracy.



NOTICE Drilling and other modifications to the cab structure are forbidden! The reason is that the ROPS protection may not function as intended if the cab structure is modified.



Service Information Document Title: Auxiliary start



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Auxiliary start WARNING Never boost-start the machine by connecting directly to the starter motor. This may result in uncontrolled machine movements. When using another machine to boost-start, it must not touch the machine that is being started. Auxiliary start with start cables Check the following before connecting; - That the ignition is OFF in both machines. - That the machine cannot start to move when started. - That the machines have the same system voltage. - That the start cables are dimensioned for the max. current rating that the battery can generate. - Start cables, with regards to cracks, oxidation and other defects. - That battery cables are intact and connections are connected securely. - That the machines do not touch each other.



WARNING When using start cables, the positive and negative connection must not come into contact. Risk of personal injury. Connect start cables as follows:



Figure 1 Connecting start cables - Connect the first start cable (A) to the battery's plus terminal (1) on the machine to be started. - Connect the other end of the cable (A) to the battery's plus terminal (2) on the assisting machine. - Connect the other start cable (B) to the battery's minus terminal (3) on the assisting machine. - Connect the other end of the cable (B) to the frame (4) on the machine to be started. Check that good electric contact is obtained. Auxiliary start: - Check that the start cables are connected securely and correctly (figure). - Start the engine in the assisting machine. - Start the engine in the machine to be started. If the engine does not started within 30 seconds, wait for at least two minutes before the next start attempt.



Remove the start cables follows:



Figure 2 Removing start cables - Remove the cable (B) from the frame (1) on the machine that has been started with auxiliary start. - Remove the other end of the start cable (B) from the battery's minus terminal (2) on the assisting machine. - Remove the cable (A) from the battery's plus terminal (3) on the assisting machine. - Remove the other end of the start cable (A) from the battery's plus terminal (4) on the machine that has been started with auxiliary start.



Service Information Document Title: Function Group: Electronic control system, description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Electronic control system, description General vehicle electronics The new vehicle electronics, based on the data bus principle, lay the foundation for being able to proceed with development and design of the system. The improved diagnostic possibility makes for easier, faster and safer troubleshooting. Further, the operator’s demand for information is fulfilled, through added functionality of the instrument, with the possibility of obtaining read-outs of important information from the different electronic control units. Conventional control system



Figure 1 Conventional system with connections In principle, a conventional control system is designed in such a way that one or several of the vehicle’s components have their own control unit that receives signals from various sensors (earlier generations of excavators have only been equipped with a vehicle control system). Each control unit serves its own component and sends signals to the other control units and operating controls by way of electrical cabling. For example, an engine control unit that receives signals from various sensors on the engine and eventually from other control units on the vehicle. Engine speed control switch position, travel speed signal, etc. are sent to the engine control unit by way of cabling from different sensors and switches. There must be one or several connections (sockets) in the system, where tools can be plugged in for programming and for read-out of information and eventual error codes. In the future, the individual machine components will require several control units per component, and machine electronics will become increasingly complex. In time, this will limit the possibilities for a conventional control system to handle its task. Data bus system



Figure 2 All control units (ECU) are connected via data buses Volvo CE’s new vehicle electronics are based on the principle that all communication between the control units in the system takes place by way of two data buses. The main vehicle components are equipped with their own control units, that are connected to the buses for communication with each other. Simplified, this can be described as follows; when the operator wants to increase speed, a signal is sent from the engine speed control switch or pedal (T mode) to the vehicle control unit and, through a data bus, the signal is transmitted to the engine control unit. The engine control unit communicates with the other control units by way of the buses, either by asking a question or by receiving direct communication that all is in order to be able to "execute the command". If a malfunction should appear in a system, a signal is sent out on the information bus, which makes it possible to read the information, either on the operator’s instrument, the instrument electronic control unit (I-ECU), or with a VCADS Pro connected to the service connection. The data bus system provides a very flexible solution with extensive add-on possibilities.



Service Information Document Title: Function Group: Communication with data buses



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Communication with data buses



Figure 1 Communication E-ECU



Engine electronic control unit



ACM



After treatment control module



I-ECU



Instrument electronic control unit



ECC



Electronic climate control unit



V-ECU



Vehicle electronic control unit



PC3601



Service socket for VCADS Pro



W-ECU



Caretrack system



General The vehicle electronics are based on the principle that all communication between control units in the system takes place via two data buses. The machine's four control units are connected to the buses to be able to communicate with each other. Communication between the different control units as well as reporting from control units to service sockets takes place on data buses CAN/J1939 and J1708/J1587. The buses adhere to SAE-standard and consist of two pair-twisted cables. The purpose of the twisting is to protect the bus from electrical interference. If a malfunction should occur in the system, a signal is sent on the information bus, making it possible to read the information, either on the operator's instruments (I-ECU) or VCADS Pro. The figure shows the principle for how the control units and service sockets are connected to the buses. CAN/J1939 control bus The system's control signals are sent via this bus. The control bus is very fast, which is a requirement for control of the whole system to function and quickly adapt to varying conditions. The main communication alternative is the CAN/J1939 bus. However, for E–ECU, some control data is only sent on the J1708/J1587 bus.



J1708/J1587 information bus The information bus is connected to the control units and service socket. Information and diagnostic signals are sent on this bus. In addition, some control data is sent from the engine control unit via this bus. The bus also functions as "back-up" for the control bus if it doesn't work for some reason. Via the information bus, the system's status is updated continuously and is available for reading. By connecting VCADS Pro to service sockets, it's possible to read error codes, perform tests, empty logged information, upload parameters and upload software.



Service Information Document Title: Data buses, function



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Data buses, function



Figure 1 The oscilloscope display shows voltage level on the data bus Data buses constitute a way to transmit information between different components. In conventional systems, primarily analogue signals have been used. Analogue signals mean that different voltage levels represent different values. A simplified example of analogue signals: 1 Volt = 10 °C (50 °F), 2 Volt = 20 °C (68 °F), 3 Volt = 30 °C (86 °F), etc. Data buses use digital communication. This means that voltage only varies between two different values, either "high" or "low". By combining these high and low signals, it is possible to describe different values. The illustration shows an oscilloscope display where voltage is measured on the data bus. As is evident in the illustration, the greatest part of the time is "silent" on the bus, but every so often, a number of fast impulses can be seen. A collection of impulses is called a message. The enlarged oscilloscope display shows a message that consists of a combination of high and low voltage levels. Messages and information content



Figure 2 Information content The different voltage levels are represented by the different digits in the binary number system. The binary number system only has two digits, ones and zeros. The ones normally represent a high voltage, and the zeros represent a low voltage. Note in the example from the oscilloscope display, in this case, ones are shown as low voltage and zeros are shown as high voltage, and this depends on which bus and on which cables the measurement is performed. Every individual binary digit is called a "bit". This message consists of four groups of binary digits. The start and stop bits are shaded since they do not contain any information. Each group constitutes 1 Byte = 8 bits. One Byte can represent a value between 0 (0+0+0+0+0+0+0+0) and 255 (128+64 +32+16+8+4+2+1). Figure shows the information content in the four different parts of the message. The square in the illustration shows the different binary and decimal values that the information in the message contains. NOTE! The information is sent out on the bus with the "lowest" digit first of the binary digits. The normal way of noting binary numbers is shown in the square in the illustration.



Figure 3 Voltage levels binary data The purpose of the start and stop bits is only to function as markers for where the group begins and ends. In figure, only the start and stop bits are marked, the other information is shaded. Identification number



Figure 4 Identification of control units and components Abbreviation



Explanation



MID



Message Identification D escription (identification of control unit). There is a unique number for each control unit.



PID



Parameter Identification D escription (identification of parameter/value). There is a unique number for each parameter.



PPID



Proprietary Parameter I dentification Description (Volvo-uniqueidentification of parameter/value). There is a Volvo-unique number for each parameter.



SID



Subsystem Identification D escription (identification of component). The SID-number depends on which control unit (MID) that they are sent from. Each control unit has its own number series for SID. The exceptions are SID-numbers 151 –255 which are general for all systems.



PSID



Proprietary Subsystem I dentification Description. (Volvo-uniqueidentification of component).



FMI



Failure Mode I dentifier (identification of failure type).



Figure 5 Identification of control units and components The message consists of four parts, A, B, C and D. Message on data bus Part



Explanation



A



MID. MID 128 shows that the message comes from the engine control unit.



B



PID. PID 100 shows component oil pressure sensor.



C



Data part. In this example, it is shown what the engine oil pressure is. The value can vary between 000 for minimum oil pressure and 255 for maximum oil pressure.



D



Check sum. In this example, 240. The check sum is a check that the message is reasonable.



Service Information Document Title: Function Group: Service connection and programming connection



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Service connection and programming connection



Figure 1 Electronic system architecture E-ECU



Engine control unit



ACM



After treatment control module



I-ECU



Instrument control unit



MATRIS



MAchine TRacking Information System



V-ECU



Vehicle control unit



VCADS Pro



Volvo Computer Aided Diagnostic System Professional



ECC



Electronic climate control unit



J1587



Information bus serial data 9.6 k bps



W-ECU



CareTrack system



J1939



Control bus serial data 256 k bps



Figure 2



A: Service socket The service connection (socket) and programming socket are located by the radio. The service socket is connected to the information bus and is used for communication with the following external equipment. VCADS Pro is the PC-tool used for:     



Programming of control units Downloading of vehicle parameters Reading of error codes Testing and checking of functions/components Calibration



When troubleshooting, this is of very significant importance, since all vital parts in the vehicle electronics can be checked with VCADS Pro. MATRIS is Volvo CE’s PC software for reading vehicle history. Logged vehicle parameters are compiled, processed and presented in the form of different diagrams. I-ECU operator's display unit is used for:    



Reading of error codes Showing machine information/status for engine, electric and hydraulics Showing software (program) version in control unit Showing status of inputs and outputs on control units



Service Information Document Title: Function Group: Instrument control unit IECU, function description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Instrument control unit I-ECU, function description



Figure 1 I-ECU, position The Instrument electronic control unit (I-ECU) is mounted on the right-hand side wall in the Cab. The I-ECU displays the information received from the sensors and switches of the machine to alert the operator of any abnormality. The I-ECU contains a coolant temperature gauge, fuel gauge, and alert indicators to show machine conditions.



Figure 2 I-ECU A: Central warning light B: Gauge screen C: Main screen D: Indicator screen The I-ECU receives information on the data bus. The information is processed and presented on the information display.



Service Information Document Title: Keypad, description



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Keypad, description



Figure 1 Keypad for display unit and HVAC ( Heating, Ventilation , Air conditioning) system Keypad is located on the right instrument panel. It is connected to the Instrument control unit (I-ECU). Button function Button



Digit



Description



Button



Digit



Description



1



Fan speed control +



-



HVAC system on/off



2



Temperature control +



0



Arrow up, Browse upwards



3



Air flow direction



-



Rear view camera



4



Fan speed control –



-



Previous screen or escape



5



Temperature control –



-



Arrow down, Browse downwards



6



Air flow circulation



-



Selection, Acknowledge



7



Automatic mode selection



-



Automatic idling



8



Air conditioner



-



Overload warning



9



Defrost selection



-



Buzz stop



-



Hammer/shear selection



HVAC control buttons HVAC control buttons are used to control the HVAC system. Refer to the 387 HVAC system. Rear view camera button Rear view camera button turns on/off “Rear view camera screen”. When the rear view camera screen is turned on , whole IECU screen displays only view from “rear view camera”.



Figure 2 Rear view camera Buzz stop button Buzz stop button is used to activates or deactivates “ Travel alarm” function of V-ECU. When this button is pressed so that the function is activated, partial backlight fro this button is turned on. Overload warning button Overload warning button activates or deactivates “Overload warning” function. This function is to display the symbol and to sound an alarm if the “Overload signal” is detected. When this button is pressed so that the function is activated, partial backlight for this button is turned on. Automatic idle button Automatic idle button activates or deactivates “ Automatic idle” function of V-ECU. When this button is pressed so that the function is activated, partial backlight for this button is turned on. The engine speed will be lowered automatically to idle mode to reduce fuel consumption if any of control levers, travel levers (pedals) or engine speed control switch are not operated for 5 seconds or more. If any of the above is operated, the engine speed returns to the speed set with the engine speed control switch. Arrow up button This button is used to scroll items up and adjust the each segment on the screen. Arrow down button This button is used to scroll items down and adjust the each segment on the screen. ESC button This button is used to go back to the previous screen or to escape without saving. The ESC button is also used to turn OFF the warning lamp and sound. Hammer / shear selection button Hammer / shear selection button is used to activates or deactivates “X1 function” of V-ECU.



Service Information Document Title: Function Group: Engine control unit E-ECU, function description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Engine control unit E-ECU, function description



Figure 1 E-ECU The D13H engine’s unit injectors are controlled entirely by electronics, with regards to injected fuel amount and injection timing. The system is called EMS 2 (Engine Management System 2). The central part in the system, the control unit is located on the left side of the engine. The control unit receives continuous information from V-ECU (requested target engine speed) and a number of sensors on the engine, and calculates the fuel amount and at what time the fuel should be injected into the cylinders. The control signals to the unit injectors run through electrical cabling to the unit injector fuel valves. The control unit stores information if a malfunction should occur, or if something in the system is abnormal. Even malfunctions that occur sporadically are stored in the control unit and can thus be traced at a later time. Functions    



Control of fuel volumes and unit injectors Monitoring of temperatures Detecting of engaged preheating Operating speed (rpm)



Service Information Document Title: Function Group: Vehicle control unit V-ECU, function description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Vehicle control unit V-ECU, function description The V-ECU is mounted on the inside left cab wall. The technical regulations define the specifications for a V-ECU that is to be used in Volvo excavators equipped with I-ECU, E-ECU, ECC and W-ECU with data links SAE J1587and J1939.



Figure 1 V-ECU The V-ECU is a main control unit and controls solenoid valves, relays and proportional solenoid valves for hydraulics according to switches in the cab as well as machine sensors with CAN communication with I-ECU, E-ECU, ECC and W-ECU in Volvo excavator. It also handles logging of machine data in order to give service personnel access to machine information. Functions                  



Self-diagnostics Indication of machine status Emergency operation Anti-theft system Safe start and stop X1 control X1 pressure control X3 control Quick fit control Electro hydraulic pump control Automatic Power Boost and one-touch Power Boost Boom float position Cooling fan control Reversible cooling fan control Automatic engine shut-off Travel alarm control Overload warning Automatic idle



Service Information Document Title: Function Group: Electronic climate control unit ECC, description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Electronic climate control unit ECC, description The electronic climate controller, ECC, is located at the air conditioner unit. This is a full automatic controller, and controls the fan speed, the heater, the air conditioner, the indoor/outdoor air selection and the air distribution. ECC has the serial interface to I-ECU, and the different functions can be controlled by the keypad.



Figure 1 ECC The control unit receives continuous information about temperature, pressure, rpm, etc. from a number of sensors. The control unit is connected to the other control units via data link J1587/1708 for communication. Functions   



Control of temperature, air distribution, and ventilation in cab Control of soft start, AC-compressor Monitoring of temperature and pressure



Service Information Document Title: CareTrack description



Function Group: W-ECU,



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



CareTrack W-ECU, description General CareTrack is a telematics system enabling machine owners to track and monitor machines from a computer with connection to the Internet, regardless of how far away the machine is. By logging in to the CareTrack portal, it is possible to get information about the machines' condition, at any time. For example, when they have been used, at what work mode they have been operated, how much fuel they have consumed, or the exact positions of the machines. CareTrack uses GSM (Global System for Mobile communication, same as is used for mobile telephones) for direct connection to the machines' built-in computers (ECUs). By using a combination of the GSM-net and the satellite-based GPS-system (Global Positioning System), CareTrack can move information from a machine to a computer connected to the Internet, via the CareTrack portal. The CareTrack unit consists of a built-in GPS receiver, satellite modem, and two antennas. When the machine is running, it is online, and can be localized - at any time and in any place. After having logged in via the secure CareTrack portal, the machines can be tracked and monitored online, in real-time. However, the machine must be running to send real-time information, all other information is sent within 24 hours. CareTrack is available on several continents, but in principle CareTrack works everywhere there is GSM coverage. Where there is no coverage, satellite link can be used. CareTrack is available in two versions, “Basic” and “Advanced”.



Figure 1



CareTrack unit 1. 2.



W-ECU Satellite modem



Figure 2



1. 2. 3.



GSM and GPS antenna. Antenna for satellite communication. W-ECU



CareTrack “Basic”           



Machine position: the exact position in latitude and longitude Real-time machine data: total number of machine hours Geographic restriction: The user indicates the geographic limits within which the machine must stay. If it wanders outside the limits, an alarm is sent via e-mail and an SMS to mobile telephone. Time limit: the uses determines between what times and on what days the machine may be used. Here as well, an alarm via e-mail and to mobile telephone is sent if the time limit is exceeded. Position report: summary of the machine's geographic movements Reports on daily use: shows how many hours the machine has operated and when it was started and stopped. Reports are available per day, week, or month. Service reminders: send via e-mail and on the mobile telephone Service history: every machine's service history can be seen on the secure web portal Forwarding of service reminders: to co-workers or service provider Service reports: summary of current service Message when it's time to replace parts: informs about replacement of certain wear parts that are not included in the normal service program, and reminds when it's time for replacement



CareTrack “Advanced” Contains everything in CareTrack “Basic” as well as the following functions:        



  



Machine utilization: for example, daily reports on the previous 24 hours activities for all machines Incident reports: summary of events that are outside certain limits Performance report and productivity report: compare the individual machines' (or different shifts) performance and productivity Alarms and warnings: alarm on the instrument panel can be sent via e-mail and mobile telephone as soon as they occur History of alarms and warnings: summaries of alarms and warnings Error codes: summaries of error codes History of error codes Forwarding of alarms, warnings, and error codes: enables the dealer to check the machine before it arrives. This can lead to fewer service trips, that the service technician can bring the right parts the first time, and it can minimize downtime. Matris, complete download Matris, partial download Fuel consumption in real-time: available on the web portal and is shown in simple graph form



System description



Figure 3



1. 2. 3. 4. 5. 6. 7. 8.



Network node, control station. CareTrack portal, for users. E-mail, Matris, and Internet. Satellite link for machine data. Satellite for communication. GSM-link for machine data. Machine. Satellite for GPS positioning.



Satellite communication Satellite communication consists of a number of satellites that orbit the Earth at low altitude. Each satellite's coverage is a few thousand kilometres in diameter. However, since satellites move quickly across the Earth's surface a powerful signal may be lost just a few minutes later. Signal-noise ratio Signal-noise ratio, often abbreviated SNR or S/N, is a term that defines the relationship between the signal and the noise effect that distorts the signal, that is, SNR compares the level of the useful signal (, e.g., music) with the background noise. The higher the ratio the less one is disturbed by the background noise. For example, a CD-player has a ratio (= dynamics) of approx. 90 dB. A record player may be able to handle 25 dB. There are many factors that may give CareTrack a low S/N ratio: sources of interference close by, high buildings, thick forests, high mountains, operating in a tunnel, thunderstorm, long distance to ground station (GSM), or that the communication satellite is at the outer limit of its range. Doppler effect The Doppler effect is a phenomena that entails a change of the frequency (oscillation rate) of a signal, e.g., sound or noise, depending on if the source is getting closer to or is moving away from the observer. An example of eh Doppler effect are sirens on ambulances or police cars, that seem to increase (= a higher tone) when approaching the observer, and decrease in frequency (= a lower tone) when they have passed. The software in CareTrack uses the Doppler effect to calculate if a communication satellite is approaching the machine or moving away from the machine. Basic settings for CareTrack 1. 2.



W-ECU (CareTrack unit) is installed in the machine. VCADS Pro is connected and the W-ECU is configured with chassis-ID, "sat-on", and "GSM-off".



3. 4. 5. 6. 7. 8.



Restart of the W-ECU. The machine sends an activation message via GSM (SMS) or satellite to the network node for CareTrack. A machine card is generated in the network node. The user logs in to the CareTrack portal and enters data about the machine, e.g., chassis-ID. Settings are sent to the machine. The machine is now ready for monitoring and tracking in CareTrack.



Service Information Document Title: I-ECU, I/O list



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



I-ECU, I/O list I-ECU connector (IA) pin Pin No.



Description



Pin No.



Description



IA1



+24 V(ACC)



IA10



Alternator



IA2



Illumination



IA11



Quickfit solenoid



IA3



Automatic greasing



IA12



Fuel level sensor (−)



IA4



Fuel level senser (+)



IA13



–



IA5



5 V (Sensor power)



IA14



–



IA6



J1939_H (CAN1)



IA15



V-ECU status



IA7



J1587_A



IA16



J1939_L (CAN1)



IA8



Battery ground



IA17



J1587_B



IA9



+24 V (Battery)



IA18



Battery ground



I-ECU connector (IB) pin Pin No.



Description



Pin No.



Description



IB1



Rear view video signal 1



IB8



Rear view video signal 2



IB2



High beam



IB9



Rear view video signal 2 ground



IB3



Turn signal, Left-hand



IB10



Pattern change switch 1



IB4



Turn signal, right-hand



IB11



Pattern change switch 2



IB5



Pump manual switch



IB12



–



IB6



Rear view video power



IB13



Signal ground



IB7



Rear view video signal 1 ground



IB14



Sensor ground



I-ECU connector (IB) pin Pin No.



Description



Pin No.



Description



IC1



Rear view video signal 3



IC3



Rear view video signal 4



IC2



Rear view video signal 3 ground



IC4



Rear view video signal 4 ground



Figure 1 I-ECU, connector IA



Connector, IA



IB



Connector, IB



IC



Connector, IC



Service Information Document Title: V-ECU, I/O list



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



V-ECU, I/O list V-ECU connector (VA) pin, specifications Pin No.



Description



Pin No.



Description



VA1



X1 flow preset proportional valve, left-hand +



VA36



Power boost solenoid



VA2



X1 flow preset proportional valve, left-hand –



VA37



Boom conflux Arm in conflux



VA3



X1 switch, left-hand



VA38



Travel solenoid



VA4



X1 proportional valve, left-hand



VA39



Engine speed control switch signal



VA5



Pump, manual



VA40



Hydraulic oil tank temperature sensor + 5 V



VA6



X1 proportional valve, left-hand +



VA41



—



VA7



—



VA42



Buzzer stop and confirm switch (confirm)



VA8



X3 proportional valve, left-hand +



VA43



Travel pressure monitor



VA9



Hydraulic oil fan motor proportional valve +



VA44



Power max mode switch



VA10



Hydraulic oil fan motor proportional valve –



VA45



—



VA11



X1/X3 proportional switch ground



VA46



Induction sensor, backhoe type remote control valve



VA12



Travel alarm relay



VA47



Emergency engine stop



VA13



X1 1/2 pumps selection solenoid



VA48



Overload pressure monitor, signal



VA14



Engine speed control



VA49



Overload pressure monitor, ground



VA15



—



VA50



Engine fan direction relay



VA16



Buzzer stop and confirm switch (stop)



VA51



X3 switch, right-hand



VA17



Float safety pressure monitor



VA52



DPF switch (start)



VA18



Travel speed selection switch, signal



VA53



X3 right proportional valve, –



VA19



Attachment pressure monitor (auto idle)



VA54



X3 proportional valve, left-hand –



VA20



Control lock



VA55



X1 proportional valve, right-hand + X1 right



VA21



—



VA56



X1 main flow control proportional valve +



VA22



Induction sensor, ISO type remote control valve



VA57



X3 switch, left-hand



VA23



Quick fit switch



VA58



Start motor relay, 1st



VA24



X1 pressure control RH proportional valve +



VA59



Boom float solenoid



VA25



X1 pressure control RH proportional valve –



VA60



Fuse for solenoid and relay



VA26



Overload pressure monitor, power 5 V



VA61



Main relay



VA27



X1/X3 proportional switch power +12 V



VA62



—



VA28



X1 switch, right-hand



VA63



Hydraulic oil tank temperature sensor ground



VA29



X1 proportional valve, right-hand –



VA64



Hammer select solenoid



VA30



X1 main flow control proportional valve –



VA65



Shear select solenoid



VA31



X3 right proportional valve, + X3 rotator right



VA66



X1 pressure monitor



VA32



Pump power shift, signal



VA67



—



VA33



Fuse for proportional valve



VA68



—



VA34



V-ECU status



VA69



Float position switch



VA35



Fuse for PWM power



VA70



DPF switch (stop)



V-ECU connector (VB) pin, specifications Pin No. Description



Pin No.



Description



VB1



Boost and hammer switch



VB9



Ignition switch (ACC)



VB2



Ignition switch (C)



VB10



X3 proportional switch



VB3



X1 proportional switch



VB11



Engine speed control switch



VB4



J1587_B (white)



VB12



J1587_A (red)



VB5



—



VB13



—



VB6



CAN_L (J1939_ L, green )



VB14



CAN_H (J1939_ H, yellow)



VB7



Battery ground



VB15



Battery +24 V



VB8



Battery ground



VB16



Battery +24 V



Figure 1



V-ECU, connector VA



Connector, VA



VB



Connector, VB



Service Information Document Title: ECC, I/O list



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



ECC, I/O list Pin No. Description



Pin No. Description



BB1– BB6



–



BB36– BB41



–



BB7



–



BB42



Voltage feed (+24V)



BB8



Refrigerant pressure switch



BB43



–



BB9



–



BB44



–



BB10



SAE J1587A



BB45



Air mix actuator, cold air



BB11



SAE J1587B



BB46



Air blower



BB12



Foot actuator, left, closed



BB47



Air blower



BB13



Foot actuator, left, open



BB48



Air mix actuator, warm air



BB14



Face actuator, open



BB49



–



BB15



Face actuator, closed



BB50



Refrigerant temperature sensor



BB16



Foot actuator, right, open



BB51



Ambient temperature sensor



BB17



Foot actuator, right, closed



BB52



–



BB18



–



BB53



–



BB19



Engine start switch



BB54



Diesel heater signal



BB20



Air mix actuator voltage feed (+5V)



BB55



–



BB21



Diesel heater relay



BB56



Cab door switch



BB22



Ground to all actuators



BB57



–



BB23



Air conditioner compressor clutch



BB58



SAE J1939_H



BB24



Coolant temperature sensor



BB59



–



BB25



–



BB60



Air intake actuator, indoor air



BB26



Cab temperature sensor



BB61



–



BB27



Air mix actuator feedback



BB62



–



BB28



–



BB63



Air intake actuator, outdoor air



BB29



–



BB64



–



BB30



–



BB65



–



BB31



–



BB66



Voltage feed (+24V)



BB32



–



BB67



Voltage feed (+24V) to actuators



BB33



–



BB68



–



BB34



SAE J1939_L



BB69



Ground



BB35



–



BB70



Ground



Figure 1 Electronic climate controller, ECC



Service Information Document Title: W-ECU, I/O list



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



W-ECU, I/O list Pin No.



Description



1



–



10



–



2



–



11



J1587A, AVSS 0.85OR/R2 0.75OR



3



–



12



Ground, AVSS 0.85SB/R2 0.75OR



4



–



13



–



5



–



14



Switch key, AVSS 0.85R/R2 0.75R



6



–



15



–



7



BAT+, AVSS 0.85OR//R2 0.75OR



16



–



8



–



17



J1587B, AVSS 0.85OR/R2 0.75OR



9



–



18



–



Figure 1 W-ECU A: W-ECU for CareTrack GSM/GPS B: W-ECU for CareTrack Satellite



Pin No. Description



Service Information Document Title: Emergency description



Function Group: operation, 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Emergency operation, description When the J1939 and J1587 communication line is not available, it is impossible to control the engine speed with the V-ECU. Then the operator must use the emergency control switch to control the engine speed. According to input switch, the V-ECU determines engine control mode and main pump operation. For the wiring diagram, see 370 Wiring diagram SCH03. Input signals Pin No.



ECU



Description



VA47



V-ECU



Engine limp home switch, SW2704



Pin No.



ECU



Description



VA32



V-ECU



Pump power shift 1, PWM9141



Output signal



Function description Low idling speed If the following conditions are applied, the V-ECU sends a signal to the pump power shift valve to set the engine control mode as I2 mode.  



Communication error between V-ECU and E-ECU. Emergency engine stop switch is Off (position 1).



High idling speed If the following conditions are applied, the V-ECU sends a signal to the pump power shift valve to set the engine control mode as H mode.  



Communication error between V-ECU and E-ECU. Emergency engine stop switch is On (position 2).



Engine stop If the emergency engine stop switch is in the STOP position, the E-ECU loses electric power and the engine stops.



Service Information Document Title: Anti-theft system



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Anti-theft system The optional anti-theft system is only displayed if the optional equipment is selected. It can be activated with VCADS Pro service tool. To display anti-theft system screen on booting screen, a period of time must pass after turning off the engine. The default time is 30 seconds and it is adjustable by VCADS Pro service tool.



Figure 1 Anti-theft system screen Input signals J1939 Input messages ECU



Description



Keypad



Pin code



V-ECU, I-ECU



Code lock option



V-ECU, I-ECU



Code lock confirm



Parameters Code



Name



ABP[T1]



Code lock protection



ABQ



Code lock protection PIN code



[T1]Parameters of V-ECU and I-ECU For more information, see 301 Software parameters, description. Output signals Pin No.



ECU



Description



VA58



V-ECU



Start motor relay, 1st



J1939 Output messages ECU



Description



V-ECU, I-ECU[T1]



Code lock option



V-ECU, I-ECU



Code lock confirm



[T1]When the V-ECU is not available, I-ECU can send shut-off request. Function description Control of anti-theft function, V-ECU



  



V-ECU waits till the I-ECU sends a status message of “pin code matched”. If there were no status message, the V-ECU releases “start lock relay” and sends shut-off message to the E-ECU. If the V-ECU receives “pin code matched”, the V-ECU sends a pin code confirmation message to the I-ECU.



Control of anti-theft function, I-ECU   



I-ECU waits till the pin code input is completed from keypad. If the pin code valve is equal to the stored value, the I-ECU sends the status of message of “pin code matched” Once this anti-theft function is passed, then the anti-theft function will not be engaged when the machine is turned ON until 30 seconds after the machine is turned OFF.



Service Information Document Title: Start lock, description



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Start lock, description The starter motor operation is carefully limited so that the antitheft function can be performed. Input signals Pin No.



ECU



Description



VA20



V-ECU



Control lockout lever, SW9118



Input messages ECU



Description



I-ECU



Code lock condition



Parameters Code



Name



ABP



Anti-theft protection



For more information, see 301 Software parameters, description. Output signal Pin No.



ECU



Description



VA58



V-ECU



Start motor relay, 1st, RE3301



Condition for activation If the following condition is applied, start lock relay RE3301 will be ON.   



Start switch, ON Control lockout lever, lower position (OFF) If there is anti-theft system option, code lock password must be matched.



Service Information Document Title: Safe start and description



Function Group: stop, 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Safe start and stop, description The function describes the safe start and stop. This function contributes to component protection and enhancement of durability. Input signals Pin No.



ECU



Description



VB2



V-ECU



Ignition key switch (C)



VB9



V-ECU



Ignition key switch (ACC))



VA39



V-ECU



Engine speed control switch, SW2701



VA19



V-ECU



Attachment pressure monitor, SE9111



VA17



V-ECU



Float safety pressure monitor, SE9140



VA20



V-ECU



Control lockout lever, SW9118



VB10



V-ECU



X3 proportional switch, SW9161



VA57



V-ECU



X3 switch, left-hand, SW9405



VA51



V-ECU



X3 switch, right-hand, SW9406



Input messages ECU



Description



E-ECU



Power off allowed signal



I-ECU



Power off allowed signal



E-ECU



Engine speed



Parameters Code



Name



BFJ



Connect X1 flow control



FYZ



Connect X3 proportional control



FYY



Connect X3 On / Off control



For more information, see 301 Software parameters, description. Output signal Pin No.



ECU



Description



VA61



V-ECU



Main relay 1, RE3101



Output messages Code



Name



V-ECU



Ignition key status



V-ECU



Shutdown request



V-ECU



Engine speed request



Safe start If the ignition switch is turned to start position and the engine is starting, the following takes place:  



If there is no releasing condition, the engine speed control mode goes to I2 regardless of the engine control switch mode. If there is releasing condition, the engine speed control mode goes back to the engine control switch indicating mode.



Releasing condition:  



Position change on engine control switch. Control lockout lever, upper position (ON)



Safe stop If the ignition switch is turned to OFF position, V-ECU sends shut down request to the E-ECU and I-ECU, and the following takes place:  



V-ECU saves its data and then cuts off the main relay after 4.5 seconds from ignition key OFF if there is no power OFF allowed signal from I-ECU and E-ECU. V-ECU saves its data and then cuts off the main relay after 2 seconds from receiving the power OFF allowed signal from I-ECU and E-ECU both.



Service Information Document Title: X1 control, description



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



X1 control, description This is for X1 option attachment control. The function controls X1 option applications which are hammer and shear. Input signal Pin No.



ECU



Description



VB01



V-ECU



Boost / Hammer switch



VA03



V-ECU



X1 switch, left-hand



VA28



V-ECU



X1 switch, right-hand



VB03



V-ECU



X1 proportional switch



VA66



V-ECU



Pressure monitor, hammer or shear (X1), SE9112



VA20



V-ECU



Control lockout lever, SW9118



Pin No.



ECU



Description



VA06



V-ECU



X1 proportional valve 1, PWM9123 X1 left solenoid (hammer), MA9121



VA55



V-ECU



X1 proportional valve 2, PWM9124 X1 right solenoid, MA9122



VA56



V-ECU



X1 main flow control proportional valve, PWM9109



VA13



V-ECU



1/2 pump select solenoid, MA9116



VA64



V-ECU



Hammer select solenoid, MA9117



VA65



V-ECU



Shear select solenoid, MA9118



VA01



V-ECU



left-hand X1 flow preset proportional valve, PWM9129



VA24



V-ECU



Right-hand X1 flow preset proportional valve, PWM9130



Output signal



Following tables describe how the function controls X1 application depending on single and double acting with 1 switch, 2 switch, proportional switch and pedal. For the X1 set values, see 301 Software parameters, description. 1 switch control and single acting This function describes a single acting with 1 switch control. Input signals     



VCADS Pro parameter IIN, 1 button RCV control lever VCADS Pro parameter FYW, X1 1way switch VCADS Pro parameter HNI, X1 single acting Hammer / shear selection button on keypad SW9118, control lockout lever



Condition for output functions     



Output functions



X1 left solenoid (hammer), MA9121 VCADS Pro parameter IIN, FYW, HNI “ON” “ON” Hammer / shear selection button “ON” Control lockout lever “ON” Select 1–way on the I-ECU 1 button control lever, switch “ON”



2 switch control and double acting This function describes a double acting with 2 switch control. Input signals     



VCADS Pro parameter IIO 4 button RCV control lever VCADS Pro parameter CVS, X1 2way switch X1 selection switch SW9118, control lockout lever 1–way or 2–way on the IECU



Condition for output functions  



Output functions







VCADS Pro parameter IIO, CVS “ON” Hammer / shear selection button “ON” Control lockout lever“ON”







Select 1–way on the I-ECU







MA9117, hammer solenoid “ON”











X1 left solenoid (hammer), MA9121 “ON”







MA9117, hammer select solenoid “ON” Control lever hammer switch “ON”







Select 2–way on the I-ECU







MA9118, shear solenoid “ON”



 



MA9118, shear select solenoid “ON” Control lever LH, RH switch “ON”







MA9121/MA9122 “ON”



select



select



1 switch control and pedal This function describes 1 switch control with pedal on a double acting. In case of single acting, there exists only MA9117, hammer selection solenoid with X1 pedal. Input signals  



  



VCADS Pro parameter FYW, 1 way switch VCADS Pro parameter HOJ, X1 pedal 1–way or 2–way on the IECU X1 selection switch SW9118, control lockout lever



Condition for output functions 



Output functions







VCADS Pro parameter FYW, HOJ “ON” Hammer / shear selection button “ON” Control lockout lever “ON”







Select 1–way on the I-ECU







MA9117, hammer solenoid “ON”







MA9117, hammer select solenoid “ON” 1 button control lever, switch “ON”







MA9121, X1 left solenoid (hammer) “ON”







Hammering







MA9117, hammer select solenoid “ON” Pedal “Forward”







Select 2–way on the I-ECU







MA9118, shear solenoid “ON”















select



select



 



MA9118, shear select solenoid “ON” 1 button control lever, switch “ON”







MA9121, X1 left solenoid (hammer) “ON”



 



MA9118, shear select solenoid “ON” Pedal “Forward”







Shear moves.



 



MA9118, shear select solenoid “ON” Pedal “Reverse”







Shear moves direction.



opposite



Proportional control This function describes proportional control with proportional switch. If the parameter set value FYV, proportional control, is “0”, V-ECU convert proportional signal to ON/OFF signals to control hammer/shear solenoid. Input signals  



  



VCADS Pro parameter IKM, proportional control lever VCADS Pro parameter FYV, proportional control 1–way or 2–way on the IECU X1 selection switch SW9118, control lockout lever



Condition for output functions 



Output functions







VCADS Pro parameter IKM, FYV “ON” Hammer/shear selection button “ON” Control lockout lever “ON”







Select 1–way on the I-ECU







MA9117, hammer solenoid “ON”











PWM9123, X1 proportional valve 1 “ON”







MA9117, hammer select solenoid “ON” Proportional switch slide “left”







Select 2–way on the I-ECU







MA9118, shear solenoid “ON”



 



MA9118, shear select solenoid “ON” Proportional switch slide “left”







PWM9123, X1 proportional valve 1 “ON”



 



MA9118, shear select solenoid “ON” Proportional switch slide “right”







PWM9124, X1 proportional valve 2 “ON”







select



select



Flow control Input signals  



VCADS Pro parameter BFJ, flow control VCADS Pro parameter HOI, 2–pump flow



Condition for output functions



Output functions



 



VCADS Pro parameter BFJ, “ON” VCADS Pro parameter HOI, “OFF”







1 pump control







SE9112, Hammer pilot pressure sensor “ON” Comparison between set flow (I-







MA9116, 1/2 pump select solenoid “OFF” PWM9109, X1 main flow















ECU) and X1 flow maximum + X1 flow minimum If X1 set flow < X1 flow maximum and X1 flow minimum, V-ECU calculate current on the proportional valve according to the set flow on the I-EUC.



control proportional valve “ON”



 



VCADS Pro parameter BFJ, “ON” VCADS Pro parameter HOI, “ON”







2 pump control







SE9112, Hammer pilot pressure sensor “ON” Comparison between set flow (IECU) and X1 flow maximum + X1 flow minimum If X1 set flow > X1 flow maximum and X1 flow minimum, the current on the proportional valve will be decided according to modified flow value, X1' : X1 set flow on the I-ECU – 1 flow maximum (1 pump max.)







MA9116, 1/2 pump select solenoid “ON” PWM9109, X1 main flow control proportional valve “ON” Pump 1 displacement will be decided according to X1'. Pump 2 displacement will be maximum.



















Service Information Document Title: X1 pressure description



Function Group: control, 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



X1 pressure control, description X1 pressure control V-ECU controls to limit the maximum pressure of X1 system pressure according to X1 flow rate setting and X1 pressure setting values from the I-ECU. For a X1 pressure setting parameter value, see 301 Software parameters, description. Input signal Pin No.



ECU



Description



VA39



V-ECU



Engine speed control switch



Input message ECU



Description



I-ECU



X1 flow rate setting



I-ECU



X1 pressure setting



E-ECU



Engine speed



Output signal Pin No.



ECU



Description



VA1



V-ECU



PWM9129, left-hand X1 flow preset proportional valve (+)



VA2



V-ECU



PWM9129, left-hand X1 flow preset proportional valve (-)



VA24



V-ECU



PWM9130, right-hand X1 flow preset proportional valve (+)



VA25



V-ECU



PWM9130, right-hand X1 flow preset proportional valve (-)



Input signals     



VCADS Pro parameter FYX, X1 presetting pressure X1 flow rate setting value on I-ECU X1 pressure setting value on I-ECU SW2701, Engine speed control switch Current engine speed



Condition for output functions   



VCADS Pro parameter FYX, X1 presetting pressure “ON” Calculating actual flow rate setting If X1 pressure setting is maximum setting value then the output current jumps down to 0 mA.



Output functions 







Outputting the current of the PWM9129, X1 flow presetting proportional valve, left hand Outputting the current of the PWM9130, X1 flow presetting proportional valve, right hand



Service Information Document Title: X3 control, description



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



X3 control, description This is for X3 option attachment control. Input signal Pin No.



ECU



Description



VA20



V-ECU



Control lockout lever, SW9118



VB10



V-ECU



X3 proportional switch



VA57



V-ECU



Rotator switch, left-hand



VA51



V-ECU



Rotator switch, right-hand



Parameters Code



Description



FYZ



Connect X3 proportional control



FYY



Connect X3 On / Off control



IIO



4 switch control lever installed



IKM



Proportional control lever installed



LBR



Connect X3 On / Off solenoid



For more information, see 301 Software parameters, description. Output signal Pin No.



ECU



Description



VA8



V-ECU



X3 left proportional valve, PWM9145 X3 solenoid valve, rotator left, MA9110



VA31



V-ECU



X3 right proportional valve, PWM9146 X3 solenoid valve, rotator right, MA9111



Output messages ECU



Description



I-ECU



X3 stop command



V-ECU



X3 control (on, on / off, proportional)



On / off control solenoid Input signals    



VCADS Pro parameter IIO, 4 button RCV control lever VCADS Pro parameter FYY, X3 on/off control SW9118, control lockout lever X3 switch, left hand



Condition for output functions    



VCADS Pro parameter, IIO, FYY“ON” Control lockout lever “ON” 4 button RCV control lever, switch “ON” Select “Toggle” or “Push-button” at the X3 operation setup on the I-ECU



Output functions 



MA9110, X3 solenoid valve, rotator left “ON” or MA9111, X3 solenoid valve, rotator right, “ON”







X3 switch, right hand 



Select “Toggle” at the X3 operation setup on the I-ECU







Pressing the on-off switch once activates the proportional valve. Pressing this on-off switch again deactivates the proportional valve.







Select “Push-button” at the X3 operation setup on the I-ECU







On-off timing of solenoid valve is same with a switch of control lever.



Proportional control Input signals    



VCADS Pro parameter IKM, proportional control lever VCADS Pro parameter FYZ, X3 proportional control SW9118, control lockout lever X3 proportional switch



Condition for output functions    







Output functions



VCADS Pro parameter, IKM, FYZ“ON” Control lockout lever “ON” Proportional control lever, switch “ON” Select “Toggle”, “Push-button” or “Proportional” at the X3 operation setup on the I-ECU







PWM9145, X3 left proportional valve, “ON” or PWM9146, X3 right proportional valve, “ON”



Select “Toggle” at the X3 operation setup on the I-ECU







X3 proportional valve acts like solenoid valve. Sliding the proportional switch once activates the proportional valve. Sliding this proportional switch again deactivates the proportional valve.











Select “Push-button” at the X3 operation setup on the I-ECU



 







Proportional current control



Select “Proportional” at the X3 operation setup on the I-ECU







X3 proportional valve acts like solenoid valve. On-off timing of proportional valve is same with a switch of control lever.



The current is transmitted to the proportional valve in proportion to the operating angel of control lever.



Figure 1



The proportional current for proportional solenoid valve is controlled by RCV PWM, proportional control lever duty (%). If the proportional control lever duty (%) is between 47 % and 53 %, V-ECU recognize that the switch is off.



Service Information Document Title: Quick fit description



Function Group: control, 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Quick fit control, description This is for the Quick fit option attachment control. V-ECU receives the related switch signals and sends them to the I-ECU, and then I-ECU activates the solenoid. Input signals Pin No.



ECU



Description



VA23



V-ECU



Quick fit switch, SW9104



VA42



V-ECU



Buzz stop/confirm switch (confirm), SW9160



VA16



V-ECU



Buzz stop/confirm switch (buzz stop), SW9160



VA20



V-ECU



Control lockout lever, SW9118



Parameters Code



Description



CNQ



Quick fit installed



For more information, see 301 Software parameters, description. Output signals Pin No.



ECU



Description



VA11



I-ECU



Quick fit solenoid, MA9109



I-ECU



Alarm



I-ECU



Quick fit indicator



I-ECU



Central warning light



Function description Quick fit release Input signals   



VCADS Pro parameter CNQ, Quick fit SW9118, control lockout lever Quick fit switch SW9104



Condition for output functions



Output functions



  



VCADS Pro parameter CNQ, ON Control lockout lever, ON Quick fit switch, ON[T1]







  



VCADS Pro parameter CNQ, ON Control lockout lever, OFF Quick fit switch, ON







[T1]The quick fit switch is ON only If the quick fit switch is pressed from OFF to ON.



  



  



Quick fit solenoid MA9109, ON Central warning lamp, ON Quick fit indicator, ON Buzzer, ON



Quick fit solenoid MA9109, OFF Central warning lamp, ON Quick fit indicator, ON Buzzer, ON



Audible warning and confirm switch  



When the buzzer sounds, if the buzzer stop switch is ON, the buzzer will be OFF. If the confirm switch is ON for confirming that quick fit is in closed position, the buzzer, warning lamp and indicator will be off



Service Information Document Title: Function Group: Mode selection, description 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Mode selection, description This function allows the operator to select the engine speed and work mode according to the working condition and environment to optimize the machine performance and fuel efficiency. The V-ECU continuously receives the current engine speed from the E-ECU. It balances engine output horsepower and hydraulic pump drive horsepower by changing the pump swash angle with driving proportional solenoid valve PWM9101 to keep pump torque below the engine torque developed at the selected engine speed. NOTE! P mode is not applied to North America. Input signals Pin No.



ECU



Description



VA39



V-ECU



Engine speed control switch, SW2701



VA44



V-ECU



Power Max mode selection switch, SW9110



VA20



V-ECU



Control lockout lever, SW9118



Parameter Code



Description



DST2



Power Max mode option



LUH



Engine control mode with power max switch



Output signals J1939 output message ECU



Signal name



V-ECU



Engine speed request



V-ECU



Mode status message



J1587 Output message ECU



Signal name



V-ECU



Percent accelerator pedal position



Function description Input signals    



Engine speed control switch, SW2701 Power max. mode selection switch, SW9110 Power max mode option parameter, LUH[T1] Engine speed



Conditions for out functions  



Engine speed control switch step-9 Power max mode selection switch pushed[T2]



Out functions  



Pump Max. torque : 100 % Engine speed which corresponds to P mode



  



Engine speed control switch, SW2701 Power max mode option parameter, LUH Engine speed







Engine step-9



speed



control



switch



 



Pump Max. torque : 95 % Engine speed which corresponds to H mode







Engine speed step-6/7/8



control



switch



 



Pump Max. torque : 90 % Engine speed which corresponds to G mode







Engine speed step-3/4/5



control



switch



 



Pump Max. torque : 70 % Engine speed which corresponds to F mode Power boost solenoid valve, ON Boom / arm conflux cut-off solenoid valve, ON Travel speed selection solenoid valve, ON



  







Engine speed step-1/2



control



switch



 



Pump Max. torque : 40 % Engine speed which corresponds to I mode



[T1]V-ECU applies control specification values according to the option parameter, LUH status. [T2]P mode and H mode are selected in rotation each push of power max mode selection switch. Specification proportional solenoid valve current and max pump input torque, see 270 Engine - Pump control, specification. P mode (Full duty operation) 



P (Power maximum) mode functions on the P mode selection switch ON with step-9 of the engine speed control switch to maximize working capacity and working speed by utilizing 100% of the rated engine output horsepower. This mode is for heavy duty excavating operations which require powerful digging and lifting force.



H mode (Heavy duty operation) 



H mode functions on step-9 of the engine speed control switch and the power maximum mode selection switch OFF to increase the working capacity and working speed by utilizing 95% of the rated engine output horsepower.







This mode is for slightly heavy duty excavating operations which require powerful digging and lifting force.



G mode (General duty operation) 







G mode functions over a 3 step range as follows: Step-6/7/8 utilize 90% of the rated engine output horsepower and is recommended for general duty operations that are below the level which require maximum engine output. These positions provide the most efficient, fuel saving, economical machine performance for general excavating and loading operations.



F mode (Fine duty operation) 



Fmode functions over a 3 step range as follows: Step-3/4/5 utilize 70% of the rated engine output horsepower. At the same time, the V-ECU activates the boom / arm conflux shut-off solenoid valves and shuts off summation of the two hydraulic pumps when operating the boom or arm. Also, the V-ECU activates the power boost solenoid valve. It provides fine controllability for precise smooth movements and maximum lifting force at mid-range engine speeds.







Description of boost control, see 301 Boost control, description. This mode is recommended for finishing/levelling work and when fine precision control of the boom and arm is essential.



I mode (Idling operation) 



I mode functions over a 2 step range as follows: Both steps minimize the output of the pumps. Step-1 is the low idle speed set at engine starting. Step-2 is the auto idle speed and is available if the auto idling selection switch is in the ON position. Description of auto idle, see 301 Auto Idle.



Signal condition of control lock  



If the control lockout lever is goes from the upper position to lower position, V-ECU sets the engine control mode to the I2 mode and saves the previous engine control mode. If the control lockout lever moves from the lower position to upper position, V-ECU sets the engine control mode to the previous mode.



Figure 1



A. B. C. D.



Control lockout lever, ON Control lockout lever, OFF Previous engine speed control mode I2 mode



Service Information Document Title: Boost control, description



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Boost control, description Automatic power boost When high pressure is required like travelling in fixed speed or high pressure is needed for fine control (F-mode), working pressure will be boosted automatically by the V-ECU to enhance machine performance. Input signal Pin No.



ECU



Description



VA39



V-ECU



Engine speed control switch, SW2701



VB1



V-ECU



Power boost / Hammer switch



VA19



V-ECU



Attachment pilot pressure monitor, SE9111



VA43



V-ECU



Travel pilot pressure monitor, SE4216



Input messages ECU



Description



Keypad



X1 activate button



Parameter Code



Name



HOQ



Boost lasting time



For more information, see 301 Software parameters, description. Output signal Pin No.



ECU



Description



VA36



V-ECU



Boost solenoid valve, MA9125



Output messages ECU



Description



V-ECU



Boost indicator status



Function description F mode boost If F mode selected,



Figure 1 Indicator, power boost 



V-ECU turns on the boost solenoid valve signal.







V-ECU sets the boost indicator status to ON.



One touch boost If the power boost switch is turned on,    



V-ECU turns on the boost solenoid valve signal for 9 seconds. For repeated button press, this one touch boost function is initiated after finishing 9 seconds turning on. The time 9 seconds can be changeable with VCDS Pro service tool. V-ECU set the boost indicator status to ON.



Deactivation of one touch boost If the FYW “connect X1 one-way switch or HNI “ connect X1 single acting” is selected, and hammer solenoid valve is activating condition by X1 activation button, the one touch power boost is deactivated.



Service Information Document Title: Boom float description



Function Group: position, 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Boom float position, description Float position means that both the boom cylinder piston and piston rod are connected to the hydraulic tank. This means that only the weight of the arm and bucket lowers the boom when right control lever is pushed forward. This function allows the attachment to float on the ground, so that the operator easily works leveling operation and reduces the fuel consumption using weight of attachment and the material loaded. Input signal Pin No.



ECU



Description



VA69



V-ECU



Float position switch



Parameter Code



Name



BNJ



Float position function



For more information, see 301 Software parameters, description. Output signal Pin No.



ECU



Description



VA59



V-ECU



Boom float solenoid valve, MA9120



Output messages ECU



Description



V-ECU



Float position indication



V-ECU



Float position solenoid, MID187 PPID1128



Function description



Figure 1 Indicator, float position For float position control, boom float solenoid valve must be installed. When the float position parameter BNJ is selected and the float position switch is On, the float position solenoid valve is activated and the indicator is shown on the I-ECU. NOTE! When the boom float function is on, the function will remain even if the ignition key is turned off and on again. The indicator on the instrument panel will be also displayed



Service Information Document Title: Cooling fan control



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]EXC, EC480D L [GB]



Cooling fan control Hydraulic oil cooling system The function controls cooling fan speed according to the input from the hydraulic oil temperature sensor. Input signals Pin No.



ECU



Description



VA40



V-ECU



Hydraulic oil temperature sensor, SE9105



Pin No.



ECU



Description



VA9



V-ECU



Hydraulic oil fan motor proportional valve



Output signals



Function description If the hydraulic oil temperature is below 60 °C, the output current will be the maximum current. The maximum current will cause low oil flow via the proportional valve to the cooling motor in port and reduce cooling fan rpm to half speed.



Figure 1 Fan speed control curve A. B. C. D.



Maximum current Full speed Half of full speed Minimum current



a. b.



Expected rotating speed of cooling fan Current for hydraulic oil fan motor proportional valve



If the hydraulic oil temperature is higher than 90 °C, the output current will be the minimum current. The minimum current will cause full oil flow via the proportional valve to the cooling motor in port and increase cooling fan rpm to maximum speed.



See also, 9113 Hydraulic oil cooling system, description.



Service Information Document Title: Automatic engine shut-off



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Automatic engine shut-off This function shuts down the engine automatically after the machine has been idled for a certain period of time, to conserve fuel consumption. The operator will be warned of the pending shut-down and have the opportunity to avoid it. The automatic engine shut down time which is set 5 minutes can be changed with VCADS Pro only. Input signal Pin No.



ECU



Description



VA20



V-ECU



Control lockout lever, SW9118



VA39



V-ECU



Engine speed control switch, SW2701



Parameters Code



Name



FAU



Automatic Engine shut-down



FAV



Automatic Engine shut-down time



For more information, see 301 Software parameters, description. Output signal Pin No.



ECU



Description



VA58



V-ECU



Start motor relay, RE3301



–



I-ECU



Information message display



–



I-ECU



Beeping sound



–



I-ECU



Warning message display



Function description Engine shut-down time will be reduced in real time while the machine is in the automatic engine shut-down conditions.



Figure 1 Time sequence A. B. C. D.



Automatic engine shut-off conditions Countdown screen display Beeping sound Warning screen display



Automatic engine shut-down conditions 



Option parameter (FAU) is activated



    



Engine is running over 500 rpm Control lockout lever is down (off) The engine speed control switch is not changed DPF regeneration is not on progress Alert message of “Automatic Engine Shut-off” on I-ECU has not disappeared with ESC button on keypad



Display countdown screen



Figure 2







When the shut-off time reaches 1 minute, the information message with countdown screen will be displayed on IECU



Beeping sound 



When the shut-off time reaches 3 seconds, beeping sound will be generated 3 times



Display warning screen



Figure 3



 



When the time ends, the information messaged will be changed to the warning message. The start motor relay will be turned OFF and the shut-off request will remain to be activated until the key switch is turned OFF.



Service Information Document Title: DPF regeneration control



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB] Go back to Index Page



DPF regeneration control DPF regeneration control The tier 4i engine has an exhaust aftertreatment system (EATS) in form of diesel particulate filter (DPF). This function activates or deactivates DPF regenerator based on the engine conditions and user confirmation. Input signal Pin No.



ECU



Description



VB19



V-ECU



DPF regeneration switch (start), SW2506



VB46



V-ECU



DPF regeneration switch (stop), SW2506



Function description   



When the E-ECU sends pre-defined status of DPF regeneration, the I-ECU shows message to the operator. If the operator presses the start DPF switch, the I-ECU sends a command to the E-ECU. E-ECU starts regeneration with the DPF switch start signal. When the operator presses the stop DPF switch, E-ECU stops regenerating.



Figure 1 Indicator, regeneration required



Figure 2 Indicator, on regeneration It is not possible to regenerate when the soot load is too low (below 100%) For the operation of the regeneration, see the operator's manual. There are four levels of regeneration message. Each level has different alarming screen. Alarming screen consist of “central warning”, “check screen” and “ indicator”. Level 1 If the following conditions are valid, the indicator remains.



Figure 3 Check screen Conditions:   



DPF status signal from E-ECU; Low (100 %) DPF lamp command signal from E-ECU; indicator of regeneration illuminate Engine speed is over 600 rpm



Alarm screen of regeneration request:     



Yellow central warning lamp. Check screen and an indicator. Check screen can be dismissed by pressing ESC button and pop up again after 15 minutes if screen was dismissed. Check screen can be come out after key off and on. Check screen can be come out when the other message are dismissed on the screen.



If the operator presses start DPF switch while the regeneration indicator is shown, the regeneration will be started immediately. Level 2 When the first regeneration message is ignored, the level 2 check message is shown



Figure 4



Conditions:   



DPF status signal from E-ECU; Middle (120 %) DPF lamp command signal from E-ECU; indicator of regeneration blink Engine speed is over 600 rpm



Alarm screen of regeneration request:     



Yellow central warning lamp. Check screen and an indicator. Check screen can be dismissed by pressing ESC button and pop up again after 15 minutes if screen was dismissed. Check screen can be displayed after turning key off and on. Check screen can be displayed when the other message are dismissed on the screen.



If the operator presses start DPF switch while the regeneration indicator is shown, the regeneration will be started immediately. Level 3 When the second regeneration message is ignored, the level 3 warning message is shown Conditions:    



DPF status signal from E-ECU; High (130 %) PPID 326 MID 128 FMI 0; active DPF lamp command signal from E-ECU; indicator of regeneration blink Engine speed is over 600 rpm



Alarm screen of regeneration request:    



Red central warning lamp and blink. Warning screen and an indicator. Warning screen cannot be dismissed by pressing ESC or ENTER button. Warning screen can be displayed when other message are dismissed on the screen.



Figure 5 Warning screen for level 3 A. B. C.



First warning screen Second warning screen Third warning screen



 



If the operator sets control lockout lever at lower position, the second warning screen is shown. If the operator sets engine speed as I2 mode, the third warning screen is shown.



The regeneration only can start in condition of third warning screen; control lockout lever at a lower position and I2 mode. Level 4 When the third regeneration message is ignored, the level 4 warning message is shown



Figure 6



Conditions:  



DPF status signal from E-ECU; High (200 %) PPID 326 MID 128 FMI 11; active



 



DPF lamp command signal from E-ECU; indicator of regeneration blink Engine speed is over 600 rpm



Alarm screen of regeneration request:  



Red central warning lamp and blink. Warning screen and an indicator.



NOTE! Regeneration is only possible with VCADS Pro service tool. Cancel ongoing regeneration



Figure 7



The regeneration can be cancelled by pressing stop of regeneration switch while regeneration is being fulfilled. The regeneration automatically cancels when:  



errors are present control lockout lever is in upper position



I-ECU shows check screen for 5 seconds and yellow central warning lamp is shown.



Service Information Document Title: DPF regeneration control



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB] Go back to Index Page



DPF regeneration control DPF regeneration control The tier 4i engine has an exhaust aftertreatment system (EATS) in the form of a diesel particulate filter (DPF). This function activates or deactivates DPF regenerator based on the engine conditions and user confirmation. Input signal Pin No.



ECU



Description



VB19



V-ECU



DPF regeneration switch (start), SW2506



VB46



V-ECU



DPF regeneration switch (stop), SW2506



Parameters Code



Name



Description



NPH



Regeneration type



0 = regeneration function disabled (used for tier2 engines) 1 = manual regeneration function (used for tier4 engines) 2 = automatic regeneration function



NOTE! Due to the production process of the DPF, increased smoke generation occurs during the first regeneration. It is not possible to regenerate when the soot load is too low (Below 100%). During regeneration, indicator (B) will be displayed. If DPF regeneration stop is pressed while regeneration is being fulfilled, indicator (B) will be displayed until the exhausted gas temperature is at normal operation temperature.



Figure 1



Indicator (B), on regeneration DPF regeneration cancel condition (while regeneration)



Figure 2 Check screen for regeneration cancel  



When DPF regeneration stop is pressed, the check screen for regeneration cancel would show up for 5 seconds. When the control lockout lever is set to upper position on level 3, the check screen for regeneration cancel would show up for 5 seconds.



WARNING Risk for fire.



Regeneration generates hot exhaust and causes hot exhaust pipe. Do not perform regeneration in a flammable environment. When DPF regeneration;  



Make sure that there is no flammable material around the machine, this is important to prevent risk of fire. Move the machine to safety area, if there is a risk that people may get too close and then perform the regeneration.



There are four messages about the levels of regeneration. Each level has a different alarm screen which consists of warning screen, check screen and indicator. 



Level 1



Figure 3 Indicator, regeneration required The soot load is 100 ~ 114%. - Central warning lamp will light up with yellow color. - Check screen and indicator will be displayed. NOTE! Check screen can be dismissed by pressing ESC button, it will pop up again after 15 minutes if screen was dismissed.



Check screen can be displayed after the key is turned off and on. If DPF regeneration switch is pressed to position 1, the regeneration will start immediately. Operator can move the machine during the regeneration status of engine. Machine condition to start regeneration - Coolant temperature is over 70℃.



Figure 5 Information screen (green) Semi-auto regeneration (optional equipment) Semi-auto function is available only in level 1 and level 2. After check screen (A) shown, check screen (B) will be displayed. After 1 minute, the machine starts regeneration automatically if it meets below conditions. Machine condition to start semi-auto regeneration - Control lockout lever is unlocked position - No system fault Otherwise operator can start or stop the regeneration immediately by pressing DPF regeneration switch.



Figure 6







Level 2 The soot load is 115 ~ 125%. When the first regeneration message is ignored; - Central warning lamp will light up with yellow color. - Check screen and indicator will be displayed. NOTE! Check screen can be dismissed by pressing ESC button, it will pop up again after 15 minutes if screen was dismissed.



Check screen can be displayed after the key is turned off and on. Due to engine protection, the engine power is reduced gradually even engine rpm goes up. If DPF regeneration switch is pressed to position 1, the regeneration will start immediately. Operator can move the machine during the regeneration status of engine.



Figure 8 Check screen for level 2 A. B.



Regeneration required (yellow) Regeneration starts in 1 min (yellow)(optional equipment)



Machine condition to start regeneration - Coolant temperature is over 70℃.



Figure 9 Information screen (green) Semi-auto regeneration (optional equipment) Semi-auto function is available only in level 1 and level 2. After check screen (A) shown, check screen (B) will be displayed. After 1 minute, the machine starts regeneration automatically if it meets below conditions. Machine condition to start semi-auto regeneration - Control lockout lever is unlocked position - No system fault Otherwise operator can start or stop the regeneration immediately by pressing DPF regeneration switch.



Figure 10







Level 3 The soot load is 126 ~ 161%. When the second regeneration message is ignored; - Central warning lamp will blink with red color. - Warning screen and indicator will be displayed. NOTE! Warning screen can not be dismissed by pressing ESC button or SELECT button.



Warning screen can be displayed when other messages are dismissed on the screen. Due to engine protection, the engine power is widely reduced and machine operation is limited. A→C - If the regeneration status is changed to the level 3 while the control lockout lever is set to upper position, the first warning screen (A) is shown. Then, if the control lockout lever is set to lower position, the third warning screen (C) is shown. B→C - If the regeneration status is changed to the level 3 while the control lockout lever is set to lower position and the engine speed control switch is set to any mode except I2 mode, the second warning screen (B) is shown. Then, if the engine speed control switch is set to I2 mode, the third warning screen (C) is shown. NOTE! DPF regeneration only can be started in condition of the third warning screen (C). The machine needs to be stand-still to run the regeneration. Operator can not move the machine during the regeneration status of engine.



Figure 12



A. B. C.



First warning screen for level 3 (red) Second warning screen for level 3 (red) Third warning screen for level 3 (red)



Machine condition to start regeneration - Coolant temperature is over 70℃.



Figure 13 Information screen (green) 



Level 4 The soot load is over 162%. When the third regeneration message is ignored; - Central warning lamp will blink with red color. - Warning screen and indicator will be displayed. NOTE! Warning screen can not be dismissed by pressing ESC button or SELECT button.



Warning screen can be displayed when other messages are dismissed on the screen.



Figure 15 Warning screen for level 4 (red) Due to engine protection, the engine power is reduced maximally even engine rpm goes up.



DPF regeneration can not be performed by the operator. The regeneration needs to be done by a service technician. NOTE! DPF regeneration is only possible with VCADS Pro.



Service Information Document Title: Travel alarm



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Travel alarm The function is used to warn the surrounding area when the machine is moving. For the wiring diagram, see, 370 Wiring diagram SCH12. Input signals Pin No.



ECU



Description



VA43



V-ECU



Travel pressure monitor, SE4216



Input messages ECU



Description



Keypad



Travel alarm / buzzer stop



Parameters Code



Name



BFQ



Connect travel alarm



For more information, see 301 Software parameters, description. Output signals Pin No.



ECU



Description



VA12



V-ECU



Travel alarm relay, RE4206



Function description If the following conditions are applied, the travel alarm request will be on.  



Parameter BFQ, ON Travel pressure monitor, ON



When the buzzer stop button on Keypad is activated, the travel alarm is OFF.



Service Information Document Title: Overload warning



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Overload warning This function monitors the overload pressure sensor and warns the driver when the pressure of boom cylinder is over the setting pressure. Input signal Pin No.



ECU



Description



VA48



V-ECU



Overload pressure monitor, SE9401



Parameters  



(HXY), Overload (IKN), Overload boom cylinder pressure setting



See also, 301 Software parameters, description. Function description Overload function on / off



Figure 1 Overload select indicator    



Parameter HXY enable this function. I-ECU sets function on / off with the signal of pressing overload select button from keypad. If the overload select button is ON, overload select indicator (green) is shown on the I-ECU and the backlight for this button is turned on. Enable function status is saved when the key is turned off and on.



Overload warning



Figure 2 Warning screen



Figure 3 Overload warning indicator When the overload function is ON, if the value of pressure sensor is over the setting value, there are several alarm actions:    



Warning screen (only once since key on) Buzzer is sounding Warning lamp is blinking Overload warning indicator (red) is shown on the I-ECU



If the pressure goes below the setting pressure or the overload function is OFF:   



Buzzer is off Warning lamp is off Overload warning indicator (red) disappears



If the warning screen pops up, it remains with buzzer and lamp until it is cancelled by ESC button. Buzzer and warning lamp can be cancelled by pressing ESC button if the sensor pressure is below the setting pressure. The warning screen is cancelled only by pressing ESC button twice regardless of the pressure.



Service Information Document Title: Auto Idle



Function Group: 301



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Auto Idle The purpose of the auto idle function is to automatically enter idle mode when the machine is not operated for some time. When the machine is put in idle mode engine speed is decreased in order to lower the fuel consumption. After the engine has decelerated, if the operator touches one of the remote control valves (control levers, pedals) or turns the engine speed control switch or pushes one of the rotator switches, engine speed is increased to the selected speed of the engine speed control switch. For the wiring diagram, see 370 Wiring diagram SCH08. Input signals Pin No.



ECU



Description



VA39



V-ECU



Engine speed control switch, SW2701



VA19



V-ECU



Attachment pressure monitor, SE9111



VA17



V-ECU



Float safety pressure monitor, SE9140



VA20



V-ECU



Control lockout lever, SW9118



VB10



V-ECU



X3 proportional switch, SW9161



VA57



V-ECU



X3 / Rototilt rotator switch left-hand, SW9405



VA51



V-ECU



X3 / Rototilt rotator switch left-hand, SW9406



–



Keypad



Auto idle selection switch



Input messages ECU



Description



Keypad



Auto idle selection switch



Parameters Code



Name



BFJ



Connect X1 flow control



FYZ



Connect X3 proportional control



FYY



Connect X3 On / Off control



For more information, see 301 Software parameters, description. Output signals Output messages ECU



Description



V-ECU



Auto idle selection switch status



See also, 301 Software parameters, description. Releasing conditions:    



Attachment pressure monitor, ON Float safety pressure monitor, ON Control lockout lever, ON / OFF change Control lockout lever and X3 switch operation, ON







Engine speed control switch, change



Automatic idle delay time Default time is 5 seconds and changeable from 3 to 20 seconds on the I-ECU



Service Information Document Title: Function Group: VCADS Pro, 17030-3 - 301 Parameter, programming



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



VCADS Pro, 17030-3 - Parameter, programming Caution: It is inadvisable to change any parameter settings without the user knowing exactly what is to be done. Typically, parameters are only to be changed when installation instructions, service bulletins or other similar things inform the user to do so. Incorrectly adjusting parameters can have a serious impact on the machine. How to change a parameter To change a parameter the user must follow these steps:    



Run the parameter programming operation and locate the parameter they would like to change by navigating through the options. Changes can be made to the parameter setting by altering the “valve” column. Click the button labeled “continue” followed by “program” on the confirmation dialogue box that appears. If prompted, enter your static / Digipass password. Click the “stop” button followed by the “close” button. Turn the machine off when prompted to apply the parameter changes.



NOTE! Changing the vehicle parameters requires an internet connection. NOTE! The user will be prompted if charges apply to changing a particular parameter.



Figure 1 Example of parameter programming Parameter programming template This function includes creation, editing and application of templates for parameter programming. The advantage of using templates is when several vehicles require programming with the same set of parameters and values. It makes the programming procedure considerably faster and reduces the chance of inconsistencies between machines. For instructions on how to program parameters using a template see the “Programming” section in the Help section of VCADS Pro on your VCADS Pro service tool.



Service Information Document Title: Function Group: Software parameters, 301 description



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Software parameters, description New Incorrectly set parameters may cause malfunction symptoms. Check the parameter values so that these are reasonable by comparing them to the correct values and limits. Use VCADS Pro to check the parameters. There are two types of parameters that can be programmed, machine parameters and customer parameters. Machine parameters are of the accessory type or legal requirements, and requires on-line connection to the Volvo data base VDA (Vehicle Data Administration) to enable programming. Customer parameters do not require on-line connection, they can be programmed directly. NOTE! Default set parameters in the description can be different according to the options installed on the machine and to the changes made during machines lifetime. Engine control unit (E-ECU, MID 128) Code AIZ



AJJ



Titles in VCADS Pro



Default set



Set range



Description in VCADS Pro



Additional explanation



Fuel consumption, calibration percent



0%



A percentage correction value between +10 and -10 is programmed to compensate for any fuel consumption. For example the value 4 means an increase of 4% and -4 a decrease of 4%. The following formula gives the correction value: (consumption according to the customer’s fuel records - consumption according to display) / consumption according to display x 100 = the correction value. Round off the value to the nearest integer. When the compensation is complete reset the mileage and fuel data.



If the real fuel consumption is lower or higher than the value shown in Matris or I-ECU, you can adjust the displayed value to the real value. The cause of the differences could be fuel quality, working conditions, driver behavior, machine conditions. Example: real consumption, 95L displayed consumption, 100L Adjust, -5%



Crank reference offset



0.0



from –10 to +10%



-3.0 – 3.0 degrees



Calibration of the crank position during production – compensates for production tolerances in the sensor wheel and when installing the engine speed (RPM) sensor. ATJ



Injector cylinder 1, calibration



Trim code



–



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 9 characters. ATK



Injector cylinder 2, calibration



Trim code



–



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 9 characters. ATL



Injector cylinder 3, calibration



Trim code



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 9 characters.



–



ATM



Injector cylinder 4, calibration



Trim code



–



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 9 characters. ATN



Injector cylinder 5, calibration



Trim code



–



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 9 characters. ATO



Injector cylinder 6, calibration



Trim code



–



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 9 characters. AU



Max engine speed stationary



2300



600 – 2600 r/min



CNS



Maximum torque limit



5000



0 – 4000 Nm



Limits the engine torque value over the entire rpm – range. DN



Cust data, Fleet ID



–



–



The customer unit number can be entered here. – (maximum 13 characters). The Fleet ID can be set via the cluster menu. DX



Cust data, engine ECU password



–



–



– FXE



Engine governor type



0 = MinMax



Engine governor type



–



IUI



Request reset when faulty component replaced



0 = No



– –



Request reset when faulty component replaced. May – only be used when performance related component has been replaced and after given fault search instructions without exception. JAA



The PTO is drive shaft



0 = No



–



If true, disables the drive line protection (torque limit – for low vehicle speed) when the PTO is engaged (PTO mode or PTO Switch On from VP2 / PID89). JVL



Injector cylinder 1, calibration E3 Glitch trim



Trim code



–



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 13 characters. Used for E3 Glitch trim. JVM



Injector cylinder 2, calibration E3 Glitch trim



Trim code



–



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 13 characters. Used for E3 Glitch trim. JVN



Injector cylinder 3, calibration E3 Glitch trim



Trim code



–



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 13 characters. Used for E3 Glitch trim. JVO



Injector cylinder 4, calibration E3 Glitch trim



Trim code



The new trim code must be programmed after –



–



replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 13 characters. Used for E3 Glitch trim. JVP



Injector cylinder 5, calibration E3 Glitch trim



Trim code



–



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 13 characters. Used for E3 Glitch trim. JVQ



Injector cylinder 6, calibration E3 Glitch trim



Trim code



–



The new trim code must be programmed after – replacing the unit injector. The trim code (T/C) is shown on the injector label and consists of up to 13 characters. Used for E3 Glitch trim. LVG



ACM Burner states



–



–



The state of the ACM (Aftertreatment Control Module) – burner: 1 : Burner state wait 2 : Burner state igniter cleaning 3 : Burner state preparation 4 : Burner state ignition 5 : Burner state warm up 6 : Burner state ramp up 7 : Burner state temp control 8 : Burner state cool down 9 : Burner state shut down 10 : Burner state error 11 : Burner state power down 12 : Burner state active diagnostics LVH



ACM Burner Status



–



–



The state of the ACM (Aftertreatment Control Module) – burner: 1 : Burner status ok 2 : Burner status lost frame 3 : Burner status too low engine speed 4 : Burner status too high exhaust temp 5 : Burner status too high heat temp 6 : Burner status too high DPF temp 7 : Burner status too high flame temp 8 : Burner status controllability error 9 : Burner status ignition high flame temp 255 : Burner status major error YA



Idle target engine speed



730 rpm



Idle speed, desired value



Normal value: 700-900 rpm



0–2000 rpm



Instrument control unit (I-ECU, MID 140) Code ABP



Titles in VCADS Pro



Default set



Description in VCADS Pro



Additional explanation



Anti-theft protection



–



Set range OFF/ON



Activates the anti-theft device that prevent starting of This parameter is also valid for V-ECU the vehicle ABQ



Anti-theft protection PIN code



0123



0–9999



Select PIN code for anti-theft device



This parameter is also valid for V-ECU NOTE! The first ZEROs are not displayed. e.g. '0001' is shown as '1' while '1000' is shown as '1000'.



BGR



FZA



HXY HXZ



IAA



IKN



IKM



IKO ITQ



ITR



Central greasing installed



–



OFF/ON



Automatic lubrication system installed and activated



This parameter enables the diagnostic of the automatic lubrication system so that the operator gets an error message on the display when the automatic lubrication system has an error.



Connect JS pattern option



–



Connect joystick pattern option



This parameter enables the diagnostic of the control lever's pattern changer and the symbols on the display which pattern mode is selected “BHL” or “SAE ISO”.



Option Overload



–



Option Overload



With this parameter the overload warning is activated.



Option X1/X3 Pin Code



–



Option X1/X3 Pin Code



With this option the operator has to type in a pin code when he want to change the setting for the X1 working tool or X3 settings in the hydraulic menu of the I-ECU.



X1/X3 Pin Code



0123



X1/X3 Pin Code



Select PIN code for X1 or X3 settings. NOTE! The first ZEROs are not displayed. e.g. '0001' is shown as '1' while '1000' is shown as '1000'.



Overload boom cylinder pressure setting



270.00



Overload starting pressure



Active overload warning if boom cylinder pressure is higher than this valve



Proportional switch control lever installed



–



Indicates control lever with proportional switch



This parameter sets the default setting for X1 or X3 to proportional. (Only use if proportional control lever is installed!)



Quick fit installed



–



Connect the quick fit option.



–



No. of Cameras installed



–



No. of Cameras installed



Values higher than 4 are not valid for wheeled excavator.



Theft Deterrent Time Delay



30 sec



OFF/ON



OFF/ON OFF/ON



0–9999



0–65535.00 kPa



OFF/ON



OFF/ON 0–10



0–9000 sec



After shutdown, the vehicle can be restarted within this – time limit without identification. IZT



X1 special attach type



-



0–3



Show whether special attach installed and type if This parameter is also valid for V-ECU attached. 0: SA not installe 1: Double acting 2: Single acting with Bucket 3: Single acting without Bucket JEP



MZU



Fuel tank type



-



1–5



Option fuel tank type



Fuel level sensor ( = fuel sender) represents the height of the fuel in the tank. This parameter is used to reflect different shapes and size of tanks so that the cluster shows exact volume-based value. 1 : EC700C, 2 : EC140C, 3 : ECR235C, 4 : ECR145C, 5 : ECR305C



Long life hydraulic oil type



250



0–250



Initial interval time setting is different by hydraulic oil This parameter is set at first and cannot change type. Parameter value means service interval hour. 250 : Long life hydraulic oil type



Caretrack control unit (W-ECU, MID 142) Code IGU



Titles in VCADS Pro



Default set



Description in VCADS Pro



Additional explanation



Satellite Modem



–



Set range OFF/ON



The parameter activates satellite modem function for For the machines which is in the region where can not Caretrack. This function also needs hardware to be use GSM communication. installed. ON: Satellite modem installed. OFF: Satellite modem not installed. IHA



GSM Modem



–



OFF/ON



The parameter activates GSM Modem function for For the machine which is in the region where it can use Caretrack. GSM communication. ON: GSM Modem is used for Caretrack communication. OFF: GSM Modem is not used for Caretrack communication JDC



CARETRACK Power Supply Options



–



0–1



Activates functionality for Care Track to communicate Recommended if satellite communication is installed. without key-dependent power supply. 0: The Care Track control unit need key-dependent power supply to communicate. 1: The Care Track control unit communicates without key-dependent power supply. The battery disconnect switch must be turned on. NOTE! When the parameter is set to 1 the control unit consume current which should be taken in consideration when battery disconnect switch is turned on.



Climate control unit (ECC MID 146) Code GYC



GYP



Titles in VCADS Pro



Default set



Set range



Description in VCADS Pro



Additional explanation



Air conditioning installed



–



Air conditioning installed



Describes if the machine is equipped with air conditioning unit 0 : not installed, 1 : installed



Air Condition cycling level



4



Defines the temperature cycling levels of AC 0 : not used 1 : levels are 3 and 7 °C 2 : levels are 2 and 5 °C 3 : levels are 4 and 8 °C 4 : levels are 1 and 6 °C



The temperature after the evaporator is defined by a reference value. In order to prevent ice formation on the evaporator the AC will shut off when temperature falls below the “low” level and AC will turn on again when temperature rises above the “high” level. The “low” and “high” levels are defined with this “AC cycling level” parameter. The reasons for having these different cycling levels are:



0–1



0–250











To prevent ice formation on the evaporator at geographic places where the climate is warm and has high humidity (e.g. Florida). In this case the levels can be high. To speed up the cooling performance. In this case the levels should be low. This can only be done at geographic places with dry climate.



HGO



HGP



HSZ



HXD



Enable Fan Lim Door Open



–



0–1



Limit fan speed when cab door open



This parameter defines that the fan (cab blower) speed is decreased when the cab door is open. 0 : not enabled, 1 : enabled



Enable Model Based Diagnosis



–



Activate model based diagnosis



With this parameter you can “add on” additional diagnosis. 0: No “add on”. The ECU is only doing the normal built in diagnosis. 1: Make diagnosis of duct temperature, heat failure, water valve and blower. NOTE! Not applicable for wheeled excavator



Pump for recirculation of water



–



Pump for recirculation of water



This parameter is set when water recirculation pump is installed, needed for the function “Cab heat timer” 0 : not installed 1 : installed NOTE! Parameter HSZ and HXD are used together.



Heater Installed



–



0: Heater core not installed 1: Heater core installed



This parameter is set for machines where heater core is installed 0: Heater core not installed 1: Heater core installed NOTE! Parameter HSZ and HXD are used together.



0–1



0–1



0-250



Vehicle control unit (V-ECU, MID 187) Code ABP



Titles in VCADS Pro



Default set



Description in VCADS Pro



Additional explanation



Anti-theft protection



–



Set range OFF/ON



Activates the anti-theft device that prevent starting of This parameter is also valid for I-ECU. the vehicle. BFJ



BFQ



BNJ



Connect X1 flow control



–



OFF/ON



Connect X1 flow control



This parameter enables the limitation of the max. X1 flow which was set in the X1 tool settings in the I-ECU. (The option must be installed.) This parameter is always set if there is X1 option.



Connect travel alarm



–



Connect travel alarm



This parameter enables the travel alarm when travelling. The travel alarm can be turned off immediately with the switch on the keypad.



Float position, function



–



OFF/ON



OFF/ON



Option equipment Float position function installed YES The option must be installed. = 1; NO = 0 CVS



Connect X1 two way switch



–



OFF/ON



This option allows you to use the X1 function with two The option must be installed. pressure lines by choosing which line (or both) you want to have pressure on. FYV



Connect X1 proportional control



–



OFF/ON



Connect X1 proportional valve control



This parameter is always set with proportional switch



control lever (IKM) FYW



Connect X1 one-way switch



–



Connect X1 single-way switch



This parameter allows you to use the X1 function with one pressure lines



Connect X1 presetting pressure



–



Connect X1 presetting pressure



This parameter enables the limitation of the max. of X1 pressure. X1 pressure is set in the X1 tool settings in the I-ECU.



Connect X3 On/Off control



–



Connect X3 On/Off valve control



The option must be installed.



Connect X3 proportional control



–



Connect X3 proportional valve control



This parameter is always set with proportional switch control lever (IKM)



Connect JS pattern option



–



Connect joystick pattern option



This parameter enables the diagnostic of the control lever's pattern changer and the symbols on the display which pattern mode is selected “BHL” or “SAE ISO”. This parameter is also valid for I-ECU



Connect X1 single acting



-



Connect X1 single acting



The option must be installed.



HOI



Connect X1 2–pump



-



Connect X1 2–pump



The option must be installed.



HOJ



Connect X1 pedal



-



Connect X1 pedal



The option must be installed.



Connect dozer blade



-



Connect dozer blade



The option must be installed.



Connect X2



-



Connect X2



The option must be installed.



Boost remaining time



9 sec



Boost lasting time



This parameter defines the time how long the power boost function will be active when pressing the power boost switch on the control lever. NOTE! For wheeled excavator this time should not be longer than 30 sec.



Oil cooler type



-



Oil cooler type



This parameter is set depending on the oil cooler type. 1: Modine oil cooler 2: AKG oil cooler



1 switch control lever installed



-



Indicates control lever 1 switch



The option must be installed.



4 switch control lever installed



-



Indicates control lever 4 switch



The option must be installed.



Proportional switch control lever installed



-



FYX



FYY FYZ



FZA



HNI



HOK HOL HOQ



IAK



IIN IIO IKM



OFF/ON



OFF/ON



OFF/ON OFF/ON



OFF/ON



OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON 3–255 sec



0–1



OFF/ON OFF/ON OFF/ON



Indicates control lever 3 switch with proportional The option must be installed. switch This parameter is also valid for I-ECU IZT



X1 special attach type



-



0–3



Show whether special attach installed and type if 1. Similar to proportional control + double acting attached. combination in standard option. Diagnostics for the 0: SA not installe proportional input/output components are not 1: Double acting disabled in case of field modification of the 2: Single acting with Bucket components.



JEN



3: Single acting without Bucket



2. Similar to 1 switch control + single acting combination. Flow rate request for harvest tool is inputted through 2 piece boom RCV sensor. 3. Similar to 1 switch control + single acting combination. Flow rate request for harvest tool is inputted through bucket RCV sensor and bucket spool control the flow. 1 : type A, 2way control, 2 : type B, 1way inter conflux, 3 : type C, 1way harvest



Swing alarm installed



–



OFF/ON



–



0–1



When swing alarm is installed on the machine, the vehicle buzzer sounds whenever swing operation is implemented. This option is used to warn the people who work around the machine because the swing radius is usually larger than the width of the machine. JGX



Reversible fan installed



Reversible airflow direction control in hydraulic oil/ The option must be installed. engine coolant cooling system. 0: This equipment don't have reversible fan. 1: This equipment have reversible fan. JGY



Reversal interval time at auto mode



60 min



20–120 min



Reversal rotation interval time at auto 1 mode in the Defines the time between the reversible cycles in auto reversible fan. mode. JGZ



Reversal time at manual mode



60 sec



20–180 sec



Reversal rotation time of reversible fan at manual Defines the time how long the fan runs in reversible mode. direction. JHA



Fan clutch installed



-



OFF/ON



-



OFF/ON



If this parameter is set, V-ECU requests the fan speed (RPM) from E-ECU to control the fan clutch. This is for the control unit to know if the machine has fan clutch. LBR



Connect X3 ON/OFF solenoid



0: This equipment does not have an X3 ON/OFF X3 ON/OFF option is of two types and one is operated solenoid valve. by a proportional valve and the other is a operated by 1: This equipment have an X3 ON/OFF solenoid valve. solenoid valve. This parameter defines X3 is acting by solenoid valve. LFL



Cooling System Selection



-



0–1



Cooling system can be divided into 2 types: “tropical” Standard cooling system is based on 40°C and tropical and “standard” cooling system. cooling system is based on 47°C or 50°C. 0: Standard cooling system will be adapted. The cooling fan speed is different between the 2 types 1: Tropical cooling system will be adapted. of cooling systems. LUH



Engine control mode with power max switch



-



OFF/ON



-



OFF/ON



The machine has two types of engine control mode. One is I2 mode to H mode (9 steps) and the other is I2 mode to P mode (10 steps: add power max mode) This parameter is used to set when the power max switch is installed on the machine for using power max mode. 0: This is used when the machine doesn't have power max mode and power max switch. 1: This is used when the machine has power max mode and power max switch. FAU



Automatic engine shut off Activation of the function automatic engine shut off. The function automatically shuts off the engine after being idle for a certain time. See parameter FAV for engine shut off time.



FAV



Automatic engine shut off, time



5



Setting of time in minutes until automatic engine shut off . The function automatically shuts off the engine after being idle for the selected time. NFZ



Reduced torque Reduced torque when operating in high altitude. Torque setting 50 to 100 %, step: 5



100 (100 %)



2–50 min



Service Information Document Title: General fault information



Function Group: diagnosis 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



General fault diagnosis information The section entitled "Troubleshooting" describes how troubleshooting is performed of symptoms and malfunctions related the electrical system. Information regarding the different functions of electrical components, measurement values, and possible malfunction detection is also available. The basis for all fault diagnosis is that a fault, symptom or function disturbance has been recorded. Faults can be indicated by:     



flashing red central warning lamp buzzer sounding flashing amber central warning lamp error texts in the display panel an error symptom is detected.



Different actions should be taken depending on the manner in which the fault is indicated.  



For faults resulting in: Flashing amber central warning lamp - promptly inspect the cause during following stop. For faults resulting in: Flashing red central warning lamp - stop the machine immediately and investigate the cause of the fault!



WARNING Continued operation following a malfunction indication may result in damage to persons and property. It is of the utmost importance to determine the cause of the fault as quickly as possible when one is suspected or found. The first step in fault diagnosis is to collect information from the operator regarding the fault symptom. Afterwards, attempt to localise the cause of the fault by performing checks in a specific order, see 302 Troubleshooting strategy. To facilitate and make troubleshooting more effective, there is a number of tools available, e.g., diagnostics section in PROSIS and VCADS Pro service tool, see 302 Troubleshooting tools.



WARNING During troubleshooting and all work with the electrical system, carefully follow all instructions in Electrical system, work instructions.



Service Information Document Title: Troubleshooting strategy



Function Group: 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Troubleshooting strategy The basis for all troubleshooting is that a malfunction, symptom or defect is noticed. Troubleshooting strategy and procedures are illustrated in the following flow chart. Start



Basic data collection, see 302 Collection of basic data.



Check for error messages. Error texts found? YES     



NO Note error messages. Troubleshoot using error code description, see diagnostics section in PROSIS. Repair the defect/malfunction. Activate the concerned component or function. Read-out of error messages. Problem solved?



YES



NO



OK



Perform parameter check, see 301 Software parameters, description. Any parameters incorrectly set? YES



NO



Re-program parameter. Problem solved? YES



NO



OK



Troubleshoot using additional information.[ 1] 



The included steps in the troubleshooting strategy are described below. 1.



Basic data collection. The basis for all troubleshooting is a symptom or malfunction. In order to establish a basis for troubleshooting, data should be collected about the symptom/malfunction. A data collection model is available as 302 Collection of basic data.



2.



Error messages give a clear indication of what has caused the symptom or malfunction. Therefore, read off error messages from the information display unit before troubleshooting is started. For information about error messages' design, see 302 Information display, check. NOTE! If new or repeated error messages are generated during troubleshooting, then these must be solved first before continuing to troubleshoot. A. B. C.



If error message is generated, troubleshooting shall be performed according to the diagnostics section in PROSIS. Error messages are registered and compared with new or recurring error messages. To verify that the problem has been repaired, the appropriate machine components/functions must be activated to allow the control unit to conduct a self-diagnosis and display new or recurring error messages. The machine should be started and the component/function should be activated in order to



D.



3.



ensure that a self-diagnosis is conducted. Error messages are examined to verify that the symptom/malfunction has been repaired and to ensure that no additional defects have occurred as a result of the repair procedure.



Parameters are checked to make sure that reasonable values are set. See 301 Software parameters, description.



[ 1]Additional information includes wiring diagrams, function descriptions and component troubleshooting.



Service Information Document Title: Lead and connector checks



Function Group: 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Lead and connector checks General An important part of electrical system fault diagnosis is lead and connector checks, which can provide the cause of malfunctions in the form of loose connections or damaged electrical leads. NOTE! Before troubleshooting leads and connectors is conducted, the appropriate fuses should be checked. Checking should be performed 302 Special tools for troubleshooting.



with



multimeter,



multi-pin



breakout



box,



and



cable



adapters,



see



For repairs of electrical cabling and connectors, see separate Service manual: CABLES AND CONNECTORS. Refer to the wiring diagrams to find suitable test points.



NOTICE The following should be observed when working on electrical systems.  



Testing should not be conducted by sticking objects through electrical lead insulation. Exercise caution while testing with a test cable in connectors to avoid damage to or widening of connector pins and sleeves.



NOTE! For troubleshooting of information bus and control bus, see diagnostics section in PROSIS. Connector and cable terminal checks For all tests and checks during which connectors are dismantled, connectors and cable terminals should be visually checked as follows: 1. 2. 3.



Look for cable terminal oxidation. Oxidation can impair the contact. Check for cable terminal damage, correct placement in the insulator and that the leads are correctly connected to the terminals. Check for good mechanical contact in the cable terminals. Use a separate cable terminal for checking.



Figure 1 Connector, mechanical contact check Open circuit, check



Open circuits in electrical cables and cable harnesses can be caused by chafing due to friction, pressure due to squeezing and tension load. Checks for open circuits are conducted as follows: 1. 2. 3.



Dismantle the appropriate connector in both ends of the cable harness. Conduct a resistance test between the lead ends. The resistance should be ≈ 0 Ω for an open circuit. Shake the cable harness and pull lightly on the connectors simultaneously during testing to find possible open circuits.



Figure 2 Check for open circuit with resistance testing



Figure 3 Troubleshooting open circuit Short circuit to ground, check A short circuit between the power supply lead and ground often leads to fuse failure. A check for short circuit to ground is conducted as follows: 1. 2. 3. 4.



Ignition in position 1. Close all breakers, activate circuit functions and check if any fuses are tripped. Dismantle the appropriate connector to the circuit components so they do not to affect the test. Resistance test between lead and ground. The resistance should be ∞ Ω for a lead without short circuit to ground.



Figure 4 Check for short circuit to ground (frame ground connection) with resistance testing



Figure 5 Basis for test of short circuit to ground (frame ground connection) Short circuit to voltage, check A short circuit between a lead and voltage often leads to fuse failure. 1.



2.



Test the voltage with a multimeter on suitable circuit points while the switch is connected and the sensor is activated. The voltage value is dependent on several parameters. See wiring diagram, signal description and component information. Dismantle the appropriate connector in both ends of the cable harness. Resistance test between the leads that can be short-circuited with each other. The resistance should be ∞ Ω for leads which are not cross short-circuited.



Figure 6 Check for short circuit to voltage with resistance testing



Figure 7 Basis for test of short circuit to voltage Contact resistance and oxidation, check Loose contacts or temporary recurring malfunctions can be difficult to diagnose and are often caused by corrosion,



vibrations of poorly connected leads. Dampness in the connectors can also cause contact problems as well as damaged pins or sleeves. Resistance in the connectors and leads should be ≈ 0 Ω. Some resistance, however, can occur due to corrosion in the cable terminals. If the contact resistance is too large, function disruption can occur. The amount of resistance that may occur without disruption varies according to the circuit load. To check contact resistance and oxidation, see Connector and cable terminal checks.



NOTICE Shake the cable harness and pull lightly on the connectors while measuring to find eventual loose connections.



Figure 8



Pins and sleeves, cleaning 1. 2. 3. 4.



Open the battery disconnect switch. Clean the connectors using compressed air. Spray the connectors with contact spray. Avoid spraying for preventive purposes. Use compressed air once again on the connectors.



Figure 9 Connectors, spraying with contact spray



Service Information Document Title: Collection of basic data



Function Group: 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Collection of basic data General Collection of basic data is the first step in all troubleshooting. This is done to quickly get an improved overall picture of how the problem shows up. In addition to information about the excavator and customer, it is important to gather as much information as possible with regards to the circumstances and sequence of events when the malfunction occurred. Often, the operator can provide valuable information regarding the circumstances when the malfunction occurred. The operator is almost always the one who notices a malfunction first. Since it is seldom possible to recreate the experienced problems, without having exactly the same conditions, the information from the operator is of great importance in order to be able to make correct evaluations for continued troubleshooting. Interview the operator using the following questions. Note the answers in writing and keep them together with the work order. The operator should be able to answer the following questions: General data    



Customer information Information about the dealer Operator Machine specifications:       







Machine Serial number Operating hours Engine type Engine number Model year Delivery date



Have any error codes been generated?



Description of malfunction or symptom         



Describe the malfunction. When did the malfunction occur? How was the malfunction noticed and what happened just before it was noticed? Does the malfunction reappear? How often does the malfunction occur? For how long does the malfunction last when it occurs? Does the malfunction always occur during the same conditions, and what are those conditions? Does the operator have an idea of what may be the probable cause of the malfunction? Does the problem still exist?



Engine information    



Under what operating conditions does the malfunction occur? External circumstances that affect the malfunction? Is the engine difficult to start? Is there abnormal smoke development?



     



Are there abnormal sounds from the engine? Have changes in fuel consumption, oil consumption or engine power been confirmed? What type of fuel is used? Are additives used in the fuel? If yes, which ones? What previous repairs, adjustments/service have been done to the engine? Other information?



Service Information Document Title: VCADS Pro service tool



Function Group: 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



VCADS Pro service tool General



Figure 1 VCADS Pro computer The following is a brief description of the VCADS Pro service tool. The name VCADS Pro is short for Vehicle Computer Aided Diagnostic System Professional. Design of VCADS Pro



Figure 2 Initial display VCADS Pro contains programs for:   



Testing components and functions Downloading software for control units Storing performed work operations on job card



Operations



Date: 2014/7/14



Figure 3 Example, tests and programming possibilities Under Operations, there are several tests and programming possibilities divided according to function group. The tests show, for example, sensor values, as well as graphic display of how a signal varies in time. Programming is used to reprogram control units. Read-out of error codes



Figure 4 Operations, read-out of error codes Read-out of error codes from operations, function group 1 - Service and maintenance. To pin-point malfunction causes, it's advantageous to use the service tool VCADS Pro. From VCADS Pro, it's possible to obtain error codes of the SAE-type, from which the malfunction cause can be determined, see 302 SAE error codes, translation to error messages, general. Parameters



Figure 5 Example, read-out parameters Reading out and programming of parameters is done from operation, function group 1 - Service and maintenance. For more information on parameters, see 301 Software parameters, description. Job card



Figure 6 Example, job card The job card function is used to store work operations that have been performed with VCADS Pro, for example, test results and results of error code read-outs and programming of parameters. The job card is stored locally in the computer in question.



Service Information Document Title: Troubleshooting tools



Function Group: 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Troubleshooting tools Service manual Service information for troubleshooting is available in the service manual. The different types of information are listed below:  















Instructions for lead and connector checks A general description of these checks can be found in 302 Lead and connector checks. Wiring diagrams Wiring diagrams are an important aid during troubleshooting and provide lead designation, lead colours and component and connector designations, etc. Component diagram Supplemental information to the wiring diagrams is available in the form of component lists that illustrate the location machine components. Function descriptions The purpose of function descriptions is to explain the machine's sub-functions with regards to input and output signals and association to other functions. Function descriptions are found in the different function groups. Error messages and troubleshooting information The PROSIS diagnostics section contains the error messages' conditions, possible causes, reactions from control unit, and noticeable symptoms/malfunctions.



VCADS Pro VCADS Pro is a PC-based service tool which has been developed in order to facilitate the troubleshooting procedure. Components/functions can be activated and values can be examined with VCADS Pro through the use of tests. Error text examination can also be conducted using VCADS Pro. For a description of VCADS Pro, see the separate operator's manual and 302 VCADS Pro service tool. Display unit The information display unit is used to read error texts, see 302 Information display, check. Special tools 302 Special tools for troubleshooting includes tools that recommended when conducting troubleshooting.



Service Information Document Title: Information display, check



Function Group: 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Information display, check Read-out of information from the figure “Check”



Figure 1



Example – Check Hydraulic system failure Check In the figure “Check”, information is shown about which systems or functions to check/troubleshoot. The information is presented with symbol and explaining text. To return to previous figure, press [ESC]. For more information, press SELECT, which gives a new figure “Detail info”. Detail info The following information is shown under Detail info:  



   



Fault Active: indicates if the malfunction/error is active or inactive Error Code: shows any error code in the form of component designation followed by FMI (failure/error cause). If the problem cannot be associated to a component designation, the error code is shown instead according to SAEstandard (e.g., MID128 PID123 FMI12). Source: shows which control unit detected the error/failure First event: logged date for first time that the failure/error occurred Number of events: number of times that the failure/error has been detected Last event: last date for failure/error detection



Service Information Document Title: Conditions when checking



Function Group: 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Conditions when checking The following checks (measurements) are mostly described using symbols, in order to clarify the conditions and to reduce reading time. The symbols are described below.



NOTICE When checking components, i.e. relays and solenoid valves controlled by a control unit, certain conditions must be fulfilled. Conditions are described in the function group to which the component belongs.



NOTICE To avoid changing functioning components, check the connectors with regards to loose connections and oxidation. See 302 Lead and connector checks. General symbols Symbol



Description



Symbol



Description



Battery disconnect switch in position Off.



Ignition in position 0, 1,or 3.



Engine at idle speed, ignition in position 1.



Resistance measurement



Diode measurement



Voltage measurement (DC)



Voltage measurement (AC)



Component



Ground connection Measuring control unit and cable harness, symbols Measuring through cable harness to ECU. Component disconnected. Symbol



Description Measuring connector with pin.



Symbol in test



Description Measuring adapter.



with



Checking cable harness, symbols Measuring cable harness only. Component and ECU disconnected. Symbol



Description Measuring with multipin breaker box and test pin.



Symbol



Description Measuring with multipin breaker box and adapter.



Measuring of cable harness, shortcircuiting to ground.



Measuring of cable harness, shortcircuiting to ground.



Checking component/cable harness, symbols Measuring component with or without connected cable harness. Symbol



Description Measuring adapter.



Symbol



Description



with



Measuring shortcircuiting to ground with adapter.



Measuring against component with test pins.



Measuring shortcircuiting to ground in component with test pin.



Measuring component with connected cable harness. ECU disconnected.



Measuring shortcircuiting to ground through cable harness.



Checking sub-system, symbols Symbol



Description



Symbol



Description



Multi-pin breaker box and adapter connected between ECU and cable harness.



Two multi-pin breaker boxes and adapter connected between ECU and cable harness.



Adapter connected between component and cable harness. ECU connected.



Multi-pin breaker box and adapter connected between ECU and cable harness. Test instrument ground to ground connection.



Service Information Document Title: Special tools troubleshooting



Function Group: for 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Special tools for troubleshooting The recommended measuring tools for checking electrical cables and components, for example, are listed below. Part no./Designation



Specification



9998699 Adapter



Multi-pin breaker box 62 pin with D-SUB connector. The multi-pin breaker box is universal and can be used for measuring a number of different connector types.



14576840 Measuring tool



The measuring tool is used for measuring V-ECU, connector VA, VB and VC. This tool includes multi-pin breaker box and adapter cables.



9990062 Cable



Extension cable 2.5 m for multi-pin breaker box 9998699.



9993893 Break out harness



The adapter cable is used for measuring V-ECU and ECC.



9990014 Break out harness



The adapter cable is used for measuring engine control unit (E-ECU) connector EA and EB. NOTE! For active measuring of E-ECU, 2 adapter cables are required.



88890074 Multimeter



Multimeter used for fault diagnosis. (Similar multimeters can also be used)



88890016 Break out harness



Adapter cable for measuring against component with 2 pin, 3 pin, 4 pin, 6 pin, 8 pin, or 12 pin connectors. Used together with multi-pin breaker box 9998699 and template 88890019.



88890019 Template



Template for multi-pin breaker box 9998699. Adapted to adapter cable 88890016.



88830037 Template



Template for multi-pin breaker box 9998699. Used together with 9993900 and 88830028.



9990133 Template



Used together with 9990020.



88830028 Break out harness



The adapter cable is used for measuring I-ECU.



8920-01805 Break out harness



The adapter cable is used for measuring flow control valve.



9990025 Break out harness



The adapter cable is used for measuring electric distribution box (EDB) connectors.



9998534 Break out harness



Adapter cable for measuring against component with 4 pin connectors.



9998567 Break out harness



Adapter cable for measuring against component with 7 pin connectors.



88890024 Break out harness



Adapter cable for measuring against component with 2 pin, 3 pin, 4 pin and 6 pin connectors.



88890119 Break out harness



Adapter cable for measuring against component with 4 different coded 2 pin connectors.



9990216 Break out harness



Adapter cable for measuring against component with 2 pin, 3 pin and 4 pin connectors.



Service Information Document Title: Error codes, build-up



Function Group: 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Error codes, build-up Display unit The error codes shown on the display unit, I-ECU are built up from a character combination with the following appearance and meaning.



Figure 1 Example of error code "Temperature sensor engine oil, too high voltage" Position 1 Indicates which type of component or function that has generated the error code. Abbreviations are found in the first 2–3 letters of the error codes. HE



Heating element



MA



Solenoid valve



PWM



Pulse width modulated valve



RE



Relay



SE



Sensor or monitor



SW



Switches



Positions 2a and 2b States component number where 2a signifies function group and 2b is a consecutive number within the function group. Position 3 States FMI-code and based on SAE standard J1587. FMI means Failure Mode Identifier and states which type of error that has caused the error code. 00



Data valid but above normal operating range



01



Data valid but below normal operating range



02



Intermittent or incorrect data



03



Abnormally high voltage or short-circuit to higher voltage Abbreviated in error code texts "high voltage"



04



Abnormally low voltage or short-circuit to lower voltage Abbreviated in error code texts "too low voltage"



05



Abnormally low current or open circuit Abbreviated in error code texts "too low current"



06



Abnormally high current or short-circuit to frame ground Abbreviated in error code texts "high current"



07



Incorrect reply from mechanical system Abbreviated in error code texts "mechanical error"



08



Abnormal frequency



09



Abnormal updating rate



10



Abnormally wide variations



11



Unidentifiable malfunction Abbreviated in error code texts "other error"



12



Defective unit or component



13



Calibration value outside limits



14



Special instructions



15



Reserved for future use



NOTE! FMI 0 and 1 indicate to values outside normal operating range. These generate an error code with a warning. Warning is shown on the display unit and through red central warning lamp.



Figure 2 Red central warning



Service tool VCADS Pro The error codes in VCADS Pro are built up as follows. Position figure



in Abbreviation



Explanation



1



MID



Message Identification Description (identification of control unit). There is a unique number for each control unit.



2



PID



Parameter Identification Description (identification of parameter/value). There is a unique number for each parameter.



PPID



Proprietary Parameter Identification Description (Volvo-unique identification of parameter/value). There is a Volvo-unique number for each parameter.



SID



Subsystem Identification Description (identification of component). The SID-number depends on which control unit (MID) that they are sent from. Each control unit has its own number series for SID. The exceptions are SID-numbers 151–255 which are general for all systems.



PSID



Proprietary Subsystem Identification Description (Volvo-unique identification of component).



FMI



Failure Mode Identifier (identification of failure type).



3



Figure 3 Error code screen in service tool VCADS Pro Position 1, MID Indicates the control unit that generated the error code. Based on SAE standard J1587. 128



Engine electronic control unit



140



Instrument electronic control unit



146



Electronic climate control unit



187



Vehicle electronic control unit



Position 2, PID, PPID, SID, PSID Indicates the component/parameter that generated the error code. Based on SAE standard J1587. Position 3, FMI Indicates the FMI code. FMI means Failure Mode Identifier and the code indicates which type of malfunction has generated the error code. FMI is based on SAE standard J1587. Components with Volvo-specific FMI number For a few components FMI has a Volvo-specific meaning (not according to SAE standard J1587), see for example, error code, MID187 PPID1319 (MA9103).



Service Information Document Title: AL3201, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



AL3201, description and measuring Op nbr 302-447 88830028 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 88830037 Template



Description Function



Supplies the power to the electric system and charges the battery



References



370 Wiring diagram SCH01



VCADS Pro Test



Figure 1



Measuring Measuring point 31 –



B1+ – BS –



Correct value ≈0Ω



≈ Uᵇᵃᵗ



Condition



Test method



Date: 2014/7/14



15 –



≈ Uᵇᵃᵗ



L – IA10



≈0Ω



Verifying Measuring point IA10 –



Correct value ≈ 24 V



Condition



Test method



Service Information Document Title: BA3101, description measuring



Function Group: and 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



BA3101, description and measuring Op nbr 302-488 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990014 Break out harness 14576840 Measuring tool



Description Function



Voltage feed to vehicle control unit V-ECU and engine control unit E-ECU



References



370 Wiring diagram SCH02



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



VB15 – VB7 VB16 – VB8 EB57 – EB58 EB60 –EB59



≈ Uᵇᵃᵗ



Condition



Test method



VB7 – VB8 – EA57 – EB58 – EB59 – EB61 –



≈0Ω



Service Information Document Title: CU9901, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



CU9901, description and measuring Op nbr 302-117 88830028 Break out harness 9990062 Cable 9998699 Adapter 88890074 Multimeter 88830037 Template



Description Function



Supplies the grease to the bearings



References



370 Wiring diagram SCH20



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



2–



≈ Uᵇᵃᵗ



1–



IA3 –



≈0Ω



≈∞Ω



Condition



Test method



Date: 2014/7/14



3–



≈ Uᵇᵃᵗ (SW9900, ON)



Verifying Measuring point



Correct value



IA3 –



≈ Uᵇᵃᵗ (active) ≈ 0 V (inactive)



Condition



Test method



Service Information Document Title: FU18, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



FU18, description and measuring Op nbr 302-448 88890074 Multimeter 14576840 Measuring tool 9990025 Break out harness 9990133 Template



Description Function



Checks the power supply to proportional valve



References



370 Wiring diagram SCH08



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



VA35 –



≈ Uᵇᵃᵗ



VA60 –



Condition



Test method



Date: 2014/7/14



Service Information Document Title: FU26, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



FU26, description and measuring Op nbr 302-449 88890074 Multimeter 14576840 Measuring tool 9990025 Break out harness 9990133 Template



Description Function



Checks the power supply to relays and solenoid valves



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



VA33 –



≈ Uᵇᵃᵗ



Condition



Test method



Date: 2014/7/14



Service Information Document Title: FX1005, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



FX1005, description and measuring Op nbr 302-289 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 9998567 Break out harness



Description Function



Monitors water level in the fuel filter (SE2302) Preheats the fuel in fuel filter (HE2301)



References



370 Wiring diagram SCH03 370 Wiring diagram SCH04



VCADS Pro Test



Figure 1 EB8, feed EB10, ground Measuring Measuring point



Correct value



2–3



≈ ∞ Ω⁽ᵃ⁾



Condition



Test method



Date: 2014/7/14



3–



2–



3–



≈ 0.8 x Uᵇᵃᵗ



≈0Ω



≈∞Ω



Verifying Measuring point



Correct value



2–3



≈ 0.8 x Uᵇᵃᵗ



(a) Fuel filter drained of water



Condition



Test method



Service Information Document Title: FX1006, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



FX1006, description and measuring Op nbr 302-290 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 9998534 Break out harness



Description Function



Measures the engine oil level (SE2205) and temperature (SE2202)



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1



EA31, signal EA11, ground EB4, signal oil level + EB3, signal oil level –



Measuring SE2202 Measuring point



Correct value



3–4



≈ Resistance according to the graph below



Condition



Test method



Date: 2014/7/14



3–



3–



4–



EA11 – 4 EA31 – 3



≈5V



≈∞Ω



≈0Ω



≈0Ω



Verifying SE2202 Measuring point



Correct value



Condition



EA11 – EA31



≈ Resistance according to the able below



Test method



SE2202 resistance values Temp (° C)



Temp (° F)



Resistance



0



32



1.00 kΩ



20



68



1.08 kΩ



60



140



1.24 kΩ



80



176



1.31 kΩ



100



212



1.40 kΩ



120



248



1.47 kΩ



Measuring SE2205 Measuring point



Correct value



1–2



≈ 12 Ω⁽ᵃ⁾



1– 2–



≈∞Ω



Condition



Test method



EB4 – 2 EB3 – 1



≈0Ω



(a) At normal oil level and oil temperature 25 ° C (77 ° F ) Verifying SE2205 Measuring point



Correct value



EB3 – EB4



≈ 12 Ω⁽ᵃ⁾



Condition



(a) At normal oil level and oil temperature 25 ° C (77 ° F )



Test method



Service Information Document Title: FX1007, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



FX1007, description and measuring Op nbr 302-291 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990216 Break out harness



Description Function



Measures charge-air pressure (SE2508) and temperature (SE2507)



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1 EA7, feed EA22, EA47, signal EA11, ground Measuring SE2507 Measuring point



Correct value



1–2



≈ Resistance according to the table below



2–



≈5V



Condition



Test method



Date: 2014/7/14



≈∞Ω



2–



≈0Ω



1–



Verifying SE2507 Measuring point



Correct value



EA11 – EA47



≈ Resistance according to the table below



Condition



Test method



SE2507 resistance values Air temp (° C)



Air temp (° F)



Resistance



Air temp (° C)



Air temp (° F)



Resistance



-40



-40



168 kΩ



60



140



1.2 kΩ



-20



-4



48.4 kΩ



80



176



0.6 kΩ



0



32



16.2 kΩ



100



212



340 Ω



20



68



6.2 kΩ



120



248



195 Ω



40



104



2.6 kΩ



140



284



117 Ω



Measuring SE2508 Measuring point



Correct value



1–4



≈ 1.1 V (at normal air pressure 101 kPa)



3–



1–



3– 4–



≈5V



≈0Ω



≈∞Ω



Condition



Test method



EA22 – 4



≈0Ω



Verifying SE2508 Measuring point



Correct value



EA22 – EA11



≈ 1.1 V (at normal air pressure 101 kPa)



SE2508 voltage values



Figure 2



Condition



Test method



Service Information Document Title: FX1008, description measuring



Function Group: and 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



FX1008, description and measuring Op nbr 302-292 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 9998534 Break out harness



Description Function



Measures the position (SE2502) and temperature (SE2501) at the air filter



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1 EB31, signal EB18, ground Measuring SE2501 Measuring point



Correct value



3–4



≈ Resistance according to the table below



3–



≈5V



Condition



Test method



4–



3–



≈0Ω



≈∞Ω



Verifying SE2501 Measuring point



Correct value



Condition



EB18 – EB31



≈ Resistance according to the table below



Test method



SE2501 resistance values Air temperature ( °C)



Air temperature ( °F)



Resistance (Ω)



0



32



16.4 kΩ



30



86



4.0 kΩ



60



140



1.2 kΩ



90



194



460 Ω



120



248



200 Ω



Measuring SE2502 Measuring point



Correct value



1–2



≈ 330 Ω



1–



≈ 0.8 x Uᵇᵃᵗ



2–



1–



Condition



Test method



Condition



Test method



≈0Ω



≈∞Ω



Verifying SE2502 Measuring point



Correct value



EA29 – EA15



≈3V



Service Information Document Title: FX1032, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



FX1032, description and measuring Op nbr 302-298 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890016 Break out harness 88890019 Template



Description Function



Controls master air in atomization module Controls atomization air in atomization module Controls fuel injector in atomization module



References



370 Wiring diagram SCH05



VCADS Pro Test



Figure 1



45 / 49 / 53, feed 9, master solenoid – 29, automization solenoid – 41, fuel injector + 37, fuel injector –



Measuring Measuring point



Correct value



Condition



Test method



Date: 2014/7/14



45 – 9 45 – 29



≈ 59 Ω



41 – 37



≈ 2.1 Ω



45 – EK1 9 – EK2 45 – EK3 29 – EK4 41 – EK5 37 – EK6



≈0Ω



EK1 –



≈∞Ω



EK2 – EK3 – EK4 – EK5 – EK6 – Verifying Measuring point



Correct value



45 – 9 45 – 29



≈ 59 Ω



Condition



Test method



Service Information Document Title: HE2501, description measuring



Function Group: and 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



HE2501, description and measuring Op nbr 302-001 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter



Description Function



Preheats the induction air for the engine



References



370 Wiring diagram SCH03



VCADS Pro Test



Figure 1 EB7, diagnostic signal Measuring Measuring point HE2501 –



Correct value



Condition



≈ 0.1–0.2 Ω



30 (RE2501) –



≈ Uᵇᵃᵗ



EB7 – 30a (RE2501)



≈0Ω



Test method Measure directly on the heating coil



Verifying Measuring point



Correct value



Condition



Test method



EB7 –



≈ 1.8 Ω



Service Information Document Title: IG2501, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



IG2501, description and measuring Op nbr 302-301 88890074 Multimeter 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890016 Break out harness 88890019 Template



Description Function



Control aftertreatmemt burner ignition coil



References



370 Wiring diagram SCH05



VCADS Test



Pro



Figure 1 13, signal 21, ground 45/49/53, feed Measuring Measuring point



Correct value



49 – 21



≈ 59 kΩ



49 –



≈ Uᵇᵃᵗ



Condition



Test method



Date: 2014/7/14



21 –



≈∞Ω



13 –



Verifying Measuring point



Correct value



49 – 21



≈ 59 kΩ



Condition



Test method



Service Information Document Title: MA2301-MA2306, description and measuring



Function Group: 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA2301-MA2306, description and measuring Op nbr 302-002 9990014 Break out harness 9990062 Cable 9998699 Adapter 88890074 Multimeter



Description Function



Unit injectors for fuel



References



370 Wiring diagram SCH03



VCADS Pro Test



23712-3 Injectors shut off, manual High voltage side, EA59, EA60, EA61, EA62 Low voltage side, EA12, EA16, EA20, EA24, EA28, EA32, EA36, EA40, EA44, EA48, EA52, EA56



Date: 2014/7/14



Measuring Measuring point



Correct value



EA12 – EA62 EA16 – EA59 EA20 – EA62 EA24 – EA59 EA28 – EA62 EA32 – EA59 EA36 – EA61 EA40 – EA60 EA44 – EA61 EA48 – EA60 EA52 – EA61 EA56 – EA60



≈ 2.3–2.8 Ω (20 °C)



EA59 –



≈∞Ω



EA60 – EA61 – EA62 – EA59 – EA60 – EA61 – EA62 –



≈ 4.4 V ≈ 5.0 ~ 5.5 V



Condition



Test method



Service Information Document Title: Function Group: MA2506, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA2506, description and measuring Op nbr 302-280 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990014 Break out harness



Description Function



Controls engagement and disengagement of the air pump



References



370 Wiring diagram SCH05



VCADS Pro Test



Figure 1 45/49/53, feed 33, return cable Measuring Measuring point



Correct value



2–1



≈ 13 Ω



33 – 1 45/49/53 – 2



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



2–



Verifying Measuring point



Correct value



45 – 33



≈ 14 Ω



Condition



Test method



Service Information Document Title: Function Group: MA2507, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA2507, description and measuring Op nbr 302-281 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990014 Break out harness



Description Function



Controls fuel shut off function



References



370 Wiring diagram SCH05



VCADS Pro Test



Figure 1 45 / 49 / 53, feed 25, fuel shut off valve Measuring Measuring point



Correct value



45 – 25



≈ 43 Ω



1– 2–



≈∞Ω



Condition



Test method



Date: 2014/7/14



45 / 49 /53 – 1 25 – 2



≈0Ω



Verifying Measuring point



Correct value



45 – 25



≈ 43 Ω



Condition



Test method



Service Information Document Title: Function Group: MA9109, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA9109, description and measuring Op nbr 302-450 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890016 Break out harness 88890019 Template 88830028 Break out harness 88830037 Template



Description Function



Controls the quickfit cylinder



References



370 Wiring diagram SCH17



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 28 Ω (20 °C) (SW9104, ON)



IA11 – 1



≈0Ω



Condition



Test method



Date: 2014/7/14



2–



1–



≈0Ω



≈∞Ω



Verifying Measuring point



Correct value



IA11 –



≈ 28 Ω (20 °C) (SW9104, ON)



Condition



Test method



Service Information Document Title: Function Group: MA9110, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA9110, description and measuring Op nbr 302-451 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890016 Break out harness 88890019 Template 88830028 Break out harness 88830037 Template



Description Function



Controls the X3 left solenoid



References



370 Wiring diagram SCH16



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 23 Ω (20 °C)



VA8 – 1



≈0Ω



2–



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point VA8 –



Correct value ≈ 23 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: MA9116, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA9116, description and measuring Op nbr 302-452 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890016 Break out harness 88890019 Template 88830028 Break out harness 88830037 Template



Description Function



Controls the 1/2 pump select function for X1



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 28 Ω (20 °C)



VA13 – 1



≈0Ω



2–



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point VA13 –



Correct value ≈ 28 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: MA9117, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA9117, description and measuring Op nbr 302-453 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890016 Break out harness 88890019 Template 88830028 Break out harness 88830037 Template



Description Function



Controls the hammer selection function



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 28 Ω (20 °C)



VA64 – 1



≈0Ω



2–



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point VA64 –



Correct value ≈ 28 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: MA9118, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA9118, description and measuring Op nbr 302-454 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890016 Break out harness 88890019 Template 88830028 Break out harness 88830037 Template



Description Function



Controls the shear selection function



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 28 Ω (20 °C)



VA65 – 1



≈0Ω



2–



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point VA65 –



Correct value ≈ 28 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: MA9120, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA9120, description and measuring Op nbr 302-455 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890016 Break out harness 88890019 Template 88830028 Break out harness 88830037 Template



Description Function



Controls the boom float function



References



370 Wiring diagram SCH17



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 28 Ω (20 °C)



VA59 – 1



≈0Ω



2–



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point VA59 –



Correct value ≈ 28 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: MA9121, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA9121, description and measuring Op nbr 302-456 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890016 Break out harness 88890019 Template 88830028 Break out harness 88830037 Template



Description Function



Controls X1, Left



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 28 Ω (20 °C)



VA6 – 1



≈0Ω



2–



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point VA6 –



Correct value ≈ 28 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: MA9122, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA9122, description and measuring Op nbr 302-457 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890016 Break out harness 88890019 Template 88830028 Break out harness 88830037 Template



Description Function



Controls X1, Right



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 28 Ω (20 °C)



VA55 – 1



≈0Ω



2–



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point VA55 –



Correct value ≈ 28 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: MA9123, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA9123, description and measuring Op nbr 302-458 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890016 Break out harness 88890019 Template 88830028 Break out harness 88830037 Template



Description Function



Controls conflux cutoff function for Boom Up



References



370 Wiring diagram SCH08



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 28 Ω (20 °C)



VA37 – 1



≈0Ω



2–



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point VA37 –



Correct value ≈ 28 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: MID128 SID230, 302 description and measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MID128 SID230, description and measuring Op nbr 302-460 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter



Description Function



Controls engine speed and stop by engine limp home switch



References



370 Wiring diagram SCH03



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



2–



≈ Uᵇᵃᵗ



1 – EB15



≈0Ω



1– 2–



≈∞Ω



Condition



Test method



Date: 2014/7/14



2–1



≈ 0 Ω (SW2704, ON)



Verifying Measuring point



Correct value



EB15 –



≈ Uᵇᵃᵗ (active)



Condition



Test method



Service Information Document Title: Function Group: MID140 PID251, 302 description and measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MID140 PID251, description and measuring Op nbr 302-461 88830028 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 88830037 Template



Description Function



Checks the system clock



References



370 Wiring diagram SCH01 370 Wiring diagram SCH02



VCADS Pro Test



Figure 1



Measuring Measuring point IA8 –



Correct value ≈0Ω



IA18 –



IA9 –



≈ Uᵇᵃᵗ



Condition



Test method



Date: 2014/7/14



Verifying Measuring point



Correct value



IA9 – IA8



≈ Uᵇᵃᵗ



Condition



Test method



Service Information Document Title: Function Group: MID140 PPID1144, 302 description and measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MID140 PPID1144, description and measuring Op nbr 302-462 88830028 Break out harness 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890074 Multimeter 88830037 Template



Description Function



Checks the function of the operating check clock



References



370 Wiring diagram SCH02



VCADS Test



Pro



Figure 1



Measuring Measuring point



Correct value



VA34 – IA15



≈0Ω



Condition



Test method



Condition



Test method



Verifying Measuring point IA15 –



Correct value ≈ 10 ~ 14 V



Date: 2014/7/14



Service Information Document Title: Function Group: MO2501, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MO2501, description and measuring Op nbr 302-284 9990062 Cable 9990014 Break out harness 9998699 Adapter 9998567 Break out harness 88890074 Multimeter



Description Function



Controls the sliding nozzle ring of VGT



References



370 Wiring diagram SCH05



VCADS Test



Pro 25536-3 Variable geometry turbo calibration 25537-3 Variable geometry turbo function, test



Figure 1



Measuring Measuring point



Correct value



Condition



Test method



Date: 2014/7/14



1 (VGT SRA) –



2 (VGT SRA) –



≈ Uᵇᵃᵗ



≈0Ω



EB57/EB60 – 1 (VGT ≈ 0 Ω SRA)



EB57/EB60 – FU22



≈0Ω



Fuse disconnected Verifying Measuring point



Correct value



EB57/EB60 –



≈ Uᵇᵃᵗ



Condition



Test method



Service Information Document Title: Function Group: MO2504, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MO2504, description and measuring Op nbr 302-286 9990062 Cable 9998699 Adapter 9990014 Break out harness 88890074 Multimeter



Description Function



EATS fuel pump feeds the fuel to the inlet of the Atomization Module



References



370 Wiring diagram SCH05



VCADS Pro Test



Figure 1 45 / 49 / 53, feed + 17, fuel pump – Measuring Measuring point EK12 –



Correct value ≈∞Ω



EK13 –



EK12 –



45 / 49 /53 – EK12 17 – EK13



Verifying



≈ Uᵇᵃᵗ



≈0Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



45/49/53 – 17



> 3.75 V



Condition



Test method



Service Information Document Title: Function Group: MO3301, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MO3301, description and measuring Op nbr 302-017 9998699 Adapter 9990014 Break out harness 9990062 Cable 14576840 Measuring tool 88890074 Multimeter 88890016 Break out harness 88890019 Template 9990025 Break out harness 9990133 Template



Description Function



Starts the engine



References



370 Wiring diagram SCH03



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



Small screws on the ≈ 14Ω relay of the starter motor



30 (RE3301) – (RE3301, removed)



≈ Uᵇᵃᵗ



Condition



Test method



Date: 2014/7/14



EB29 –



VA58 –



≈∞Ω



≈ 350 Ω



Verifying EB29 – 87 (RE3301) (RE3301, removed)



≈ 14 Ω



Service Information Document Title: Function Group: PWM2503, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



PWM2503, description and measuring Op nbr 302-287 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990014 Break out harness



Description Function



Controls the EGR valve position



References



370 Wiring diagram SCH03



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 15.4 Ω (20 °C)



EB9 – 1 EB13 – 2



≈0Ω



1– 2–



Verifying



≈∞Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



EB9 – EB13



≈ 15.4 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: MA9111, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



MA9111, description and measuring Op nbr 302-489 14576840 Measuring tool 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890016 Break out harness 88890019 Template



Description Function



Controls the X3 right solenoid



References



370 Wiring diagram SCH16



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 23 Ω (20 °C)



VA31 – 1



≈0Ω



2–



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point VA31 –



Correct value ≈ 23 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: PWM9109, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



PWM9109, description and measuring Op nbr 302-466 14576840 Measuring tool 88890074 Multimeter 8920-01805 Break out harness



Description Function



Controls the X1 flow



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 11.5 Ω (20 °C)



VA56 – 1 VA30 – 2



≈0Ω



1–



Condition



Test method



Condition



Test method



≈∞Ω



2–



Verifying Measuring point



Correct value



Date: 2014/7/14



VA56 – VA30



≈ 11.5 Ω (20 °C)



Service Information Document Title: Function Group: PWM9123, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



PWM9123, description and measuring Op nbr 302-467 14576840 Measuring tool 88890016 Break out harness 88890019 Template 88890074 Multimeter 9998699 Adapter



Description Function



Controls the X1, hammer and shear left-hand proportional function



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 11.5 Ω (20 °C)



VA6 – 1 VA4 – 2



≈0Ω



1– 2–



Verifying



≈∞Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



VA6 – VA4



≈ 11.5 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: PWM9124, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



PWM9124, description and measuring Op nbr 302-468 14576840 Measuring tool 88890016 Break out harness 88890019 Template 88890074 Multimeter 9998699 Adapter



Description Function



Controls the X1, shear right-hand proportional function



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 11.5 Ω (20 °C)



VA55 – 1 VA29 – 2



≈0Ω



1– 2–



Verifying



≈∞Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



VA55 – VA29



≈ 11.5 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: PWM9129, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



PWM9129, description and measuring Op nbr 302-469 14576840 Measuring tool 88890016 Break out harness 88890019 Template 88890074 Multimeter 9998699 Adapter



Description Function



Controls X1 pressure setting function



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 19 Ω (20 °C)



VC19 – 1 VA20 – 2



≈0Ω



1– 2–



Verifying



≈∞Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



VC1 – VC2



≈ 19 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: PWM9130, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



PWM9130, description and measuring Op nbr 302-470 14576840 Measuring tool 88890016 Break out harness 88890019 Template 88890074 Multimeter 9998699 Adapter



Description Function



Controls X1 pressure setting function



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 19 Ω (20 °C)



VA24 – 1 VA25 – 2



≈0Ω



1– 2–



Verifying



≈∞Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



VC24 – VC25



≈ 19 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: PWM9141, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



PWM9141, description and measuring Op nbr 302-471 14576840 Measuring tool 88890074 Multimeter 8920-01805 Break out harness



Description Function



Controls the pump flow



References



370 Wiring diagram SCH08



VCADS Pro Test



91303-3 - Proportional valve for power changing, amperage, test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 17.5 Ω



VA5 – 2 VA32 – 1



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



2–



Verifying Measuring point



Correct value



VA32 – VA5



≈ 17.5 Ω



Condition



Test method



Service Information Document Title: Function Group: PWM9143, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



PWM9143, description and measuring Op nbr 302-472 14576840 Measuring tool 88890074 Multimeter 88890016 Break out harness 88890019 Template 9998699 Adapter



Description Function



Controls the cooling fan speed



References



370 Wiring diagram SCH16



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 24 Ω



VA9 – 1 VA10 – 2



≈0Ω



1– 2–



Verifying



≈∞Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



VA9 – VA10



≈ 24 Ω



Condition



Test method



Service Information Document Title: Function Group: PWM9145, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



PWM9145, description and measuring Op nbr 302-473 14576840 Measuring tool 88890074 Multimeter 88890016 Break out harness 88890019 Template 9998699 Adapter



Description Function



Controls the X3 left proportional function



References



370 Wiring diagram SCH16



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 11.5 Ω (20 °C)



VA8 – 1 VA54 – 2



≈0Ω



1– 2–



Verifying



≈∞Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



VA8 – VA54



≈ 11.5 Ω (20 °C)



Condition



Test method



Service Information Document Title: Function Group: PWM9146, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



PWM9146, description and measuring Op nbr 302-474 88890074 Multimeter 14576840 Measuring tool 88890016 Break out harness 88890019 Template 9998699 Adapter



Description Function



Controls the X3 right proportional function



References



370 Wiring diagram SCH16



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 11.5 Ω (20 °C)



A31 – 1 A53 – 2



≈0Ω



1– 2–



Verifying



≈∞Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



A31 – A53



≈ 11.5 Ω (20 °C)



Condition



Test method



Service Information Document Title: RE2501, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



RE2501, description and measuring Op nbr 302-028 88890074 Multimeter 9998699 Adapter 9990062 Cable 9990014 Break out harness



Description Function



Activates the preheating coil



References



370 Wiring diagram SCH03



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



86 – 31



≈ 20 Ω (20°C)



86 –



≈ Uᵇᵃᵗ



Condition



Test method



Date: 2014/7/14



EB25 –



≈∞Ω



Verifying Measuring point



Correct value



B25 –



≈ Uᵇᵃᵗ (inactive) ≈ 0 V (active)



Condition



Test method



Service Information Document Title: RE3101, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



RE3101, description and measuring Op nbr 302-476 9990062 Cable 14576840 Measuring tool 9990025 Break out harness 9990133 Template 9998699 Adapter 88890074 Multimeter



Description Function



Activates the battery connection and power cut-off



References



370 Wiring diagram SCH01



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



86 – 85



≈ 307 Ω



Condition



Test method



Date: 2014/7/14



VA61 – 86



VA61 –



85 –



86 –



≈0Ω



≈∞Ω



≈0Ω



≈ Uᵇᵃᵗ



Verifying Measuring point VA61 –



Correct value ≈ 307 Ω



Condition



Test method



Service Information Document Title: RE3301, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



RE3301, description and measuring Op nbr 302-144 88890074 Multimeter 14576840 Measuring tool 9990025 Break out harness 9990133 Template 9998699 Adapter 9990062 Cable



Description Function



Controls the start lock



References



370 Wiring diagram SCH03



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



86 – 85



≈ 348 Ω



Condition



Test method



Date: 2014/7/14



VA58 – 86



VA58 –



85 –



86 –



≈0Ω



≈∞Ω



≈0Ω



≈ Uᵇᵃᵗ



Verifying Measuring point VA58 –



Correct value ≈ 348 Ω



Condition



Test method



Service Information Document Title: RE4206, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



RE4206, description and measuring Op nbr 302-477 88890074 Multimeter 14576840 Measuring tool 9990133 Template 9990025 Break out harness 9998699 Adapter 9990062 Cable



Description Function



Controls the travel alarm



References



370 Wiring diagram SCH12



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



86 – 85



≈ 348 Ω



VA12 – 86



≈0Ω



VA12 –



≈∞Ω



Condition



Test method



Date: 2014/7/14



85 –



≈0Ω



Verifying Measuring point



Correct value



VA12 –



≈ Uᵇᵃᵗ (active)



Condition



Test method



Service Information Document Title: SE2203, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2203, description and measuring Op nbr 302-031 88890074 Multimeter 9990014 Break out harness 9998534 Break out harness 9998699 Adapter 9990062 Cable



Description Function



Measures the engine oil pressure



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1



EB17, feed 5 V EB11, signal EB18, ground



Measuring Measuring point 1–



Correct value ≈5V



Condition



Test method



Date: 2014/7/14



4–



EB11 – 2



1–



≈0Ω



≈0Ω



≈∞Ω



2–



Verifying Measuring point



Correct value



EB11 –EB18



≈ Voltage according to the graph below



SE2203 voltage values



Figure 2



Condition



Test method



Service Information Document Title: SE2301, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2301, description and measuring Op nbr 302-032 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 9998534 Break out harness



Description Function



Measures feed pressure after the fuel filter



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1



EB16, signal EB17, feed 5V EB18, ground



Measuring Measuring point 1–



Correct value ≈5V



Condition



Test method



Date: 2014/7/14



4–



1–



≈0Ω



≈∞Ω



2–



EB16 – 2



≈0Ω



Verifying Measuring point



Correct value



EB16 – EB18



≈ 0.5 V



SE2301 voltage values



Figure 2



Condition



Test method



Service Information Document Title: SE2303, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2303, description and measuring Op nbr 302-034 88830028 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 88830037 Template 88890016 Break out harness 88890019 Template



Description Function



Measures the fuel level



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1 IA4, feed 5 V IA12, ground Measuring Measuring point



Correct value



1–2



≈ Resistance according to the table below



1–



≈5V



Condition



Test method



Date: 2014/7/14



≈0Ω



2–



≈∞Ω



1–



Verifying Measuring point



Correct value



Condition



IA4 – IA12



≈ Resistance according to the table below



Test method



SE2303 resistance values Display machine Full tank



in Distance of float Resistance (Ω) (mm) ± 5



Display machine



in Distance of float Resistance (Ω) (mm) ± 5



> 617



82



323



232



617



92



302



242



596



102



281



252



575



112



260



262



554



122



239



272



533



132



218



282



512



142



197



292



491



152



176



302



470



162



155



312



449



172



134



322



428



182



113



332



407



192



92



342



386



202



71



352



365



212



50



399



344



222



Empty tank



Service Information Document Title: SE2509, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2509, description and measuring Op nbr 302-095 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 9998534 Break out harness



Description Function



Measures crankcase pressure



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1



EB17, feed 5 V EB18, ground EB28, signal



Measuring Measuring point



Correct value



2–4



≈3 V (at normal air pressure 101 kPa)



Condition



Test method



Date: 2014/7/14



1–



4–



1–



≈5V



≈0Ω



≈∞Ω



2–



EB28 – 2



≈0Ω



Verifying Measuring point



Correct value



EB28 – EB18



≈3 V (at normal air pressure 101 kPa)



Condition



Test method



Service Information Document Title: SE2510, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2510, description and measuring Op nbr 302-478 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990014 Break out harness



Description Function



Measures exhaust temperature



References



370 Wiring diagram SCH05



VCADS Test



Pro



Figure 1 42, signal 55, ground Measuring Measuring point



Correct value



1–2



≈ Resistance according to the table below



1–



2–



≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point



Correct value



42 – 55



≈ Resistance according to the table below



Condition



Test method



SE2510 resistance values Temperature ( °C)



Temperature ( °F)



Resistance (Ω)



Voltage (V)



-40



-40



170



0.73



0



32



201



0.84



25



77



220



0.90



50



122



239



0.96



100



212



276



1.08



200



392



349



1.29



300



572



420



1.48



400



752



488



1.64



500



932



554



1.78



600



1112



618



1.91



700



1292



679



2.02



800



1472



738



2.12



850



1562



767



2.18



Service Information Document Title: SE2514, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2514, description and measuring Op nbr 302-303 88890074 Multimeter 9990014 Break out harness 9998699 Adapter 9990062 Cable 9998534 Break out harness



Description Function



Measures the turbo speed



References



370 Wiring diagram SCH03



VCADS Pro Test



Figure 1 EA41, frequency + EA42, frequency – Measuring Measuring point



Correct value



1–2



≈ 0.9 kΩ



1–



≈∞Ω



2–



EA42 – 1 EA41 – 2



≈0Ω



Condition



Test method



Date: 2014/7/14



Verifying Measuring point



Correct value



EA41 – EA42



≈ 0.6 V AC



Condition



Test method



Service Information Document Title: SE2515, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2515, description and measuring Op nbr 302-304 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890024 Break out harness



Description Function



Measures the EGR differential pressure



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1 EA7, feed 5 V EA21, signal EA11, ground Measuring Measuring point 4–



2–



Correct value ≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



4–



EA21 – 1



≈0Ω



Verifying Measuring point



Correct value



EA21 – EA11



≈ 0.5 V



Condition



Test method



Service Information Document Title: SE2516, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2516, description and measuring Op nbr 302-305 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 88890119 Break out harness



Description Function



Measures EGR temperature after cooler



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1 EB48, signal EB18, ground Measuring Measuring point



Correct value



2–1



≈ Resistance according to the table below



2–



1–



≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



2–



≈∞Ω



Verifying Measuring point



Correct value



EB18 – EB48



≈ Resistance according to the table below



Condition



Test method



SE2516 resistance values Temperature ( °C)



Temperature ( °F)



Resistance (Ω)



Voltage (V)



-40



-40



170



0.73



0



32



201



0.84



25



77



220



0.90



50



122



239



0.96



100



212



276



1.08



200



392



349



1.29



300



572



420



1.48



400



752



488



1.64



500



932



554



1.78



600



1112



618



1.91



700



1292



679



2.02



800



1472



738



2.12



850



1562



767



2.18



Service Information Document Title: SE2519, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2519, description and measuring Op nbr 302-307 88890074 Multimeter 9998699 Adapter 9990062 Cable 9990014 Break out harness



Description Function



Measures differential pressure of DPF.



References



370 Wiring diagram SCH05



VCADS Pro Test



Figure 1 50, feed 5 V 26, signal 54, ground Measuring Measuring point 3–



2–



Correct value ≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



3–



26 – 1



≈0Ω



Verifying Measuring point



Correct value



26 – 54



≈ 0.5 V



Condition



Test method



Service Information Document Title: SE2521, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2521, description and measuring Op nbr 302-309 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter



Description Function



Measures the exhaust temperature before the DPF filter



References



370 Wiring diagram SCH05



VCADS Pro Test



Figure 1 34, signal 55, ground Measuring Measuring point



Correct value



1–2



≈ Resistance according to the table below



1–



2–



≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point



Correct value



34 – 55



≈ Resistance according to the table below



Condition



Test method



SE2521 resistance values Temperature ( °C)



Temperature ( °F)



Resistance (Ω)



Voltage (V)



-40



-40



170



0.73



0



32



201



0.84



25



77



220



0.90



50



122



239



0.96



100



212



276



1.08



200



392



349



1.29



300



572



420



1.48



400



752



488



1.64



500



932



554



1.78



600



1112



618



1.91



700



1292



679



2.02



800



1472



738



2.12



850



1562



767



2.18



Service Information Document Title: SE2522, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2522, description and measuring Op nbr 302-310 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990014 Break out harness



Description Function



Measures the exhaust gas temperature after the DPF filter



References



370 Wiring diagram SCH05



VCADS Pro Test



Figure 1 39, signal 55, ground Measuring Measuring point



Correct value



1–2



≈ Resistance according to the table below



1–



2–



≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point



Correct value



39 – 55



≈ Resistance according to the table below



Condition



Test method



SE2522 resistance values Temperature ( °C)



Temperature ( °F)



Resistance (Ω)



Voltage (V)



-40



-40



170



0.73



0



32



201



0.84



25



77



220



0.90



50



122



239



0.96



100



212



276



1.08



200



392



349



1.29



300



572



420



1.48



400



752



488



1.64



500



932



554



1.78



600



1112



618



1.91



700



1292



679



2.02



800



1472



738



2.12



850



1562



767



2.18



Service Information Document Title: SE2527, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2527, description and measuring Op nbr 302-315 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990014 Break out harness 9998534 Break out harness



Description Function



Measures nozzle pressure



References



370 Wiring diagram SCH05



VCADS Pro Test



Figure 1 50, feed 5 V 43, signal 54, ground Measuring Measuring point ES1 –



ES2 –



Correct value ≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



ES1 –



≈∞Ω



ES3 –



43 – ES3



≈0Ω



Verifying Measuring point



Correct value



43 – 54



≈ 0.5 V



Condition



Test method



Service Information Document Title: SE2528, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2528, description and measuring Op nbr 302-316 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990014 Break out harness 9998534 Break out harness



Description Function



Measures fuel pressure



References



370 Wiring diagram SCH05



VCADS Pro Test



Figure 1 50, feed 5 V 22, signal 54, ground Measuring Measuring point ES1 –



ES2 –



Correct value ≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



ES1 –



≈∞Ω



ES4 –



22 – ES4



≈0Ω



Verifying Measuring point



Correct value



22 – 54



≈ 0.5 V



Condition



Test method



Service Information Document Title: SE2529, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2529, description and measuring Op nbr 302-317 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990014 Break out harness



Description Function



Measures flame temperature Informs the ACM (After treatment control module) that a flame is lit



References



370 Wiring diagram SCH05



VCADS Test



Pro



Figure 1 50, feed 5 V 23, signal 54, ground Measuring Measuring point



Correct value



1–3



≈ 1 kΩ



1–



≈5V



Condition



Test method



Date: 2014/7/14



2–



1–



≈0Ω



≈∞Ω



3–



23 – 3



≈0Ω



Verifying Measuring point



Correct value



Condition



23 – 54



≈ Voltage according to the table below



Test method



SE2529 voltage values Temperature ( °C)



Temperature ( °F)



Voltage (V)



-40



-40



4.50



0



32



4.38



100



212



4.08



200



392



3.78



300



572



3.49



400



752



3.19



500



932



2.89



600



1112



2.59



700



1292



2.29



800



1472



1.99



900



1652



1.69



1000



1832



1.40



1100



2012



1.10



1200



2192



0.80



1300



2372



0.50



Service Information Document Title: SE2703, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2703, description and measuring Op nbr 302-045 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990216 Break out harness



Description Function



Measures cam shaft rpm



References



370 Wiring diagram SCH03



VCADS Pro Test



Figure 1 EA45, frequency + EA46, frequency – Measuring Measuring point



Correct value



1–2



≈ 0.9 kΩ



1–



≈∞Ω



2–



EA45 – 1 EA46 – 2



Verifying



≈0Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



EA45 – EA46



≈ 1.2 V AC



Condition



Test method



Service Information Document Title: SE8701, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE8701, description and measuring Op nbr 302-479 88890074 Multimeter 8920-01805 Break out harness 14576840 Measuring tool



Description Function



Measures the air conditioner refrigerant pressure at the high side



References



370 Wiring diagram SCH10



VCADS Test



Pro



Figure 1



Measuring Measuring point



Correct value



1–2



≈ 0 Ω (active)



1–



≈ Uᵇᵃᵗ



2 – BB8



≈0Ω



Verifying



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



BB8 –



≈ Uᵇᵃᵗ (active)



Condition



Test method



Service Information Document Title: SE8702, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE8702, description and measuring Op nbr 302-059 88890074 Multimeter 8920-01805 Break out harness 14576840 Measuring tool



Description Function



Measures the evaporator temperature



References



370 Wiring diagram SCH10



VCADS Pro Test



Figure 1 BB50, signal BB48, ground Measuring Measuring point



Correct value



1–2



≈ Resistance according to the table below



2–



1–



≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



2–



≈∞Ω



Verifying Measuring point



Correct value



Condition



BB50 – BB48



≈ Resistance according to the table below



Test method



SE8702 resistance values Air temp. (°C)



Air temp. (°F)



Resistance



-40



-40



83.1 kΩ



-30



-22



43.4 kΩ



-20



-4



23.7 kΩ



-10



+14



13.5 kΩ



0



+32



8.0 kΩ



+10



+50



4.9 kΩ



+20



+68



3.1 kΩ



+30



+86



2.0 kΩ



+40



+104



1.3 kΩ



+50



+122



0.9 kΩ



+60



+140



0.6 kΩ



+70



+158



430 Ω



+80



+176



310 Ω



+90



+194



230 Ω



Service Information Document Title: SE8705, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE8705, description and measuring Op nbr 302-328 88890074 Multimeter 14576840 Measuring tool 8920-01805 Break out harness



Description Function



Measures the ambient air temperature



References



370 Wiring diagram SCH10



VCADS Pro Test



Figure 1 BB51, signal BB48, ground Measuring Measuring point



Correct value



1–2



≈ Resistance according to the table below



1–



2–



≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point



Correct value



Condition



BB51 – BB48



≈ Resistance according to the table below



Test method



SE8705 resistance values Air temp. (°C)



Air temp. (°F)



Resistance



-40



-40



83.1 kΩ



-30



-22



43.4 kΩ



-20



-4



23.7 kΩ



-10



+14



13.5 kΩ



0



+32



8.0 kΩ



+10



+50



4.9 kΩ



+20



+68



3.1 kΩ



+30



+86



2.0 kΩ



+40



+104



1.3 kΩ



+50



+122



0.9 kΩ



+60



+140



0.6 kΩ



+70



+158



430 Ω



+80



+176



310 Ω



+90



+194



230 Ω



Service Information Document Title: SE8706, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE8706, description and measuring Op nbr 302-060 88890074 Multimeter 8920-01805 Break out harness 14576840 Measuring tool



Description Function



Measures the cab interior temperature



References



370 Wiring diagram SCH10



VCADS Pro Test



Figure 1 BB26, signal BB48, ground Measuring Measuring point



Correct value



1–2



≈ Resistance according to the table below



1–



2–



≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point



Correct value



Condition



BB26 – BB48



≈ Resistance according to the table below



Test method



SE8706 resistance values Air temp. (°C)



Air temp. (°F)



Resistance



-30



-22



44.3 kΩ



-20



-4



24.2 kΩ



-10



+14



13.8 kΩ



0



+32



8.1 kΩ



+10



+50



5.0 kΩ



+20



+68



3.1 kΩ



+30



+86



2.0 kΩ



+40



+104



1.3 kΩ



+50



+122



0.9 kΩ



+60



+140



0.6 kΩ



Service Information Document Title: SE2603, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2603, description and measuring Op nbr 302-042 9998699 Adapter 9990014 Break out harness 9990062 Cable 88890074 Multimeter 9990008 Measuring equipment



Description Function



Monitors coolant level



References



370 Wiring diagram SCH04



VCADS Test



Pro



Figure 1 EB23, signal EB10, ground Measuring Measuring point



Correct value



1–2



≈ ∞ Ω (normal level) ≈ 0 Ω (low level)



2–



1–



≈ 0.8 x Uᵇᵃᵗ



≈0Ω



Condition



Test method



Date: 2014/7/14



2–



≈∞Ω



Verifying Measuring point



Correct value



EB23 – EB10



≈ 0.8 x Uᵇᵃᵗ (normal level)



Condition



Test method



Service Information Document Title: SE2606, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2606, description and measuring Op nbr 302-043 9998699 Adapter 9990014 Break out harness 9990062 Cable 88890074 Multimeter 9990216 Break out harness



Description Function



Measures coolant temperature in the engine



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1 EB27, signal EB18, ground Measuring Measuring point



Correct value



1–2



≈ Resistance according to the table below



1–



2–



≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



≈∞Ω



1–



Verifying Measuring point



Correct value



EB27 – EB18



≈ Resistance according to the table below



Condition



Test method



SE2606 resistance values Temp (° C)



Temp (° F)



Resistance



Temp (° C)



Temp (° F)



Resistance



-40



-40



45.3 kΩ



60



140



0.6 kΩ



-20



-4



15.5 kΩ



80



176



320 Ω



0



32



5.9 kΩ



100



212



190 Ω



20



68



2.5 kΩ



120



248



110 Ω



40



104



1.2 kΩ



140



284



70 Ω



Service Information Document Title: SE2701, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2701, description and measuring Op nbr 302-044 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter 9990216 Break out harness



Description Function



Measures engine rpm on crankshaft



References



370 Wiring diagram SCH03



VCADS Pro Test



Figure 1 EA38, frequency + EA37, frequency – Measuring Measuring point



Correct value



1–2



≈ 0.9 kΩ



1–



≈∞Ω



2–



EA37 – 1 EA38 – 2



Verifying



≈0Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



EA37 – EA38



≈ 11.5 V AC



Condition



Test method



Service Information Document Title: SE9401, description measuring



Function Group: and 302



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



SE9401, description and measuring Op nbr 302-481 14576840 Measuring tool 88890016 Break out harness 88890074 Multimeter 88890019 Template 9998699 Adapter



Description Function



Measures the pressure applied to the digging unit for warning the overload



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1 VA26, feed 5 V VA48, signal VA49, ground Measuring Measuring point A–



B–



Correct value ≈5V



≈0Ω



Condition



Test method



A–



≈∞Ω



C–



VA48 – C



≈0Ω



Verifying Measuring point



Correct value



VA48 – VA49



≈ 1.2 V



Condition



Test method



Service Information Document Title: SID211, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SID211, description and measuring Op nbr 302-482 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter



Description Function



Supplies 5V to the sensors



References



370 Wiring diagram SCH04



VCADS Test



Pro



Figure 1 EB17, Power supply (+5V) EB18, Ground Measuring Measuring point 4–



Correct value ≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈5V



Verifying Measuring point



Correct value



EB17 – EB18



≈5V



Condition



Test method



Service Information Document Title: SID232, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SID232, description and measuring Op nbr 302-483 9990014 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter



Description Function



Supplies 5V to the sensors



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1 EA7, Power supply (+5V) EA11, Ground Measuring Measuring point 1–



3–



Verifying



Correct value ≈0Ω



≈5V



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



EA7 – EA11



≈5V



Condition



Test method



Service Information Document Title: Function Group: SW2701, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SW2701, description and measuring Op nbr 302-147 14576840 Measuring tool 88890074 Multimeter



Description Function



Controls the engine rpm according to the work condition



References



370 Wiring diagram SCH03



VCADS Test



Pro



Figure 1



VB11, feed 24 V VA39, signal VA14, ground



Measuring Measuring point 1–



3–



Correct value ≈ 24 V



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



3–



2 – VA39



≈0Ω



Verifying Measuring point



Correct value



VA39 – VA14



≈ 0.5 ~ 4.5 V



Condition



Test method



Service Information Document Title: Function Group: SW3301, description and 302 measuring



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



SW3301, description and measuring Op nbr 302-265 14576840 Measuring tool 88890074 Multimeter



Description Function



Supplies the power to the electrical system and activates the engine starter motor



References



370 Wiring diagram SCH01



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



30 – BR / ACC / C / R2



≈ Resistance according to the table below X=0Ω –=∞Ω



30 –



≈ Uᵇᵃᵗ



Condition



Test method



ACC – VB9



≈0Ω



Verifying Measuring point



Correct value



VB9 –



≈ Uᵇᵃᵗ (SW3301, ON)



Condition



Test method



Service Information Document Title: Function Group: SW9160, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SW9160, description and measuring Op nbr 302-485 14576840 Measuring tool 88890074 Multimeter



Description Function



Confirms the selection of the quick fit function, and stop the buzzer



References



370 Wiring diagram SCH17



VCADS Pro Test



Figure 1



Measuring Measuring point 1–



Correct value ≈∞Ω



2– 3– 4– 5– 6– 2–3 2–1 5–6 5–4



≈ 0 Ω (SW9160, ON) ≈ ∞ Ω (SW9160, OFF)



Condition



Test method



Date: 2014/7/14



3–



≈ 24 V



4–



2–



≈0Ω



5–



Verifying Measuring point A16 – A42 –



Correct value ≈ 0 V (active)



Condition



Test method



Service Information Document Title: Function Group: SW9161, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SW9161, description and measuring Op nbr 302-486 14576840 Measuring tool 88890074 Multimeter



Description Function



Controls the X3 proportionally with the left hand control lever



References



370 Wiring diagram SCH16



VCADS Pro Test



Figure 1 VA27, feed 12 V VB10, signal VB11, ground Measuring Measuring point 1–



Correct value ≈∞Ω



2– 3– 1–



3 – VB10



Verifying



≈ 12 V



≈0Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



VB10 – VA11



≈ 2.0 ~ 7.0 V



Condition



Test method



Service Information Document Title: Function Group: SW9162, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SW9162, description and measuring Op nbr 302-487 14576840 Measuring tool 88890074 Multimeter



Description Function



Controls the X1 proportionally with the right hand control lever



References



370 Wiring diagram SCH15



VCADS Pro Test



Figure 1 VA27, feed 12 V VB3, signal VA11, ground Measuring Measuring point 1–



Correct value ≈∞Ω



2– 3– 1–



3 – VB3



Verifying



≈ 12 V



≈0Ω



Condition



Test method



Date: 2014/7/14



Measuring point



Correct value



VB3 – VA11



≈ 2.0 ~ 7.0 V



Condition



Test method



Service Information Document Title: Function Group: SAE J1939/CAN control 302 link, description and measuring



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



SAE J1939/CAN control link, description and measuring Op nbr 302-490 14576840 Measuring tool 88890016 Break out harness 9998699 Adapter 88890074 Multimeter 88890019 Template 9993893 Break out harness 9990014 Break out harness 88830028 Break out harness



Description Function



The system control signals are sent on the control link. NOTE! The voltage on the control link varies, depending on the intensity of signals on the link. The measured values should therefore be regarded as guiding values only.



References



370 Wiring diagram SCH02



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



IA16 – IA6



≈ 60 Ω⁽ᵃ⁾



Condition



Test method



IA16 – IA6



≈ 120 Ω



IA16 – VB6 IA6 – VB14 (I-ECU – V-ECU)



≈0Ω



IA16 – 34 IA6 – 58 (I-ECU – ECC)



≈0Ω



IA16 – 4 IA6 – 3 (I-ECU – Keypad)



≈0Ω



IA16 – EB55 IA6 – EB51 (I-ECU – E-ECU)



≈0Ω



≈∞Ω IA16 –



≈∞Ω IA6 –



(a) Terminating resistors (120 Ω) located internally in E-ECU and I-ECU Verifying Measuring point



Correct value



IA16 – IA6



≈ 0 – 1.5 V



IA6 –



IA16 –



≈ 2.5 – 3.5 V



≈ 1.5 – 2.5 V



Condition



Test method



Service Information Document Title: Function Group: SAEJ1939/CAN7 Control 302 link, descripton and measuring



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



SAEJ1939/CAN7 Control link, descripton and measuring Op nbr 302-607 14576840 Measuring tool 88890016 Break out harness 9998699 Adapter 88890074 Multimeter 88890019 Template 9993893 Break out harness 9990014 Break out harness 88830028 Break out harness



Description Function



The system control signals are sent on the control link. NOTE! The voltage on the control link varies, depending on the intensity of signals on the link. The measured values should therefore be regarded as guiding values only.



References



370 Wiring diagram SCH05



VCADS Pro Test



Figure 1



Measuring Measuring point



Correct value



CAN7H – CAN7L



≈ 50 ~ 70 Ω



Condition



Test method



CAN7H – CAN7L



≈ 100 ~ 140 Ω



EB52 – 14 EB56 – 10 (E-ECU – ACM)



≈0Ω



EB52 – 5 EB56 – 6 (E-ECU – VGT SRA)



≈0Ω



EB52 –



EB56 –



≈∞Ω



≈∞Ω



Verifying Measuring point EB52 –



EB56 –



EB52 – EB56



Correct value ≈ 2.5 ~ 3.0 V



≈ 2.0 ~ 2.5 V



≈ 0 ~ 1.0 V



Condition



Test method



Service Information Document Title: Function Group: Power supply, ACM 302 (Aftertreatment Control Module), description and measuring



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Power supply, ACM (Aftertreatment Control Module), description and measuring Op nbr 302-495 88890074 Multimeter 9998699 Adapter 9990062 Cable 9990014 Break out harness



Description Function



Voltage feed to after treatment control module (ACM)



References



370 Wiring diagram SCH02 370 Wiring diagram SCH05 370 Wiring diagram SCH30



VCADS Test



Pro —



Figure 1 60 / 61 / 62, feed 57 / 58 / 59, ground Measuring Measuring point



Correct value



60 / 61 / 62 –



≈ Uᵇᵃᵗ



Condition



Test method



57 / 58 / 59 –



≈0Ω



Service Information Document Title: Function Group: Power supply ECC, 302 description and measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Power supply ECC, description and measuring Op nbr 302-113 88890074 Multimeter 9998699 Adapter 9993893 Break out harness 88830115 Template 9990062 Cable



Description Function



Voltage feed to climate control unit (ECC).



References



370 Wiring diagram SCH01 370 Wiring diagram SCH10 370 Wiring diagram SCH11 370 Wiring diagram SCH30



VCADS Test



Pro —



Figure 1 BB42, feed BB66, feed BB69, ground BB70, ground Measuring Measuring point



Correct value



Condition



Test method



Date: 2014/7/14



BB42 –



≈ Uᵇᵃᵗ



BB66 –



BB69 – BB70 –



≈0Ω



Service Information Document Title: Function Group: Power supply I-ECU, 302 description and measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Power supply I-ECU, description and measuring Op nbr 302-112 88890074 Multimeter 88830028 Break out harness 9998699 Adapter



Description Function



Voltage feed to instrument control unit (I-ECU).



References



370 Wiring diagram SCH02 370 Wiring diagram SCH30



VCADS Test



Pro —



Figure 1 IA9, feed IA8, ground IA18, ground IB14, ground Measuring Measuring point



Correct value



IA9 –



≈ Uᵇᵃᵗ



Condition



Test method



Date: 2014/7/14



IA8 – IA18 – IB14 –



≈0Ω



Service Information Document Title: Function Group: Power supply W-ECU, 302 description and measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Power supply W-ECU, description and measuring Op nbr 302-133 88890074 Multimeter 9998699 Adapter 9993893 Break out harness 9990062 Cable



Description Function



Voltage feed to CareTrack control unit (W-ECU)



References



370 Wiring diagram SCH24 370 Wiring diagram SCH30



VCADS Test



Pro —



Figure 1 14, feed 7, feed 12, ground Measuring Measuring point



Correct value



14 –



≈ Uᵇᵃᵗ



7-



12 –



≈0Ω



Condition



Test method



Date: 2014/7/14



Service Information Document Title: SE9105, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE9105, description and measuring Op nbr 302-104 14576840 Measuring tool 88890016 Break out harness 88890019 Template 88890074 Multimeter 9998699 Adapter



Description Function



Measures the hydraulic oil temperature



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1 VA40, signal VA63, ground Measuring Measuring point



Correct value



1–2



≈ Resistance according to the table below



1–



2–



≈5V



≈0Ω



Condition



Test method



Date: 2014/7/14



1–



≈∞Ω



Verifying Measuring point



Correct value



VA40 – VA63



≈ Resistance according to the table below



Condition



Test method



SE9105 resistance values Oil temp.( °C)



Oil temp.(°F)



Without self-heating R—NTC IN(Ω)



Rs(COMP.) IN(Ω)



-40



-40



75780



3817



-30



-22



39860



3652



-20



-4



21860



3396



-10



+14



12460



3039



0



+32



7353



2599



+10



+50



4482



2119



+20



+68



2813



1655



+30



+86



1814



1250



+40



+104



1200



924



+50



+122



810



675



+60



+140



560



492



+70



+158



395



359



+80



+176



283



264



+90



+194



206



196



+100



+212



153



147



+110



+230



115



112



+120



+248



88



86



+130



+266



68



67



+140



+284



53



52



Service Information Document Title: Function Group: SW2506, description and 302 measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SW2506, description and measuring Op nbr 302-484 14576840 Measuring tool 88890016 Break out harness 9990062 Cable 88890074 Multimeter 9998699 Adapter 88890019 Template



Description Function



Activates/deactivates DPF regeneration



References



370 Wiring diagram SCH05



VCADS Test



Pro



Figure 1



Measuring Measuring point



Correct value



3 – VA52 1 – VA70



≈0Ω



Condition



Test method



Condition



Test method



Verifying Measuring point



Correct value



Date: 2014/7/14



VA52 –



≈ Uᵇᵃᵗ⁽ᵃ⁾



VA70 –



≈ Uᵇᵃᵗ⁽ᵇ⁾



(a) DPF regeneration start switch ON (b) DPF regeneration stop switch ON



Service Information Document Title: Function Group: SAE J1708/1587 302 Information link, description and measuring



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



SAE J1708/1587 Information link, description and measuring Op nbr 302-006 9990014 Break out harness 14576840 Measuring tool 88830028 Break out harness 9998699 Adapter 9990062 Cable 88890074 Multimeter



Description Function



The information link is connected to control units and the service/programming socket. Information and diagnostic signals are sent on the link. NOTE! The voltage on the information link varies, depending on the intensity of signals on the link. The measured values should therefore be regarded as guiding values only.



References



370 Wiring diagram SCH02



VCADS Test



Pro



Figure 1



Measuring Measuring point



Correct value



IA7 – IA17



≈ ∞ Ω⁽ᵃ⁾



Condition



Test method



IA7 – VB12 IA17 – VB4 (I-ECU – V-ECU)



≈ ∞ Ω⁽ᵇ⁾



IA7 – 10 IA17 – 11 (I-ECU – ECC)



≈ ∞ Ω⁽ᵇ⁾



IA7 – EA34 IA17 – EA33 (I-ECU – E-ECU)



≈ 0 Ω⁽ᵇ⁾



IA7 – 01 IA17 – 05 (I-ECU – ACM)



≈ 0 Ω⁽ᵇ⁾



IA7 –



≈ ∞ Ω⁽ᵇ⁾



IA17 –



(a) All ECU is disconnected from the information link except the I-ECU. (b) All ECU is disconnected from the information link. Verifying Measuring point



Correct value



IA7 – IA17



≈ 2.0 – 4.0 V



IA17 –



IA7 –



≈ 0 – 1.5 V



≈ 3.5 – 4.5 V



Condition



Test method



Service Information Document Title: SE2203, description measuring



Function Group: and 302



Information Type: Service Information



Profile: EXC, EC480D L [GB]



SE2203, description and measuring Op nbr 302-031 88890074 Multimeter 9990014 Break out harness 9998534 Break out harness 9998699 Adapter 9990062 Cable



Description Function



Measures the engine oil pressure



References



370 Wiring diagram SCH04



VCADS Pro Test



Figure 1



EB17, feed 5 V EB11, signal EB18, ground



Measuring Measuring point 1–



Correct value ≈5V



Condition



Test method



Date: 2014/7/14



4–



EB11 – 2



1–



≈0Ω



≈0Ω



≈∞Ω



2–



Verifying Measuring point



Correct value



EB11 –EB18



≈ Voltage according to the graph below



SE2203 voltage values



Figure 2



Condition



Test method



Service Information Document Title: Function Group: Power supply E-ECU, 302 description and measuring



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Power supply E-ECU, description and measuring Op nbr 302-110 88890074 Multimeter 9998699 Adapter 9990014 Break out harness 9990062 Cable



Description Function



Voltage feed to engine control unit (E-ECU).



References



370 Wiring diagram SCH02 370 Wiring diagram SCH03



VCADS Test



Pro —



Figure 1 EB57, feed EB60, feed EA57, ground EB58, ground EB59, ground EA61, ground Measuring Measuring point



Correct value



EB57 –



≈ Uᵇᵃᵗ



EB60 –



Condition



Test method



Date: 2014/7/14



EA57 – EB58 – EB59 – EA61 –



≈0Ω



Service Information Document Title: Battery, description



Function Group: 311



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Battery, description The battery consists of two 12 V batteries connected in series, which together give 24 V. The batteries are used to start the engine, supply the current to the electrical components and store the current from the alternator. The batteries should be in good condition when troubleshooting the electrical system. If needed, charge the batteries with a battery charger. If the batteries do not take a charge, check the electrolyte in the battery cell.



WARNING If a tool touches a cable connected between the positive terminal and the chassis, there is danger that it will cause sparks. Battery post clamps must be tightly connected. If loosely connected, the terminal may burn or be eroded by sparks caused by defective contact. Battery acid can burn or blind you. If acid gets on your skin or in your eyes, immediately wash with plenty of clean water and consult a doctor immediately. NOTE! When removing the battery, first disconnect the cable with the black tube from the ground (normally, from the negative (–) terminal). NOTE! Battery power may be lowered under severe cold weather. In this case, warm up the batteries and start the engine.



Service Information Document Title: Battery, storage



Function Group: 311



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Battery, storage Batteries gradually lose their charge through self-discharge, which is dependent on storage temperature and charge level. A fully charged battery stored in a cool place loses insignificant capacity in a three-month period. A battery that is partially charged and/or is stored at room temperature loses capacity faster. Therefore, always store batteries fully charged and as cool as possible, however, not at freezing temperature. During longterm storage, the battery should be checked periodically and trickle-charged if needed.



Service Information Document Title: Function Group: Battery charging capacity, 311 checking



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Battery charging capacity, checking Op nbr 311-001 1. Park the machine in the service position A, see 091 Service positions. 2. Using the ignition key open the battery disconnect switch cover and turn OFF the battery disconnect switch.



Figure 1 Battery disconnect switch off position 3. Open the battery box cover.



4. Figure 2 1. Tool box bracket Remove the tool box and tool box bracket.



5. Figure 3 1. Battery cover Remove the battery cover.



6. Figure 4 1. Electrolyte refilling cap 1). Checking battery and cable connection   



Loosen soiled connection terminals. Clean the battery poles (+ and –) and terminals, and grease with an acid-free and acid-resistance grease. Ensure that the terminal connections contact well when assembling.



2). Checking the battery voltage 



Check the voltage between positive terminal (+) and negative terminal (–) If the measured value is below 21 V, replace the batteries.



3). Checking the acid level    



Remove sealing caps. The electrolyte level should stand approximately 10 mm (0.4 in) above the cell plates. If the level is too low, refill the distilled water. Screw sealing caps back on.



3). Checking the acid density 



Measure the acid density of individual cells with a standard acid testing device. Acid density in [kg/l] at 20° C[ °F]



Charge level



Normal



Tropics



1.28



1.23



well charged



1.20



1.12



half charged, recharge



1.12



1.08



discharged, charge immediately



7. Reinstall the battery cover. 8. Reinstall the tool box bracket and tool box. 9. Turn ON the battery disconnect switch 10. Close the battery disconnect switch cover and lock it.



Service Information Document Title: Battery, charging



Function Group: 311



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Battery, charging WARNING Battery charging generates hydrogen gas, which may be explosive. Short-circuiting, an open flame or a spark near the battery may cause a powerful explosion.



Make sure ventilation is adequate when charging batteries. Never smoke near batteries. The batteries must be in good condition when troubleshooting the electrical system. Check the battery voltage with a voltmeter. Also check the electrolyte fluid in the battery cells with a densitometer. If needed, charge the batteries with a battery charger according to the instructions in the Operator's Manual.



NOTICE Always turn off the current to the battery charger before disconnecting the charging clamps.   



Batteries may only be charged with a battery charger. Check that the battery connections are attached securely and free from rust and dirt. Check the voltage when the batteries are at rest, that is, before attempting to start. Each battery must be at least half-charged.



If the batteries do not charge:  



Check the density in the battery cells. Measure the charging voltage between the alternator's B+ connection and the chassis with a voltmeter. Correct charging voltage is 28.5 ±0.5V .



Charge level



Voltage



Acid weight g/cm3 -20 °C



0 °C



+20 °C



+40 °C



Fully charged battery



12.7 V



1.30



1.29



1.28



1.27



Half-charged battery



12.4 V



1.23



1.22



1.21



1.20



Discharged battery



11.6 V and lower



1.14



1.13



1.12



1.11



NOTE! Difference in density between the cells may not exceed 0.04 g/cm3 .



Service Information Document Title: Batteries, replacing



Function Group: 311



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Batteries, replacing Op nbr 311-002 1. Park the machine in the service position A, see 091 Service positions. 2. Using the ignition key open the battery disconnect switch cover and turn OFF the battery disconnect switch.



Figure 1 Battery disconnect switch off position 3. Open the battery box cover. 4. Remove the tool box and tool box bracket.



Figure 2 1. Tool box bracket 5. Remove the battery cover.



Figure 3 1. Battery cover 6. Disconnect the ground cable and extension cable and positive cable from battery.



Figure 4



1. 2. 3. 4.



Positive Cable Extension cable Ground cable Battery fixing bracket



7. Remove the bracket fixing the batteries.



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 8. Replace the batteries with new ones. 9. Reinstall the bracket and battery cables to the batteries. NOTE! Make sure that the battery terminals are firmly fixed. 10. Reinstall the battery cover. 11. Reinstall the tool box bracket and tool box. 12. Turn ON the battery switch. 13. Close the battery disconnect switch cover and lock it.



Service Information Document Title: Function Group: Battery disconnector 311 switch, installing new



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Battery disconnector switch, installing new Op nbr 371-901 1. Place the machine in the service position A, see 091 Service positions. 2. Using the ignition key open the battery disconnect switch cover and turn OFF the battery disconnect switch.



Figure 1 Battery disconnect switch off position 3. Open the battery box cover. 4. Remove the tool box and tool box bracket.



Figure 2 1. Tool box bracket 5. Remove the battery disconnect switch protector.



Figure 3 1. Battery disconnect switch protector 6. Disconnect the positive cable and cable to the starter motor.



Figure 4



1. 2.



Positive cable Cable to the starter motor



7. Remove the screws fixing the battery disconnect switch from the bracket.



Figure 5



1.



Screws



8. Replace the battery disconnect switch with a new one.



9. Install the cables. 10. Reinstall the battery disconnect protector. 11. Reinstall the tool box bracket and tool box. 12. Turn ON the battery disconnect switch. 13. Close the battery disconnect switch cover and lock it.



Service Information Document Title: Earth lead to replacing



Function Group: battery, 311



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Earth lead to battery, replacing Op nbr 311-006 1. Place the machine in the service position A, see 091 Service positions.



2. Figure 1 Using the ignition key open the battery disconnect switch cover and turn OFF the battery disconnect switch. 3. Open the battery box cover. 4. Remove the tool box and tool box bracket.



Figure 2



5. Remove the battery cover.



Figure 3 1. Battery cover 6. Remove the ground cable from the battery minus terminal and ground point on the superstructure.



Figure 4



1. 2.



Ground cable Ground point



7. Install the new ground cable. 8. Reinstall the battery cover. 9. Reinstall tool box bracket and tool box. 10. Turn ON the battery disconnect switch. 11. Close the battery disconnect switch cover and lock it.



Service Information Document Title: Alternator, description



Function Group: 320



Profile: EXC, EC480D L [GB]



Alternator, description



Figure 1 Alternator 1. 2. 3. 4. 5. 6. 7. 8. 9.



BB2+ B1+, M8, tightening torque;15 Nm (11 lbf ft) Terminal W Terminal L Terminal 15 Terminal BS Terminal DFM Regulator



Information Type: Service Information



Date: 2014/7/14



Service Information Document Title: Charging, description



Function Group: 320



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Charging, description When the starter motor is activated and the engine starts:   



The alternator generates current to activate all the electrical systems, and the extra current charges the battery. After the engine starting, the battery charge warning lamp is turned off because the signal from "L" goes to the IECU. I-ECU recognize charging status. The current flows to the hour meter, which operates during engine running condition.



Service Information Document Title: Alternator, test



Function Group: 321



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Alternator, test Op nbr 321-075



Wire harness test The following test must be performed with alternator installed, all wiring harness leads connected and the ignition switch “ON.” Connect a voltmeter from: 1. Alternator “B–” TERMINAL and frame ground. 2. Alternator “B+” TERMINAL and ground (B–).



Figure 1 Alternator 1. 2. 3. 4. 5. 6. 7. 8. 9.



B– B2+ B1+, M8, tightening torque;15 Nm (11 lbf ft) Terminal W Terminal L Terminal 15 Terminal BS Terminal DFM Regulator



3. Alternator five pin connector TERMINAL (5, 6, 7) and ground (B–). NOTE! A zero volt reading on either of these tests indicates an open circuit between the voltmeter connection point and the battery. 4. Repair/replace wiring harness as required.



The following test must be performed with all accessories turned “OFF.” Connect a voltmeter from:



Output voltage test 5. Alternator “B+” TERMINAL (2) and ground. 6. Operate the engine at a low idle. 7. If the voltage is 28 V or more, the voltage regulator is defective. 8. If the voltage is lower than battery voltage, the alternator inner coil is defective. Remove the alternator and replace it with a new one.



Service Information Document Title: Function Group: Alternator, replacing incl 321 function check



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Alternator, replacing incl function check Op nbr 321-002



D12E engine 1. Place the machine in the service position, see 091 Service positions 2. Turn OFF the battery disconnect switch.



Figure 1



3. Remove the screws fixing the rear engine hood.



Figure 2



1.



Screws



4. Remove the air hose.



Date: 2014/7/14



Figure 3



1.



Air hose



5. Turn the belt tension adjusting screw counterclockwise to loosen the belt tension and remove the belt.



Figure 4



1. 2. 3.



Compressor belt Screw Connector



6. Remove the connector and screws fixing the compressor. Put the compressor aside. 7. Disconnect the ground cable, the five pin connector and the positive battery cable.



Figure 5



1.



Ground cable



2. 3.



Positive battery cable Five pins connector



8. Remove the nut on the lower guard. Then, loosen the screw on the upper mounting guard. Swing the alternator.



Figure 6



9. While holding the alternator, remove the screw from the upper guard. Remove the alternator from the engine compartment.



10. Install the new alternator. 11. Connect the ground cable, the five pin connector and the positive battery cable. 12. Install the compressor and connect the connector. 13. Turn the belt tension adjusting screw counterclockwise to loosen the belt tension and install the belt and adjust to proper tension. 14. Install the air hose. 15. Reinstall the engine rear hood. 16. Turn ON the battery disconnect switch. 17. Check the machine operation.



Service Information Document Title: Starting operation



Function Group: 330



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Starting operation Power supply 



The negative terminal (–) of battery is grounded to the machine. When the battery disconnect switch is in the OFF position, the power supply is disconnected.



If the battery disconnect switch is turned to the ON position and the start switch to the OFF position, the current flows in the following circuits.  



Battery (+) → Starter motor terminal (30:1) → Alternator(B1+) Battery (+) → Circuit breaker (FC02, 80 A) → Battery relay (RE3101)            



Fuse (FU11, 10A) → I-ECU Fuse (FU07, 10A) → Joystick Fuse (FU22, 15A) → Limp home switch Fuse (FU06, 10A) → V-ECU Fuse (FU18, 10A) → V-ECU Fuse (FU34, 10A) → Wiper motor Fuse (FU27, 15A) → Seat heater Fuse (FU16, 10A) → Cigarette lighter Fuse (FU32, 10A) → Quickfit switch (Removable counterweight solenoid for only EC480D) Fuse (FU02, 10A) → Socket for option (PO3904) Fuse (FU26, 10A) → V-ECU Fuse (FU21, 10A) → Travel alarm







Battery (+) → Circuit breaker (FC02, 80A) → Battery relay (RE3102)



   



Fuse (FU09, 15A) → Water separator heater (option), Automatic grease Fuse (FU04, 20A) → Work light, boom and superstructure Fuse (FU14, 10A) → Work light, Cab and counterweight Fuse (FU19, 10A) → Beacon light







Battery (+) → Circuit breaker (FC02, 80A) → Fuse (FU29, 15A) →Socket for option (PO3904)







Battery (+) → Circuit breaker (FC02, 80A) → Fuse (FU24, 15A) →Start switch, I-ECU (IA9)



When the start switch is turned to the ON position, current flows in the following circuits. 



Start switch terminal (B+) → ACC terminal →   



V-ECU (VB9) ECC (19) Alternator (15)







Start switch terminal (B+) → BR terminal → Battery relay (RE3101, RE3102) coil → Ground







Start switch terminal (B+) → BR terminal → Resistance (R3201)→ Alternator (L), I-ECU warning lamp signal



Engine starting If the start switch is turned to the START position, the current flows in the following circuits.



  



Start switch terminal (B+) Terminal C → Start power relay (RE3302) coil → Ground V-ECU (VA58) → Start relay (RE3301) → Ground



When start power relay and start relay are operated: 



Fuse (FU22, 15A) → Start power relay (RE3302 )→ Start relay (RE3301) → Start motor relay coil → E-ECU (B29) → EECU ground



Description of start lock, see 301 Engine start. Description of safe start and stop, see 301 Safe start and stop, description.



Service Information Document Title: Function Group: Starter switch (engine start 330 switch), replacing



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Starter switch (engine start switch), replacing Op nbr 334-011 1. Park the machine in the service position A, see 091 Service positions 2. Turn OFF the battery disconnect switch. 3. Open the upper cover on the right-hand control box, see 881 Instrument panel, replacing (right) 4. Disconnect the wire harness connectors from control box wire harness.



Figure 1



1. 2.



Key assembly Wire harness connectors



5. Remove the nut securing the starter switch. 6. Replace the switch with a new one. 7. Tighten the nut and connect the wire harnesses. 8. Close the upper cover. 9. Check engine starting.



Service Information Document Title: Starter motor, description



Function Group: 331



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Starter motor, description The starter motor MO3301 is supplied directly from the battery disconnection switch and has a built-in start relay, which is supplied with voltage by the control unit E-ECU. The relay RE3301 is controlled by V-ECU when the ignition key SW3301 is turned to position 2.



Figure 1 Starter motor 1. 2. 3. 4. 5. 6.



Terminal 30, tightening torque: 24 Nm (17.8 lbf ft) Solenoid relay Terminal 86, + Terminal 85, E-ECU (EB29) Terminal 31:1, ground Terminal 50, tightening torque: 1.2 Nm (0.9 lbf ft)



Service Information Document Title: Starter motor, tests



Function Group: 331



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Starter motor, tests Op nbr 331-021



Wire harness test The following test must be performed with starter motor installed, all wiring harness leads connected and the ignition switch “OFF.” Connect a voltmeter from: 1. Starter motor Terminal 30 and ground.



Figure 1 Starter motor 1. 2. 3. 4.



Terminal 30 Terminal 50 Stater motor Solenoid relay



NOTE! A zero volt reading on this test indicates an open circuit between the voltmeter connection point and the battery. 2. Repair/replace wiring harness as required. The following test must be performed with starter motor installed, all wiring harness leads connected and the ignition switch “Start.” Connect a voltmeter from:



Operating voltage test 3. Starter motor Terminal 50 and ground. If the voltage is higher than 24 V and engine does not start, the starter motor is defective. 4. Remove the starter motor and replace it with a new one.



Service Information Document Title: Starter motor, replacing



Function Group: 331



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Starter motor, replacing Op nbr 331-018 1. Park the machine in the service position A, see 091 Service positions 2. Turn OFF the battery disconnect switch. 3. Open the engine hood. 4. Remove the under cover of the engine. 5. Remove the ground cable from the starter motor.



Figure 1



1. 2. 3. 4.



Main cable Wire-harness of solenoid Ground cable Mounting screw



6. Remove the main cable and wire-harness of solenoid from the starter motor. 7. Remove 3 mounting screws and take the starter motor out.



8. Install the new starter motor. 9. Connect main cable and wire-harness and ground cable to starter motor and tighten screws. 10. Reinstall the rear engine hood. 11. Turn ON the battery disconnect switch and check engine starting.



Service Information Document Title: Starter relay, replacing



Function Group: 331



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Starter relay, replacing Op nbr 331-081 1. Park the machine in the service position A, see 091 Service positions 2. Open the side door of the cab rear. 3. Open the cover of the Electrical distribution box. 4. Pull out the starter relay, RE3301.



Figure 1



1.



Starter relay, RE3301



Date: 2014/7/14



5. Replace it with a new one. 6. Close the cover of the Electrical distribution box and side door.



Service Information Document Title: Starter switch, testing



Function Group: 334



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Starter switch, testing Op nbr 334-002 88890074 Multimeter



1. Turn off the battery disconnect switch. 2. Remove the right-hand control panel. 3. Disconnect the starter switch wires from the control panel main wire harness.



Figure 1 Start switch 4. Use an ohmmeter or a continuity tester to test all positions of the starter switch for continuity at the switch terminals. Turn the key to each of three switch positions shown in the table. Continuity should exist between the switch terminals marked with an “X” for each switch position. If no continuity exists, the switch is defective and must be replaced. Switch terminal Switch position



B+



BR



R1



R2



C



ACC



OFF



X



–



–



–



–



–



ON



X



X



–



–



–



X



START



X



X



–



X



X



X



5. Replace it with a new one if the switch is defective. Reconnect the wiring removed in Step 3, and reinstall the instrument panel. 6. Turn on the battery disconnect switch.



Service Information Document Title: Work lights and lights, description



Function Group: extra 350



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Work lights and extra lights, description See 370 Wiring diagram SCH07.



Date: 2014/7/14



Service Information Document Title: Function Group: Work lighting, replacing 356 one head lamp assy



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Work lighting, replacing one head lamp assy Op nbr 356-056 1. Park the machine in the service position E, see 091 Service positions



Right side 2. For the right-hand work light, open the battery box cover. and remove the plate protecting work light.



Figure 1



1.



Plate



3. Disconnect the wire harness connector from the work light.



Figure 2



1. 2.



Connector Screw



4. Remove the screw and replace with a new one.



Left side 5. For the left-hand work light, remove the under cover of the lower cab.



Figure 3



1.



Under cover



6. Disconnect the wire harness connector from the work light.



Figure 4



1. 2.



Connector Screw



7. Remove the screw.



8. Install the work light. 9. Connect the wire harness. 10. Reinstall the under cover and plate.



Service Information Document Title: Horn, replacing



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Horn, replacing Op nbr 362-002 1. Park the machine in the service position A, see 091 Service positions. 2. Disconnect the wire-harness connector from the horn.



Figure 1



1.



Connector



3. Remove the screws of the horn from the bracket.



Figure 2



1.



Screws



4. Install the new one. 5. Connect the wire-harness connector to the horn. 6. Check the horn operation.



Date: 2014/7/14



Service Information Document Title: Function Group: Rotating beacon, replacing



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Rotating beacon, replacing Op nbr 362-041 1. Park the machine in the service position A, see 091 Service positions. 2. Remove the screw from the bracket.



Figure 1



1. 2.



Rotating beacon light Screw



3. Install a new beacon. 4. Check the rotating beacon operation.



Date: 2014/7/14



Service Information Document Title: Travel alarm, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Travel alarm, replacing Op nbr 362-051 1. Park the machine in the service position A, see 091 Service positions. 2. Remove the under cover of lower engine. 3. Disconnect the connector of the travel alarm and remove the screw fixing the connector.



Figure 1



1. 2. 3.



Connector Screw Screw



4. Remove screws fixing the travel alarm.



5. Install a new travel alarm. 6. Connect the wire harness of the travel alarm and install the screw fixing the connector. 7. Reinstall the under cover. 8. Check the travel alarm operation after starting the machine.



Service Information Document Title: Function Group: Windscreen wiper, 363 replacing controller



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Windscreen wiper, replacing controller Op nbr 363-091 1. Park the machine in the service position A, see 091 Service positions. 2. Turn OFF the battery disconnect switch. 3. Move the operator's seat to the front position, and fold the backrest forward. 4. Remove plastic casing over the cab fan.



Figure 1



1.



Plastic casing



5. Remove two screws fixing the radio cover.



Figure 2



1.



Screw



Date: 2014/7/14



6. Disconnect wire harness connector and antenna cable from radio.



Figure 3



1. 2.



Connector Antenna cable



Take out radio cover. 7. Disconnect the connector of auxiliary heater (option).



Figure 4



1.



Connector



8. Disconnect the connectors of voltage converter and wiper motor controller.



Figure 5



1. 2.



Connector Connector



9. Remove the screw fixing the voltage converter and wiper controller support.



Figure 6



1.



Screw



10. Remove the screws fixing the wiper controller.



Figure 7



1.



Screw



11. Reinstall a new controller. The installing procedure is the reverse order of removal. 12. Check the wiper controller operation.



Service Information Document Title: Windscreen wiper replacing motor



Function Group: front, 363



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Windscreen wiper front, replacing motor Op nbr 363-002 1. Park the machine in the service position A, see 091 Service positions. 2. Turn off the battery disconnect switch. 3. Remove the washer fluid nozzle from cab front.



Figure 1 Wiper motor 1. 2. 3. 4. 5. 6.



Nut Rubber boot Packing Wiper motor swing shaft Fluid nozzle Wiper arm



4. Remove the wiper arm and blade. NOTE! Be careful when removing the wiper and blade not to damage the washer fluid nozzle. 5. Remove the nut and rubber boot and packing from the wiper motor swing shaft. 6. Remove the screw fixing the wiper motor cover on the roof and take out the cover. 7. Disconnect the motor wire harness connector from cab wire harness connector.



Figure 2 Motor 1. 2.



Wire harness Motor



8. Remove the screws fixing the wiper motor bracket on the cab and take out the motor. 9. Remove the screws fixing motor on the bracket and replace the motor with a new one. 10. Reinstall the screws and other items. 11. Check the wiper motor operation.



Service Information Document Title: Windscreen replacing switch



Function Group: wiper, 363



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Windscreen wiper, replacing switch Op nbr 363-003



1. Turn OFF the battery disconnect switch. 2. Open cab door and fix it into position.



Figure 1



1.



Cab door



3. Lift off the switch assembly from RH control panel and disconnect wire harness connector.



Figure 2



1.



Switch assembly



4. Replace with a new switch and connect wire harness connector.



5. Reinstall the switch assembly. 6. Check the switch operation.



Service Information Document Title: Function Group: Windscreen flusher pump, 363 replacing



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Windscreen flusher pump, replacing Op nbr 363-004 1. Park the machine in the service position A, see 091 Service positions. 2. Open left side door in front of radiator and disconnect wire harness connectors.



Figure 1 1. Washer tank assembly 2. Upper washer pump, MO3601 3. Lower washer pump, MO3604 4. Fluid hose 5. Screw 3. Remove the washer fluid hoses. NOTE! Prepare a container to collect washer fluid.



4. Remove the screws of washer fluid tank. 5. Remove the pump and replace it with a new one. 6. Reinstall the washer fluid tank 7. Reinstall the hoses and wire harness connectors. 8. Check the washer fluid pump operation.



Date: 2014/7/14



Service Information Document Title: Windscreen description



Function Group: wiper,



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Windscreen wiper, description 



By the use of the wiper controller, the upper and lower (option) wiper motor provides various functions.



NOTE! If the upper window is lifted up or the lower window is pulled up, the limit switch is activated, so upper and lower (option) wiper motor do not work.



Figure 1 Windscreen wiper 1. 2.



Upper windscreen wiper Lower windscreen wiper







If the upper wiper switch is at the ON position, the upper wiper motor moves the arm/blade from the PARK position (on the left side of the upper window) onto the upper window, and sweeps the blade through 65°. When the upper wiper is switched to the OFF position, the arm / blade stops sweeping on the left side of the upper window. Pushing the washer switch sprays the washer solution onto the window, and after about 0.5 second, the upper and lower (option) wiper motor engage. When the washer switch operation is stopped, the wiper blades wipe the windows 3 more times, and then return to the park position. Lifting the front window while the upper and lower (option) wiper motor are running immediately stops the operation. However, lowering the window will not automatically restart the wiper motors. The wiper switch must be turned OFF and then ON again to activate the wiper function.











Service Information Document Title: Wiper description



Function Group: controller,



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Wiper controller, description  



The wiper controller receives information from the upper wiper switch, lower wiper switch (option), washer switch, upper window limit switch and lower window limit switch, to control the wiper motor and washer pump operation. While the wiper motor and washer pump are operating, the wiper controller receives the operating information from the wiper motor.



Figure 1 Wiper controller 1



AVS 1.25 GN/W



9



AVS 0.85 BL/W



2



AVS 0.85 W/BL



10



AVS 0.85 BN/GR



3



AVS 0.85 BL/Y



11



AVS 0.85 GN/Y



4



AVS 0.85 BN/W



12



AVS 0.85 R/GN



5



AVS 0.85 BL/Y



13



AVS 0.85 W



6



AVS 0.85 SB



14



AVS 0.85 GN/SB



7



AVS 0.85 GN



15



AVS 0.85 Y



8



AVS 0.85 GN/R



16



AVS 0.85 W/BL



Service Information Document Title: Upper wiper description



Function Group: motor,



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Upper wiper motor, description  



The upper wiper motor system is composed of a motor, arm, blade, controller and limit switch. When the motor rotates once, the wiper blade operates reciprocally right and left by the linkage.



Figure 1 Upper wiper motor 1



Positive, auxiliary park feed (Y)



2



Park feed (GN)



3



Negative, GND (SB)



4



Positive, n2 speed (BL)



5



Positive, n1 speed (R)



Service Information Document Title: Lower wiper description



Function Group: motor,



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Lower wiper motor, description 



The lower wiper motor system is composed of a motor, arm, blade, controller and limit switch.



Figure 1 Lower wiper motor 1



Park feed (GN)



2



Negative, GND (SB)



3



Positive, auxiliary park feed (Y)



4



Positive, n1 speed (R)



Service Information Document Title: Window limit description



Function Group: switch,



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Window limit switch, description 



If the upper window is lifted up or the lower window is pulled up, the upper or lower window limit switch is activated and connects the ground circuit of wiper controller to stop the upper and lower (option) wiper motors.



Figure 1 Upper window limit switch 1. 2. 3.



Normally opened (AVS 0.85 BL) Common (AVS 0.85 Y) Normally closed (AVS 0.85 GN)



Figure 2 Lower window limit switch 1. 2.



Common (AVS 0.85 Y) Normally closed (AVS 0.85 GN)



Inspection method







Test the continuity between the terminals at normally opened and normally closed position by test meter.



Service Information Document Title: Function Group: Pre-heating relay, replacing 364



Information Type: Service Information



Profile: EXC, EC480D L [GB] Go back to Index Page



Pre-heating relay, replacing Op nbr 364-056 1. Park the machine in the service position A, see 091 Service positions. 2. Turn OFF the battery disconnect switch. 3. Open the engine hood. 4. Disconnect the three wire harnesses from the pre-heating relay.



Figure 1



1. 2.



Nut Screw



5. Remove the preheating relay mounting screws.



6. Replace new preheating relay. 7. Mount the preheating relay. 8. Reconnect wire harnesses to the relay. 9. Check the preheating replay operation.



Date: 2014/7/14



Service Information Document Title: Function Group: Pre-heating relay, replacing 364



Information Type: Service Information



Profile: EXC, EC480D L [GB] Go back to Index Page



Pre-heating relay, replacing Op nbr 364-056 1. Park the machine in the service position A, see 091 Service positions. 2. Turn OFF the battery disconnect switch. 3. Open the engine hood. 4. Disconnect the three wire harnesses from the pre-heating relay.



Figure 1



1. 2.



Nut Screw



5. Remove the preheating relay mounting screws.



6. Replace new preheating relay. 7. Mount the preheating relay. 8. Reconnect wire harnesses to the relay. 9. Check the preheating replay operation.



Date: 2014/7/14



Service Information Document Title: Control lockout switch, replacing



Function Group: lever 364



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Control lockout lever switch, replacing Op nbr 364-003 1. Park the machine in the service position A, see 091 Service positions. 2. Remove the upper cover of left-hand control box. 3. Remove the screw fixing the control lockout lever and lift out. 4. Remove the screw fixing cover on the limit switch assembly. 5. Remove the screws fixing the limit switch assembly. 6. Disconnect wire harness connector from control box wire harness.



Figure 1



1. 2. 3. 4. 5. 6. 7. 8. 9.



Wire harness assembly Control lockout lever Cover Limit switch assembly Screw Washer Screw Washer Washer



7. Replace it with a new limit switch assembly.



Date: 2014/7/14



NOTE! When installing the limit switch, turn the switch and make the contacting point is ON. 8. Reinstall the cover and lever. 9. Check the engine starting and attachment operation.



Service Information Document Title: Start switch, description



Function Group:



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Start switch, description 



The switch selectively routes power supply to various electrical components of the engine start / stop and accessory circuits.



Figure 1 Start switch



Figure 2 Start switch, circuit 1



START



2



ON



3



OFF



Figure 3 Connection of terminals



Service Information Document Title: Function Group: Emergency engine speed control switch, description



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Emergency engine speed control switch, description



Figure 1 Emergency engine speed control switch ES



Emergency switch



U



Upper position, emergency mode



N



Neutral position, normal operation mode



D



Down position, emergency engine stop



Date: 2014/7/14



Service Information Document Title: Function Group: Auto/Manual pump control switch, description



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Auto/Manual pump control switch, description



Figure 1 Manual pump control switch A. B.



Pump manual control position Pump automatic control position



Date: 2014/7/14



Service Information Document Title: Connectors, overview



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Connectors, overview Connector LA3512 MA9117 MA9118 MA9120 MO2601 MA9116 MA9121 MA9122 MA9120 MA2602 MA9109 MA4212 MA9125 MA9124 MA9123 MA9126 PWM9123 PWM9124 CN4602 SE9105 CNRC SA3602 SA3603 SW2304 SW2302 / SW2303B LA3513 PWM9145 PWM9146 MA9110 MA9111 CN2501 MO3603 SWJS4BL (B), male connector SWJS4BR (C), female connector SWJS4BR (B), male connector



Plug-in side (female)



Pin-side (male)



Date: 2014/7/14



CU8702 SO3902



PC3601



CR3901



PO3904 CNDH SWJSPBL



CU3601 CNIC 2



CNIC 1 CNCA 1 CNAC



–



–



–



CNCA 2



CNRH 1 CNRH 2 CNLH 2



SE8705 SE8706 DI2601 DI3604 DI3605 PWM9109 CNCWT MO8709 SWJS4BL (A) SWJS4BR (A) PWM9141 CNLH 1



VA, V-ECU



VB, V-ECU



Female



–



SE8701 SE9112 SE9111 SE4216 SE9140



–



CON, EDB



–



MO3601 MO3604



–



SE9141 SE9142 CNBO MO2302 SW2302 / SW2303A CU9901 SE2303 / SE2304 CNPS CNEN 1 CNEN 2 CNACM CNDPF



SE9401



MO8501 / HE8501



–



SW9103



SW2704



–



SW3503 SW9160 SW9104 SW2301 SW3607 SW9900 SW2506 SW3505 SW3504 SW4202 SW3603 SW3608 SW3613 SW3602 SW9110



–



SW9118



PO3902



–



HE3801



–



SW3801



–



SW3301 (A) ; (1–BR, 2–ACC, 3–R1, 4–C)



SW3301 (B)



FX1008 SE2301



–



SE2603



–



AL3201



–



CNEI



FX1005



–



EK (ASU)



–



ES (ASU)



–



EA, EB (E-ECU) ACM



SE2521



–



SE2522



–



SE2510



–



SE2529



–



SE2519



–



Service Information Document Title: Function Group: V-ECU, MID 187, changing 366 pre-programmed ECU



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



V-ECU, MID 187, changing pre-programmed ECU Op nbr 366-066 1. Park the machine in the service position A, see 091 Service positions. 2. Connect VCADS Pro computer to the machine, and perform operation '17030-3 Parameter, programming'. 3. Use the function 'save all parameters to job card'. 4. Turn OFF battery disconnect switch. 5. Move the operator's seat to the front position, and fold the backrest forward. 6. Remove the screws and covers.



Figure 1



1. 2. 3.



Screw Cover Cover



7. Disconnect two wiring harness connectors from the V-ECU.



Figure 2



1.



Wiring harness connector



8. Remove two screws at the upper side of V-ECU, and loosen two screws at the bottom side of V-ECU.



Figure 4



1.



Screws



9. Lift off the V-ECU, and replace it with a new one. 10. Install four screws fixing V-ECU to the cab. 11. Connect two wiring harness connectors to the V-ECU.



Figure 5



1.



Wiring harness connectors



12. Fit the plastic casing over the cab fan.



Figure 6



13. Return the operator's seat to the original position. 14. Connect VCADS Pro computer to the machine, and perform operation 17030-3 Parameter, programming'. Now the customer parameters are changed according to the job card saved at step 2. 15. Start the machine and check that no error messages appear.



Service Information Document Title: Function Group: V-ECU, MID 187, changing 366 non-programmed ECU



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



V-ECU, MID 187, changing non-programmed ECU Op nbr 366-064 1. Park the machine in the service position A, see 091 Service positions. 2. Down load software to VCADS Pro computer for target machine. 3. Connect the VCADS Pro computer to the machine, and perform the operation '36646-3 MID 187 control unit, programming'. 4. When VCADS Pro 'MID 187 ECU, programming' window appears, follow the instructions for replacing V-ECU. 5. Turn OFF battery disconnect switch. 6. Move the operator's seat to the front position, and fold the backrest forward. 7. Remove the screws and covers.



Figure 1



1. 2. 3.



Screw Cover Cover



8. Disconnect two wiring harness connectors from the V-ECU.



Figure 2



1.



Screw



Figure 3 NOTE! Concerning JA connector, 70 pins, pull up the locking device to disconnect it. NOTE! Concerning JB connector, 16 pins, pull out the red locking device to disconnect it. 9. Remove two screws at the upper side of V-ECU, and loosen two screws at the bottom side of V-ECU.



Figure 4



1.



Screw



10. Lift off the V-ECU, and replace it with a new one. 11. Install four screws for fixing V-ECU to the cab. 12. Connect two wiring harness connectors to the V-ECU.



Figure 5



13. Reinstall the screws of the plastic plate between fan and seat and screws of the cassette cover, and connect the wire harness connector of outlet and diesel heater switch. 14. Fit the plastic casing over the cab fan.



Figure 6



15. Return the operator's seat to the original position. 16. After replacing V-ECU, press OK button of VCADS Pro operation '36646-3 MID 187 control unit, programming'. Now VCADS Pro starts the programming of software and parameters to the new V-ECU. 17. Start the machine and check that no error messages appear.



Service Information Document Title: Engine speed switch, replacing



Function Group: control 367



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Engine speed control switch, replacing Op nbr 367-075



1. Turn OFF the battery disconnect switch. 2. Open cab door (1) and fix it into position.



Figure 1



3. Remove screws (1) and open cover (2). NOTE! Screw tightening torque: (3.61 ± 0.36 lbf.ft) ( 4.9 ± 0.49 N.m) ( 0.5 ± 0.05 kgf.m)



Figure 2 Instrument panel, right 4. Disconnect connector (1) and remove cover (2).



Date: 2014/7/14



Figure 3



5. Remove the screw (1), and remove cover (2). NOTE! Screw tightening torque: (3.61 ± 0.36 lbf.ft) ( 4.9 ± 0.49 N.m) ( 0.5 ± 0.05 kgf.m)



Figure 4



6. Remove the screws (1), and open the panel (2).



Figure 5



7. Disconnect connector (2) of speed control switch (1).



Figure 6



8. Unlock locking plate (1), and then push out the speed control switch.



Figure 7



9. Install the new speed control switch. The installation procedure is the reverse order of removal. 10. Check the machine operation.



Service Information Document Title: Function Group: Component list: Alternator, 370 batteries, capacitors, electronic units, voltage outlet



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component list: Alternator, batteries, capacitors, electronic units, voltage outlet Marking



Description



Wiring diagram



AL3201



Alternator



370 Wiring diagram SCH01



BA3101



Battery 1



370 Wiring diagram SCH01



BA3102



Battery 2



370 Wiring diagram SCH01



E-ECU



Engine control unit



370 Wiring diagram SCH02 370 Wiring diagram SCH03 370 Wiring diagram SCH10 370 Wiring diagram SCH16



I-ECU



Instrument control unit



370 Wiring diagram SCH02 370 Wiring diagram SCH04 370 Wiring diagram SCH17 370 Wiring diagram SCH22



V-ECU



Vehicle control unit



370 Wiring diagram SCH02 370 Wiring diagram SCH03 370 Wiring diagram SCH08 370 Wiring diagram SCH15 370 Wiring diagram SCH16 370 Wiring diagram SCH17



W-ECU



Wireless control unit



370 Wiring diagram SCH24



CU3601



Wiper controller



370 Wiring diagram SCH13



ECC



Electronic climate control unit



370 Wiring diagram SCH10



CU8702



Diesel heater controller



370 Wiring diagram SCH11



CU9901



Central lubrication system control unit



370 Wiring diagram SCH20



Service Information Document Title: Component list, coils



Function Group: Heating 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component list, Heating coils Marking



Description



Wiring diagram



FX1005



Fuel filter, water indication and electrically heated 370 Wiring diagram SCH03 element



HE2501



Element, preheating coil



370 Wiring diagram SCH03



HE3801



Cigarette lighter



370 Wiring diagram SCH14



HE8501



Seat heater



370 Wiring diagram SCH14



HE8701



Diesel heater, cab (option)



370 Wiring diagram SCH11



Service Information Document Title: Component list, Lights



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component list, Lights Marking



Description



Wiring diagram



LA3501



Interior light



370 Wiring diagram SCH14



LA3512



Working light, front left, 1st



370 Wiring diagram SCH07



LA3513



Working light, front right, 1st



370 Wiring diagram SCH07



LA3514



Working light, reart right, 1st



370 Wiring diagram SCH07



LA3515



Working light, counterweight



370 Wiring diagram SCH07



LA3521



Working light, front left CAB, 1st



370 Wiring diagram SCH07



LA3522



Working light, front right CAB, 1st



370 Wiring diagram SCH07



LA3533



Working light, left, 3rd



370 Wiring diagram SCH07



LA3534



Working light, right, 3rd



370 Wiring diagram SCH07



LA3535



Working light, left 4th



370 Wiring diagram SCH07



LA3536



Working light, right, 4th



370 Wiring diagram SCH07



LA3601



Rotating warning beacon, 1st



370 Wiring diagram SCH14



Service Information Document Title: Function Group: Component list, Solenoid 370 valves



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component list, Solenoid valves Marking



Description



Wiring diagram



FX1032



Master-solenoid, Automization-solenoid, Fuel injector 370 Wiring diagram SCH05 (PWM2504, PWM2505, MA2514)



MA2301



Unit injector 1



370 Wiring diagram SCH03



MA2302



Unit injector 2



370 Wiring diagram SCH03



MA2303



Unit injector 3



370 Wiring diagram SCH03



MA2304



Unit injector 4



370 Wiring diagram SCH03



MA2305



Unit injector 5



370 Wiring diagram SCH03



MA2306



Unit injector 6



370 Wiring diagram SCH03



MA2506



Air pump clutch



370 Wiring diagram SCH05



MA2507



Fuel shut-off valve



370 Wiring diagram SCH05



MA2602



Engine fan solenoid, rotation direction



370 Wiring diagram SCH16



MA4212



Travel solenoid



370 Wiring diagram SCH08



MA8701



Air conditioning compressor solenoid



370 Wiring diagram SCH10



MA9115



Removal counterweight



370 Wiring diagram SCH17



MA9121



X1 left solenoid (hammer)



370 Wiring diagram SCH15



MA9122



X1 right solenoid



370 Wiring diagram SCH15



MA9123



Boom conflux solenoid



370 Wiring diagram SCH08



MA9124



Arm in conflux solenoid



370 Wiring diagram SCH08



MA9125



Power boost solenoid



370 Wiring diagram SCH08



MA9126



Hydraulic safety



370 Wiring diagram SCH08



MA9109



Quick fit solenoid



370 Wiring diagram SCH17



MA9110



X3 rotator left solenoid



370 Wiring diagram SCH16



MA9111



X3 rotator right solenoid



370 Wiring diagram SCH16



MA9116



1/2 pump select solenoid



370 Wiring diagram SCH15



MA9117



Hammer select solenoid



370 Wiring diagram SCH15



MA9118



Shear select solenoid



370 Wiring diagram SCH15



MA9120



Boom float solenoid



370 Wiring diagram SCH17



PWM2503



EGR



370 Wiring diagram SCH03



PWM9109



X1 main flow control proportional valve



370 Wiring diagram SCH15



PWM9123



X1 proportional valve 1



370 Wiring diagram SCH15



PWM9124



X1 proportional valve 2



370 Wiring diagram SCH15



PWM9129



Left-hand X1 flow preset proportional valve



370 Wiring diagram SCH15



PWM9130



Rightt-hand X1 flow preset proportional valve



370 Wiring diagram SCH15



PWM9141



Pump power shift 1



370 Wiring diagram SCH08



PWM9143



Fan motor proportional valve, hydraulic oil



370 Wiring diagram SCH16



PWM9145



X3 left proportional valve (optional)



370 Wiring diagram SCH16



PWM9146



X3 right proportional valve (optional)



370 Wiring diagram SCH16



Service Information Document Title: Component list, Motors



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component list, Motors Marking



Description



Wiring diagram



MO2302



Refueling pump motor



370 Wiring diagram SCH18



MO2504



Fuel pump



370 Wiring diagram SCH05



MO3301



Starter motor



370 Wiring diagram SCH01 370 Wiring diagram SCH03



MO3601



Windscreen washer motor



370 Wiring diagram SCH13



MO3602



Windscreen wiper motor



370 Wiring diagram SCH13



MO3603



Windscreen wiper motor, lower



370 Wiring diagram SCH13



MO3604



Windscreen washer motor, lower



370 Wiring diagram SCH13



MO8501



Air suspension



370 Wiring diagram SCH14



MO8701



Cab fan motor



370 Wiring diagram SCH10



MO8703



Air conditioner, intake actuator



370 Wiring diagram SCH10



MO8704



Air conditioner, face actuator



370 Wiring diagram SCH10



MO8705



Air conditioner, foot right-hand actuator



370 Wiring diagram SCH10



MO8706



Air conditioner, foot left-hand actuator



370 Wiring diagram SCH10



MO8707



Air conditioner, mix actuator



370 Wiring diagram SCH10



MO8709



Fuel pump motor, diesel heater (optional)



370 Wiring diagram SCH11



Service Information Document Title: Component list, Relays



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component list, Relays Marking



Description



Wiring diagram



RE2501



Preheating relay, induction air



370 Wiring diagram SCH03



RE2601



Engine fan direction relay



370 Wiring diagram SCH16



RE3101



Main relay 1



370 Wiring diagram SCH01



RE3102



Main relay 2



370 Wiring diagram SCH01



RE3301



Starter motor relay, 1st



370 Wiring diagram SCH03



RE3302



Starter motor relay, 2nd



370 Wiring diagram SCH01 370 Wiring diagram SCH03



RE3611



Horn relay



370 Wiring diagram SCH12



RE3701



Spare relay 1st



370 Wiring diagram SCH01



RE3702



Spare relay 2nd



370 Wiring diagram SCH01



RE4206



Travel alarm relay



370 Wiring diagram SCH12



RE8701



Air conditioning unit relay, 1st



370 Wiring diagram SCH11



Service Information Document Title: Component list, Sensors



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component list, Sensors Marking



Description



Wiring diagram



FX1005



Fuel filter, water indication and electrically heated 370 Wiring diagram SCH03 element (SE2301/HE2301)



FX1006



Engine oil sensor, level and temperature



FX1007



Engine sensor, induction/charge air, temperature 370 Wiring diagram SCH04 and pressure



FX1008



Air filter, position monitor and temperature sensor



370 Wiring diagram SCH04



SE2203



Pressure sensor, engine oil



370 Wiring diagram SCH04



SE2301



Pressure sensor, fuel



370 Wiring diagram SCH04



SE2303/SE2304



Fuel level/auto stop sensor



370 Wiring diagram SCH04



SE2509



Pressure sensor, crank house



370 Wiring diagram SCH04



SE2515



Pressure sensor, EGR differential



370 Wiring diagram SCH04



SE2516



Temperature sensor, EGR



370 Wiring diagram SCH04



SE2527



Nozzle pressure



370 Wiring diagram SCH05



SE2528



Fuel pressure



370 Wiring diagram SCH05



SE2603



Level monitor, coolant



370 Wiring diagram SCH04



SE2606



Temperature sensor, engine coolant



370 Wiring diagram SCH04



SE2514



Speed sensor, turbo



370 Wiring diagram SCH03



SE2521



Filter inlet temperature sensor



370 Wiring diagram SCH05



SE2522



Filter outlet temperature sensor



370 Wiring diagram SCH05



SE2510



Exhaust temperature sensor



370 Wiring diagram SCH05



SE2529



Flame temperature sensor



370 Wiring diagram SCH05



SE2519



Pressure sensor, DPF



370 Wiring diagram SCH05



SE2701



Speed sensor, engine, 1st (crankshaft)



370 Wiring diagram SCH03



SE2703



Speed sensor, camshaft (engine)



370 Wiring diagram SCH03



SE3602



Limit switch, upper wiper



370 Wiring diagram SCH13



SE3603



Limit switch, lower wiper



370 Wiring diagram SCH13



SE4216



Travel pressure monitor



370 Wiring diagram SCH08



SE9111



Attachment pressure monitor (auto idle)



370 Wiring diagram SCH08



SE8701



Pressure monitor, air conditioning refrigerant



370 Wiring diagram SCH10



SE8702



Temperature monitor, air conditioning refrigerant



370 Wiring diagram SCH10



SE8705



Temperature monitor, ambient



370 Wiring diagram SCH10



SE8706



Temperature monitor, cab



370 Wiring diagram SCH10



SE8301



Position monitor, left door



370 Wiring diagram SCH14



SE9105



Temperature sensor, hydraulic oil tank



370 Wiring diagram SCH04



SE9112



Pressure monitor, hammer or shear (X1)



370 Wiring diagram SCH15



SE9140



Pressure monitor, float safety



370 Wiring diagram SCH17



SE9141



Inductive sensor, ISO type control lever



370 Wiring diagram SCH04



SE9142



Inductive sensor, Backhoe type control lever



370 Wiring diagram SCH04



370 Wiring diagram SCH04



SE9401



Pressure monitor, overload



370 Wiring diagram SCH04



SE9901



Pressure monitor, automatic central lubrication



370 Wiring diagram SCH20



Service Information Document Title: Component list, Switches



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component list, Switches Marking



Description



Wiring diagram



SW3301



Ignition switch



370 Wiring diagram SCH01



SW3101



Battery disconnection switch



370 Wiring diagram SCH01



SW3801



Keyboard



370 Wiring diagram SCH02



SW2301



Fuel heater switch



370 Wiring diagram SCH03



SW2701



Engine speed control switch



370 Wiring diagram SCH03



SW2713



Engine limp home switch



370 Wiring diagram SCH03



SW2506



DPF switch



370 Wiring diagram SCH05



SW3504



Working lights, front



370 Wiring diagram SCH07



SW3505



Working lights, rear



370 Wiring diagram SCH07



SW4202



Travel speed switch



370 Wiring diagram SCH08



SW9103



Pump manual switch



370 Wiring diagram SCH08



SW9110



Power max mode switch



370 Wiring diagram SCH08



SW9118



Control lockout lever



370 Wiring diagram SCH08



SW3902



Audio remote control



370 Wiring diagram SCH12



SWJS4BL



Control lever left-hand 4 button switch (SW3609, 370 Wiring diagram SCH12 SW9405, SW9406) 370 Wiring diagram SCH16



SWJSPBL



Control lever proportional and switch (SW3609, 370 Wiring diagram SCH12 SW9161, SW9165) 370 Wiring diagram SCH16



SW3602



Windscreen wiper, upper



370 Wiring diagram SCH13



SW3603



Windscreen wiper, lower (optional)



370 Wiring diagram SCH13



SW3608



Windscreen washer, upper



370 Wiring diagram SCH13



SW3613



Windscreen washer, lower (optional)



370 Wiring diagram SCH13



SW3503



Interior light



370 Wiring diagram SCH14



SW3607



Rotating warning beacon, 1st



370 Wiring diagram SCH14



SWJS4BR



Control lever right-hand 4 button switch (SW9108, 370 Wiring diagram SCH15 SW9163, SW9464, SW9158) 370 Wiring diagram SCH17



SWJSPBR



Control lever right-hand proportional and switch 370 Wiring diagram SCH15 (SW9162, SW9108, SW9158) 370 Wiring diagram SCH17



SW9104



Quick fit switch, 1st



370 Wiring diagram SCH17



SW9115



Removal counterweight switch



370 Wiring diagram SCH17



SW9160



Buzzer stop/confirm switch



370 Wiring diagram SCH17



SW2302/ SW2303



Fuel filler pump auto stop switch



370 Wiring diagram SCH18



SW2304



Fuel pump switch



370 Wiring diagram SCH18



SW9900



Automatic lubrication switch



370 Wiring diagram SCH20



Service Information Document Title: Component list, Fuses



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component list, Fuses Circuit breaker Breaker



Capacity



Designation



Wiring diagram



FC02



80 A



Main fuse



370 Wiring diagram SCH01 370 Wiring diagram SCH23



FC03



20 A



B+ fuse



370 Wiring diagram SCH01 370 Wiring diagram SCH23



Fuses in distribution box Fuse



Capacity



Designation



Wiring diagram



FU01



10 A



Horn



370 Wiring diagram SCH12



FU02



10 A



Power outlet, ECU power



370 Wiring diagram SCH01



FU03



10 A



Spare 1



—



FU04



20 A



Working light, front



370 Wiring diagram SCH07



FU05



10 A



Spare 4



—



FU06



—



—



—



FU07



10 A



V-ECU



370 Wiring diagram SCH08



FU08



15 A



Engine fan direction



370 Wiring diagram SCH16



FU09



15 A



Fuel filter, electrically heated element 370 Wiring diagram SCH03 Auto lubrication 370 Wiring diagram SCH20



FU10



10 A



Spare 5



FU11



10 A



I-ECU 370 Wiring diagram SCH04 Audio, horn, travel alarm Inductive sensor (ISO/Backhoe type control lever)



FU12



—



—



—



FU13



10 A



Spare 3



—



FU14



15 A



Working light, rear



370 Wiring diagram SCH07



FU15



10 A



Spare 6



—



FU16



10 A



Cigarette lighter



370 Wiring diagram SCH14



FU17



15 A



Fuel refueling pump



370 Wiring diagram SCH18



FU18



10 A



V-ECU (for solenoid valves, relays)



370 Wiring diagram SCH08



FU19



10 A



Rotating warning beacon



370 Wiring diagram SCH14



FU20



15 A



Diesel heater, Air conditioner



370 Wiring diagram SCH11



FU21



10 A



Travel alarm



370 Wiring diagram SCH12



FU22



15 A



E-ECU



370 Wiring diagram SCH03



FU23



—



—



—



FU24



15 A



Ignition switch, I-ECU



370 Wiring diagram SCH01



FU25



15 A



Voltage converter for audio and 370 Wiring diagram SCH12 power outlet



FU26



10 A



X1 option, Boom float



—



370 Wiring diagram SCH15



FU27



15 A



Air suspension / seat heater



370 Wiring diagram SCH14



FU28



10 A



Iinterior light



370 Wiring diagram SCH14



FU29



15 A



W-ECU



370 Wiring diagram SCH01 370 Wiring diagram SCH24



FU30



15 A



Spare 7



—



FU31



—



—



—



FU32



10 A



Quick fit



370 Wiring diagram SCH17



FU33



15 A



Spare 8



—



FU34



10 A



Wiper and washer



370 Wiring diagram SCH13



FU35



30 A



ACM



370 Wiring diagram SCH02



FU36



10 A



DPF



370 Wiring diagram SCH05



Service Information Document Title: Component Miscellaneous



Function Group: list, 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component list, Miscellaneous Marking



Description



Wiring diagram



AN3901



Antenna



370 Wiring diagram SCH12



CR3901



Audio



370 Wiring diagram SCH12



IG2501



Ignitor



370 Wiring diagram SCH05



IM3812



Hour meter



370 Wiring diagram SCH04



PC3601



Socket for VCADS Pro



370 Wiring diagram SCH02



PO3902



Power outlet 14 VDC



370 Wiring diagram SCH12



PO3904



Socket for communication



370 Wiring diagram SCH02 370 Wiring diagram SCH24



R3201



Resister (220 ohm)



370 Wiring diagram SCH01



RC3903



Rear view camera



370 Wiring diagram SCH22



R9101



Manual resister 1



370 Wiring diagram SCH08



SA3602



Horn, 1st



370 Wiring diagram SCH12



SA3603



Horn, 2nd



370 Wiring diagram SCH12



SA3901



Speaker, left-hand



370 Wiring diagram SCH12



SA3902



Speaker, right-hand



370 Wiring diagram SCH12



SA4206



Travel alarm



370 Wiring diagram SCH12



SO3902



Voltage converter



370 Wiring diagram SCH12



Service Information Document Title: Wiring harnesses Profile: EXC, EC480D L [GB]



Wiring harnesses Harness layout



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Figure 1 Harness layout



Service Information Document Title: Control system diagram



Function Group: 370



Profile: EXC, EC480D L [GB]



Control system diagram



Information Type: Service Information



Date: 2014/7/14



Figure 1 Control system diagram



Service Information Document Title: Function Group: Wiring diagram, electrical 370 distribution box



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Wiring diagram, electrical distribution box



Date: 2014/7/14



Figure 1 EDB circuit diagram



Service Information Document Title: Component designations



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Component designations The components in the electrical system are grouped in sixteen component groups according to standard SS-IEC 750 . The component group is indicated by a letter according to the following table. Each separate component has a running number after the letter. Description



Designation



Antenna



ANT



Diodes



DI



Alternator



AL



Sensors and monitors



SE



Indicator light



LC



Cassette radio



CRR



Control unit



CU



Lights



LA



Solenoid valve



MA



Motor



MO



Proportional valve



PWM



Relay



RE



Service connection



IS



Horn, speakers



SA



Voltage converter



SO



Power (electric) source



BA



Switches



SW



Control unit



V-ECU, E-ECU, I-ECU, W-ECU, ECC



Fuses



FU



Timers and counters



IM



Connections and connectors



PO



Heaters



HE



Service Information Document Title: Explanation of diagrams



Function Group: wiring 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Explanation of wiring diagrams



Figure 1 Example of cable and component markings 1. 2. 3. 4. 5. 6.



Reference, cable (lead) has permanent connection to wiring diagram SCH11_diesel heater:0 C (Diagram number_ function : coordinates) Component marking Diagram number Cable/lead color, see table below Cable/lead marking Key dependent voltage supply (30, 15A, 15B)



7. 8. 9. 10. 11.



Frame grounding point (31GE, 31GF) Splicing point Connector with pin numbers Connection with pin marking Coordinate system



Cable (lead) colors on wiring diagrams are outlined in the following table. Code & color Code



Color



Code



Color



BL



Blue



R



Red



BN



Brown



SB



Black



GN



Green



VO



Violet



GR



Grey



W



White



OR



Orange



Y



Yellow



P



Pink



LG



Light green



Service Information Document Title: Electrical symbols designations



Function Group: and 370



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Electrical symbols and designations Designation



Symbol



Explanation



AL



Alternator with charging regulator



BA



Battery



CU



Electronic control unit



DI



Diode



ECC



Climate control unit



E-ECU



Engine control unit



FU



Fuse



HE



Heaters



I-ECU



Instrument control unit



IM



Instrument, i.e. hour meter



LA



Light



LC



Control light, fixed light Control light, flashing light



Date: 2014/7/14



MA



Solenoid valve



MO



Electric motor Starter motor



PO



Power outlets



PWM



Proportional solenoid valve



R



Resistor



RE



Relay



RFX



Relay



SA



Audible signal



SE



Speed sensor



Level sensor



Temperature sensor



Pressure sensor



Pressure switch



Mechanical switch



Position switch



SW



Switch Switch



V-ECU



Vehicle control unit



Ground connection



Ground connection engine block



Shielded cable



Service Information Document Title: Wiring diagram



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Wiring diagram SCH01



Power feeding, Alternator, Battery



370 Wiring diagram SCH01



SCH02



ECU power and communication



370 Wiring diagram SCH02



SCH03



Starting system



370 Wiring diagram SCH03



SCH04



Warning and sensor



370 Wiring diagram SCH04



SCH05



ACM and ASU system



370 Wiring diagram SCH05



SCH07



Work light



370 Wiring diagram SCH07



SCH08



Machine control



370 Wiring diagram SCH08



SCH10



Electric climate control unit



370 Wiring diagram SCH10



SCH11



Diesel heater



370 Wiring diagram SCH11



SCH12



Audio, horn and travel alarm



370 Wiring diagram SCH12



SCH13



Wiper and washer



370 Wiring diagram SCH13



SCH14



Seat heater, Beacon light and Cab interior light



370 Wiring diagram SCH14



SCH15



X1 control



370 Wiring diagram SCH15



SCH16



X3 and cooler control



370 Wiring diagram SCH16



SCH17



Quick fit and float



370 Wiring diagram SCH17



SCH18



Fuel refilling pump



370 Wiring diagram SCH18



SCH20



Automatic lubrication system



370 Wiring diagram SCH20



SCH22



Rear view camera



370 Wiring diagram SCH22



SCH24



CareTrack system



370 Wiring diagram SCH24



SCH30



Ground



370 Wiring diagram SCH30



Service Information Document Title: Wiring diagram SCH30



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH30 Ground



Information Type: Service Information



Date: 2014/7/14



Figure 1



Marking



Designation



Marking



Designation



31GF1



Ground, superstructure



31GC1



Ground



31GF2



Ground, superstructure



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH01



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH01 Power feeding



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH01



Marking



Designation



Marking



Designation



BA3101



Battery 1



RE3101



Main relay 1



BA3102



Battery 2



RE3102



Main relay 2



FC02



Fuse, main (80 A)



RE3701



Spare relay 1



FC03



Fuse, B+



RE3702



Spare relay 2



SW3101



Battery disconnection switch



MO3301



Starter motor



SW3301



Ignition switch



AL3201



Alternator



R3201



Resistor (220 ohm)



FU24



Ignition switch / I-ECU



FU29



Spare, W-ECU



FU02



Spare, W-ECU



31GE1



Ground, engine



31GE2



Ground, engine



31GF3



Ground, superstructure



31GE3



Ground, engine



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH02



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH02 ECU power and communication



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH02



Marking



Designation



Marking



Designation



I-ECU



Instrument control unit



FU35



Fuse, ACM



V-ECU



Vehicle control unit



PC3601



Socket for VCADS pro



E-ECU



Engine control unit



SW3801



Keypad



ECC



Electronic climate control unit



PO3904



Socket for communication



ACM



Aftertreatment control unit



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH03



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH03 Starting and Engine speed control system



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH03



Marking



Designation



Marking



Designation



FX1005



Fuel filter, water indication and electrically RE2501 heated element (SE2302/HE2301)



Preheating relay



HE2501



Element, preheating - induction air



RE3301



Start motor relay, 1st



MA2301



Unit injector 1



RE3302



Start motor relay, 2st



MA2302



Unit injector 2



SE2701



Speed sensor, engine, 1st (crankshaft)



MA2303



Unit injector 3



SE2703



Speed sensor, camshaft (engine)



MA2304



Unit injector 4



SE2514



Speed sensor, turbo



MA2305



Unit injector 5



SW2301



Fuel heater switch



MA2306



Unit injector 6



SW2701



Engine speed control switch



PWM2503



EGR



SW2713



Engine limp home switch



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH04



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH04 Warning and sensor



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH04



Marking



Designation



Marking



Designation



FX1005



Fuel filter, water indication and electrically SE2515 heated element (SE2302/HE2301)



Pressure sensor, EGR differential pressure



FX1006



Engine oil sensor, level and temperature SE2516 (SE2205/SE2202)



Temperature sensor, EGR



FX1007



Engine sensor, charge air, temperature and SE2603 pressure sensor (SE2507/SE2508)



Level monitor, coolant



FX1008



Air filter, position monitor and temperature SE2606 sensor (SE2501/SE2502)



Temperature sensor, engine coolant



IM3812



Hour meter



SE9105



Temperature sensor, hydraulic oil tank



SE2203



Pressure sensor, engine oil



SE9141



Inductive sensor, ISO type control lever



SE2301



Pressure sensor, fuel



SE9142



Inductive sensor, Backhoe type control lever



SE2303/ SE2304



Fuel level/auto stop sensor



SE9401



Pressure monitor, overload



SE2509



Pressure sensor, crank house



FU11



Fuse (I-ECU, SE9141, SE9142)



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH05



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH05 Warning and sensor



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH04



Marking



Designation



Marking



Designation



ASU



After treatment support unit



SE2519



Pressure sensor, DPF



FU36



Fuse, 10A, ACM



SW2506



DPF switch



MA2506



Air pump clutch



MO2501



VGT turbo



SE2521



Filter inlet temperature sensor



FX1032



Master-solenoid, Automization-solenoid, Fuel injector (PWM2504, PWM2505, MA2514)



SE2522



Filter outlet temperature sensor



MO2504



Fuel pump



IG2501



Ignitor



MA2507



Fuel shut-off valve



SE2510



Exhaust temperature sensor



SE2527



Nozzle pressure



SE2529



Flame temperature sensor



SE2528



Fuel pressure



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH07



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH07 Work lights



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH07



Marking



Designation



Marking



Designation



LA3512



Working light, front left, 1st



LA3533



Working light, left, 3rd



LA3513



Working light, front right, 1st



LA3534



Working light, right, 3rd



LA3514



Working light, rear right, 1st



LA3535



Working light, left 4th



LA3515



Working light, counterweight



LA3536



Working light, right, 4th



LA3521



Working light, front left CAB, 1st



SW3504



Working light, front



LA3522



Working light, front right CAB, 1st



SW3505



Working light, rear



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH08



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH08 Machine control



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH08



Marking



Designation



Marking



Designation



MA4212



Travel solenoid



SE9111



Attachment pressure monitor (auto idle)



MA9123



Boom conflux solenoid



SW4202



Travel speed switch



MA9124



Arm in conflux solenoid



SW9103



Pump manual switch



MA9125



Power boost solenoid



SW9110



Power max mode switch



PWM9141



Pump power shift 1



SW9118



Control lockout lever



SE4216



Travel pressure monitor



FU18



Fuse, 10A, V-ECU



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH10



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH10 Electronic climate controller



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH10



Marking



Designation



Marking



Designation



MA8701



Air conditioning compressor solenoid



MO8707



Air conditioner



MO8701



Cab fan motor



SE8701



Pressure monitor, refrigerant



MO8703



Air conditioner, intake actuator



SE8702



Temperature refrigerant



MO8704



Air conditioner, face actuator



SE8705



Temperature monitor, ambient



MO8705



Air conditioner, foot right-hand actuator



SE8706



Temperature monitor, cab



MO8706



Air conditioner, foot left-hand actuator



Figure 2 Component position



air



monitor,



air



conditioning conditioning



Service Information Document Title: Wiring diagram SCH11



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH11 Diesel coolant heater



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH11



Marking



Designation



Marking



Designation



RE8701



Air conditioning unit relay, 1st



MO8708



Water pump (option)



CU8702



Time control unit, diesel heater (option)



MO8709



Fuel pump, diesel heater (option)



HE8701



Diesel heater, cab (option)



FU20



Fuse, 15A, CU8702, HE8701



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH12



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH12 Audio, horn and alarm



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH12



Marking



Designation



Marking



Designation



ANT3901



Antenna



SA3603



Horn, 2nd



CR3901



Audio



SA4206



Travel alarm



PO3902



Power outlet, 14 VDC



SO3902



Voltage converter, 20A



RE3611



Horn relay



SW3902



Audio remote control



RE4206



Travel alarm relay



SWJS4BL



Control lever left-hand 4 button switch (SW3609, SW6405, SW6406) 



SA3602



Horn, 1st



SWJSPBL



SW3609, horn switch



Control lever left-hand proportional and switch (SW3609, SW9161, SW9165) 



SW3609, horn switch



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH13



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH13 Wiper and washer



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH13



Marking



Designation



Marking



Designation



CU3601



Wiper controller



SW3603



Windscreen wiper, lower (option)



MO3601



Windscreen washer motor



SW3608



Windscreen washer, upper



MO3602



Windscreen wiper motor



SW3613



Windscreen washer, lower (option)



MO3603



Windscreen wiper motor, lower



SE3602



Limit switch, upper wiper



MO3604



Windscreen washer motor, lower



SE3603



Limit switch, lower wiper



SW3602



Windscreen wiper, upper



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH14



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH14 Seat heater, beacon light, and room light



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH14



Marking



Designation



Marking



Designation



HE3801



Cigarette lighter, 28VDC



SE8301



Position monitor, left door



LA3501



Interior light



SW3503



Interior light switch



LA3601



Rotating warning beacon, 1st



SW3607



Rotating warning beacon switch, 1st



MO8501/ HE8501



Air suspension motor / seat heater



FU19



Fuse, 10A, SW3607



FU27



Fuse, 15A, MO8501/HE8501



FU28



Fuse, 10A, SW3503



FU16



Fuse, 10A, HE3801



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH15



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH15 X1 control



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH15



Marking



Designation



Marking



Designation



MA9116



1/2 pump select solenoid



PWM9124



X1 proportional valve 2



MA9117



Hammer select solenoid



PWM9129



Left-hand X1 flow preset proportional valve



MA9118



Shear select solenoid



PWM9130



Right-hand X1 flow preset proportional valve



MA9121



X1 left solenoid (hammer)



SE9112



Pressure monitor, hammer or shear (X1)



MA9122



X1 right solenoid



SWJS4BR



Control lever right-hand 4 button switch (SW9108, SW9163, SW9164, SW9158)   



PWM9109



X1 main flow control proportional valve



SWJSPBR



Control lever right-hand proprional and switch (SW9162, SW9108, SW9158)  



PWM9123



X1 proportional valve 1



SW9108, boost switch SW9163, X1 switch, left-hand SW9164, X1 switch, right-hand



SW9108, boost switch SW9162, X1 proportional switch



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH16



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH16 X3 and cooler control



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH16



Marking



Designation



Marking



Designation



MA2602



Engine fan solenoid valve, rotation direction



PWM9145



X3 left proportional valve (option)



MA9110



X3 solenoid valve, rotator left



PWM9146



X3 right proportional valve (option)



MA9111



X3 solenoid valve, rotator right



RE2601



Engine fan direction relay



FU08



Fuse, 15A, RE2601



SWJSPBL



Control lever left-hand proportional and switch (SW3609, SW9161, SW9165) 



PWM9143



Fan motor proportional valve, hydraulic oil



SWJS4BL



Control lever left-hand 4 button switch (SW3609, SW9405, SW9406)  



Figure 2 Component position



SW9161, X3 proportional switch



SW9405, X3 switch, left-hand SW9406, X3 switch, right-hand



Service Information Document Title: Wiring diagram SCH17



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH17 Quick fit and float



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH17



Marking



Designation



Marking



Designation



MA9109



Quick fit solenoid



SW9115



Removal counterweight switch



MA9115



Removal counterweight soelnoid



SW9160



Buzzer stop/confirm switch



MA9120



Boom float solenoid



FU32



Fuse, 10A, SW9104



SE9140



Pressure monitor, float safety



SWJS4BR



Control lever right-hand 4 button switch (SW9108, SW9163, SW9164, SW9158) 



SW9104



Quick fit switch, 1st



SWJSPBR



Control lever right-hand proportional and switch (SW9162, SW9108, SW9158) 



Figure 2 Component position



SW9158, boom float switch



SW9158, boom float switch



Service Information Document Title: Wiring diagram SCH18



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH18 Fuel refueling pump



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram SCH18



Marking



Designation



Marking



Designation



MO2302



Refuelling pump motor



SW2304



Fuel pump switch



SW2302/ SW2303



Fuel filler pump auto stop switch



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH20



Function Group: 370



Profile: EXC, EC480D L [GB]



Wiring diagram SCH20 Auto lubrication system



Information Type: Service Information



Date: 2014/7/14



Figure 1 Wiring diagram20



Marking



Designation



Marking



Designation



CU9901



Central lubrication system control unit



SW9900



Automatic lubrication switch



SE9901



Pressure monitor, lubrication



Figure 2 Component position



automatic



central



Service Information Document Title: Wiring diagram SCH22



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Wiring diagram SCH22 Rear view camera



Figure 1 Wiring diagram SCH22 Marking



Designation



Marking



Designation



RC3903



Rear view camera (option)



IECU



Instrument control unit



Figure 2 Component position



Service Information Document Title: Wiring diagram SCH24



Function Group: 370



Information Type: Service Information



Date: 2014/7/14



Profile: EXC, EC480D L [GB]



Wiring diagram SCH24 CareTrack system



Figure 1 Wiring diagram SCH24 Marking



Designation



Marking



Designation



WECU



Wireless control unit (option)



PC3601



Socket for VCADS Pro



PO3904



Socket for communication



—



—



Figure 2 Component position



Service Information Document Title: Engine wire replacing



Function Group: harness, 371



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Engine wire harness, replacing Op nbr 371-090



Removal 1. Park the machine in the service position A, see 091 Service positions. 2. Turn OFF the battery disconnect switch and remove the start key before starting to work. 3. Remove the engine rear hood and open the engine hood.



Figure 1



1.



Engine rear hood



4. Remove the under cover below the engine. 5. Remove the 2 nuts fixing the cables from the start motor. Remove the mounting clamp.



Figure 2



1. 2.



Mounting clamp Nuts



6. Disconnect the connector of engine camshaft sensor and remove the cable tie.



Figure 3



1. 2.



Cable tie Engine camshaft sensor, SE2703



7. Open the side door of main pump compartment. Remove the rubber cover.



Figure 4



1.



Rubber cover



8. Disconnect the connectors of EGR solenoid valve and the engine crankshaft speed sensor. Remove the mounting clamps.



Figure 5



1. 2. 3.



Mounting clamps Engine crankshaft speed sensor, SE2701 EGR solenoid valve, PWM2503



9. Remove the 2 screws from the mounting clamps, and the a cable tie.



Figure 6



1. 2.



Screws Cable tie



10. Disconnect the connector of charged air temperature / boost air pressure sensor. Remove the 2 cable ties.



Figure 7



1. 2.



Charged air temperature, SE2507 / boost air pressure sensor, SE2508 Cable ties



11. Remove the screws and loosen the screws to the clamps, and then disconnect the hose to the oil trap.



Figure 8



1. 2.



Screws Clamps



12. Disconnect the interface connector and remove the cable ties.



Figure 9



1. 2.



Cable ties Interface connector



13. Remove the cover of junction box with screwdriver.



Figure 10



1.



Cover of junction box



14. Remove the two screws and take out junction box from engine.



Figure 11



1.



Screws



15. Remove the screws to the clamps and disconnect the connector to the E-ECU and sensors.



Figure 12



1. 2.



Screws E-ECU EA, EB connector



3. 4. 5.



Oil pressure sensor, SE2203 Crankcase pressure sensor, SE2509 Oil level/temperature sensor, FX1006 (SE2205/SE2509)



16. Remove the screws to the clamp and disconnect the connector of the alternator, compressor and air pump clutch.



Figure 13



1. 2. 3. 4.



Screws Alternator, AL3201 Air compressor, MA8701 Air pump clutch, MA2506



17. Remove the two screws from the engine preheating.



Figure 14



1.



Screws



18. Remove the screw and pull out the wire harness of the unit injectors. Remove the cable ties.



Figure 15



1. 2.



Cable ties Screw



19. Disconnect the connector of the engine coolant temperature, EGR temperature and EGR differential pressure sensor. Remove the mounting clamp.



Figure 16



1. 2. 3. 4.



Engine coolant temperature sensor, SE2606 EGR temperature sensor, SE2516 EGR differential pressure sensor, SE2515 Clamp



20. Disconnect the connector of the turbo speed sensor, VGT position sensor. Remove the cable tie.



Figure 17



1. 2. 3.



Turbo speed sensor, SE2514 VGT position sensor and CAN based control, MO2501 Cable tie



21. Remove the valve cover.



Figure 18



1.



Valve cover



22. Disconnect the connector of the unit injectors.



Figure 19



1.



Unit injector, MA2306



2. 3. 4. 5. 6.



Unit injector, MA2305 Unit injector, MA2304 Unit injector, MA2303 Unit injector, MA2302 Unit injector, MA2301



Installing 23. Reinstall the new wire harness. The installing procedure is the reverse order of removal. 24. Turn ON the battery disconnect switch and check the machine operation.



Service Information Document Title: Electrical distribution box



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Electrical distribution box WARNING Before working on the electrical distribution box, the battery must be completely disconnected. It's not sufficient to turn off the battery disconnect switch as some connections in the electrical distribution box are supplied directly from the battery. Relay and fuse, see 370 Component list, Relays and 370 Component list, Fuses.



Figure 1 Electrical distribution box A: Decal B: Circuit board



Service Information Document Title: Function Group: Electrical distribution box, circuit board replacing



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Electrical distribution box, circuit board replacing Op nbr 372-002 1. Park the machine in the service position B, see: 091 Service positions. 2. Turn OFF the battery disconnect switch. 3. Remove the cover from the electrical distribution box.



Figure 1



1.



Cover



4. Remove 2 screws fixing the bracket.



Figure 2



1.



Screw



5. Mark the position of connectors and disconnect them. Remove the cable.



Date: 2014/7/15



Figure 3



1. 2.



Connector Cable



6. Remove 6 screws fixing the circuit board.



Figure 4



1.



Screw



7. Take out the diodes, fuses and relays and install them to a new board.



Figure 5



1. 2. 3.



Diode Fuse Relay



NOTE! Check cable, fuses, diodes and relays for corrosion and dirt on the contacts. If necessary clean them or replace part with new one.



8. Install new board using the fixing screws.



NOTICE Exceeding the tightening torque can cause damage on the component. 9. Reconnect all connectors and cable. 10. Install distribution box cover and turn ON the battery disconnect switch. 11. Check that the machine is working in correct way.



Service Information Document Title: Fuse, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Fuse, description



Figure 1 Fuse unit



NOTICE Always install a fuse of the same type with the correct amperage rating to prevent electrical system damage from overload. Fuse (blade-type) color codes Amperage rating



Color



Amperage rating



Color



3A



Violet



15 A



Light blue



4A



Pink



20 A



Yellow



5A



Tan



25 A



Natural (White)



7.5 A



Brown



30 A



Light green



10 A



Red



Fuse, continuity test Fuse failure is often caused by a fine crack in the fuse, and this kind of crack is very hard to detect by visual inspection. Checking fuse continuity with a tester is far superior to eye inspection.



Service Information Document Title: Relay, description



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Relay, description Main relay  



RE3101, Main relay 1 RE3102, Main relay 1



Mini relay      



RE3301, Sstarter motor, 1st RE3302, Starter motor, 2nd RE8701, Air conditioning unit, 1st RE3611, Horn RE4206, Travel alarm RE2601, Engine fan direction



Troubleshooting Concerning the relay troubleshooting information, see 370 Component list, Relays.



Date: 2014/7/15



Service Information Document Title: Function Group: Instruments and controls, 380 overview Profile: EXC, EC480D L [GB]



Instruments and controls, overview Cab interior



Figure 1 Cab, instruments and controls 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.



Instrument control unit I-ECU Right instrument panel Rear instrument panel Left instrument panel Control lever left-hand Optional pedal (straight travel) Travel pedals Travel levers Optional pedal (X1) Control lever right-hand



Information Type: Service Information



Date: 2014/7/15



Service Information Document Title: Function Group: Instruments and controls, 380 front instrument panel



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Instruments and controls, front instrument panel



Figure 1 Main instrument (I-ECU) and keypad Item



Description



Item



Description



1



Central warning lamp



5



Arrow up button



2



Gauge screen



6



Arrow down button



3



Main screen



7



ESC button



4



Indicator screen



8



Selection button



3–A



Engine speed screen



3–B



Mode screen



3–C



Time and HVAC screen



Date: 2014/7/15



Service Information Document Title: Function Group: Instruments and controls, 380 left instrument panel



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Instruments and controls, left instrument panel



Figure 1 Left instrument panel Item



Marking



Description



1



SW3902



Audio remote control switch



2



SW9104



Quick fit switch



3



SW9160



Buzzer stop and confirm switch



4



SW3503



Interior light



5



SW2704



Emergency engine stop switch



6



SW9103



Pump manual switch



7



SW9118



Control lockout lever



8



SWJS4BL



Control lever left-hand 4 button switch



SWJSPBL



Control lever left-hand proportional and switch



Date: 2014/7/15



Service Information Document Title: Function Group: Instruments and controls, 380 right instrument panel



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Instruments and controls, right instrument panel



Figure 1 Right instrument panel Item



Marking



Description



1



SW3602



Windscreen wiper, upper



2



SW9110



Power maximum mode switch



3



SW3603



Windscreen wiper switch, lower (optional)



4



SW3608



Windscreen washer switch, upper



SW3613



Windscreen washer switch, lower (optional)



5



SW2701



Engine speed control switch



6



SW2703



Keypad



7



SW3301



Ignition switch



8



SW2506



DPF switch



9



PO3902



Power outlet, 14VDC



10



HE3801



Cigarette lighter, 28VDC



Date: 2014/7/15



11



SW2301



Fuel heater switch



12



SW3607



Rotating warning beacon switch



13



SW9900



Automatic lubrication switch



14



SW3505



Working light switch, rear



15



SW3504



Working light switch, front



16



SW4202



Travel speed switch



17



SWJS4BR



Control lever right-hand 4 button switch



SWJSPBR



Control lever left-hand proportional and switch



Service Information Document Title: Function Group: Instruments and controls, 380 rear instrument panel



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Instruments and controls, rear instrument panel



Figure 1 Rear instrument panel Item



Marking



Description



1



CR3901



Radio and Cassette / CD player (optional)



2



HE8701



Cab auxiliary heater (optional)



3



PC3601



Service socket for VCADS Pro and MATRIS



Date: 2014/7/15



Service Information Document Title: Hour meter, replacing



Function Group: 383



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Hour meter, replacing Op nbr 383-001 1. Place the machine position A according 091 Service positions. 2. Disconnect the battery disconnect switch. 3. Remove the blower from the duct.



Figure 1



1.



Blower



4. Disconnect 2 screws fixing the hour meter.



Figure 2



1.



Screw



5. Disconnect the hour meter connector.



Date: 2014/7/15



Figure 3



1.



Connector



6. Replace the hour meter with a new one. 7. Reinstall the connector and screws. 8. Reinstall the blower and turn ON the battery disconnect switch. 9. Check the hour meter operation.



Service Information Document Title: Control lockout switch, description



Function Group: lever 386



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Control lockout lever switch, description When the control lockout lever is in the up position, the hydraulic system, swing and travel unit will work. When the control lockout lever is in the down position, the servo pressure is cut off to functions, which are operated with control levers and pedals.



Figure 1 Control lockout lever switch 1. 2. 3. 4. 5. 6. 7. 8. 9.



Wire harness assembly Control lockout lever Cover Limit switch assembly Screw Washer Screw Washer Washer



Figure 2 Limit switch N.O = Normally open N.C = Normally closed



COM = Common NOTE! Switch mounting torque (M3 X 16 mm): 0.3 kg m (0.2 lbf ft)



Service Information Document Title: Function Group: Fuel level sender, replacing 386



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Fuel level sender, replacing Op nbr 386-011 1. Place the machine position A according 091 Service positions. 2. Remove cable ties fixing the fuel level sender cable. 3. Remove the slip protection. 4. Remove the screws fixing fuel sender cover on the fuel tank.



Figure 1



1. 2. 3.



Cable tie Slip protection Screw



5. Disconnect the connector.



Figure 2



Date: 2014/7/15



1.



Connector



6. Remove the screws fixing the fuel sender and replace the sender with a new one.



Figure 3



1. 2. 3.



Screw Fuel sender assembly Wire harness



7. Connect the wire harness connector. 8. Reinstall the fuel sender cover and slip protector. 9. Tie the fuel sender cable.



Service Information Document Title: Function Group: Engine temperature sensor, 386 replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Engine temperature sensor, replacing Op nbr 386-006 1. Park the machine in the service position A, 091 Service positions. 2. Open the engine hood. 3. Disconnect wire harness connector (SE2606).



Figure 1



1.



Connector (SE2606)



4. Remove the engine coolant temperature sensor from engine body and replace it with a new one. 5. Close the engine hood. 6. Check the sensor operation.



Service Information Document Title: Function Group: Engine oil pressure sensor, 386 replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Engine oil pressure sensor, replacing Op nbr 386-007 1. Park the machine in the service position A, see 091 Service positions. 2. Remove the screws fixing the rear engine hood.



Figure 1



1.



Screw



3. Disconnect wire harness connector (SE2203).



Figure 2



1.



Connector



4. Remove the engine oil pressure sensor from engine body and replace it with a new one. 5. Reinstall the rear engine hood.



6. Check the sensor operation.



Service Information Document Title: Engine rotation sensor, replacing



Function Group: speed 386



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Engine rotation speed sensor, replacing Op nbr 386-038 1. Place the machine position A according 091 Service positions. 2. Open the door of pump compartment. 3. Remove the rubber cover.



Figure 1



1.



Rubber cover



4. Disconnect wire harness connector (SE2701).



Figure 2



1.



Connector (SE2701)



Date: 2014/7/15



5. Remove the engine rotation speed sensor (flywheel) from engine body and replace it with a new one. 6. Reinstall the rubber cover and close the right side door. 7. Check the sensor operation.



Service Information Document Title: Function Group: Engine rotation speed 386 sensor (camshaft), replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Engine rotation speed sensor (camshaft), replacing Op nbr 386-088 1. Park the machine in the service position A, see091 Service positions. 2. Open the engine hood. 3. Disconnect wire harness connector (SE2703).



Figure 1



1.



Connector (SE2703)



4. Remove the engine rotation speed sensor (camshaft) from engine body and replace it with new one. 5. Close the engine hood. 6. Check the sensor operation.



Service Information Document Title: Function Group: Hydraulic oil temperature 386 sensor, replacing



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Hydraulic oil temperature sensor, replacing Op nbr 386-017 1. Park the machine in the service position A, see 091 Service positions. 2. Open the side door of the pump compartment 3. Disconnect the wire harness connector from sensor.



Figure 1



1.



Connector



4. Remove the sensor from the hydraulic oil tank and replace it with a new one. 5. Connect the wire harness connector to the sensor. 6. Close the side door of the pump compartment. 7. Check the sensor operation.



Date: 2014/7/15



Service Information Document Title: Auto idling replacing



Function Group: sensor, 386



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Auto idling sensor, replacing Op nbr 386-044 1. Park the machine in the service position A, see 091 Service positions. 2. Disconnect the wire harness connector (SE9111) from automatic idling sensor.



Figure 1



1.



Connector



3. Replace the sensor with a new one. 4. Start the engine and operate the attachment and stop it to check automatic engine RPM drop.



Service Information Document Title: Menu tree



Function Group: 387



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Menu tree Menu tree on the I-ECU display unit Main menu is divided into seven function groups as follows. 1. 2. 3. 4. 5. 6. 7.



Engine Hydraulics Electrical system Vehicle information Service Setup Vehicle message



Main menu description, see Display unit in the operator’s manual Menu tree (User Mode) Menu tree on the I-ECU display unit Main Engine



Sub 1



Sub 2



Engine Oil pressure Engine oil level



Hydraulics



Reversible fan



OFF Manual Auto 1 Auto 2



Oil temperature Hammer operation hours X1 work tool X3 response mode



Electrical system



Voltage



Vehicle information



Model



Soft Normal Active



Serial number Work timer Average fuel consumption Current fuel consumption Ambient temperature Service



Engine oil/filter Fuel filter / Water separator Hydraulic oil Hydraulic oil filter



Setup



X1 work tool



New Change Delete



X3 operation



Change Delete



Sub 3



Toggle Push Proportional Auto idle time Language



English Korean Chinese German ...



Units



Metric US



Time/Date



Clock format



24h AM/PM



Date format



yy/mm/dd mm/dd/yy dd/mm/yy



Time/Date set Display light Keypad backlight Vehicle message



Message 1 Message 2 ...



Contrast (Day) Contrast (Night)



Service Information Document Title: Service mode



Function Group: 387



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Service mode



Figure 1 A: Service mode indicator There are two levels of access control on I-ECU, “User Mode” and “Service Mode”. For special purpose such as service or diagnosis, “Service Mode” supports special functions and information. Entering Service Mode : “ Service mode” is activated when the SELECT button on keypad is pressed for more than 3 seconds highlighting the “Service” menu.



In “Service Mode”, there are 3 items, Engine system, Hydraulic system and Electrical system, which have sub menus to show the value of various sensor, switches and valves etc. Exit Service Mode : “Service Mode” is deactivated when the SELECT button on keypad is pressed for more than 3 seconds in the Service mode.



Menu tree on Service mode Menu tree on the I-ECU display unit Main Engine



Sub 1



Sub 2



1. Engine RPM



1. Engine RPM 1(8)



2. Engine sensor



2. Engine sensor 2(8)



3. Engine status



3. Engine status 4(8)



4. EGR



4. EGR 5(8)



5. VGT



5. VGT 6(8)



6. DPF



6. DPF 7(8)



2. Engine sensor 3(8)



7. DPF 8(8)



Hydraulics



1. Cooling system



1. Cooling system 1(8)



2. Pressure switch



2. Pressure switch 2(8)



3. Pressure sensor



2. Pressure sensor 4(8)



4. Solenoid



4. Solenoid 5(8) 4. Solenoid 6(8) 4. Solenoid 7(8)



5. Proportional valve



5. Proportional valve 8(8) 5. Proportional valve 8(8)



Electrical system



1. Power supply



1. Power supply 1(12)



2. On/Off input



2. On/Off input 2(12) 2. On/Off input 3(12) 2. On/Off input 4(12) 2. On/Off input 5(12) 2. On/Off input 6(12) 2. On/Off input 7(12) 2. On/Off input 8(12)



3. Analog input



3. Analog input 9(12)



4. PWM input



4. PWM input 10(12)



5. On/Off output



5. On/Off output 11(12)



6. Climate system



6. Climate system 12(12)



Service Information Document Title: Engine system



Function Group: 387



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Engine system Engine system Screen on Service mode Engine system Screen name Engine



Item Engine initial screen



Display



Description



Engine 1. Engine RPM 2. Engine sensor 3. Engine status 4. EGR 5. VGT 6. DPF



1.Engine RPM 1(8)



Engine 1. Engine RPM Engine RPM



xxxx rpm xxxx: Value [rpm]



Requested speed



Request RPM



xxxx rpm xxxx: Value [rpm]



Engine % load



Engine % load



xxx % xxx: Value [%]



2. Engine sensor 2(8)



Engine 2. Engine sensor



2(8)



Engine oil pressure



Oil press



xxxx bar xxxx: Value [bar]



Engine oil temperature



Oil temp



xxx °C xxx: Value [°C]



Engine oil level



Oil level



xxx % xxx: %



Coolant temperature



Coolant temp



xxx °C xxx: Value [°C]



Coolant level



Coolant level



xxx % xxx: %



2. Engine sensor 3(8)



Engine 2. Engine sensor



3(8)



Boost temperature



Boost temp



xxx °C xxx: Value [°C]



Boost pressure



Boost press



xxxx bar xxxx: Value [bar]



Air inlet temperature



Inlet temp



xxx °C xxx: Value [°C]



Air inlet pressure



Inlet press



xxxx bar xxxx: Value [bar]



Barometric pressure



Barometer



xxxx bar xxxx: Value [bar]



4. EGR 5(8)



Engine 4. EGR



5. VGT 6(8)



1(8)



Engine speed



EGR Differential Pressure



EGR diff press



EGR Temperature



EGR temp



Engine



5(8) xxx bar xxxx: Value [bar] xxx °C xxx: Value [°C]



5. VGT Turbo speed



6. DPF 7(8)



6(8)



Turbo speed



xxx rpm xxxx: Value [rpm]



Engine 6. DPF



7(8)



Exhaust gas temperature



Exhaust temp



xxx °C



xxx: Value [°C]



Flame temperature



Flame temp



xxx °C



xxx: Value [°C]



DPF inlet temperature



DPF inlet temp



xxx °C



xxx: Value [°C]



DPF outlet temperature



DPF outlet temp



xxx °C



xxx: Value [°C]



DPF Differential Pressure



DPF diff press



xxxx mbar



xxxx: Value [mbar]



6. DPF 8(8)



Engine 6. DPF



8(8)



Soot level



Soot level



xxx %



xxxx: %



Ash level



Ash level



xxx %



xxx: %



Service Information Document Title: Hydraulic system



Function Group: 387



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic system Engine system Screen on Service mode Engine system Screen name Hydraulics



Item



Display



Hydraulic initial screen



Description



Hydraulics 1. Cooling system 2. Pressure switch 3. Pressure sensor 4. Solenoid 5. Proportional valve



1.Cooling system 1(9)



Hydraulics 1. Cooling sys Hydraulic oil temperature



Oil temp



Cooling fan control valve Cooling fan current



2. Press switch 2(9)



1(8) xxx °C xxx: Value [°C] xxxx mA xxxx: Value [mA]



Hydraulics 2. Pressure switch



2(8)



Attach port pressure switch



Attach port press



x x: '0' / '1'



Travel port pressure switch



Travel port press



x x: '0' / '1'



Hammer switch



port



pressure Hammer port press



Float port pressure switch Overload switch



port



Float port press



pressure Overload press SW



2. Press switch 3(9)



x x: '0' / '1' x x: '0' / '1' x x: '0' / '1'



Hydraulics 2. Pressure switch Swing pressure switch



3. Press switch 4(9)



Swing



3(8) x x: '0' / '1'



Hydraulics 3. Pressure sensor Overload pressure sensor



Overload



5(10) xxx.x bar xxx.x: Value [bar]



4. Solenoid 5(9)



Hydraulics 4. Solenoid



4(8)



Travel motor solenoid



Travel motor



x x: '0' / '1'



Boost solenoid



Boost



x x: '0' / '1'



Float position solenoid



Float position



x x: '0' / '1'



Quickfit solenoid



Quick fit



x x: '0' / '1'



Boom + Arm conflux cutoff Conflux cut-off solenoid 4. Solenoid 6(9)



x x: '0' / '1'



Hydraulics 4. Solenoid X1 2 pumps solenoid



selection X1 2 pump



5(8) x x: '0' / '1'



Hammer selection solenoid



Hammer select



x x: '0' / '1'



Shear selection solenoid



Shear select



x x: '0' / '1'



X1 left–hand solenoid



control X1 LH control



x x: '0' / '1'



X1 right–hand solenoid



control X1 RH control



x x: '0' / '1'



4. Solenoid 7(9)



Hydraulics 4. Solenoid Reversible fan solenoid



Fan reverse



6(8) x x: '0' / '1'



X3 left–hand solenoid



control X3 LH control



x x: '0' / '1'



X3 right–hand solenoid



control X3 RH control



x x: '0' / '1'



5. Proportional valve (PPRV) 8(9)



Hydraulics 5. Proptnl val Power shift PPRV current



7(8)



Power shift



xxxx mA xxx: Value [mA]



X1 Flow control valve current X1 flow ctrl



xxxx mA xxx: Value [mA]



X1 pressure control PPRV 1 X1 press ctrl 1 current



xxxx mA xxx: Value [mA]



X1 pressure control PPRV 2 X1 press ctrl 2 current



xxxx mA xxx: Value [mA]



5. Proportional valve (PPRV) 9(9)



Hydraulics 5. Proprtnl val



8(8)



X1 control LH PPRV current



X1 LH control



xxxx mA xxx: Value [mA]



X1 control LH PPRV current



X1 RH control



xxxx mA xxx: Value [mA]



X3 control LH PPRV current



X3 LH control



xxxx mA xxx: Value [mA]



X3 control LH PPRV current



X3 RH control



xxxx mA xxx: Value [mA]



Service Information Document Title: Electrical system



Function Group: 387



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Electrical system Electrical system Screen on Service mode Electrical system Screen name Electrical system



Item



Display



Electrical initial screen



Description



Electrical system 1. Power supply 2. On/Off input 3. Analog input 4. PWM input 5. On/Off output 6. Climate system



1.Power supply 1(12)



Electrical system 1. Power supply



1(12)



Battery (I-ECU input) voltage I-ECU volt



xx.x V xx.x: Value [V]



Battery voltage



input) V-ECU volt



xx.x V xx.x: Value [V]



Battery (E-ECU input) voltage E-ECU volt



xx.x V xx.x: Value [V]



(V-ECU



Alternator voltage



ALT-L volt



2. On/Off input 2(12)



x x: '0' / '1'



Electrical system 2. On/Off input



2(12)



Start switch (ACC)



Start SW-ACC



x x: '0' / '1'



Start switch (R2)



Start SW-R2



x x: '0' / '1'



Control lockout lever switch



Ctrl lockout lever



x x: '0' / '1'



Automatic idling selection Auto idle sel SW switch



x x: '0' / '1'



Power switch



x x: '0' / '1'



maximum



mode Power max SW



2. On/Off input 3(12)



Electrical system 2. On/Off input



3(12)



Quickfit switch



Quick fit SW



x x: '0' / '1'



Quickfit confirmation switch



Q/F confirm SW



x x: '0' / '1'



Quickfit buzzer stop switch



Q/F buzzer stop SW



x x: '0' / '1'



Keypad switch



Keypad



Travel speed select switch



Travel speed SW



2. On/Off input 4(12)



xx xx: Value x x: '0' / '1'



Electrical system 2. On/Off input



4(12)



X1 selection switch



X1 select SW



x x: '0' / '1'



Boost switch



Boost/Hammer SW



x x: '0' / '1'



Rototilt selection switch



Rototilt sel SW



x x: '0' / '1'



DPF



regeneration



start DPF start SW



x x: '0' / '1'



switch DPF regeneration switch



stop DPF stop SW



2. On/Off input 5(12)



x x: '0' / '1'



Electrical system 2. On/Off input



5(12)



X1 left switch



X1 LH SW



x x: '0' / '1'



X1 right switch



X1 RH SW



x x: '0' / '1'



X3 left switch



X3 LH SW



x x: '0' / '1'



X3 right switch



X3 RH SW



x x: '0' / '1'



2. On/Off input 6(12)



Electrical system 2. On/Off input



6(12)



Pattern change switch 1 (I- Pattern SW1 (I-ECU) ECU)



x x: '0' / '1'



Pattern change switch 2 (I- Pattern SW2 (I-ECU) ECU)



x x: '0' / '1'



Pattern change switch 1 (V- Pattern SW1 (V-ECU) ECU)



x x: '0' / '1'



Pattern change switch 2 (V- Pattern SW2 (V-ECU) ECU)



x x: '0' / '1'



Float position switch



x x: '0' / '1'



2. On/Off input 7(12)



Float position SW Electrical system 2. On/Off input



7(12)



Overload select switch



Overload sel SW



x x: '0' / '1'



Automatic lubrication switch



Auto lub SW



x x: '0' / '1'



2. On/Off input 8(12)



Electrical system 2. On/Off input



8(12)



Illumination switch



Illumination SW



x x: '0' / '1'



Automatic/manual switch



Auto/Manual SW



x x: '0' / '1'



3. Analog input 9(12)



Electrical system 3. Analog input



9(12)



Fuel level sensor



Fuel level



xx.x V xxx: Value [V]



Fuel level sensor



Fuel level



xxx % xxx: Value [%]



4. PWM input 10(12)



Electrical system 4. PWM input Engine speed control (RPM) RPM control SW switch Engine speed control (RPM) RPM ctrl SW switch step



10(12) xxx % xxx: Value [%] step zz z: Value [1...9]



X1 proportional switch



X1 proport SW



xxx % xxx: Value [%]



X3 proportional switch



X3 proport SW



xxx % xxx: Value [%]



5. On/Off output 11(12)



Electrical system On/Off outp



11(12)



V-ECU power cut off relay



V-ECU cut off RE



x x: '0' / '1'



V-ECU status



V-ECU status



x x: '0' / '1'



Start lock relay



Start lock RE



x x: '0' / '1'



Travel alarm relay



Travel Alarm RE



x x: '0' / '1'



Reversible fan relay



Fan reverse RE



x x: '0' / '1'



6. Climate system 12(12)



Electrical system 6. Climate sys



12(12)



Cabin temperature



Cabin temp



xxx °C xxx: Value [°C]



Ambient temperature



Ambient temp



xxx °C xxx: Value [°C]



Evaporator temperature



Evaporator temp



xxx °C xxx: Value [°C]



Compressor ON/OFF



Compressor



Blower motor speed



Blower speed



x x: '0' / '1' xxx % xxx: Value [°C]



Service Information Document Title: Function Group: Control types for X1 and X3 387 operation



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Control types for X1 and X3 operation



Figure 1 Control types for X1 and X3 There are three control types for X1 and X3 operation as follows. – Toggles – Push – Proportional If a machine has a “proportional control option” for X1 or X3, the user can set one of these 3 types. Otherwise the user is only allowed to set one of 2 types that are “Toggle” or “Push”. Control using on/off switch on the control lever



Figure 2 Control lever with on/off switch 1. Toggle type in I-ECU Actuator for X1 or X3 is activated by pressing the on/off switch on the control lever and it will stay active even when the switch is released. The actuator will be deactivated when the same switch is pressed again or the other switch for opposite direction is pressed.



2. Push type in I-ECU Actuator for X1 or X3 is activated while the on/off switch is depressed (ON position). The function will be deactivated when the on/off switch is released.



Control using proportional switch on the control lever



Figure 3 Control lever with proportional switch 1. Toggle and Push-button type in I-ECU These controls with proportional switch are similar as the ones with on/off switch but it has a special point to activate the actuator because the proportional switch also has a proportional value. In toggle type, the actuator will be activated by moving the proportional switch to one direction and it will be deactivated when the switch is moved to same direction again or to opposite direction.



2. Proportional type in I-ECU Actuator for X1 or X3 is activated proportional to the movement of the proportional switch.



Service Information Document Title: Rear view replacing



Function Group: camera, 387



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Rear view camera, replacing Op nbr 387-019 1. Place the machine position A according 091 Service positions. 2. Disconnect the battery disconnect switch. 3. Remove the undercover.



Figure 1



1.



Undercover



4. Disconnect the rear view camera connector.



Figure 2



1.



Connector



5. Remove the secondary lock with tool 11709651 or a small screwdriver.



Date: 2014/7/15



Figure 3



1.



Secondary lock



6. Hold aside the primary lock with tool 11709651 or a small screwdriver and pull out the cable with insulator.



Figure 4



1.



Insulator



7. Remove 2 screws fixing the bracket.



Figure 5



1.



Screw



8. Remove 2 screws fixing the camera cover to the bracket.



Figure 6



1.



Screw



9. Replace the rear view camera with a new one.



Figure 7



1.



Rear view camera



10. Reinstall the camera cover and bracket. 11. Reinstall the rear view camera connector. 12. Connect the rear view camera connector and reinstall the undercover. 13. Turn ON the battery disconnect switch and check the rear view camera operation.



Service Information Document Title: Function Group: Audio remote controller, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Audio remote controller, description



Figure 1 Audio remote controller S1



Volume down



AUD



Audio system



S2



Volume up



1



Switching signal (SW+)



S3



Audio source selection



2



Switching signal (SW-)



S4



Search up



3



Ground



S5



Search down



4



Illumination



S6



Mute



5



N/A



S7



Power on/off



6



Power from audio system



REM



Audio remote controller



Service Information Document Title: Radio, description



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Radio, description



Figure 1



Item



Description



Item



Description



1



Audio mode



7



Tune seek



2



FM / AM



8



Preset 4



3



Preset 1



9



Preset 5



4



Preset 2



10



Preset 6



5



Preset 3



11



LCD



6



Power / Volume



Date: 2014/7/15



Service Information Document Title: Function Group: Radio with CD and MP3 player, description



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Radio with CD and MP3 player, description CD and MP3 player with radio



Figure 1



Item



Description



Item



Description



1



Power / Volume



10



Preset 1 / REW



2



Seek track



11



Preset 2 / FF



3



LCD



12



Preset 3 / SCR



4



CD door



13



Preset 4 / RDM



5



BSM (Best Station Memory)



14



Preset 5 / RPT



6



Search adjuster / Audio mode



15



Preset 6 / MARK



7



CD indicator



16



Eject



8



FM / AM



17



Auxiliary jack



9



CD / AUX



Connection



Date: 2014/7/15



Figure 2



Pin connections Item



Description



Item



Description



1



Power (12 V)



9



Tail (+)



2



Ground, tail



10



Not available



3



Not available



11



Right speaker (+)



4



Right speaker (-)



12



Power signal from remote controller



5



Left speaker (-)



13



Ground, remote controller



6



Not available



14



Left speaker (+)



7



Antenna



15



Not available



8



Back up (+)



16



Ground



Service Information Document Title: Radio, replacing



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Radio, replacing Op nbr 393-021 1. Park the machine in the service position A, see 091 Service positions. 2. Turn OFF the battery disconnect switch. 3. Move the operator's seat to the front position, and fold the backrest forward. 4. Remove plastic casing over the cab fan.



Figure 1



1.



Plastic casing



5. Remove the radio front cover.



Figure 2



1.



Radio front cover



6. Remove two screws fixing the radio casing. Take out radio casing.



Date: 2014/7/15



Figure 3



1. 2.



Screws Radio casing



7. Disconnect the connector of auxiliary heater (option).



Figure 4



1.



Connector



8. Remove screws fixing the radio support.



Figure 5



1. 2. 3.



Screw Connector Antenna cable



Figure 6



9. Disconnect wire harness connector and antenna cable from cassette. 10. Remove the radio from the radio support.



Figure 7



11. Install the new radio to the radio support. Then connect the wire harness connector and antenna cable to new radio. 12. Install the screw fixing the radio support. 13. Install the casing and front cover. 14. Fit the plastic casing over the cab fan. 15. Return the operator's seat to the original position. 16. Turn ON the battery disconnect switch. 17. Check the radio operation.



Service Information Document Title: DC–DC description



Function Group: converter,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



DC–DC converter, description 



The converter lowers battery voltage of 24V to supply the working voltage for cassette.



Figure 1 DC-DC converter Inspection method 



Put the tester in the voltage measuring position, and measure the voltage across the output and ground terminals.



Service Information Document Title: Voltage replacing



Function Group: converter,



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Voltage converter, replacing Op nbr 393-001 1. Park the machine in the service position A, see 091 Service positions. 2. Turn OFF the battery disconnect switch. 3. Move the operator's seat to the front position, and fold the backrest forward. 4. Remove plastic casing over the cab fan.



Figure 1



1.



Plastic casing



5. Remove two screws fixing the radio cover.



Figure 2



1.



Screw



Date: 2014/7/15



6. Disconnect wire harness connector and antenna cable from radio.



Figure 3



1. 2.



Connector Antenna cable



Take out radio cover. 7. Disconnect the connector of auxiliary heater (option).



Figure 4



8. Disconnect the connectors of voltage converter and wiper motor controller.



Figure 5



1. 2.



Connector Connector



9. Remove the screw fixing the voltage converter support.



Figure 6



1.



Screw



10. Remove the screws fixing the voltage converter.



Figure 7



1.



Voltage converter



11. Reinstall a new voltage converter. The installing procedure is the reverse order of removal. 12. Check the voltage converter operation.



Service Information Document Title: Antenna, replacing



Function Group: 395



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Antenna, replacing Op nbr 395-021 1. Park the machine in the service position A, see 091 Service positions. 2. Remove the cab rear bracket.



Figure 1 1. Bracket 2. Cab cover 3. Remove the door cushion. 4. Remove the cab cover and put it on the cab. 5. Disconnect the wire harness and antenna cable connector from cab wire harness and antenna cable. 6. Remove the antenna from cab body.



Figure 2



1. 2.



Antenna Screw



7. Install a new antenna. 8. Reconnect the wire harness and antenna cable connector to the cab wire harness and antenna cable. 9. Reinstall the cab cover and bracket and cushion. 10. Check radio operation.



Service Information Document Title: Speaker, replacing



Function Group: 395



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Speaker, replacing Op nbr 395-031 1. Park the machine in the service position A, see 091 Service positions. 2. Remove the screws fixing speaker. 3. Disconnect the wire harness connector.



Figure 1



1.



Speaker



4. Install a new speaker. 5. Connect the wire harness connector. 6. Reinstall the screws. 7. Check the speaker operation.



Date: 2014/7/15



Service Information Document Title: Function Group: W-ECU, MID142, changing 398 pre-programmed ECU



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



W-ECU, MID142, changing pre-programmed ECU Op nbr 398-002 88890180 Interface 88890027 Cable VCADS Pro VCADS Pro Service Tool



1. Park the machine in the service position A, see091 Service positions. 2. Connect VCADS Pro computer to the machine , and perform the operation '17030-2 Parameter programming'. 3. Use the function 'save all parameter to job card'. 4. Move the operator's seat to the front position, and fold the backrest forward. 5. Remove the screws and covers.



Figure 1



1. 2. 3.



Screw Cover Cover



6. Disconnect all connectors of the W-ECU and remove the screw fixing the W-ECU.



Figure 2



1. 2. 3. 4.



W-ECU connector GPS connector GSM connector Screw



7. Remove the satellite system from the W-ECU if this system is installed.



Figure 3



1.



Satellite system



NOTE! The satellite system is optional equipment.



8. Install the new W-ECU and connect all connectors. 9. Connect the satellite system and attach it to the new W-ECU if this system is installed. NOTE! Remove the rubber plug from W-ECU. 10. Reinstall the plastic casing over the cab fan. 11. Return the operator's seat back to the original position. 12. Connect VCADS Pro computer to the machine, and perform the operation '17030-2 Parameter programming'. Now the customer parameters are changed according to the job card saved at step 2.



13. Check the machine operation. When registering the machine on the CareTrack web site, make sure the machine is outdoors and the ignition key is in the Running position for approximately 30 minutes, to allow the correct transfer of set-up data between the machine and the CareTrack system.



Service Information Document Title: Function Group: W-ECU, MID142, changing 398 non-programmed ECU



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



W-ECU, MID142, changing non-programmed ECU Op nbr 398-003 88890180 Interface 88890027 Cable VCADS Pro VCADS Pro Service Tool



1. Park the machine in a suitable service position, see: 091 Service positions. 2. Download the W-ECU software for the target machine to the VCADS Pro computer. 3. Connect the VCADS Pro computer to the machine and perform the operation 39736–3, MID 142 ECU programming. 4. When in VCADS Pro the MID 142 ECU programming window appears, follow the instructions for replacing W-ECU. 5. Move the operator's seat to the front position, and fold the backrest forward. 6. Remove the screws and covers.



Figure 1



1. 2. 3.



Screw Cover Cover



7. Disconnect all connectors of the W-ECU and remove the screw fixing the W-ECU.



Figure 2



1. 2. 3. 4.



W-ECU connector GPS connector GSM connector Screw



8. Remove the Satellite system from the W-ECU if this system is installed.



Figure 3



1.



Satellite system



NOTE! The satellite system is optional equipment.



9. Install the new W-ECU and connect all connectors. 10. Connect the satellite system and attach it to the new W-ECU if this system is installed. NOTE! Remove the rubber plug from W-ECU. 11. Reinstall the plastic casing over the cab fan. 12. Return the operator's seat back to the original position. 13. After replacing W-ECU, press OK button of VCADS Pro operation '39736-3 MID 142 control unit, programming'. Now VCADS Pro starts the programming of software and parameters to the new W-ECU.



14. Check the machine operation. When registering the machine on the CareTrack web site, make sure the machine is outdoors and the ignition key is in the Running position for approximately 30 minutes, to allow the correct transfer of set-up data between the machine and the CareTrack system.



Service Information Document Title: CareTrack replacing



Function Group: antenna,



Information Type: Service Information



Profile: EXC, EC480D L [GB]



CareTrack antenna, replacing Op nbr 398-001



Satellite antenna, replacing 1. Park the machine in the service position A. See 091 Service positions. 2. Disconnect the cable from the satellite antenna with loosening the nut.



Figure 1



1.



Nut



3. Remove the pole.



Figure 2



1.



Pole



4. Remove the nut fixing the antenna.



Date: 2014/7/15



Figure 3



1.



Nut



5. Replace the antenna with a new one. 6. Connect the cable to the antenna with tightening the nut.



7. Check the antenna operation. When registering the machine on the CareTrack web site, make sure the machine is outdoors and the ignition key is in the Running position for approximately 30 minutes, to allow the correct transfer of set-up data between the machine and the CareTrack system.



GSM/GPS antenna, replacing 8. Take out the cables from the roof and disconnect 2 connectors from the GSM/GPS antenna.



Figure 4



1.



Connector



9. Remove the nut fixing the antenna.



Figure 5



1.



Nut



10. Replace the antenna with a new one. 11. Install the nut fixing the antenna. 12. Connect 2 connectors from the GSM/GPS antenna and put in the cables into the roof. 13. Check the antenna operation. When registering the machine on the CareTrack web site, make sure the machine is outdoors and the ignition key is in the Running position for approximately 30 minutes, to allow the correct transfer of set-up data between the machine and the CareTrack system.



Thank you for your purchase. Have a nice day.



file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/7/15 8:45:02]



Service Information Document Title: Function Group: Power transmission, 400 description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Power transmission, description The excavator's power transmission is a generic name of all components that transmit motive force to perform the various functions of the excavator. The mechanical power from the engine transmitted via the pump coupling is converted to hydraulic power by the main pumps. Hydraulic power from the main pump goes to the travel motors, swing motor and hydraulic cylinders via the main control valve, where it is converted back to mechanical power, that actuates the travel action, swing action and attachments. The reduction gears of the planetary mechanisms convert the high speed rotation of the hydraulic motor into low speed, high torque rotating force, at the track unit / sprocket for travel, and at the swing unit / ring gear for swing. The center passage 360° rotating unit allows high pressure hydraulic flow from the main control valve to the track motors. The unit rotates with the superstructure without twisting hoses therefore oil flow is not obstructed by swing.



Service Information Document Title: Function description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Function description The track unit is operated by hydraulic power from the main pump and servo pump. The engine power transmitted via the pump coupling is converted from mechanical power to hydraulic power. When the engine is running, the travel system is ready to be operated; the remote control valve pedal controls the main control valve travel spool via servo hydraulic power to change track motor rotational direction. Function track unit (Forward)    



The pedal remote control valve is pushed forward. The swash plate angle increases and the main control valve travel spool is moved from left to right by the servo hydraulic circuit. Then the hydraulic motor is operated by main hydraulic power and the motor shaft transmits power through the reduction gears. The reduction gears of the planetary mechanism convert the high speed rotation of the hydraulic motor shaft into low speed high torque rotation at the track unit for forward travel.



Function track unit (Reverse)    



The pedal remote control valve is pushed backward. The swash plate angle increases and the main control valve travel spool is moved from right to left by the servo hydraulic circuit. Then the hydraulic motor is operated by main hydraulic power and the motor shaft transmits power through the reduction gears. The reduction gears of the planetary mechanism convert the high speed rotation of the hydraulic motor shaft into low speed high torque rotation at the track unit for reverse travel.



Gearbox, torque flow



Figure 1 Gearbox, torque flow A



Input (Hydraulic motor output)



B



Torque flow



The input rotation of the hydraulic motor is transmitted to No. 1 sun gear (S1) and this drives No.1 planetary gears (P1). The No. 1 planetary gears (P1) drive No. 1 ring gears (R1) with the same force as the meshing tangential force with No. 1 sun gear (S1), and also No. 1 carrier (C1) with the same force as the meshing reaction force. In other words, No. 1 planetary gears (P1) revolve rotating. This rotation of No. 1 carrier (C1) becomes the output of the 1st stage, and is transmitted directly to No. 2 sun gear (S2). (No. 1 carrier is spline–coupled with No. 2 sun gear.) Similarly the revolution of No.2 planetary gears (P2) are transmitted through No. 2 carrier (C2) to No.3 sun gear (S3). Since No. 3 carrier (C3) supporting No.3 planetary gears (P3) are fixed, No. 3 planetary gears (P3) do not revolve, but rotates to drive No. 3 ring gears (R3). Therefore, the rotating case is driven by the overall driving torque of No. 1, 2 and 3 ring gears. This reduction ratio is expressed as shown below:



where, Z: =Number of teeth of each gear The direction of rotation is reverse to that of the input shaft



Service Information Document Title: Track gearbox, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Track gearbox, description The unit includes planetary gearbox, 3 stages, rotating housing type. An important piece of advice given is “to perfectly” design the main hydraulic system. The illustrations show the parts and the main functions of the gearbox. Track gearbox illustrations show



Figure 1 Track gearbox A



Track gearbox



1



Screws 8 Tightening torque: 190 Nm (141 lbf ft) (19.4 kg m)



B



Track motor 1st Red assembly



15 Bush + Bearing



2



Oil breather plug 9 Tightening torque: 60 ~ 80 Nm (44.4 ~ 59.2 lbf ft) (6.1 ~ 8.2 kg m)



Sun gear



16 Lifetime seal



3



Washers



10 2nd Red assembly



17 Discs retainer



4



Cover assembly



11 Sun gear



18 Hub



5



O-ring



12 Screws, Apply Loctite #277 or equivalent locking fluid Tightening torque: 2000 Nm (1480 lbf ft) (204 kgf m)



6



Pad



13 3nd Red assembly



19 Screws



7



Sun gear



14 Bush



20 O-ring seal



Service Information Document Title: Track gearbox, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Track gearbox, description



Figure 1 Track gearbox 1



Screw Tightening torque: 190 Nm (141 lbf ft) (19.4 kg m)



25



Spiral ring



2



Oil breather plug Tightening torque: 60~80 Nm (14.4~59.2 lbf ft) (6.1~8.2 kg m)



26



Brake piston



3



Washers



14



Bush



27



Spring



4



O-ring



15



Housing + bearing



28



Spring retainer



5



Pad



16



Lifetime seal



29



Circlip



6



Cover assembly



17



Discs retainer



30



O-ring



7



Sun gear



18



Hub



31



Motor adaptor



8



1st red assembly



19



Brake shaft



32



Screws



9



Sun gear



20



Sintered disc



33



O-ring seal



10



2nd red assembly



21



Steel disc



34



Screws



11



Sun gear



22



Backup ring



35



O-ring



12



Screws Tightening torque: 2000 Nm (1480 lbf ft) (204 kg m)



36



Clrclip



13



3nd red assembly



37



O-ring



23



O-ring



24



O-ring



Figure 2 Track gearbox, sectional view



Service Information Document Title: Function Group: Track gearbox, maintenance standard



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track gearbox, maintenance standard Special tools, track gearbox 14609308 Impact puller 14609309 Lifting device 8932-00380 Impact puller 8932-00400 Drive ring The parts are precision finished and must be handled carefully. Keep the parts of the planetary carrier (s) together, do not mix the bearings, gears, pins and thrust washers. Seals Replace the seals and O-ring, although they appear not damaged. Part replacement criteria 1. 2.



Replace all parts that appear damaged or are not within the allowable value. Replace some parts in sets, i.e. gears, bearings, pins and thrust washers.



Tightening torques for gearbox Position



Thread size



Tightening torque: Nm (kgf m) (lbf ft)



Tool (allen wrench)



16



M12 × 35k (grade)=12.9



145.1 (14.8) (107)



10



17



M12 × 65k (grade)=12.9



145.1 (14.8) (107)



10



36



M30 × 2k (grade)=8.8



1500.4 (153) (1105)



22



45



M16 × 35k (grade)=8.8



205.9 (21) (151)



14



47



M20 × 50k (grade)=8.8



402.1 (41) (295)



17



31



M22 × 1.5 (plug)



59.8 (6.1) (44)



10



Installation of the track drive on the machine Fix the gear motor to the machine frame by using nos. M20 Screws tightening torque: 705 Nm (71.9 kgf m) (521.7 lbf ft) Fix the track motor and gearbox assembling screws tightening torque: 290 ±29.4 Nm (29.6 ±3 kgf m) (214.6 ±21.8 lbf ft) NOTE! Apply thread locking before assembling track motor mounting screws. Sprocket fixing to the track drive Fix the sprocket to the gear motor by using nos. M20 Screws tightening torque: 585 Nm (60 kgf m) (433 lbf ft) Lubrication oil The gearbox is lubricated by oil splash in oil bath, the suggested oil type is SAE 80W/90 or SAE 85W/140 with EP features corresponding to : MIL-L-2105C API GL5 During the running the oil must not always exceed the temperature of 90 ~ 95 °C (195 ~ 205 °F) (intermittent) Oil replacement   NOTE!



1st oil changes at 150 hours Following oil changes Every 1000 hours or 1 year



Regardless of the operating hours the oil must be replaced at least once per year. NOTE! Do not mix different types, classifications or brands of oil! NOTE! Drain the oil while it is still warm to flush out any contaminants. Oil replacing procedure



Figure 1 Position, oil replacement 1. 2.



Fill and level port Drain port



   



Rotate the gearbox until the drain plug and the fill plug are on the vertical axis. Remove the 2 plugs in the end cover and drain the oil into a suitable container. Ensure that the O-ring on each plug is not damaged, then install the plugs and torque to specification. Refill the gearbox through the fill port until oil exits from the level check port. Oil capacity: 4311 Track gearbox, specifications. Tightening torque plug (1), (2): 4311 Track gearbox, description.



Operating checks     



Check the oil level prior to operating the track function. Check for oil leakage on the gearbox assembly. Check for loose mounting screws. Check for abnormal sound or vibration while rotating. Check for any abnormal temperature increase after operating for a short time.



WARNING The temperature of the case is high just after running. Use a thermometer to measure. Do not touch directly by hand to prevent a burn injury. NOTE! The temperature of the case must be lower than 85 ~ 90 °C, during continuous operation.



Remove air in the track motor before operating.



1.



Check that the gearbox axis is horizontal. Rotate the gearbox housing until the drain plug is on the bottom of the vertical axis of the end cover.



The gearbox is supplied with oil plugs (draining, filling and level) equipped with an hole that allows the air to bleed. NOTE! Remove the oil plugs with care. When the gearbox is warm, the air inside can be pressurized and this can cause their strongly expulsion towards the worker. 2. 3. 4. 5. 6. 7.



Loose with caution the plugs (2~3 rounds) counterclockwise. Clean the plug to be sure that the air bleed hole is not obstructed. Wait a few seconds to allow the pressurized air to bleed from the gearbox. Remove the plugs and let the oil flow in a large enough container; in order to facilitate the draining must be oil still warm. Wait a few minutes until all the oil is drained and then proceed to screw on the plugs. Proceed with the oil fill-up following the procedures given.



NOTE! Never mix mineral oils with synthetic oils and vice versa.



Do not dispose of the oil in the natural environment but be careful to eliminate it in compliance with the relative rules and regulations that govern locally.



Tightening torque plug. See track gearbox, description.



Track gearbox, troubleshooting Special tools: 11666051 Pressure gauge 14290266 Hose Troubleshooting, track gearbox Trouble



Causes



Remedy



Gearbox does not rotate.



Motor overloaded.



Reduce the load.



Gearbox is damaged.



Replace the gearbox.



Oil leakage from mating joint Liquid gasket improperly applied. surfaces. Mating surface damaged.



Casing leakage. Floating seal leakage. Abnormal operating temperature.



Abnormal operating sound.



Disassembly and re-apply. Repair or replace.



Loosen screws.



Tighten to specified torque.



Loosen plug.



Tighten to specified torque.



Cracks or pin holes.



Replace the housing.



Cover damaged.



Replace the cover.



Sliding surface worn.



Replace the floating seal assembly.



O-ring distorted.



Replace the O-ring.



Insufficient gear oil.



Refill to specified level.



Gear or bearing damaged.



Replace the gearbox.



Hydraulic and gear oil mixed.



Replace the motor oil seal.



Gearbox is damaged.



Replace the gearbox.



Service Information Document Title: Track gearbox, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track gearbox, replacing Op nbr 431-111 14548448 Pump 14560748 Track pin press 14566479 Pin kit



1. Remove the track shoes over the master pin and remove the pin to split the track chain. Insert a bar into the track link to guide the track assembly. Rotate the track backward to remove the track chain from the drive sprocket. See7753 Track chain assembly, removing to remove the master pin and the track chain. 2. Remove the screws.



Figure 1 Removal, screws 1. 2.



Mounting screws Sprocket



3. Hold the sprocket with the hoist and remove the sprocket from the track unit carefully.



Figure 2 Removal, sprocket 1.



Sprocket



2.



Hoist



NOTE! After disconnecting the hose, install a plug to prevent oil leakage and contamination. 4. Remove the screws and track motor cover. See 700 Undercarriage, tightening torque.



Figure 3 Removal, motor cover 1. 2.



Screws Cover



5. Remove the track motor high pressure hoses.



Figure 4 Removal, hoses 1. 2. 3. 4. 5.



Drain hose Track frame Mounting screws 2nd speed hose High pressure hoses



6. Remove the track motor drain hose. 7. Remove the track motor 2nd speed hose. 8. Remove the fittings. 9. Hold the track unit with hoist 700 Undercarriage, tightening torque.



and



remove



the



mounting



10. Remove the track unit with hoist, and move to the workbench safely.



WARNING



screws



from



track



frame.



See



The parts are heavy. Take appropriate safety cautions when handling them.



Figure 5 Removal, track unit 1. 2.



Hose Track unit



11. Remove the screws and hold track motor with hoist. Move the track motor to a new track gearbox.



Figure 6 Removal, track gearbox 1. 2.



Screws Track motor



NOTE! Do not reuse removed seals when reassembling. 12. Install a new track gearbox in reverse order of the removal procedure. 13. Install the track chain over the drive sprocket, insert a bar into the track link to guide the track assembly. Rotate the track forward until the master pin link is at the idler. Install the master pin and the track shoes. See 7753 Track chain assembly, installingto install the master pin and the track chain.



Service Information Document Title: Function Group: Track gearbox, replacing cover



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Track gearbox, replacing cover Op nbr 431-117 14609309 Lifting device



1. Park the machine in the service position B. See 091 Service positions. Rotate the gearbox until the drain plug is at the bottom. 2. Remove the slowly 2 plugs on the cover and drain the oil into a suitable container. NOTE! Prepare container for collecting oil.



Figure 1 Removal, plugs 1. 2.



Level plug Drain plug



3. Remove the screws and cover. NOTE! Be careful falling cover (55 kg, 121 lbs).



WARNING The parts are heavy. Take appropriate safety precautions.



Date: 2014/7/15



Figure 2 Removal, gearbox cover 1. 2.



Gearbox cover mounting screws Gearbox cover



4. Install the new gearbox cover to the track gearbox. See tightening torque screws: 4311 Track gearbox, description. NOTE! Thoroughly clean the mounting surface.



Do not reuse removed seal when reassembling.



Figure 3 Applying, sealing compound 1. 2.



Gearbox cover Seal



5. Install the drain port. Fill the oil through the filling (level) port. See oil capacity 4311 Track gearbox, specifications.



Figure 4 Filling, oil



1. 2.



Level plug Drain plug



6. Install the filling (level) port. See 4311 Track gearbox, description. NOTE! Do not reuse removed seal when reassembling.



Service Information Document Title: Function Group: Track gearbox, disassembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track gearbox, disassembly Preparation before disassembly Refer to the Track gearbox description for gearbox disassembly illustrations show. See 4311 Track gearbox, description. Disassembly Op nbr 00000 14609308 Impact puller 14609309 Lifting device 8932-00380 Impact puller



NOTE! The components can be very heavy and large dimensions: pay attention during the handling. 1. Turn the gearbox upside down, unscrew and remove the 2 plugs M22 x 1,5 (2) and the 2 washers from the end cover.



Figure 1 Removal, cover (3) 2. Unscrew and remove the 21 socket head screws M14 x 40 (1), grade 12.9, from the cover.



Figure 2 Removal, cover (4) 3. Install the equipment (Raising hook Special Tool: A. See 4311 Track gearbox, maintenance standard.) on the end cover and by using a tackle, remove the end cover.



Figure 3 Removal, cover (4) 4. Remove the O-ring seal from its seat in the end cover.



Figure 4 Removal, O-ring (5) 5. Screw a socket head screw M5 x 20 in the threaded hole of the pad (6) in order to remove it from the end cover.



Figure 5 Removal, cover (4) 6. Remove the 1st stage sun gear).



Figure 6 Removal, gear (7) 7. Remove the 1st reduction assembly.



Figure 7 Removal, 1st reduction assembly (8) 8. Remove the 2nd stage sun gear.



Figure 8 Removal, 2nd stage sun gear (9) 9. Remove the 2nd reduction assembly.



Figure 9 Removal, 2nd reduction assembly (10) 10. Remove the 3rd stage sun gear. NOTE! In order to proceed with the gearbox disassembly, it is now necessary to remove it from the machine and bring it to a properly equipped workshop.



Figure 10



Removal, 3rd stage sun gear (11) 11. Unscrew the hexagon head screws M30 x 2 x 150 (12), grade 12.9, which fix the 3rd reduction assembly to the flanged hub. NOTE! When using SQ tool of socket size 1/2" or 3/4", it can be broken.



Impact socket 1" SQ should be used for a service tool (socket).



When the impact socket is not fit with screw head, modify and use it.



Figure 11 Reduction assembly (13)



Figure 12 Service tool 12. Place the gearbox on 2 spacers. By using a press and a metal stopper, remove the flanged hub from the gearbox housing, paying attention to the eventual falling down of the main bearing's balls.



Figure 13 Removal, flanged hub (18) 15: Gearbox housing



13. By using a puller remove the 3rd reduction assembly from the flanged hub.



Figure 14 Removal, reduction assembly (13) 14. By using the equipment (Puller Special Tool: B. See 4311 Track gearbox, maintenance standard.), remove the bushes from the flanged hub.



Figure 15 Removal, bushes (14) 15. By using a puller remove the inner ring of the bearing and the spacer remaining on the flanged hub.



Figure 16 Removal, inner ring 16. By using the equipment (puller special tool: C. See 4311 Track gearbox, maintenance standard.) remove the 4 planet assemblies of the 3rd reduction.



Figure 17



Removal, planet assemblies 17. View of the loose planet assembly of the 3rd reduction.



Figure 18 3rd reduction (13) NOTE! In case of oil leakages, it might be necessary to check and eventually replace the lifetime seal , which means both the metal rings parts and the O-ring seals. 18. Remove screws the half-seals from the flanged hub and from the gearbox housing.



Figure 19 Removal, screw 15: Gearbox housing 16: Half-seals NOTE! The gearbox disassembly ends with the above operation. All items are now available for the necessary inspections. The pieces that are subject to general wear and tear are the following:   



Gears. Bearings. All the seals



Replace the used or irregular parts respecting the following steps: 1. 2. 3. 4.



Accurately remove dirt, and in particular properly clean the seals, bearings and locking rings seating. Lubricate the parts before connecting them. In the case of damaged gears, for example a planetary, do not proceed to replace the individual gear but the entire reduction assembly. When reconnecting a part always replace all the seals involved. Add some grease on the seats and on the new seals to make easier the reassembly.



Evaluating that pieces to replace



Service Information Document Title: Track gearbox, assembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track gearbox, assembly Op nbr 00000 14609309 Lifting device 8932-00400 Drive ring



1. Fit the lower ball row, into the gearbox housing holding the inner raceway with spacers.



Figure 1



A



Spacers



D



Lower ball row



B



Spacers



15



Gearbox housing



C



Inner raceway



2. Remove the spacer. Insert the spacer. Drop the upper ball row. Assemble the inner raceway.



Figure 2



B



Spacers



F



Upper ball row



E



Spacers



G



Inner raceway







Carefully clean the seats using, if necessary, metallic brushes or solvent (surfaces in contact with or must be perfectly clean and dry).



Figure 3











A



Seats



C



Upper ball row



B



Seats



D



Surfaces



C



Contact



E



Metal rings



Make sure that sealing surfaces of metal rings are free from scratches or foreign substances; metallic ring surfaces must be perfectly clean and dry. We suggest to dip the metallic rings in volatile solvent or industrial decreasing alcohol. Carefully clean the lapped surface of metal rings and remove dust or fingerprints. Then lubrificate them with a thin oil film, taking care not to oil the other components.



Make ready of the lifetime seal: 3. Assemble the half seal on the tool. (tool for lifetime seal. See 4311 Track gearbox, maintenance standard.).



Figure 4 Assembly, seal 16



Half seal



D



Lifetime seal



4. Assemble the 1st half seal on the gearbox housing.



Figure 5 Assembly, seal 15



Gearbox housing



16



Half seal



5. Assemble, by using the same tool (tool for lifetime seal, see 4311 Track gearbox, tools), the 2nd half seal on the flanged hub.



Figure 6 Assembly, seal D



Lifetime seal



18



Flanged hub



16



Half seal



NOTE! Correct lifetime seal assembly check.



Figure 7 Seal (16) 6. Clean carefully the seal faces. NOTE! Apply a thin oil film on the entire metallic face of one or both seals. Oil must not contact surfaces other than the sealing faces.



Figure 8 Seal faces (16) 7. By using a tackle place the flanged hub inside the gearbox housing. By using a press and a metallic stopper, push the flanged hub against the shoulder on the gearbox housing until assembling of the unit is complete.



Figure 9



15



Gearbox housing



18



Flanged hub



8. Place the 4 bushes into their seats on the flanged hub. By using a press, push the bushes against the shoulder inside their seats into the flanged hub until assembling is complete.



Figure 10



14



Bushes



18



Flanged hub



9. Place the 4 planet assemblies of the 3rd reduction into their seats on the flanged hub, and with a press, push them against the shoulder until assembly is complete.



Figure 11



13



Reduction



18



Flanged hub



10. Place the 3rd reduction planet carrier on the flanged hub.



Figure 12



13



Reduction



18



Flanged hub



11. By using a press and a metal stopper, push the 3rd reduction planet carrier against the shoulder on the flanged hub until assembling is complete.



Figure 13



13



Reduction



18



Flanged hub



12. Apply loctite type 243 on the hexagon head screws M30 x 2 x 150 (12), grade 12.9, and insert them in the thread holes.



Figure 14



13. Tighten the hexagon head screws M30 x 2 x 150 (12), grade 12.9, by a torque wrench, at 2000 Nm (204 kg m) (1480 lbf ft) torque. NOTE! Block the gearbox by a press to avoid its rotation during the tightening screws.



When using SQ tool of socket size 1/2" or 3/4", it can be broken.



Impact socket 1" SQ should be used for a service tool (socket).



When the impact socket is not fit with screw head, modify and use it.



Figure 15 Installation, screw



Figure 16 Service tool 14. Insert the 3rd stage sun gear.



Figure 17 Sun gear (11) 15. Assemble the 2nd reduction assembly.



Figure 18 2nd reduction assembly (10) 16. Insert the 2nd stage sun gear.



Figure 19 Sun gears (9) 17. Assemble the 1st reduction assembly.



Figure 20 1st reduction assembly (8) 18. Insert the 1st stage sun gear.



Figure 21 1st stage sun gear (7) 19. Assemble the O-ring seal into its seat in the end cover.



Figure 22 O-ring seal (5) end cover (4) 20. Place the pad on the end cover and by using a press, push it against the shoulder until assembling is complete.



Figure 23 Pad (6) end cover (4) 21. Install the equipment (tool for raising hook (A). See 4311 Track gearbox, maintenance standard.) on the end cover and, by using a tackle, place the end cover on the gearbox housing .



Figure 24 Raising hook (A) 22. Tighten the nos. 16 socket head screws M14 x 40 (1), grade 12.9, by a torque wrench at 190 Nm (19.4 kg m) (141 lbf ft) torque.



Figure 25 Socket head screws 23. Insert the washers and the plugs into the oil draing-filling holes of the end cover. Tighten the plugs by a torque wrench at 60 ±80 Nm (6.1 ~ 8.2 kg m) (14.4 ~ 59.2 lbf ft).



Figure 26



NOTE! Before assembling the hydraulic motor, verify by a depth slide gauge the correct assembly of the unit checking the axial distance as shown in the scheme.



Figure 27 Assembly, sun gear



Final test and reinstallation 24. Check the product by remounting it to the machine. Check the function of the transmission following all the checks. After having reassembled the gearbox, fit the hydraulic motor. Fill the gear motor with the lubricant oil.



Service Information Document Title: Function description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Function description The swing system consists of swing motor, swing gearbox and swing ring gear. The oil supplied from main pump passes through control valve to rotate swing motor. The turning force of the motor is transmitted through gearbox, pinion and swing ring gear, making the superstructure revolve. Function swing unit (move left)    



The remote control valve lever is moved to the left side. The swash plate angle is increased and the main control valve swing spool moved from left to right by the servo hydraulic circuit. Then the hydraulic motor is operated by main hydraulic power and the motor shaft transmits power through the reduction gears. The swing gearbox pinion meshes with the internal gear of the swing ring inner race and drives it to rotate the superstructure left.



Function swing unit (move right)    



The remote control valve lever is moved to the right side. The swash plate angle is increased and the main control valve swing spool moved from right to left by the servo hydraulic circuit. Then the hydraulic motor is operated by main hydraulic power and the motor shaft transmits power through the reduction gears. The swing gearbox pinion meshes with the internal gear of the swing ring inner race and drives it to rotate the superstructure right.



Swing unit diagram. See 990 Hydraulic diagram, standard, 990 Hydraulic diagram, with option components. Gearbox, torque flow The 2-stage planetary gear reduction assembly converts the high speed / low torque output of the hydraulic motor to low speed/high torque output, which is transmitted via the reduction drive shaft pinion gear to the swing ring inner circumference gear to rotate the superstructure. Operation



Figure 1 Swing gearbox A.



Torque flow



Power supplied to the output shaft of the hydraulic motor is transmitted to the 2nd sun gear through the splines of the 1st sun gear, the 1st planetary gear, the 1st pin and the 1st carrier. In the same way, power is transmitted to output shaft through the splines of the 2nd planetary gear, the 2nd pin and the 2nd carrier. At this time, the reduction ratio of gearbox is as follows : 







1st reduction ratio i1 = (Zr / ZS1) + 1 i1 = 1st reduction ratio ZS1 = No. of gear teeth of the 1st sun gear Zr = No. of tooth of ring gear 2nd reduction ratio i2 = (Zr / ZS2) + 1 i2 = 2nd reduction ratio ZS2 = No. of gear teeth of the 2nd sun gear Accordingly the total reduction ratio of gearbox is as follows : i = i1 × i2 = (Zr / ZS1 + 1) × (Zρ / ZS2 + 1) i = Total reduction ratio



Service Information Document Title: Function Group: Swing gearbox, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing gearbox, description Model code



Figure 1 Model code 1. 2. 3. 4.



Serial No Reduction ratio code Size No. (theoretical output torque) ex. 100 = 1000 kgf m Type No. (ex. S = Slew gearbox)



Slew gearbox consists of the driving shaft as a group including the 1st planetary gear assembly, the 2nd planetary gear assembly and the 1st and 2nd sun gear pinions, the housing supporting the driving shaft, and the ring gear including the planetary gear. Slew gearbox, sectional view



Figure 2 Slew gearbox, sectional view 1



No.2 planetary gear assembly



18 Retaining ring



34 washer



2



No.2 carrier



19 Case



35 Retaining ring



3



No.2 planetary gear



20 Ring gear



36 Spring pin



4



No.2 pin assembly



21 Dowel pin



37 No.1 sun gear



5



No.2 pin



22 Screw



38 Retaining ring



6



Bushing



23 Plate



39 Level gauge



8



washer



24 Screw



40 Pipe



9



Spring pin



25 Thrust ring



41 Name plate



10 Drive shaft



26 No.2 sun gear



42 Screw



11 Collar



27 Thrust washer



43 Plug



12 Cover



28 No.1 planetary gear assembly



44 Pipe



13 O-ring



29 No.1 carrier



45 Pinion gear



14 Seal



30 No.1 planetary gear



46 Screw



15 Screw



31 No.1 pin



47 Lock washer



16 Bearing



32 Bearing



48 Plate



17 Bearing



33 washer



Figure 3 Slew gearbox



Symbol



Thread size and depth



1



69 Nm (141 lbf ft) (7 kg m)



2



57 Nm (141 lbf ft) (5.8 kg m)



3



177 Nm (141 lbf ft) (18 kg m)



4



262 ±26.5 Nm (141 lbf ft) (26.7 ±2.7 kg m)



A, B



1 5/16-12 UN-2B-19



300 Nm (222 lbf ft) (30.6 kg m)



E



Rc3/8-14



44 Nm (32.6 lbf ft) (4.5 kg m)



M



1 5/16-12 UN-2B-19



300 Nm (222 lbf ft) (30.6 kg m)



DB



3/4-16 UNF-2B-14.3



82 Nm (60.7 lbf ft) (8.37 kg m)



GI, L



Rc3/4-19



69.98 Nm (51.79 lbf ft) (7.10 kg m)



GO



–



–



PA, PB



9/16-18 UNF-2B-12.7



48 Nm (35.5 lbf ft) (4.9 kg m)



PG, SH



9/16-18 UNF-2B-12.7



48 Nm (35.5 lbf ft) (4.9 kg m)



Inlet port



Tightening torque



Outlet port



View from V



A



B



Clockwise



B



A



Counter clockwise



Service Information Document Title: Function Group: Swing gearbox, maintenance standard



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing gearbox, maintenance standard NOTE! Prior to operating the slew function, fill the gearbox with the specified oil to the correct level. Precautions for lubrication      



Check the oil level prior to operating the slew function. Check for oil leakage on the motor and gearbox assembly. Check for loose mounting screws. Check for abnormal sound or vibration while rotating. Check for any abnormal temperature increase after operating for a short time. Check the slew performance against the operating specifications.



WARNING The temperature of the case is high just after running. Do not touch directly by hand to prevent a burn injury. Check the temperature with a surface thermometer. The temperature of the case must be lower than the ambient temperature +60 °C, during continuous operation. Gear oil specification 



Use a gear oil equivalent to API classification GL4/GL5, SAE EP 90 or 140.



Gear oil replacement   



First (initial) oil replacement: 500 operating hours Subsequent oil replacement: 1000 operating hours After maintenance (initial): 250 operating hours



NOTE! Regardless of the operating hours the gear oil must be replaced at least once per year. NOTE! Do not mix different types, classifications or brands of oil. Gear oil level 



Figure 1



Take out the level gauge, wipe it on a clean cloth, re-insert, take out, and then check if the oil is within the slanting lines as shown.



Check, oil level A.



Level



* The level gauge also serves as an air breather for the gearbox. Gear oil replacement NOTE! Drain the gear oil while it is still warm to flush out any contaminants.   



Remove the drain valve cap from the drain valve and connect drain hose to drain valve and drain the oil into a suitable container. After completely draining, remove the drain hose, and then close drain valve cap. After removing oil level gauge, refill the gearbox through the oil filling pipe using a funnel that allows the pipe to breathe.



NOTE! Oil capacity: See 4312 Swing gearbox, specifications. Seals The parts are precision finished and must be handled carefully. Keep the parts of the planetary carrier(s) together, do not mix the bushing, gears, pins and thrust washers. Replace the seals and O-rings, although they appear not damaged. Part replacement criteria  



Replace all parts that appear damaged or are not within the allowable value. Replace some parts in sets, i.e. gears, bushings and thrust washers.



Part replacement criteria Item No.



Part name



Condition



37 26 30 3 20



No. 1 sun gear No. 2 sun gear No. 1 planetary gear No. 2 planetary gear Ring gear



Pitting on gear teeth surface.



30 31 32



No. 1 planetary gear No. 1 pin Needle bearing



Flaking on the needle bearing sliding surface. Partial wear



3 4



No. 2 planetary gear No. 2 pin assembly



Wear on bushing.



25



Thrust ring



Wear on the shaft contact surface.



38 35 18



Retaining ring Retaining ring Retaining ring



Abnormal wear on the face area.



8 33 34 27



Thrust washer Thrust washer Thrust washer Thrust washer



Abnormal wear on the face area.



17 16



Spherical bearing Spherical bearing



Pitting/flaking of the race or rollers. Does not rotate smoothly by hand.



14



Oil seal



Always replace.



General tools General tools



Standard value



outer



diameter



Allowable value – Diameter clearance: within φ1 mm (0.039 inch) – Area ratio: within 5%



of Diameter clearance: Diameter clearance: 0.13 ~ 0.254 mm within 0.45 mm (0.018 (0.005 ~ 0.01 in ch) inch) Oil groove depth: within 0.5 mm (0.02 inch)



No.



Description



Size



Quantity



1



Spanner



17 × 19 mm (0.67 × 0.75 inch) 24 × 27 mm (0.95 × 1.1 inch)



1 1



2



Socket wrench



–



1



3



Allen wrench



10 mm (0.39 inch) 14 mm (0.55 inch)



1 1



4



Torque wrench



3923 ~ 17652 Nm (400 ~ 1800 kgf m) (2888 ~ 12996 lbf 1 ft) 1 11768 ~ 47072 Nm (1200 ~ 4801 kgf m) (8664 ~ 34656 lbf ft)



5



Retaining ring pliers



φ35 φ42 φ90



1



6



Bearing puller



–



–



7



Plastic hammer



–



1



8



Eye bolt



M8 M12 M16 M18



2 2 2 2



9



(–) Screwdriver



150 mm (5.9 inch)



1



Slew gearbox, special tools 8920-00280 Drift 8932-00600 Drift 8920-00550 Drift 8920-00570 Drift Track gearbox troubleshooting Track gearbox troubleshooting



Gearbox does not rotate.



Oil leakage from mating joint surfaces.



Leakage from the shaft.



The machine is overloaded.



Reduce the load.



Gearbox is damaged.



Replace the gearbox.



Liquid gasket improperly applied.



Disassemble and re-apply.



Mating surface damaged.



Repair or replace.



Loose screws.



Tighten to specified torque.



Loose plug.



Tighten to specified torque.



Oil seal damaged.



Replace the oil seal.



Shaft seal contact area damaged.



Repair or replace the output



shaft.



Abnormal operating temperature.



Abnormal operating sound.



O-ring distorted.



Replace the gearbox.



Insufficient gear oil.



Refill to specified level.



Gear or bearing damaged.



Replace the gearbox.



Gearbox is damaged.



Replace the gearbox.



Service Information Document Title: Swing gearbox, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing gearbox, replacing Op nbr 431-021 1. Park the machine in the service position C. See 091 Service positions. 2.







 



When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with ignition switch at "ON" position. Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank. Mount the vacuum pump on hydraulic tank, and maintain a vacuum.



NOTICE When a hose has been disconnected, plug both the hose and the connection immediately. The hoses should be marked for correct connection. 3. Open the under cover and open oil drain valve cap and install oil drain hose. Drain the gearbox oil into a suitable container. See 4312 Swing gearbox, specifications.



Figure 1



1. 2.



Under cover: Tightening torque: 110.8 ±10.8 Nm (11.3 ±1.1 kgf m) (81.6 ±7.9 lbf ft) Oil drain hose



4. Remove the hydraulic hoses, see slew motor replacing for step 3, 4, 5 and 6. See 4412 Swing motor, replacing. 5. Remove slew gearbox mounting screws and remove silicone from both back step holes.



Figure 2 Removal, mounting screws 1. 2.



Screws Silicone



6. Install back step screws to separate the slew gearbox from the superstructure. NOTE! The gearbox housing is not removed easily because of the dowel pin.



Figure 3 Installation, back step screw 1.



Back step screw



7. Lift the slew unit with the sling, and lower to the workbench safely.



Figure 4 Removal, slew unit 1. 2.



Sling Screws



8. Remove the slew motor screws, lift the slew motor with sling, and install it to a new slew gearbox. See 400 Tightening torque, specifications. see slew motor replacing for step 11 and 12. See 4412 Swing motor, replacing. NOTE! Before installing the slew motor, thoroughly remove the sealing compound on the mounting surface. NOTE! Apply sealing compound to the mounting surface of the new slew gearbox and then install the slew motor. 9. Transfer drain pipe and dowel pin, to the new slew gearbox.



Figure 5 Transferring, drain pipe and dowel pin 1. 2.



Drain pipe Dowel pin



10. Lift the slew unit with the hoist, and install it to the machine.



Figure 6 Installation, slew unit 1. 2.



Screws Silicone



NOTE! Before installing the slew unit, thoroughly remove the sealing compound on the seat surface of the superstructure. NOTE! Apply sealing compound to the seat surface of the superstructure, and then install the slew unit. NOTE! Apply Loctite #277 or equivalent locking fluid to the mounting screws, and tighten them to the specified torque. See tightening torque screws, 400 Tightening torque, specifications. 11. The installation procedure is the reverse order of removal. See 4412 Swing motor, replacing. See tightening torque, 4412 Swing motor, description. 12. Remove the vacuum pump mounted on the hydraulic tank. 13. Fill the gearbox oil through the oil filling pipe. 14. Bleed air from the hydraulic circuit at the slew motor before operating. 15. After completion of the work, start the engine and check for leaks.



Service Information Document Title: Swing unit, replacing



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Swing unit, replacing Op nbr 431-053 14360000 Vacuum pump / 24V



1. Replacing the swing unit. See 4312 Swing gearbox, replacing.



Date: 2014/7/15



Service Information Document Title: Function Group: Swing gearbox removed, replacing seal



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Swing gearbox removed, replacing seal Op nbr 431-026 8920-00550 Drift 8920-00570 Drift



8920–00560 1. Remove the slew gearbox (stop 1 ~ 7). See 4312 Swing gearbox, replacing. 2. Remove the screws, tightening torque. See 4312 Swing gearbox, assembly.



Figure 1 Removal, screws (1) 3. Remove the cover and oil seal.



Figure 2 Removal, cover (1) and oil seal (2)



Date: 2014/7/15



4. Remove the oil seal from cover and press a new oil seal into the cover using the seal pressing jig. 



8920-00550 Drift



NOTE! Apply Loctite #277 or equivalent locking fluid to the outer diameter of the oil seal. Take care not to get any loctite on the oil seal lip.



Figure 3 Replacing, oil seal 1. 2.



Cover Oil seal



5. Install the oil seal protector onto the gear of shaft. Install the cover, and oil seal on the case and then install the screws. NOTE! Coat the mating surface of cover with liquid gasket, Apply Loctite #277 or equivalent locking fluid



Apply grease (NLGI2) to the oil seal lip.



Apply Loctite #277 or equivalent locking fluid to the threads of screws.



Figure 4 Installation, cover and oil seal A. Oil seal protector 1. Shaft (1) 2. Cover 3. Oil seal 4. Screws



6. Install the slew gearbox (stop 8 ~ 15). See 4312 Swing gearbox, replacing.



Service Information Document Title: Swing disassembly



Function Group: gearbox,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing gearbox, disassembly Precautions      



Thoroughly clean the gearbox assembly prior to disassembly. Select a clean work area. Match mark attached components to indicate proper positioning during reassembly. Take care not to mix the parts of sub assemblies i.e. planetary bearings, gears and thrust washers. Thoroughly clean all parts and the inside of the casings. Inspect and analyze all failures. Determine the root cause!



Disassembly Op nbr 00000



1. Removal of hydraulic motor. See 4412 Swing motor, replacing.   



Loose the stop valve and drain the gear oil. Remove the screws. Lift the motor off the gearbox.



Figure 1 Removal, hydraulic motor 19



Case



24



Screws



20



Ring gear



43



Stop valve



23



Plate



NOTE! Match marks "A"



Make match marks on the hydraulic motor casing, plate, ring gear, and case.



Make sure the match marks are permanent and clearly visible. 2. Removal of pinion gear. 



Remove the screws, lock washer, plate and pinion.



3. Removal of motor mount plate. 



Remove the screws and plate.



Figure 2 Removal, plate 22



Screws



46



Screws



23



Plate



47



Lock washer



45



Pinion gear



48



Plate



4. 1st sun gear. 



Remove the 1st sun gear.



Figure 3 Removal, 1st sun gear (37) 5. 1st planetary gear assembly. Remove the 1st planetary gear assembly from ring gear. Disassemble the 1st planetary gear assembly in the following order :   



Remove the retaining ring, and then thrust washer, planetary gear, needle bearing and thrust washer. Remove the thrust washer. Remove the spring pin from carrier to take out pin.



Figure 4 Removal, retaining ring 20



Ring gear



32



Needle bearing



27



Washer



33



Washer



28



1st planetary gear



34



Washer



29



Carrier



35



Retaining ring



30



Planetary gear



36



Spring pin



31



Pin



Figure 5 Removal, spring pin 29



Carrier



31



Pin



30



Gears



36



Spring pin



NOTE! Match mark gears, pins and carrier.



Do not remove pins if not worn or damaged.



Do not reuse spring pins. 6. Ring gear 



Remove the ring gear and dowel pin.



7. 2nd sun gear. 



Remove the 2nd sun gear and thrust ring.



Figure 6 Removal, 2nd sun gear



20



Ring gear



25



Thrust ring



21



Dowel pin



26



2nd sun gear



8. 2nd planetary gear assembly     



Remove the 2nd planetary gear assembly from shaft. Disassemble the 2nd planetary gear assembly in the following order : Tap spring pin into pin. Remove the pin and bushing from carrier. Remove the planetary gear thrust washers.



Figure 7 Removal, 2nd planetary gear 1



2nd planetary gear



6



2



Carrier



7



3



Planetary gear



8



Washers



9



Spring pin



10



Shaft



4 5



Pin



Bushing



NOTE! Match mark gears, pins, and carrier.



Do not mix the gears, thrust washers, bushings, and pin assemblies.



Do not reuse spring pins.



To remove spring pin, tap it into pin.



After removing pin, remove the spring pin. 9. Retaining ring 



Remove the retaining ring.



Figure 8 Removal, retaining 2



Carrier



8



Washers



3



gears



9



Spring pin



5



Pins



18



retaining ring



10. Cover and oil seal 



Remove the seal, screws, cover and collar.



Figure 9 Removal, cover 11



Collar



14



Sear



12



Cover



15



Screws



NOTE! Do not reuse oil seal and O-ring. 11. Shaft



Figure 10 Removal, shaft 10



Shaft



19



Case



13



O-ring



14



Sear



 



Block the gearbox as shown. Press shaft from case.



12. Press spherical bearing from shaft. NOTE! If it is difficult to remove spherical bearing as illustrated, use a bearing puller.



Figure 11 Removal, spherical bearing 10



Shaft



16



Spherical bearing



13. Bearing 



Remove the spherical bearing from case using puller. NOTE! Spherical bearing can also be removed using a bench press.



Figure 12



Removal, spherical bearing 17



Spherical bearing



19



Case



Service Information Document Title: Swing gearbox, assembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing gearbox, assembly Precaution 



When mounting the gearbox assembly to the superstructure, position it on the dowel pin located in the mounting plate to ensure that the drain / fill ports are properly positioned. Mount the hydraulic motor on the gearbox assembly so that the oil level gauge and plumbing connections are positioned as shown in the construction drawings. Use a torque wrench to tighten the mounting screws to the specified torque. Clean all parts with cleaning solvent and dry with compressed air. Rework damaged parts and before assembling, prepare all replacement parts. Coat the sliding parts, bearings and gears with clean gear oil. Replace the O-ring and oil seal. Use a torque wrench to tighten the screws and plugs to the specified torque.



      



Tightening torque NOTE! Slew gearbox, sectional view and tightening torque. See 4312 Swing gearbox, description. Assembly, slew gearbox Op nbr 00000 8920-00280 Drift 8932-00600 Drift 8920-00550 Drift 8920-00570 Drift



1. Shaft 



Press spherical bearing onto shaft. NOTE! Heat the spherical bearing in oil to 110 °C (230 °F) prior to installation.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 1 Assembly, spherical bearing 10



Shaft



16



Spherical bearing



2. Case  



Install the shaft assembly into case using an eye bolt (A : M16 × 2). Install the O-ring in collar, and then install it on shaft.



NOTE! Apply grease (NLGI 2) onto O-ring.



Figure 2 Assembly, shaft 10



Shaft



13



O-ring



11



Collar



19



Case



3. Cover 



Press oil seal into cover using the seal pressing jigs.



NOTE! Apply loctite onto the outer diameter of the oil seal. Take care to get any loctite on the oil seal lip.



Figure 3 Assembly, oil seal 12



Cover



14



Oil seal



Figure 4 Apply loctit 4. Cover assembly. 



Install the cover assembly on case and install the screws.



NOTE! Coat the mating surface of cover with liquid gasket, loctite.



Apply grease (NLGI2) onto the oil seal lip.



Apply Loctite #277 or equivalent locking fluid onto the threads of screws.



Figure 5 Assembly, cover



12



Cover



19



Case



15



Screws



5. Bearing  



Block case as shown. Press-fit spherical bearing into case.



NOTE! Press-fit both inner and outer race simultaneously.



Figure 6 Spherical bearing, assembly 17



Spherical bearing



19



Case



6. Retaining ring 



Fully seat spherical bearing, and install retaining ring onto shaft.



NOTE! Check if casing rotates smoothly after assembling the bearing and retaining ring.



Figure 7 Assembly, retaining ring 10



Shaft



18



Retaining ring



17



Spherical bearing



19



Case



7. 2nd planetary gear assembly.   



Insert thrust washers and planetary gear into carrier. Insert pin and bushing. Tap spring pin into the pin hole of carrier. After inserting, stake the pin into both sides of spring pins.



Figure 8 Assembly, 2nd planetary gear 2



Carrier



6



Bushing



3



Planetary gear



8



Washers



5



Pin



9



Pin



A



Stake



Figure 9 Assembly, pin 2



Carrier



6



Bushing



3



Planetary gear



8



Washers



5



Pin



9



Pin



NOTE! Align the spring pin holes in pin assembly and carrier.



Apply a dab of grease to hold thrust washers to gear.



Install the spring pin with the slit facing the end of pin.



Ensure that gears rotate smoothly. 8. 1st planetary gear assembly.   



Press-fit pins into carrier and install the spring pins. After inserting, stake both sides of spring pins. Put thrust washer on the surface of carrier. Onto pin install the thrust washer, gear including bearing, thrust washer and retaining ring.



NOTE! Check if planetary gears rotate smoothly.



Figure 10 Assembly, 1st planetary gear 27



Washer



32



Bushing



29



Carrier



33



Washers



30



Gear



34



Washer



31



Press-fit pins



35



Retaining ring



36



Spring pins



Figure 11 Checking, planetary gear 9. Ring gear and 2nd planetary assembly.    



Insert the dowel pins at four places on case. Install the ring gear onto case. Insert the 2nd planetary gear assembly into ring gear. Insert the thrust ring into 2nd planetary gear, then install the sun gear.



Figure 12 Assembly, 2nd planetary gear 1



2nd planetary gear



21



Dowel pins



19



Case



25



Ring



20



Ring gear



26



sun gear



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 13 Assembly, 2nd planetary gear NOTE!



 



Coat the mating surface of case with liquid gasket loctite. Support case.



10. 1st planetary gear assembly and 1st sun gear.  



Install the 1st planetary gear assembly into ring gear. Install the sun gear into planetary.



NOTE! Confirm that shaft rotates smoothly by turning the 1st sun gear.



Figure 14 Assembly, 1st planetary gear



10



Shaft



28



1st planetary gear



20



Ring gear



37



Sun gear



11. Plate 



Install the plate onto ring gear then install the screws.



Figure 15 Assembly, plate 19



Casing



23



Plate



20



Ring gear



28



Plate



22



Screws



A



Tap hole



NOTE! Align the match marks on casing ring gea and plat.   



Coat the mating surface of ring gear with liquid gasket loctite. Apply Loctite #277 or equivalent locking fluid onto the threads of screw. Align the tap hole with the drain pipe mounting port.



12. Motor 



Install the motor onto plate then install the screws.



NOTE! Align the match marks of the motor and plate.  



Coat the mating surface of plate with liquid gasket loctite. Apply Loctite #277 or equivalent locking fluid onto the threads of screws.



Figure 16 Assembly motor



23



Plate



24



Screws



13. Drain pipe and level gauge.  



Install the stop valve to pipe and pipe to case. Install the pipe onto the motor, and insert the level gauge.



NOTE! Apply Loctite #277 or equivalent locking fluid



Figure 17 Installation, level gauge 19



Case



43



Stop valve



39



Level gauge



44



Pipe



40



Pipe



14. Pinion gear. Put the plate on shaft and install the lock plate. Tighten mounting screw as specified torque, and bend lock plate. 



Tightening torque: 262 ±26 Nm (26.7 ±2.7 kgf m) (192.8 ±19.5 lbf ft)



NOTE! Apply Loctite #277 or equivalent locking fluid



Figure 18 Installation, pinion gear 10



Shaft



47



Lock plate



46



Screws



48



Plate



Service Information Document Title: Track motor, description



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Track motor, description



Figure 1 Track motor Item



Tightening torque



aa



108 ±10 Nm (11.0 ±52 kgf m) (79.9 ±7.4 lbf ft)



bb



400 ±20 Nm (40 ±2 kgf m) (296 ±15 lbf ft)



Pi, G1, G2



36.8 ±2.5 Nm (3.75 ±0.26 kgf m) (27.2 ±1.9 lbf ft)



Dr (L and R)



157 ±8 Nm (16.0 ±0.8 kgf m) (116.2 ±5.9 lbf ft)



Date: 2014/7/15



Figure 2 Tightening torque, track motor a–a



Counter balance valve



b–b



Counter balance valve



c–c



Shock less relief valve



J



Parking brake mechanism



K



2-speed Counter valve



L



Variable displacement mechanism Tightening torque:



A



M25 x 1.5: 65 Nm (6.6 kgf m) (48 lbf ft)



B



36.8 ±2.5 Nm (3.75 ±0.26 kgf m) (27.2 ±1.9 lbf ft)



C



412 ±20 Nm (42.0 ±2.0 kgf m) (304.9 ±14.8 lbf ft)



D



157 ±8 Nm (16.0 ±0.8 kgf m) (116.2 ±5.9 lbf ft)



E



2.45 ±0.49 Nm (0.25 ±0.05 kgf m) (1.81 ±0.36 lbf ft)



F



107.9 ±4.9 Nm (10.9 ±0.50 kgf m) (79.2 ±3.62 lbf ft)



G



39.2 ±4.9 Nm (3.99 ±0.50 kgf m) (29.0 ±3.62 lbf ft)



H



63.7 ±4.9 Nm (6.50 ±0.50 kgf m) (47.1 ±3.62 lbf ft)



I



439 ±22 Nm (44.8 ±2.25 kgf m) (324.8 ±16.3 lbf ft)



Track motor structure



Figure 3 Track motor B6



1 Case



(B2)



-9 Nut



B3



2-28 Plug



D



2 Plate assembly, base



(B2)



-10 Piston, free



C



3 Shaft



B3



2-1 Plate, base



(A1, B2)



-11 O-ring



B4



4 Cylinder, block



B3



2-2 Spool assembly



(A1, B2)



-12 O-ring



B4



5 Valve plate



(B3)



-1 Spool



(A1, B2)



-13 O-ring



B4



6 Piston assembly



(B3)



-2 Check valve



(A1, B2)



-14 O-ring



B5



7 Plate, retainer



(B3)



-3 Spring



(A1, B2)



-15 Buck-up ring



B5



8 Retainer holder



(B3)



-4 Plug



(A1, B2)



-16 Buck-up ring



C



9 Swash plate



(A1, B3)



-5 O-ring



(A1, B2)



-17 Buck-up ring



C



10 Steel ball



C



2-3 Seat, spring



B3



2-9 Valve assembly



B6



11 Piston assembly



C



2-4 Spring



B3



2-11 Orifice



C



12 Spring



C



2-5 Seat, spring



C



2-13 Spring



C



13 Roller bearing



B1



2-6 Cab assembly



C



2-14 Plug



C



14 Roller bearing



(B1)



-1 Cab



A1



2-15 O-ring



C



15 Collar



(A1, B1)



-5 O-ring



C



2-16 Spring, seat



C



16 Pin



B1



-6 Screws



C



2-17 Plug



C



17 Spring



(B2)



2-7 Relief valve assembly



C



2-19 Check valve



C



18 Friction plate



(B2)



-1 Seat, poppet



C



2-20 Spring



C



19 Disc plate



(B2)



-2 Relief valve housing



C



2-21 Plug



C



21 Brake piston



(B2)



-3 Poppet



A1



2-22 O-ring



A1



22 O-ring



(B2)



-4 Seat, spring



B3



2-23 Orifice



A1



23 Buck-up ring



(B2)



-5 Spring



B3



2-24 Orifice



A1



24 O-ring



(B2)



-6 Plug



C



2-25 Plug



A1



25 Buck-up ring



(B2)



-7 Guide, spring



A1



2-26 O-ring



C



26 Spring



(B2)



-8 Screw, set



D



2-27 Shipping, plug



C



27 Pin



A1



Seal, KIT



A1



28 Seal, oil



B3



Base plate, KIT



A1



29 O-ring



B4



Cylinder block, KIT



A1



30 O-ring



B5



Retainer plate, KIT



C



31 Plug



B6



Case, KIT



A1



32 O-ring



C



33 Screws



B6



34 Plug



D



51 Name plate



D



52 Screws



Working principle of parking brake



Figure 4 Structure of parking brake A



Brake piston



E



Spline



B



Friction plate



F



Brake piston chamber



C



Disk plate



G



Spring



D



Cylinder block



The parking brake is a kind of negative brake which consist of disk, brake piston, friction plate and spring. The cylinder block and disk are combined with a spline, and friction material is bonded on both sides of disk. The disk generates frictional force between the case, the friction plate and the brake piston by the force of spring and restricts the rotating force of the motor, achieving the best performance of the parking brake. When the pressurized oil flows into the motor, the plunger moves and the parking brake release port is opened. After the oil flows into brake piston chamber, the thrust “F” is generated, corresponding to the pressure receiving surface of brake piston and the thrust “F” becomes larger than the force of spring “f”, consequently the brake piston moves toward right. Then, the disk rotates freely between the flange holder and brake piston, and parking brake is released. When the motor is stopped, the plunger returns to the neutral position and the parking brake release port is closed. Consequently the pressurized oil in brake piston chamber flows into motor case, the parking brake acts by the force of spring.



Service Information Document Title: Track motor, description



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Track motor, description



Figure 1 Structure, track motor Port name



Port size



Description



A, B



SAE 1 1/4 ″



Oil supply (return) port



X



M14 × 1.5



Pilot pressure port for selector spool



T



M26 × 1.5



Leak return port



S



M27 × 2



Tank return port



MA, MB



M14 × 1.5



Pressure checking port



Bre



M14 × 1.5



Brake pressure check port



Bri



φ4



Brake pressure port



M



M10 × 1



1 speed regulating pressure check port



Date: 2014/7/15



Service Information Document Title: Function Group: Track motor, maintenance standard



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track motor, maintenance standard Tools for disassembly and assembly General tools No.



1



Description



Torque wrench



Standard



JIS B4650



Type and dimensions



Applicable components Parts



or



588 Nm (60 kgf m) (433 lbf ft)



2-11



2



8826 Nm (900 kgf m) (6498 lbf ft)



2-2-2, 2-7-9, 2-23, 2-25



3



17652 Nm (1800 kgf m) (12996 lbf ft)



2-6-6, 2-14, 2-17



4



54917 Nm (5600 kgf m) (40432 lbf ft)



2-7, 2-21, 33



5



Ratchet steering wheel for JIS B4641 socket wrench



–



–



6



Hexagonal bit for torque – wrench



Hexagon 2.5



2-11



Hexagon 4



2-23, 2-24



8



Hexagon 5



–



9



Hexagon 6



2-7-8, 2-25



10



Hexagon 10



2-6-6, 2-14, 2-17



11



Hexagon 12



31



12



Hexagon 14



2-2-4, 2-21, 33



Hexagon 21



–



Hexagon 36



2-7



Hexagon 2.5



2-11



Hexagon 4



2-23, 2-24



17



Hexagon 5



–



18



Hexagon 6



2-7-8, 2-25



19



Hexagon 10



2-6-6, 2-14, 2-17



20



Hex. 12



31



21



Hex. 14



2-2-4, 2-21, 33



Hexagon 19



2-7-9



23



Hexagon 21



–



24



Hexagon 36



2-7



7



13



Socket



JIS B4636



14 15 16



22



Hexagonal socket screw JIS B4648 kye



Spanner



JIS B4630



25



Minus driver



JIS B4609



6 x 100



2, 5



26



Plastic hammer



OF-05



#3



–



27



Punch



–



About 10 mm (0.39 inch)



28



Hand press



1961 Nm (200 kgf m) (1444 lbf ft) or more



29



Crane



For 400 kg (882 lbs)



30



Eyebolt



M12



1, 2, 2-1



11



Chain string (wire)



–



–



Troubleshooting, track motor Special tools, track motor 11666051 Pressure gauge 14290266 Hose In the event a failure occurs while in operation, refer to the following troubleshooting list for the causes of failure and necessary actions. 1. Troubleshooting for piston motor Phenomenon troubles



of Presumption Causes



Measures



1. Motor does not rotate. 1. The components other than piston motor and Check to see whether the inlet of motor is reduction gear do not work properly. pressurized or not. Then provide necessary repairs. 2. Sliding components of the motor are Replace excessively worn parts with new excessively worn and pressurized oil is leaked. ones. Remove scratches or burrs, clean all parts thoroughly, and reassemble them. 3. Major parts of the motor are damaged. In this Disassemble the motor and replace all case, the motor produces unusual noises. damaged parts with new ones. Clean up all parts and reassemble them. 2. Motor speed is low.



1. Insufficient inflow caused by oil pump and Check to see whether the inlet of motor is pressure control valve. pressurized or not. Then provide necessary repairs. 2. Required rpm is not obtained because of Disassemble the motor and check all sliding lowered volumetric efficiency of the motor. parts for excessive wear. Repair or replace worn parts as necessary.



3. Motor rotates unstable speed.



4. Oil leakage



at 1. Pressurized oil in large amount leaking from Disassemble the motor for excessive wear. drain port caused by wears of motor sliding Replace all worn parts with new ones. Clean surface results in a reduction or variations in up all the parts, and reassemble them. speed of rotations. Or the motor speed is affected by wear of bearings. 1. Damaged oil seals or O-rings have caused oil Replace damaged oil seals and O-rings with leakage. new ones. When inserting oil seals, take sufficient care not to damage lips. Reassemble greased oil seals and O-rings.



2. Troubleshooting for Counter Balance Valve Phenomenon troubles



of Presumption Causes



Measures



1. Motor does not rotate 1. Pilot port is not pressurized. Check if piping is not damaged. or motor speed is low. 2. Foreign substances are jammed between Remove foreign articles thoroughly. Repair plunger and base plate. damaged parts, and reassemble the parts after cleanup. If deep scratches or more than normal wear are found on the parts, the parts should be replaced with new ones. 2. Foreign substances are jammed between Remove foreign articles thoroughly. Repair plunger and base plate. damaged parts, and reassemble the parts after cleanup. If deep scratches or more than normal wear are found on the parts, the parts should be replaced with new ones. 3. Orifice is clogged.



Wash the parts before reassembly.



2. Motor does not stop 1. Foreign substances are jammed between Remove foreign articles thoroughly. Repair or stops slowly. plunger and base plate. damaged parts, and reassemble the parts after cleanup. If deep scratches or more than normal wear are found on the parts, the parts should be replaced with new ones.



2. Spring is not installed in place.



Install spring in proper position.



3. Spring is broken.



Replace spring with new one.



4. Orifice is clogged.



Remove foreign substances thoroughly, repair damaged parts, then wash the parts before reassembly.



4. The seat of the check valve is faulty or the valve itself failed. 1) Foreign matter is present. 2) The sliding surface of the check valve is rough or damaged. 3) The spring is broken.



1) Remove foreign matters completely, repair any damaged part, completely wash all parts, and then reassemble them. If the damage is too deep causing a large amount of leak, replace the valve. 2) Correct the sliding surface or replace the valve with a new one. 3) Replace the broken spring. When replacing the spring, remove foreign matter completely, repair any damaged part, wash all parts completely, and then reassemble them. If the damage is too deep causing a large amount of leak, replace the valve.



3. Shock is excessive Spring is not installed in place. when motor is stopped. 4. Unusual noises



Install spring seat in proper position.



1. Foreign substances are jammed between Remove foreign articles thoroughly. Repair plunger and base plate. damaged parts, and reassemble the parts after cleanup. If deep scratches or more than normal wear are found on the parts, the parts should be replaced with new ones. 2. Spring is broken.



Replace spring with new one. Remove foreign substances thoroughly, repair damaged parts, and then wash the parts before reassembly.



3. Orifice is clogged.



Wash the parts before reassembly.



3. Trouble shooting for Relief Valve Phenomenon troubles



of Presumption Causes



Measures



1. Motor does not rotate 1. Foreign substances are jammed between Remove foreign articles thoroughly. Repair or motor speed is low. poppet and poppet seat. damaged parts, and reassemble the parts after cleanup. If deep scratches or more than normal wear are found on the parts, the relief valve should be replaced with new ones. 2. Spring is broken.



The relief valve should be replaced with new ones.



3. Foreign substances are jammed between Remove foreign articles thoroughly. Repair relief valve and base plate. damaged parts, and reassemble the parts after cleanup. If deep scratches or more than normal wear are found on the parts, the base plate assembly and relief valves should be replaced with new ones. 4. Orifice at poppet is clogged.



Wash the parts before reassembly.



2. Motor does not stop 1. Foreign substances are jammed between Remove foreign articles thoroughly. Repair or stops slowly. poppet and poppet seat. damaged parts, and reassemble the parts after cleanup. If deep scratches or more than normal wear are found on the parts, the relief valve should be replaced with new ones. 2. Spring is broken.



The relief valve should be replaced with new ones.



3. Foreign substances are jammed between Remove foreign articles thoroughly. Repair



relief valve and base plate.



damaged parts, and reassemble the parts after cleanup. If deep scratches or more than normal wear are found on the parts, the base plate assembly and relief valves should be replaced with new ones.



4. Orifice at poppet is clogged.



Wash the parts before reassembly.



3. Shock is too large 1. Foreign substances are jammed between The relief valve should be replaced with new when the swing motion poppet and poppet guide. ones. comes to a stop. 2. Foreign substances are jammed between Remove foreign articles thoroughly. Repair relief valve and base plate. damaged parts, and reassemble the parts after cleanup. If deep scratches or more than normal wear are found on the parts, the base plate assembly and relief valves should be replaced with new ones. 3. Relief set pressure is too high.



The relief valve should be replaced with new ones.



4. Troubleshooting for Two Speed Control Valve Phenomenon troubles



of Presumption Causes



Measures



1. The machine does not 1-1. Foreign substances are jammed between Remove foreign articles thoroughly. Repair go straight. plunger and body. damaged parts, and reassemble the parts after cleanup. If deep scratches or more than normal wear are found on the parts, the parts should be replaced with new ones. 1-2. Spring is not installed in place.



Install spring in proper position.



1-3. Spring is broken.



Replace spring with new one. Remove foreign substances thoroughly, repair damaged parts, and then wash the parts before reassembly.



2. Oil leaks by unusual wear on two seed control Replace two-speed control piston with new piston. one. Remove foreign substances thoroughly, repair damaged parts, and then wash the parts before reassembly. 3. Two-speed control piston is not installed in Install two-speed control piston in proper place. position. 4. Steel balls are excessively worn.



Replace steel ball with new one. Remove foreign substances thoroughly, repair damaged parts, and then wash the parts before reassembly.



5. Troubleshooting for Parking Brake Phenomenon troubles



of Presumption Causes



1. Shortage of braking 1. Brake disk is worn. force or one-sided braking



Measures Replace disk with new one. Remove foreign substances thoroughly, repair damaged parts, and then wash the parts before reassembly.



2. Deterioration or poor contact of disk surfaces. Polish and correct the surface. Clean it before reassembly. If it is too much degraded, replace it with new one. 3. Worn or damaged springs.



Replace spring with new one. Remove foreign substances thoroughly, repair damaged parts, and then wash the parts before reassembly.



2. Unusual heating due to 1. Oil leakage due to O-ring breakage brake dragging 2. Orifice is clogged.



Replace damaged O-rings with new ones. Wash the parts before reassembly.



Service Information Document Title: Track motor, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track motor, replacing Op nbr 441-111 1. Park the machine in the service position. See 091 Service positions. NOTE! Stop the engine, and remove the residual pressure inside the hydraulic line by operating the control lever smoothly for 3~4 times with the ignition key at "ON" position. Turn the ignition key to "OFF" position.



2. Remove the screws and track motor cover.



Figure 1 Removal, motor cover NOTE! The above illustration explains the case of the EC480D. 1. 2.



3.



Screws Cover



NOTICE When a hose has been disconnected, plug both the hose and the connection immediately. The hoses should be marked for correct connection.



WARNING The parts are heavy. Take appropriate safety cautions when handling them. Remove the 2nd speed hose, drain hose and main high pressure hoses. Remove the track motor mounting screws and remove the track motor.



Figure 2 Removal, hydraulic hoses and track motor NOTE! The above illustration explains the case of the EC480D. 1. 2. 3. 4. 5.



2nd speed hose Drain hose Main high pressure hoses Motor mounting screws Track motor



4. Install the new track motor. NOTE! Do not reuse removed seals when reassembling. The installation procedure is the reverse order of removal. Tightening torque. See 4411 Track motor, description,



Service Information Document Title: Function Group: Track motor relief valve, replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track motor relief valve, replacing Op nbr 441-112 1. Park the machine in the service position B. See 091 Service positions. 2.







Apply Loctite #277 or equivalent locking fluid Stop the engine, and remove the residual pressure inside the hydraulic line by the travel control lever smoothly for 3 ~ 4 times with ignition switch at "ON" position. NOTE! Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.



3. Remove the screws and motor cover.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 1 Removal, motor cover 1. 2.



Screws Cover



4. Remove the track motor relief valve.



Figure 2



Removal, relief valve 1.



Relief valve



5. Install a new relief valve. NOTE! Do not reuse removed seals when reassembling.



Figure 3



6. Check relief valve pressure of the track motor, and adjust if necessary 7. Install the motor cover. See 700 Undercarriage, tightening torque.



Service Information Document Title: Track motor, disassembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Track motor, disassembly General repair instructions NOTE! Attention observe the following notices when carrying out repair work on hydraulic components. Op nbr 00000



1. Close all ports of the hydraulic components.



Figure 1 Hydraulic components 2. Replace all seals.



Figure 2 Seals 3. Check all seals and surfaces for wear.



Figure 3 Sealing area NOTE! Rework of sealing area with abrasive paper can damage the surface. 4. Fill up hydraulic components with hydraulic oil before start–up.



Figure 4 Filling, hydraulic oil Seal kits and component groups Op nbr 00000



1. Seal kit for drive shaft.



Figure 5 Seal kit 2. External seal kit.



Figure 6 Seal kit 3. Housing



Figure 7 Housing 4. Complete rotary group.



Figure 8 Rotary parts 5. Port plate with control piston and counterbalance valve.



Figure 9 Port plate parts 6. Relief valve/make up check valve.



Figure 10 Relief valve parts 7. Replace seal nut. First measure and record setting height.



Figure 11 Seal nut 8. When tightening, counter hold setting screw, then check setting height.



Figure 12 Tightening, Setting screw Sealing the drive shaft Op nbr 00000



Figure 13 Drive shaft seal



1. Protecting the drive shaft. Remove retaining ring and shim.



Figure 14 Removal, retaining ring 2. Screw in sheet metal screw into the holes fitted with rubber. Pull out seal with pliers.



Figure 15 Removal, seal 3. Press in shaft seal and shim with bushing to stop. NOTE! Pay attention to pressing depth ! * Mark for pressing depth. Assemble retaining ring.



Figure 16 Assembly, retaining ring HA3T–Controller Op nbr 00000



1. NOTE! Inspect O-ring, o-ring groove, housing.



Figure 17 Inspection, o-ring Removal of the relief valve



Figure 18 Removal, relief valve Op nbr 00000



1. Inspect O-ring



Figure 19 Inspection, o-ring Disassembly of the port plate Op nbr 00000



Figure 20 Disassembly, port plate 1. Note dimension X. Remove Qmin–screw.



Figure 21 Removal, Qmin-screw 2. For disassembly of the port plate, always swivel rotary group to zero position. Swivel rotary group to zero position with screw Qmax.



Figure 22 Disassembly, port plate 3. Port plate. Mark position. Loosen screws. Removal.



Figure 23 Marking, port plate



Figure 24 Checking, o-ring Check, o-ring. NOTE! Stick new o-ring with some grease. Do not swivel rotary group. Piston rings to hang out from the cylinder boring. Removal of the control Op nbr 00000



1. Braking valve



Figure 25 Removal, brake valve 2. Throttle pin



Figure 26 Removal, throttle pin 3. Valve



Figure 27 Disassembly, valve 4. Pressure control valve



Figure 28 Removal, pressure control valve 5. Pressure relief valve



Figure 29 Removal, pressure relief valve



6. Positioning piston



Figure 30 Removal, positioning piston 7. HA3T–control



Figure 31 Removal, HA3T - control 8. Check valve



Figure 32 Removal, check valve



Figure 33 Exploded view, port plate Removal of the rotary group Op nbr 00000



Figure 34 Removal, rotary group 1. Screw in threaded pin into center pin. Fix the cylinder with the disc and lock nut. Size 28 : M4 × 58 mm 55 : M5 × 71 mm 80 : M6 × 82 mm 107 : M6 × 92 mm 140 : M8 × 105 mm 160 : M8 × 105 mm 200 : M8 × 109 mm



Figure 35 Fix, cylinder 2. Press out rotary group !



Figure 36 Removal, rotary group NOTE! If the bearings are to be used again do not hit on the drive shaft. Exchanging of the rotary group Op nbr 00000



1. Complete rotary group NOTE! Setting of hydraulic part necessary.



Figure 37 Setting, part 2. Rotary group  



Mechanical port : Adjust drive shaft with bearing. Hydraulic part : Adjustment necessary.



Figure 38 View, rotary group part



Remove fixing screw (cylinder). 3. Remove cylinder.



Figure 39 Removal cylinder



4. Disassemble retaining plate.



Figure 40 Removal, screw NOTE! Screws are glued. Use Torx–tools. Inspection notes



Figure 41 Check, drive shaft Free of corrosion, erosion or fretting : no damage to splines or key ways. Pistons



Figure 42 Check, pistons No scoring and no pittings. Center pin



Figure 43 Check, center pin



No scoring and no pickings. Retaining plate



Figure 44 Check, retaining No scoring and no evidence of wear. Cylinder block/control lens



Figure 45 Check, cylinder Bores free of scoring, no evidence of wear. Faces smooth and even, free of cracks and scoring. Control housing



Figure 46 Check, control housing Sliding surface and side guides free of scoring and no wear. Visual check:



Figure 47 Check, bearing areas Bearing areas free of scoring and no evidence of wear.



Service Information Document Title: Track motor, disassembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Track motor, disassembly Structure of MSF 340VP FL/FH



Figure 1 Track motor structure A–A: Shock less relief valve B–B: Counter balance valve C–C: 2-speed control valve D–D: Parking brake mechanism E–E: Variable displacement mechanism Op nbr 00000



NOTE! Refer to the Track motor description for track motor structure illustrations show, see 4411 Track motor, description. Precautions for Disassembly 1. 2. 3. 4.



Since all parts are precisely machined, be careful for handling so that the parts may not be dented or scratched when such parts drop or contact with each other. Do not try to hit or wrench when the parts are tightly fasten. It will result in to generate burrs or damage to parts, or to oil leakage and degradation. Do not leave the parts disassembled. Parts may be soiled or may be rusted when exposed to damp air or dusts. Wash the exterior surfaces thoroughly.



5. 6.



Drain all hydraulic fluids in piston motor enclosure and oil passage ports. Select a clean working place to prevent parts from soil or dusts.



Disassembly 1. Remove cap (2-6) and take out spring (37), spring seat (36).



Figure 2



2. Remove Spool assembly (2-2) turning slowly. Be careful not to damage around the Spool assembly.



Figure 3



3. Loosen the plug (2-7-6) to remove the relief valve assembly (2-7).



NOTE! Do not move the setscrew, nut. Otherwise, the set pressure will change.



Do not disassemble the relief valve assembly because it is a functional component.



Figure 4



4. Remove plug (2-21), spring (2-20) and check valve (2-19).



Figure 5



5. Remove Plugs (2-14), (2-17). Remove Spring (2-13) and Spool Assembly (2-9).



Figure 6



6. Remove socket head bolt (33). To disassemble the motor easily, socket head bolt (33) should be loosened evenly because base plate lift up by the reactive force of springs (26). Remove the Base plate. Then, pay attention so that cylinder block (*) does not come out. When it is difficult to remove, strike it by use of plastic hammer. If it is more difficult to remove, remove it by lightly prying with screwdriver.



Figure 7



7. Remove Valve plate (5) from Base plate.



Figure 8



8. Remove O-rings (29), (30), Pins (27) and Springs (26).



Figure 9



9. Remove Brake piston (21). Blow compressed air into parking brake-releasing port on case (1). NOTE! Before work, put rag on all surface of brake piston because brake piston fly out and oil flies off while at work. After removing brake piston, remove Disk (19), Friction plate (18), (20). And then, removing O-rings (22), (24) and back up rings (23, )(25).



Figure 10



10. Remove the Cylinder Block Assembly



Figure 11



11. Disassemble Cylinder Block Assembly 12-1.) Remove Piston Assembly (6) and Retainer Plate (7) from Cylinder Block (4).



Remove Piston Assembly (6) from Retainer Plate (7). Remove Retainer Holder (8) from Cylinder Block (4). And then, remove springs (17) from Cylinder Block (4)



Figure 12



12. Remove Swash plate (9).



Figure 13



13. Remove Piston Assembly (11) and spring (12). And then remove Steel ball (10).



Figure 14



14. Remove Shaft (3).



Figure 15



Service Information Document Title: Track motor, assembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Track motor, assembly Tightening torques thread) Tightening torques for shaft screws (Metric ISO standard The values for tightening torques shown in the table are valid only for shaft screws with metric ISO standard threads and head surface dimensions in accordance with DIN 912 DIN 931 and DIN 933. These values are also valid only for light or unoiled. untreated surface as well as for use only with torque indicating wrenches and force limiting tools.



Thread size



Strength classes 8.8



10.9



12.9



Tightening torque, N·m (lbf·ft) M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30



1.1 (0.8) 2.9 (2.1) 6 (4.4) 10 (7.4) 25 (18.4) 49 (36.1) 86 (63.4) 135 (99.5) 210 (154.8) 290 (213.7) 410 (302.2) 550 (405.4) 710 (523.5) 1050 (773.9) 1450 (1068.7)



1.6 (1.2) 4.1 (3.0) 8.5 (6.3) 14 (10.3) 36 (25.8) 69 (50.9) 120 (88.4) 190 (140.0) 295 (217.4) 405 (298.5) 580 (427.5) 780 (574.9) 1000 (737.0) 1500 (1105.5) 2000 (1474.0)



19 (1.4) 4.9 (3.6) 10 (7.4) 17 (12.5) 41 (30.2) 83 (61.2) 145 (106.9) 230 (169.5) 355 (261.6) 485 (357.4) 690 (508.5) 930 (685.4) 1200 (884.4) 1800 (1326.6) 2400 (1768.8)



thread)Tightening torques for locking screws VSTI (Metric ISO fine Thread size



Tightening torque, N·m (lbf·ft)



M8 × 1 M10 × 1 M12 × 1.5 M14 × 1.5 M16 × 1.5 M18 × 1.5 M20 × 1.5 M22 × 1.5 M26 × 1.5 M27 × 2 M30 × 1.5 M33 × 2 M42 × 2 M48 × 2



5 (4) 10 (7) 20 (15) 30 (22) 30 (22) 40 (29) 50 (37) 60 (44) 70 (51) 90 (66) 100 (74) 120 (88) 200 (147) 300 (220)



thread)Tightening torques for seal–lock nuts (Metric ISO standard The values for tightening torques shown in the Thread table are valid only for seal. lock.nuts of the size strength class 8.8 and with metric ISO. standard.



Strength classes 8.8



10.9



Tightening torque, N·m (lbf·ft)



12.9



M6 M8 M10 M12 M14 M16



10 (7.4) 22 (16.2) 40 (29.5) 69 (50.9) 110 (81.1) 170 (125.3)



(Metric ISO standard thread) DIN 7985Tightening torques for cross–slotted lens head screws The values for tightening torques shown in the Thread table are valid for cross. slotted lens head size screws DIN 7985 of the strength class 8.8 and with metric ISO. standard thread. M3 M4 M5 M6 M8 M10



Strength classes 8.8



10.9



Tightening torque, N·m (lbf·ft) 1.1 (0.8) 2.9 (2.1) 6 (4.4) 10 (7.4) 25 (18.4) 49 (36.1)



Tightening torques for gearbox Position



Screw type



Tightening torque N·m (lbf·ft)



16



M12 × 35K (Grade) = 12.9



145 (107)



17



M12 × 65K (Grade) = 12.9



145 (107)



36



M30 × 2K (Grade) = 8.8



1500 (1105)



45



M16 × 35K (Grade) = 8.8



205 (151)



47



M20 × 50K (Grade) = 8.8



400 (295)



Rotary group assembly



Figure 1 Assembly, rotary group Rotary group completely assembled ready for assembly. Op nbr 00000



1. Place assembly sleeve.



12.9



Figure 2 Assembly, sleeve 2. Warm up housing to 80° C.



Figure 3 Warm-up housing 3. Insert rotary group into housing to seat position.



Figure 4 Assembly, rotary group 4. Fix zero position of cylinder with Qmin–screw.  



Disassemble cylinder fixing screw. Insert o-ring.



Figure 5 Assembly, rotary group



Rotary group adjustment 5. Determine cylinder swivel range to max. angle with screw.



Figure 6 Adjustment, rotary group 6. *Disc.



Figure 7 Adjustment, disc 7. Place centering disc.



Figure 8 Assembly, centering disc 8. Mount measuring device.



Figure 9 Mounting, measuring device 9. Check dimension X.



Figure 10 Check, dimension X NOTE! Stick control lens in sliding surface with grease.



Assembly of the port plate 10. Assembly in reversal order. Mount port plate.



Figure 11 Port plate NOTE! Take care of assembly design Tighten fixing screws with torque.



Assemble port plate. 11. Set Qmin–screw to dimension*. Assemble plug. Remove assembly sleeve.



Figure 12 Assembly, port plate



Assemble shaft seal, disc and safety ring. 12. Press–in with assembly sleeve.



Figure 13 Assembly, shaft seal NOTE! Pay attention to press–in depth.



Service Information Document Title: Track motor, assembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Track motor, assembly Op nbr 00000



NOTE! Refer to the Track motor description for track motor structure illustrations show, see 4411 Track motor, description. Precautions for Reassembly 1. 2. 3. 4. 5. 6.



Wash all parts is treated oil, and remove metal pieces and foreign substances. Ensure that there are no burrs or bruise. Replace seals, bearings and pins with new in principle. Take care not to damage seals at time of reassembly. (Apply grease prior to installation.) Protect all cleaned parts from dusts, flaws and other damages. Handle them with extreme care. Tighten bolts with specified tightening torque. (See 4411 Track motor, description and 4411 Tools) Plug all ports with shipping plug to protect dusts from entering.



Reassembly 1. Apply grease to oil seal (28) and press fit it in Case (1).



Figure 1



A. B. C. D.



Tool Oil seal Tool Case



2. Press fit the outer race of Roller bearing (13) in Case (1).



Figure 2



3. Install Springs (12) and Piston Assembly (11) on Case (1). NOTE! Apply hydraulic oil to the sliding surface of the Piston Assembly.



Figure 3



4. Install Steel ball (10). NOTE! Apply hydraulic oil to the surface of the Steel ball.



Figure 4



5. Press fit Inner race of Roller bearing (13) on shaft (3). And then, install shaft sub assembly on case (1).



Figure 5



A. B. C.



Shaft Tool Case



6. Install Swash plate (9). NOTE! Apply hydraulic oil to the surface of the Steel ball.



Figure 6



7. Install 9 Springs (17) on Cylinder block (4).



Figure 7



8. Install Retainer holder (8) on Cylinder block (4).



Figure 8



9. Install 9 Piston Assembly (6) in each holes of Retainer plate (7). NOTE! Be care for the direction of the retainer plate.



Figure 9



10. Install Piston Assembly (6) and retainer plate (7) in cylinder block (4). NOTE! Apply hydraulic oil in 9 holes of cylinder block. Apply hydraulic oil on the surface of Retainer holder (8) and Retainer plate (7).



Figure 10



11. Install Cylinder Block Assembly. NOTE! Apply hydraulic oil on the surface of Piston Assemblies (6) and Swash plate (9).



Figure 11



12. Install Friction plates (18) and Disk plates (19). NOTE! Apply enough hydraulic oil to Disk Plate.



The circular arc part of the friction plate is set to the cutting lack part of the case.



There is a part where teeth are lacked in the spline of Disk Plate. When assembling the Disk Plates, match the position of these each parts. (Refer to figure below.)



Refer to the sectional drawing for the combination of assembling Friction Plate and Disk Plate.



Figure 12



13. Apply grease to O-rings (22), (24), backup ring (23), (25), and install them to Break piston (21). And install Brake Piston (21) to Case (1) to align Pins (27) installed on base plate in No.** with holes on brake piston (21). When install it, beat on evenly outside of brake piston by using of plastic hammer. NOTE! Each backup rings should be set out side position.



Be careful of installing direction of Brake piston.



Apply grease to outside of brake piston and inside of case (1).



Figure 13



A. B. C. D.



Pins for positioning Pins for positioning Brake piston Case



14. Install Springs (26) in the holes of Brake piston (21).



Figure 14



15. Press fit Roller bearing (14) on base plate (2-1). Install pins (16) and color (15) on Base plate (2-1). NOTE! Apply grease to the surface of Valve plate (25) and Base plate (2-1).



Figure 15



16. Install O-rings (29), (30) on Case (1). Install Pins (27) on Base Plate (2-1). Install Base Plate (2-1) and Socket Head Bolt (9). NOTE! Apply grease to O-ring (25).



Do not apply grease to O-ring (30).



Be care for direction of Pin (27).



Apply hydraulic oil to the surface between Cylinder Block (4) and Valve Plate (5).



Be care for pilot line of Base Plate and Case (1).



Tighten the bolts evenly, as base plate is pushed by spring.



Figure 16



17. Place Spring (2-13) on Valve Assembly (2-9), and then install Valve Assembly on Base Plate (2-1). Tighten Plug (2-14) with O-ring (2-15). Place Spring guide (2-16) and Washer (2-18), and then tighten Plug (2-17) with O-ring (2-15). NOTE! Apply hydraulic oil to Valve Assembly before installation. Apply slight grease to O-rings (2-15).



Figure 17



18. Tighten Relief Valve Assemblies (2-7). NOTE! Apply slight grease to O-rings and Backup rings.



Figure 18



19. Place Check Valve (2-19) and Springs (2-20). Tighten plug (2-21) with O-ring (2-22). NOTE! Apply slight grease to the O-rings.



Figure 19



20. Install Spool Assembly (2-2) on base plate (2-1). Install it while turning to prevent it from sticking.



NOTE! Apply hydraulic oil to Spool Assembly before installation.



Figure 20



21. Place Spring Seats (2-3) and Springs (2-4). Install O-rings (2-10) on Base Plate (2-1). Install O-rings on Cap Assembly (2-6). Place Spring Seats (2-5) on Cap Assembly (2-6), and then install them on Base Plate (2-1). Tighten Socket Head Bolts. NOTE! Apply grease to O-rings.



Figure 21



1.



2.



Air Leak Test of Motor Remove one plug (1-27) of the reduction unit apply compressed air (0.03 MPa) through tapped hole of plug in water for two minutes, and observe that there are no bubbles. Upon completion of leak tests in subparagraphs (1) above, fill the motor case with new hydraulic fluid. Run the motor crosswise for two minutes filling hydraulic fluid at flow rate of 20 liters per minute. Confirm that there is no excessive heat, vibration or noise during running.



Quality Check After Reassembly



Service Information Document Title: Swing motor, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing motor, description Hydraulic motor Rotary group consists of cylinder block and 9 piston assemblies located in the cylinder. Both ends of cylinder block are supported by bearings. Piston assemblies are guided by return plate (123) and spring (122) so they slide smoothly on the swash plate. Valve plate (131) is pressed against the cylinder block surface by the mechanical pressure of spring (114) and hydraulic pressure working on the bushing. Between the outer diameter of the cylinder block and housing a mechanical brake for parking is mounted. The cover section has a relief valve for cushioning and an anti-cavitation valve to prevent cavitation and protect the motor from excessive shock loading. Slew ring gear The slew ring gear is a single row sealed ball bearing that supports the superstructure on the undercarriage and allows the superstructure to rotate smoothly. The outer race is bolted to the superstructure and the inner race with inner circumference gear is bolted to the undercarriage. The slew gearbox pinion meshes with the internal gear of the inner race and drives it to rotate the superstructure. Components of slew system



Figure 1 Slew system, components A



Slew unit



E



Relief valve



B



2–stage planetary gearbox



F



Anti–cavitation valve



C



Swash type axial piston hydraulic motor



G



Rebound damping valve



D



Mechanical brake



H



Delay valve



Figure 2 Slew motor 1. 2. 3.



Relief valve Rebound damping valve Lifting screw (2-M12)



Rotational direction lnlet



Outlet



View from shaft end



A



B



Clockwise



B



A



Counterclockwise



Piping port size Port



Symbol



Thread size & depth



Tightening torque, kgf·m (lbf·ft)



Main



A, B



1 5/16–12 UN-2B-19



30.6 (220.9)



Make up



M



1 5/16–12 UN-2B-19



30.6 (220.9)



Pressure Checking



PA, PB



9/16–18 UNF-2B–12.7



4.9 (35.4)



Drain



Dr



3/4–16 UNF-2B–14.3



8.37 (60.4)



Brake releasing



PG



9/16–18 UNF-2B–12.7



4.9 (35.4)



Brake pilot



SH



9/16–18 UNF-2B–12.7



4.9 (35.4)



Sectional view



Figure 3 Slew motor 031



Delay valve



355



Spring



031-1



Plug



390



Name plate



033



Screw



391



Rivet



038



Retainer



400



Rebound damping valve



051



Relief valve Retainer



4001



O-ring



051-1



O-ring



4002



Backup-ring



052



Rebound damping valve casing



401



Screw



100



Plug



437



Snap ring



101



Shaft



438



Snap ring



111



Cylinder



443



Roller bearing



113



Retainer



444



Roller bearing



114



Spring-Cylinder



451



Pin-dowel



116



Push rod



469



Plug



117



Spacer F



471



O-ring



118



Spacer



472



O-ring



121



Piston



488



O-ring



122



Shoe



491



Oil seal



123



Thrust plate



702



Piston-brake



124



Shoe plate



706



O-ring



131



Valve plate



707



O-ring



151



Plug



712



Spring-brake



161



O-ring



742



Friction plate



171



Screw



743



Mating plate



301



Casing



981



Plug



303



Valve casing



984



Plug



305



Seal cover



351



Spool



Service Information Document Title: Function Group: Swing motor, maintenance standard



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing motor, maintenance standard Hydraulic motor When high pressure oil from the hydraulic pump delivered via the main control valve, enters port of valve plate, it flows to half of the 9 pistons spaced equidistance in cylinder block and pushes the pistons out of the bores against the inclined swash plate, generating force F in an axial direction. Force F vector divides into components of radial force F1, F2, and is transmitted sequentially via pistons to cylinder block, generating a rotational torque causing the cylinder block splined to output drive shaft to rotate. The top dead center port is the starting point of the high pressure rotational cycle : for 180° the pistons move out of the bores as they slide along the swash plate toward bottom dead center port, then they begin moving into the bores discharging low pressure oil to the return circuit. If the supply port and return port are interchanged, the slew motor rotates in the opposite direction. The theoretical output torque T is calculated by the following formula. T =(p × q) / (2 × π) p : Effective differential pressure, kgf/cm2 q : Capacity per one rotation, cc/rev



Figure 1 Operation, slew motor 1 Valve plate



L Low pressure oil



2 Shoe



H High pressure oil



3 Swash plate



O Outlet port



4 Cylinder block 5 Piston 6 Drive shaft Anti–cavitation check valve



I Inlet port



Figure 2 Circuit 1. 2.



Control valve Return



The motor can be rotated faster than supplied oil flow because there is no counter-balancing valve to prevent overspeed. In order to prevent cavitation of the motor, oil compensating insufficient flow is drawn through the anti cavitation check valve. Operation When ports (P & R) are pressurized by hydraulic tank pressure, the initial condition of the relief valve is closed as shown in figure (1). When the oil pressure at port (P) is greater than spring (321) force, plus the pressure of chamber (g), the relief valve opens. As piston (303) moves, the pressure of chamber (g) varies, and as piston (302) moves spring (321) force varies. This type of relief valve controls the pressure change from P1~Ps smoothly in time interval (t) as shown in figure (5). The pressure relieving cycle is explained as follows : 



Figure (2)



When port (P) is pressurized at pressure P1, the oil flows through orifice (m) into chamber (g) and becomes pressure Pg. If pressure Pg is greater than spring (322) force, piston (303) moves left and Pg becomes less than pressure P1. Then spool (301) moves left against spring (321) and the relief valve opens. This relation is expressed in the following formula : P1 × A1 = Fsp + (Pg × A2) [Fsp : Initial tensional load setting] The oil in chamber (g) flows out to port (R) through orifice (n) in sleeve (342) when spool (301) moves. 



Figure (3)



As piston (303) reaches the end of its stroke, piston (302) moves right against spring (321) force. Then chamber (h) between adjusting plug (401) and piston (302) acts as a damper reducing the shock of the rapid pressure change. Through this operation the relief pressure can rise from P2 ~ Ps smoothly in time interval (t) as shown in figure (5). 



Figure (4)



As piston (302) contacts the bottom of adjusting plug (401), the pressure in chamber (g) becomes the same as relief pressure Ps, and the relief valve opens. 



when the pressure at port (p) is decreased



As the oil pressure at port (P) decreases, the pressure at chamber (g) decreases to hydraulic tank pressure, then spring (321) force moves spool (302) left, and spring (322) force moves piston (303) to the right. At this time some hydraulic oil flows through the check ball valve in sleeve (342) to chamber (g) to help piston (303) return to the closed position without delay.



Figure 3 Operation, relief valve Rebound damping valve



The rebound damping valves allow, fast/responsive, but smooth/gentle acceleration and retardation of the superstructure without jerking or impact, thereby greatly reducing mechanical stress on the slew mechanism and extending component service life. Operation Figure (1) shows the damping valve in neutral condition in relation to normal slew operation. Figure (2) shows the valve operating condition with brake pressure at port Am. Oil pressure applied at port Am flows through passage (L), the orifice in seat (313), and passage (m) of spool (311) to chamber (n). When pressure (P) is more than set value of spring (321) force (Ps), it moves spool (311) left compressing spring (321), pushing seat (313) to compress spring (322). Figure (3) shows the valve condition when movement of the inertia load stops, [Y point in figure (4)], and the brake pressure is lowered. When pressure (P) is less than spring (321) force (Ps), spool (311) moves right, then spring (322) starts to move seat (311) right, but the seat return is delayed since the oil in chamber (P) exits via narrow passage (g) which causes a damping function. The delay allows seat (t) to open and a passage is connected between port Am & Bm, by (l → t → r → k). This rapidly equalizes the pressure at port Am & Bm, [Z point in figure (4)], which prevents the slew motor from over running.



Figure 4 Operation, rebound damping valve A



Rebound damping valve



T



Time



P



Pressure



Slew brake The slew brake is spring applied and hydraulically released. Friction plates (742) are splined to and rotate with cylinder block (111). Mating plates (743) are splined to motor casing (301). When the remote control valve pilot pressure to SH port is blocked, the primary pilot oil pressure flow to brake piston (702) is cut off and the force of brake springs (712) acting on piston (702) squeeze the mating and friction plates together, preventing output shaft (101) from rotating thereby stopping the superstructure from slewing. When the primary pilot oil pressure reacts on the opposite side of brake piston (702) it overcomes the force of springs (712) and moves the piston creating clearance between the friction and mating plates, thereby releasing the brake.



Figure 5 Slew brake 1. 2. 3.



Oil pressure Spring force Oil pressure chamber



Slew motor, lubrication and air purging



Figure 6 Position, drain Dr 



 



Drain port Following the repair or replacement of the slew motor assembly it is necessary to prelubricate the internal components to prevent scoring/scuffing of the bearings and sliding parts. Remove the upper case drain port plug and fill the casing with the specified hydraulic oil. Oil capacity : 900 cc Prior to start up purge the air from the circuit plumbing and motor.



Precautions for lubrication      



Check that there is no contamination in the ports or plumbing before connecting to the motor. Check for oil leakage on the motor assembly. Check if the direction of rotation according to the control lever is correct. Check for abnormal sound or vibration while rotating. Check for any abnormal temperature increase after operating for a short time. Check if the hydraulic pressures are set to the specified values.



Standard for parts service and replacement The following standards of the serviceability of parts can be determined from measurements made at disassembly. However, they are general standards and when parts show excessive external damage or discoloration, top priority should be given to the determination of the extent to which parts are to be replaced, according to the purpose of disassembly and the remaining life expectancy of the parts. Wear limits



Item



Standard dimension mm (in)



Recommended value for replacement mm (in)



Remedy



Clearance between piston and cylinder 0.032 (0.0012) bore (D–d)



0.062 (0.0024)



Replace cylinder.



Gap between piston and caulked part of 0 shoe (α)



0.3 (0.0118)



Replace piston shoe assembly.



Thickness of shoe (t)



5.8 (0.2280)



Replace piston shoe assembly.



Assembled height of retainer plate and 7 (0.2760) spherical bushing (H-h)



6.5 (0.2560)



Replace spherical bushing and retainer plate as a set.



Thickness of friction plate (t)



3.6 (0.1420)



Replace



6 (0.2360)



4 (0.1570)



Standard for correcting sliding surfaces If the surface roughness of the sliding surface of a part exceeds the following standard, correct it or replace the part. Sliding surface Part



Standard surface roughness



Standard roughness requiring correction



Shoe



0.8–Z (Ra=0.2) (lapping)



3–Z (Ra=0.8)



Swash plate



0.4–Z (Ra=0.1) (lapping)



3–Z (Ra=0.8)



Cylinder



1.6–Z (Ra=0.4) (lapping)



12.5–Z (Ra=3.2)



Valve plate



0.8–Z (Ra=0.2) (lapping)



6.3–Z (Ra=1.6)



 



Lap each sliding surface to a standard roughness level or finer. If the sliding surface of the cylinder block, valve plate, retaining plate or spherical bushing is roughened, replace the parts as sub assemblies.



Slew motor, adjustment



Crossover relief valve  



  



Remove the pressure port plug PA or PB. Install the oil pressure gauge (600 kgf/cm2 : 8530 psi). Tools: 6 mm Allen wrench Fitting size of pressure checking port: PF 1/4″ Secure the superstructure by putting the bucket against an immovable object or in a trench. Operate the slew lever in the appropriate direction and check the relief pressure. Loosen lock nut and turn adjusting screw as follows :  







To increase pressure, turn clockwise. To decrease pressure, turn counter clockwise.



If the relief pressure can not be adjusted correctly, replace the relief valve assembly.



Figure 7 Position, pressure measuring PA, PB



Gauge port



1



Lock nut



2



Adjusting screw



Slew motor, tools General tools Description



Size: mm (inch)



Thread



Tools



Screw



17 (0.669)



M 20



Allen wrench



VP Plug



19 (0.748)



PF 1/4



Socket allen wrench



Plug



13 (0.512)



M8



Socket allen wrench



RO Plug



14 (0.551)



M 30



Allen wrench



Screw



10 (0.394)



M6



Spanner, socket wrench



Relief valve



41 (1.614)



M 33



Spanner, socket wrench



Plug



10 (0.394)



PT 1/2



Allen wrench



Plug



14 (0.551)



PT 3/4



Allen wrench



Special tools Special tools



Description



Size



Snap ring plier



φ52, φ60 (φ2.05, φ2.36)



Driver



(–) Medium (2)



Pry bar



10 × 8 × 200 mm (0.4 × 0.3 × 7.9 inch)



Hammer



Plastic and steel hammers



Torque wrench



Tightening torque 9.8 ~ 44 Nm (1 ~ 4.5 kgf m) (7.3 ~ 32.6 lbf ft) 39 ~ 176 Nm (4 ~ 18 kgf m) (29 ~ 130 lbf ft) 118 ~ 471 Nm (12 ~ 48 kgf m) (87 ~ 348 lbf ft)



Puller



14559282 Puller



Troubleshooting, track motor Given below are actions to be taken when you have found any abnormality with the hydraulic motor during operation. Identify possible causes Before proceeding to work, try to determine the nature of the fault, check all related systems and discuss the malfunction with the operator. Finally recheck the most likely causes of the malfunction again before dismantling the motor. Beware of dirt Many faults result from dirt. Therefore take adequate measures prior to disassembly and during assembly to prevent entry of any contamination. Handling parts Parts are precision finished and sufficient care should be taken in handling so as not to damage them. NOTE! It is recommended during assembly to replace O-rings and oil seals with new ones. Fault finding of motor It is extremely difficult to trace trouble in the hydraulic circuits. Inspect the following items and investigate whether or not the fault is caused by the motor. Inspecting the oil in casing Remove the drain plug and inspect the hydraulic oil in the casing. If a large amount of metallic particles drain out with the oil, you should suspect a failure of internal parts. Presence of abnormal sound Check whether the motor emits an abnormal sound. Pressure measurement of various points Measure pressures at various points and check for faults, instead of disassembling parts at random. Measuring the motor case drain flow 







Put the bucket in a trench to prevent the superstructure from rotating. Operate the slew lever to fully load the slew motor. The normal drain oil flow in stall condition is below approximately 25 l/min (6.5 gpm) (pressure 270 kgf cm2 : temperature 100°C). The drain oil flow during the normal slew is below 2 l/min (0.5 US gal/min).



The hydraulic motor does not rotate. Troubleshooting Phenomenon



Cause



Remedy



Pressure does not increase. 1. 2.



3.



Safety valve is not set correctly. Relief valve does not function well. a) Sticking of spool b) Clogging of spool throttle Seat of spool does not function well.



1. 2.



3.



Set valve at correct value. a) Repair or replace stuck section. b) Disassemble spool. Check seat section and replace it, if damaged.



Pressure rises. 1. 2. 3. 4. 5. 6.



Overload Seizure of moving parts Brake is not applied with release of oil pressure. Brake piston sticks. Spool sticks. Friction plate is seized.



1. 2. 3.



4. 5. 6.



Remove load. Check and repair piston/shoes, cylinder, valve plate, etc. a) Check and repair circuit. b) Check time delay valve for brake. Disassemble and check it. Disassemble and check it. Disassemble and check it. Replace seized plates.



The motor rotation is reversed. Troubleshooting Phenomenon



Cause



The motor rotation is reversed to lever direction.



1. 2.



Remedy Motor is assembled incorrectly. Piping connected to inlet and outlet is reversed.



1. 2.



Reassemble motor. Correct piping.



The slew speed does not reach the set value. Troubleshooting Phenomenon



Cause



Slew speed does not reach set value.



1. 2. 3.



Remedy Oil flow rate is insufficient. Oil temperature is high and oil leaks abnormally. Sliding parts are worn or damaged.



1. 2. 3.



Check pump's delivery flow and circuit to motor. Reduce oil temperature. Replace damaged parts.



The braking torque is insufficient. Troubleshooting Phenomenon



Cause



Remedy



Brake torque is insufficient. 1. 2. 3. 4.



Friction plate is worn. Brake piston sticks. Brake release pressure cannot be cut off. Spline for friction plates is damaged.



1.



2. 3.



4.



Disassemble and check it. Replace, if worn more than criterion. Disassemble and check it. a) Check and repair circuit. b) Check time delay valve for brake. Disassemble and check it. Replace, if damaged.



The hydraulic motor slips excessively. NOTE! Investigate the drain flow rate of the motor. If it is about 400 cm3/min (24.4 inch3/min) or lower, the motor is considered to be normal. Troubleshooting Phenomenon



Cause



Remedy



When external driving torque is applied to motor, it slips excessively.



1. 2.



Relief valve does not function well. Seat of spool does not function well.



1. 2.



Replace it. Replace it.



Oil leaks from oil seal. Troubleshooting Phenomenon



Cause



Remedy



Oil leaks from oil seal. 1. 2. 3.



4.



Lip catches particles of dirt and is damaged. Shaft is scratched or worn. Because of excessively-high casing internal pressure, lip of oil seal is turned up. Shaft is rusted.



1. 2. 3. 4.



Replace oil seal. Seal lip/shaft contact position, repair or replace parts. If drain piping is clogged, clean it out. Disassemble and repair it.



Oil leaks through mating faces. Troubleshooting Phenomenon



Cause



Remedy



Oil leaks through mating faces. 1. 2. 3. 4.



O-ring is twisted. O-ring is damaged. Seal surface is damaged. Screws are loose or damaged.



1. 2. 3. 4.



Fit it correctly and carry out reassembling. Replace it. Disassemble and repair it. Tighten to specified torque or replace if damaged.



Service Information Document Title: Swing motor, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing motor, replacing Op nbr 441-021 1. Park the machine in the service position C. See 091 Service positions. 2.







 



When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with ignition switch at "ON" position. Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank. Mount the vacuum pump on hydraulic tank, and maintain a vacuum.



NOTICE When a hose has been disconnected, plug both the hose and the connection immediately. The hoses should be marked for correct connection. 3. Remove the hydraulic hoses. NOTE! Tightening torque (1): 250 ±25.5 Nm (25.5 ±2.6 kgf m) (184 ±18.8 lbf ft)



Figure 1 Removal, hydraulic hoses (1) 4. Remove the hydraulic hoses. NOTE! Tightening torque (1): 120 ±12 Nm (12.2 ±1.2 kgf m) (88.1 ±11.8 lbf ft)



Figure 2 Removal, hydraulic hoses (1) 5. Remove the hydraulic hoses. NOTE! Tightening torque (1): 54.9 ±5.9 Nm (5.6 ±0.6 kgf m) (40.4 ±4.3 lbf ft)



Tightening torque (2): 177 ±17.7 Nm (18 ±1.8 kgf m) (130 ±13 lbf ft)



Figure 3 Removal, hydraulic hoses (1, 2) 6. Remove the hydraulic hoses. NOTE! Tightening torque (1): 25.5 ±2.9 Nm (2.6 ±0.3 kgf m) (18.8 ±2.2 lbf ft)



Figure 4 Removal, hydraulic hoses (1) 7. Remove the block (delay valve). NOTE! Disconnect at block slowly very because spring and O-ring hears block.



Figure 5 Removal, block (1) 8. Remove the slew motor mounting screws.



Figure 6 Removal, screws (1) 9. Lift the slew motor with the hoist, and lower to the workbench safely.



Figure 7 Removal, slew motor 1. 2.



Slew motor Hoist



10. NOTE! Do not reuse removed seals when reassembling. Remove the oil filling pipe and the connectors. Install them to a new slew motor.



Figure 8



1. 2.



Oil filling pipe Connectors



11. Thoroughly remove the sealing compound on slew motor and slew gearbox Apply sealing compound to the slew motor mounting surface.



Figure 9 Applying, sealing compound 1.



Sealing compound



12. Install the slew motor. See Apply Loctite #277 or equivalent locking fluid to the mounting screws. Tightening torque screws. See 400 Tightening torque, specifications. 13. The installation procedure is the reverse order of removal. Tightening torque. See 4412 Swing motor, description. NOTE! Do not reuse removed seals when reassembling. 14. Remove the vacuum pump mounted on the hydraulic tank. 15. Bleed air from the hydraulic circuit at the slew motor before operating. 16. After completion of the work, start the engine and check for leaks.



Service Information Document Title: Function Group: Swing motor relief valve, replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing motor relief valve, replacing Op nbr 441-022 1. Park the machine in the service position C. See 091 Service positions. 2.







  



When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with ignition switch at "ON" position. Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank. Mount the vacuum pump on hydraulic tank, and maintain a vacuum. After disconnecting the hose, install a plug to prevent oil leakage and contamination.



3. Remove the slew motor relief valve.



Figure 1 Replacing, relief valve 4. Install a new relief valve.



Figure 2 Relief valve 5. Remove the vacuum pump mounted on the hydraulic tank. 6. Check relief valve pressure of the slew motor, and adjust if necessary.



Service Information Document Title: Swing motor replacing seal



Function Group: removed,



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Swing motor removed, replacing seal Op nbr 441-026 1. Remove the slew motor (stop 1 ~ 9). See 4412 Swing motor, replacing. 2. Remove the retaining rings.



Figure 1 Removal, retaining rings 1. 2.



Retaining ring Retaining ring



3. Remove the seal cover from the slew motor housing.



Figure 2 Removal, seal cover



Date: 2014/7/15



1.



Seal cover



4. Remove the seal from the slew motor housing.



Figure 3 Replacing, seal 1.



Seal



5. Install a new seal to the slew motor housing. NOTE! Apply grease on lip of seal. 6. Install the seal cover to the slew motor housing.



Figure 4 Installation, seal cover 1.



Seal cover



7. Install the retaining rings.



Figure 5 Installation, retaining rings 1. 2.



Retaining ring Retaining ring



8. Install the slew motor (stop 11 ~ 16). See 4412 Swing motor, replacing.



Service Information Document Title: Swing motor, disassembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing motor, disassembly Disassemble Op nbr 00000 14559282 Puller



1. Lift the motor assembly with a wire rope and crane. Clean with cleaning solvent, and dry with compressed air. NOTE! Clean the motor thoroughly before separating from the gearbox. 2. Remove the drain plug and drain the from casing.



Figure 1 Removal, drain plug 303



Valve casing



984



Drain plug



3. Before disassembling make a match mark) on motor casing and valve casing.



Figure 2 Marking, A 301



Motor casing



303



Valve casing



NOTE! Select a clean place. Put a rubber sheet on the work bench to prevent the parts from being damaged. 4. Remove the screws and delay valve from casing.



Figure 3 Removal, delay valve 031



Delay valve



032



Screws



301



Motor casing



5. Remove the relief valve from valve casing.



Figure 4 Removal, relief valve NOTE! Replace O-ring. 6. Remove the screw and rebound damping valve from valve casing.



Figure 5 Removal, rebound damping valve 052



Delay valve



171



Rebound damping valve



303



7. Remove the Ro plug and take out spring and spool from the valve casing.



Valve casing



Figure 6 Removal, Ro plug 469



Ro plug



355



Spring



351



Spool



NOTE! Be careful not to damage the spool seat. 8. Remove the screws and valve casing from casing. When loosening the screws casing will be raised by brake springs. Remove the valve plate from the valve casing.



Figure 7 Removal, screws 131



Valve plate



401



Screws



301



Casing



712



Brake springs



303



Valve casing



Figure 8 Removal, valve plate NOTE! Be careful not to drop the valve plate from the valve casing. (Sometimes the valve plate is adhered to the cylinder.) 9. Remove the brake springs from the brake piston.



Figure 9 Removal, brake springs 712



Brake springs



10. Disassemble brake piston from casing by using the special tool.



Figure 10 Disassembly, brake piston 301



Casing



712



Brake springs



NOTE! Lift it straight, using the screw holes in the brake piston.



Special tool Part No. :14559282 Puller 11. After placing the motor horizontally, take out cylinder from drive shaft. Remove the pistons, retainer, spherical bushing, spacer and swash plate.



Figure 11 Removal, cylinder 101



Drive shaft



121



Pistons



111



Cylinder



123



Retainer



113



Bushing



124



Swash plate



117



Spacer



NOTE! When taking out the cylinder, be careful not to pull out push rod. Piston must be installed into the same bores because of wear pattern. Mark the pistons and respective cylinder bores. 12. Pull out friction plates and mating plates from casing.



Figure 12 Removal, friction and mating plates 116



Push rod



742



Plates



301



Casing



743



Mating plates



102



Shoe plate



13. Remove drive shaft and shoe plate.



Figure 13 Removal, drive shaft 101



Drive shaft



Figure 14 Removal, drive shaft NOTE!



Tape drive shaft spline to prevent oil seal damage. 14. Do next step if required. Remove the inner race of roller bearing from drive shaft with a press.



Figure 15 Removal, inner race 101



Drive shaft



443



Roller bearing



Figure 16 Removal, the inner race NOTE! Do not reuse the bearing race. A. B. C. D.



Press Drive shaft Bearing Support the inner race



15. Remove the snap ring and pull out seal cover from casing. Remove the oil seal from seal cover using a seal driver.



Figure 17 Removal, snap ring 301



Casing



437



Snap ring



305



Seal cover



491



Oil seal



Figure 18 Removal, seal cover 16. Use a slide hammer and a bearing puller or a press to remove the outer race of bearing from casing.



Figure 19 Removal, bearing outer race 301



Casing



443



Race of bearing



NOTE! Do not reuse the bearing. 17. Pull the out roller bearing from valve casing with a sliding hammer and a bearing puller.



Figure 20 Removal, roller bearing 303



Valve casing



444



Race of bearing



NOTE! Do not reuse the bearing. NOTE! Disassembling is finished. Check each component thoroughly. Oil seal replacement (When replacing the oil seal only) Op nbr 00000



1. Remove the snap ring and pull the out seal cover from casing.



Figure 21 Removal, snap ring 301



Casing



305



Seal cover



437



2. Remove the oil seal from casing with a seal driver (M4 × 0.7 screws).



Snap ring



Figure 22 Removal, oil seal 301



Casing



491



Oil seal



3. Install the new oil seal to casing and drive shaft after assembling two screws (M4 × 0.7) on the oil seal.



Figure 23 Assembly, oil sea 101



Drive shaft



301



Casing



491



Oil seal



NOTE! Coat the lip of the oil seal with grease. Be careful not to damage the lip of the oil seal, tape the shaft splines. The seal lip must face toward casing-downward in the picture. 4. Insert the seal cover and install the snap ring to casing.



Figure 24 Assembly, seal cover 101



Drive shaft



491



Oil seal



301



Casing



305



Seal cover



437



Snap ring



Service Information Document Title: Swing motor, assembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing motor, assembly Tightening torque Tightening torque, unit: Nm (kgf m) (lbf ft) Description



Item No.



Thread size



Tightening torque



Screw



401



M20



431.5 (44) (317)



VP Plug



464



PF 1/4



36.3 (3.7) (26.7)



Screw



171



M8



29.4 (3) (21.7)



RO plug



469



M30



220.7 (22.5) (162.5)



Plug



992



PT 1/2



64.7 (6.6) (47.7)



Plug



994



PT 3/4



98.1 (10) (72.2)



Relief valve



051



M33



176.5 (18) (130)



Rebound damping valve



400



M22



39.2 (7) (50.5)



Preparation Clean all part with cleaning solvent and dry with compressed air. Rework damaged parts and before assembling, prepare all replacement parts. Coat the sliding parts and bearings with clean hydraulic oil. Replace the O-rings and oil seal. Use a torque wrench to tighten the screws and plugs, to the specified torque. Assembly, slew motor Op nbr 00000 14559282 Puller



1. Place casing on the work bench with the valve casing side upward.



Figure 1 Casing 301



Casing



2. Heat the inner race of bearing and press-fit to drive shaft.



Figure 2 Assembly, inner race collar 101



Drive shaft



Figure 3 Assembly, inner race collar NOTE! Pay attention to the direction of the inner race collar. A.



Output shaft



3. Heat the inner race of bearing and press-fit to drive shaft.



Figure 4 Assembly, inner race bearing



443



Bearing



101



Drive shaft



444



Bearing



4. Install the snap ring in casing and seal cover. Install the oil seal in casing using the oil seal driver.



Figure 5 Assembly, snap ring 301



Casing



437



Snap ring



305



Seal cover



491



Oil seal



NOTE! Pay attention the direction of oil seal. The seal lip must face toward casing-upward in the drawing. Coat the lip of the oil seal with grease. 5. Using a brass tap the outer race of roller bearing until the bearing is fully seated in casing.



Figure 6 Assembly, roller bearing 301



Casing



6. Install the drive shaft to casing.



443



roller bearing



Figure 7 Assembly, drive shaft 101



Drive shaft



301



Casing



NOTE! Be careful not to damage the lip of the oil seal, tape the shaft splines. 7. Set the casing horizontally and assemble shoe plate casing side.



Figure 8 Assembly, shoe plate (124) A.



Casing side



NOTE! Insert it with the larger chamfered side of the shoe plate toward the casing. Coat lightly with grease. 8. Insert the push rods and spacer F to cylinder and install the spherical bushing with the larger O.D. toward the cylinder.



Figure 9 Assembly, push rods 111



Cylinder



116



Push rods



113



Spherical bushing



117



Spacer F



NOTE! Be careful not to damage the sliding surface of the cylinder. Insert 2 push rods into each hole. 9. Fit the piston sub assembly unit to retainer.



Figure 10 Assembly, piston 121, 122



Sub assembly unit



123



Retainer



10. Assemble the retainer with the piston sub assembly unit to the cylinder block and install the it on drive shaft aligning the splines.



Figure 11 Assembly, piston sub



101



Drive shaft



11. Set the casing with seal cover downward and assemble three mating plates and four friction plates in sequence.



Figure 12 Assembly, plates 301



Casing



742



Friction plates



305



Seal cover



743



Mating plates



NOTE! Align 4 tangs to the notches as shown. 12. Mount O-rings to casing.



Figure 13 Assembly, O-rings 301



Casing



706, 707



O-rings



NOTE! Coat the O-rings with grease. 13. Assemble brake piston to casing.



Figure 14 Assembly, brake piston 301



Casing



702



Brake piston



Figure 15 Assembly, brake piston NOTE! Place 4 notches of the brake piston as shown below. The piston is difficult to assemble because of the restriction of the O-ring; screw two M8 screws into the brake piston and tap them gently. A. B. C. D.



2-M8 Brake piston Screw hole Mounting side



14. Assemble brake springs into brake piston.



Figure 16 Assembly, brake springs 702 NOTE!



Brake piston



712



Brake springs



Confirm the springs are fitted to the brake piston completely. 15. (This procedure is needed only when roller bearing is disassembled) Install the outer race of roller bearing in valve casing while tapping it lightly.



Figure 17 Assembly, roller bearing 303



Valve casing



444



Roller bearing



NOTE! Tap evenly on the outer diameter of the outer race with a brass bar until it is fully seated. 16. Assemble valve plate to valve casing and fit O-ring.



Figure 18 Assembly, valve plate 131



Valve plate



451



Dowel pins



303



Valve casing



472



O-ring



NOTE!



Coat lightly with grease. Ensure dowel pins are installed in the valve casing. 17. Mount valve casing to casing and tighten screws to the specified torque.



Figure 19 Assembly, valve casing 301



Casing



303



Valve casing



401



Screws



NOTE! Be careful to note the mounting direction of the valve casing. (See the drawing) Be careful not to drop the valve plate or let the brake springs pop out. Tighten the screws evenly. 18. Insert the spool and spring into the valve casing and install RO plug with O-ring. Tighten the plug to the specified torque.



Figure 20 Assembly, spool 351



Spool



355



Spring



488



NOTE! Confirm the smooth movement of the spool before installing the plug. 19. Assemble relief valve to valve casing.



O-ring



Figure 21 Assembly, relief valve 051



Relief valve



303



Valve casing



302



Screws



20. Assemble delay valve with screw to casing.



Figure 22 Assembly, delay valve 031



Delay valve



301



Casing



21. Assemble O-ring to rebound damping valve sub assembly and install the valve with screw to valve casing.



Figure 23



052



Damping valve



171



Screws



161



O-ring



303



Valve casing



NOTE! Be sure to install all the O-rings. 22. Assemble plug with O-ring to casing.



Figure 24 Assembly, plug 301



Casing



Service Information Document Title: Function Group: Hydraulic pump coupling, 442 description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic pump coupling, description The coupling consists of the spline hub, the disc plate and the torsion springs, and evenly transmit the engine power to the hydraulic pump absorbing the rotating shocks. The engine torque is transmitted to the interface ring connected to the engine flywheel --> the spline hub of the coupling --> the shaft of the hydraulic pump.



Figure 1 Flexible coupling, sectional view A



Flywheel



1



Interface ring



B



Coupling



2



Disc plate



C



Flywheel housing



3



Torsion spring



D



Hydraulic pump



4



Torsion spring



E



Tightening torque : 6.5 kgf m (47 lbf ft)



5



Pin



F



Cover-pump mounting



6



Spring



G



Tightening torque : 11.3 ±1.1 kgf m (81.6 ±7.9 lbf ft)



7



Hub



8



Friction washer



9



Friction plate



10



Spring guide



11



Pin



12



Plate



13



Rivet



Service Information Document Title: Pump gearbox replacing



Function Group: flange, 442



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Pump gearbox flange, replacing Op nbr 431-036 1. Remove the hydraulic pump from the engine. See 913 Hydraulic pump, replacing to remove the hydraulic pump. 2. Remove the hydraulic pump room covers.



Figure 1 Removal, pump room covers 1.



Hydraulic pump room covers



3. Install the eye bolt on flange and attach hoist to the lifting equipment.



Figure 2 Removal, flange 1. 2. 3.



Hoist Eye bolt Flange



Date: 2014/7/15



4.



Flange mounting screw



4. Remove the screws and flange . 5. Install the new flange to the flywheel. See tightening torque: 442 Hydraulic pump coupling, description.



Figure 3



6. Install the hydraulic pump room covers. 7. Install the hydraulic pump to the engine. See 913 Hydraulic pump, replacing to install the hydraulic pump.



Service Information Document Title: Function Group: Pump gearbox coupling 442 assembly, replacing



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Pump gearbox coupling assembly, replacing Op nbr 431-031 1. Remove the hydraulic pump from the engine. See 913 Hydraulic pump, replacing to remove the hydraulic pump. 2. Remove the hydraulic pump room covers.



Figure 1 Removal, pump room covers 1.



Hydraulic pump room covers



3. Install the eye bolt on flange and attach hoist to the lifting equipment.



Figure 2 Removal, flange 1. 2. 3.



Hoist Eye bolt Flange



Date: 2014/7/15



4.



Screw



4. Remove the screws and flange . 5. After the removing mounting screws, remove the coupling assembly from the flywheel.



Figure 3 Removal, coupling assembly 1. 2.



Screw Coupling assembly



6. Install a new coupling assembly to the flywheel. NOTE! Apply Loctite #277 or equivalent locking fluid 7. Install the flange to the flywheel. 8. Install the hydraulic pump room covers. 9. Install the hydraulic pump to the engine. See 913 Hydraulic pump, replacing to install the hydraulic pump.



Service Information Document Title: Tightening specifications



Function Group:



Information Type: Service Information



torque,



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Tightening torque, specifications Center passage NOTE! Center passage, sectional view. See 4431 Center passage, description.



Center passage mounting screws tightening torque. See 400 Tightening torque, specifications.



Figure 1 Center passage port Center passage port, specifications Port



Port size



Rated pressure, MPa (kgf cm2) (psi) (bar)



Flow rate, Litres/min (gal)



Application



A



1-1/4 Flange



35.3 (360) (5120) (353)



360 (95)



Travel



B



1-1/4 Flange



35.3 (360) (5120) (353)



360 (95)



C



1-1/4 Flange



35.3 (360) (5120) (353)



360 (95)



D



1-1/4 Flange



35.3 (360) (5120) (353)



360 (95)



E



9/16-18 UNF-2B



3.9 (40) (569) (39)



5 (1.3)



Speed control



F



1-1/16-12 UNF-2B



0.49 (5) (71.1) (4.9)



45 (11.9)



Drain motor



Tightening torque, specifications Item



Tightening torque, Nm (kgf m) (lbf ft)



PT1/4 Plug



392.3 ±3.92 (40 ±0.4) (288.8 ±2.9)



PT1 Plug



490.3 ±49.0 (50 ±5) (361 ±36.1)



G. Hose (GDr) track motor



119.6 ±11.8 (12.2 ±1.2) (88.1 ±8.7)



F. Hose (FPi) track motor



25.5 ±2.9 (2.6 ±0.3) (18.8 ±2.2)



15. Plug



47.1 ±4.9 (4.8 ±0.5) (34.7 ±3.6)



H. Nipple



47.1 ±4.9 (4.8 ±0.5) (34.7 ±3.6)



I-1. Tee nipples nipple I-2. Straight nipple



119.6 ±11.8 (12.2 ±1.2) (88.1 ±8.7) 189.3 ±18.6 (19.3 ±1.9) (139.4 ±13.7)



J. Flange



175.5 ±17.7 (17.9 ±1.8) (129.2 ±13.0)



K. Nipple



189.3 ±18.6 (19.3 ±1.9) (139.4 ±13.7)



Service Information Document Title: Function Group: Center passage, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Center passage, description The center passage consists of hub, shaft, seal rings, cover, plugs, spacer and retainer ring. The hub contains oil grooves to route the flow of oil. The shaft has passages to supply oil into the hub. The seal rings prevent oil leakage between shaft and hub. The cover prevents external oil leakage, and with screws, retainer ring, fix spacer; hub and shaft are locked together. High pressure oil from the main control valve is delivered to the center passage, and flows through ports A - B or C - D to the left and right track motor, to drive the track motors. Drain oil returns to the reservoir via port G, also travel (high speed) control servo hydraulic oil flows into port B. Shaft is fixed to the under structure and hub assembly rotates freely on the shaft with the superstructure. The oil flows through circumferential grooves in the hub, therefore oil flow is not obstructed during swing. Sectional view



Figure 1 Center passage, sectional view 1



Shaft



7



O-ring



13



Screw



2



Hub



8



O-ring



14



Spring washer



3



Cover



9



O-ring



15



Plug



4



Spacer (thrust)



10



Plug - PT



16



Plug



5



Shim



11



Plug - PT



6



Seal ring



12



Retainer ring



Port connection



Main control valve Center passage



Port size



Pressure, (psi)



A



1-1/4 Flange



360 (5120)



B



Travel (reverse - left)



AL



B



1-1/4 Flange



360 (5120)



A



Travel (reverse - right)



Br



C



1-1/4 Flange



360 (5120)



A



Travel (forward - left)



BL



D



1-1/4 Flange



360 (5120)



B



Travel (forward - right)



A5 (solenoid valve)



F



9/16-18UNF-2B



40 (569)



Pi



Speed control



Hydraulic tank



G



1-1/16-12UNF-2B



5 (50)



Dr



Motor drain



Ar



kgf



cm2 Track motor



Application



Service Information Document Title: Center passage, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Center passage, replacing Op nbr 443-037 1. Park the machine in the service position C. See 091 Service positions. 2.







  



When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with ignition switch at "ON" position. Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank. Mount the vacuum pump on hydraulic tank, and maintain a vacuum. After disconnecting the hose, install a plug to prevent oil leakage and contamination.



3. Remove the motor drain hose connected to the upper side of center passage hub.



Figure 1 Removal, hoses 1. 2. 3.



Motor drain hose 2nd speed hose Motor high pressure hoses



4. Remove the 2nd speed hose. 5. Remove the motor high pressure hoses. 6. Remove the protecting plate in the middle of undercarriage.



Figure 2 Removal, protecting plate 1.



Protecting plate



7. Remove the 2nd speed hose.



Figure 3 Removal, hoses and screws 1. 2. 3. 4.



2nd speed hose Motor drain hose Motor high pressure hoses Mounting screws



8. Remove the motor drain hose. 9. Remove the motor high pressure hoses. 10. Remove the center passage mounting screws.



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 11. Install an eye bolt in the middle of the center passage cover, attach a sling to the lifting equipment. Lift the center passage, and lower to the workbench safely.



Figure 4 Removal, center passage 1. 2.



Sling Eye bolt



12. Remove the connector and tee. Install them on a new center passage 13. Install the center passage in reverse order of the removal procedure. 14. Remove the vacuum pump mounted on the hydraulic tank.



Service Information Document Title: Tightening specifications



Function Group: torque, 492



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Tightening torque, specifications Swing ring gear cover, Demolition standard



Figure 1 Swing ring gear cover Tightening torque No.



Items



Weight: kg (lbs)



Tightening torque, Nm (kgf m) (lbf ft)



1



Swing ring gear cover-front



32.1 (70.8)



–



2



Swing ring gear cover-left and right



32.5 (71.6)



–



3



Swing ring gear cover-rear



32.2 (71)



–



4



Mounting screws



8 EA



1727 ±173 (176 ±18) (1271 ±127)



5



Swing ring gear cover-grease port



6 (13)



–



6



Mounting screws



2 EA



64 ±6.9 (6.5 ±0.7) (47 ±5.1)



NOTE! Mounting screws. Apply Loctite #277 or equivalent locking fluid.



Service Information Document Title: Swing ring description



Function Group: gear, 492



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing ring gear, description



Figure 1 Swing ring gear, sectional view 1



Connector



12



Screw



2



Grease-elbow



13



Lower frame + swing ring gear mounting screws



3



Cover



14



Outer race + upper frame mounting screws



4



Packing



15



Outer race + upper frame mounting screws



5



Dowel pin



16



Clip mounting screw



6



Seal



17



Screw-flange



7



Washer-plain



18



Screw-spring



8



Pipe-LH



19



Clip-insulated single tube



9



Pipe-RH



20



Plug-hydraulic



10



Block-swing system



21



Nipple-grease



11



Swing gear-swing system



*



“S' Mark soft zone (inner race) Plug (outer race)



Tightening torque



Screws (No. 16, 17): 23 ±2.3 Nm (2.3 ±0.23 kgf m) (17 ±1.7 lbf ft) Screws (No. 22): 262 ±26.5 Nm (26.7 ±2.7 kgf m) (193 ±19.5 lbf ft) Screws (No. 13, 14, 15): 1727 ±168 Nm (176 ±17 kgf m) (1271 ±124 lbf ft) Apply Loctite #277 or equivalent locking fluid Grease-elbow (No. 2): 74 Nm (7.5 kgf m) (54 lbf ft) Grease nipple: 23 ±2.3 Nm (2.3 ±0.23 kgf m) (17 ±1.7 lbf ft) Swingw ring gear cover assembly marking, structure



Figure 2 Swing ring gear cover assembly marking A



No. datum point (dowel pin)



C



Front



B



Grease port



D



Rear



E



Dowel pin



Mark: 2, 4, 12, 14, 19, 7, 9, 17 Tightening torque: 1726.9 ±167.7 Nm (176.1 ±17.1 kgf m) (1271.4 ±123.5 lbf ft) Apply Loctite #277 or equivalent locking fluid NOTE! Do not screws assembly marking.



Service Information Document Title: Function Group: Swing ring gear inner seal, 492 replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing ring gear inner seal, replacing Op nbr 492-032 1. Remove the superstructure. See 710 Superstructure, removal. A number is wire rope (cable) (1), superstructure (2) and undercarriage (3).



Figure 1 Removal, superstructure 2. Remove the inner seal attached to the machine with a (-) screwdriver.



Figure 2 Removal, inner seal 1. 2. 3.



Inner seal Inner race Outer race



3. Remove the impurities (grease, dirt, bond, etc.) around seal groove and clean seal groove. NOTE! If impurities remain, adhesion with bond agent is not good.



Clean the seal groove and around seal groove with cleaning solvent on a soft pad. Finally clean the seal groove and around seal groove with a dry pad. 4. Clean the new seal surface with a clean pad. 5. Apply instant bond to inner seal groove. NOTE! Bond: TB1735 6. Install seal with seal lip against outer race. Start about 76 mm (3 inch) from end of seal using a blunt instrument to force seal into groove. Push seal in direction of portion already installed to avoid stretching. Before bringing ends of seal together, cut off excess length.



Figure 3 Cut, seal 7. Apply adhesive to both ends of seal. Push ends into seal groove making sure they come together. Finally, apply the bond agent to the seal and all contact parts of seal groove additionally.



Figure 4 Applying, adhesive (A) NOTE! To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using swing function. 8. Install the superstructure. See 710 Superstructure, installation.



Service Information Document Title: Swing ring gear, replacing



Function Group: 492



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing ring gear, replacing Op nbr 492-021 1. Remove the superstructure. See 710 Superstructure, removal. 2. Hold the swing ring gear with wire rope. See weight 492 Swing ring gear, specifications.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 1 Lifting, swing ring gear 1. 2.



Wire rope Swing ring gear



3. Remove the swing ring gear mounting screws and swing ring gear.



Figure 2 Removal, screws 1.



Swing ring gear



2.



Swing ring gear mounting screws



4. Replace swing ring gear outer seal and swing ring gear inner seal 492 Swing ring gear outer seal, replacing and 492 Swing ring gear inner seal, replacing.



as



necessary.



See



5. Remove the ring gear greases pipe, nipples and install to the new swing ring gear. 6. Install the swing ring gear on undercarriage so the tooth marked “S” (soft zone) is equivalent and bearing loading plug (outer race) is the left side of machine as shown. See 492 Swing ring gear, description. 7. Install the swing ring gear mounting screws. Apply Loctite #277 or equivalent locking fluid. See 492 Swing ring gear, description. 8. Apply Alvania EP #2 grease to swing ring gear teeth and pinion gear. See 492 Swing ring gear, specifications.



Figure 3 Grease (1) 9. Install the superstructure. See 710 Superstructure, installation.



Service Information Document Title: Function Group: Swing ring gear outer seal, 492 replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Swing ring gear outer seal, replacing Op nbr 492-031 1. Park the machine in the service position B. See 091 Service positions. 2. Remove the outer seal attached to the machine with a (-) screwdriver.



Figure 1 Removal, outer seal 1. 2. 3. 4.



Outer seal Outer race Inner seal Inner race



3. Remove the impurities (grease, dirt, bond, etc.) around seal groove and clean seal groove. NOTE! If impurities remain, adhesion with bond agent is not good. 4. Clean the seal groove and around seal groove with cleaning solvent on a soft pad. Finally clean the seal groove and around seal groove with a dry pad. 5. Clean the new seal surface with a clean pad.



6. Figure 2 Replacing, swing ring gear outer seal 1. 2. 3.



Swing ring gear Seal Bond: TB1735



With clearance (approximately 100 mm (3.9 inch) between (A) and (B), apply the bond agent to the seal groove and seal then insert the seal. At this time, do not apply the bond agent all over seal and seal groove. Apply the bond agent on about 300 mm (11.8 inch) of the seal and seal groove. Work quickly when inserting the seal. If the time is delayed after applying the bond agent, it will solidify. 7. When inserting the seal, pull the seal slightly and insert the seal by pushing it with a (-) screwdriver. 8. Insert the seal from (B) to (C). Grip seal (A) and (D) with both hands, and overlap the seal, and then fit the length properly. Cut the seal correctly and clean both ends of seal. NOTE! At final assembly, if the seal is too long, grip the seal with both hands and overlap the seal, and then cut the seal about 20 mm (0.79 inch) short. 9. Apply the bond agent lightly on both seal ends cut cleanly, and stretch the seal with both hands. Fit both ends of seal together in correct form and join them. Hold the seal for a while, until the ends are joined. 10. Apply the bond agent to the seal and seal groove between (B) and (C), and insert the seal quickly. 11. Finally, apply the bond agent to the seal and all contact parts of seal groove additionally. 12. Approximately 1 minute later, check the seal by rotating the superstructure of the machine slowly.



Service Information Document Title: Ring gear grease replacing



Function Group: pipe, 492



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Ring gear grease pipe, replacing Op nbr 492-091 1. Park the machine in the service position B, see 091 Service positions. Rotate the superstructure of the machine to 45°. 2. Loosen the screw of the clamp by a half turn.



Figure 1 Removal, screw and nut 1. 2.



Screw Nut



3. Loosen the nut of the pipe, and disconnect one end of the pipe. 4. Rotate the superstructure of the machine an additional 45°. 5. Loosen the nut of the pipe, and disconnect the pipe.



Figure 2 Replacing, ring gear grease pipe



Date: 2014/7/15



1. 2.



Screw Nut



6. Loosen the screw of the clamp completely, and remove the ring gear grease pipe. 7. Tighten screw of the clamp on a new ring gear grease pipe by a half turn. 8. Tighten nut of the pipe to the elbow. 9. Rotate the superstructure of the machine to the opposite direction 45°. 10. Tighten nut of the pipe to the elbow. 11. Tighten screw of the clamp completely.



Figure 3 Tightening torque 1. 2. 3. 4. 5. 6.



Grease fitting 9.8 ±1.0 Nm (1.0 ±0.1 kgf m) (7.2 ±0.7 lbf ft) Grease nipple 22.6 ±2.0 Nm (2.3 ±0.2 kgf m) (1.7 ±1.4 lbf ft) Screw 63.7 ±19.6 Nm (6.5 ±0.7 kgf m) (46.9 ±14.4 lbf ft) Clamp 48.1 ±4.9 Nm (4.9 ±0.5 kgf m) (35.4 ±3.6 lbf ft) Pipe 58.8 ±5.9 Nm (6.0 ±0.6 kgf m) (43.3 ±4.3 lbf ft) Elbow fitting 73.6 ±7.8 Nm (7.5 ±0.8 kgf m) (54.2 ±5.8 lbf ft)



Service Information Document Title: Swing ring gear removal



Function Group: cover, 492



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Swing ring gear cover, removal Swing ring gear cover, Demolition standard Op nbr 492-095 1. Park the machine in the service position B. See 091 Service positions. NOTE! Weight and tightening torque. See 492 Tightening torque, specifications.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 1 Swing ring gear cover 1. 2. 3. 4.



Swing ring cover-front Swing ring cover-left Swing ring cover-right Swing ring cover-rear



Date: 2014/7/15



5. 6. 7. 8.



Screws Spaces Swing ring cover-grease port Screws



2. Remove the grease port cover mounting screws and grease port cover. 3. Remove the front cove mounting screws and front cover. This work needs two people.



WARNING When the last bolt has been removed, the cover plate falls down. 4. Remove the rear cover mounting screws and rear cover. This work needs two people.



WARNING When the last bolt has been removed, the cover plate falls down. 5. Park the machine in the service position E. See 091 Service positions. 6. Remove the left cover mounting screws and left cover. This work needs two people.



WARNING When the last bolt has been removed, the cover plate falls down. 7. Remove the right cover mounting screws and right cover. This work needs two people.



WARNING When the last bolt has been removed, the cover plate falls down.



Service Information Document Title: Swing ring gear installation



Function Group: cover, 492



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Swing ring gear cover, installation Swing ring gear cover, Demolition standard Op nbr 492-096 1. Park the machine in the service position B. See 091 Service positions. NOTE! Weight and tightening torque. See 492 Tightening torque, specifications.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 1 Swing ring gear cover 1. 2. 3. 4.



Swing ring cover-front Swing ring cover-left Swing ring cover-right Swing ring cover-rear



Date: 2014/7/15



5. 6. 7. 8.



Screws Spaces Swing ring cover-grease port Screws



2. Install the right cover and right cover mounting screws. This work needs two people. 3. Install the left cover and left cover mounting screws. This work needs two people. 4. Park the machine in the service position E. See 091 Service positions. 5. Install the rear cover and rear cover mounting screws. This work needs two people. 6. Install the front cove and front cover mounting screws. This work needs two people. 7. Install the grease port cover and grease port cover mounting screws. 8. Check the operation of the machine.



Thank you for your purchase. Have a nice day.



file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/7/15 8:55:42]



Service Information Document Title: Frame and track description



Function Group: unit, 700



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Frame and track unit, description Upper frame type



Figure 1 Upper frame A. B. C. D.



Rops with fixed counter weight type, weight: 4102 kg (9043 lbs) Rops with removable counter weight type, weight: 4105 kg (9050 lbs) Rops With FOG and fixed counter weight type, weight: 4130 kg (9105 lbs) Rops With FOG and removable counter weight type, weight: 4132 kg (9109 lbs)



Lower frame type NOTE! See 7181 Undercarriage, description.



Date: 2014/7/15



Service Information Document Title: Superstructure, removing



Function Group: 710



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Superstructure, removing Op nbr 710-001 1. Park the machine in the service position D. See 091 Service positions. Position the machine on flat, firm and level ground, free from any obstructions or interference. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual pressure inside the hydraulic line by operating the control lever smoothly 3-4 timeswith the ignition key at "ON" position. Turn the ignition key to "OFF" position. 2. Remove the hydraulic oil hoses, stopper screw, seal cover fixing screws, clamp and seal covers from center passage.



NOTICE When a hose has been disconnected, plug both the hose and the connection immediately. The hoses should be marked for correct connection.



Figure 1 Removal, hydraulic hoses 1. 2. 3. 4.



Hydraulic oil hoses Stopper screw Seal cover fixing screw Seal cover



3. Remove the two lifting points covers from the top of counterweight. See 716 Counterweight, removing.



Figure 2 Removal, lifting points covers (1)



WARNING



4.



Risk of personal injury. Very heavy object.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



WARNING Never lift the machine with a person in the cab.



WARNING Always use classified cables, lifting straps, shackles and hooks with sufficient lifting capacity. Hold the superstructure with wire ropes (cables). Check the superstructure weight. See 710 Machine weight, specifications. Check the wire ropes length (cables). Refer to the operators manual for further operation or cab in lifting machine decal. See Operating instructions, Transporting machine, Lifting machine.



Figure 3 Lifting superstructure 1. 2. 3.



Wire rope (cable) Superstructure Undercarriage



Figure 4 Lifting points NOTE! As shown in the decal for lifting, connect lifting wire ropes (cables) or slings with sufficient strength for the machine weight at the lifting points correctly.



After installation of all hoisting equipment, lift the machine a little to check its balance, if satisfactory, lift it slowly and evenly. 5. Remove the superstructure mounting screws from the swing ring gear.



Figure 5 Removal, superstructure mounting screws 1. 2.



6.



Superstructure mounting screw Swing ring gear



WARNING The superstructure is heavy. Pay attention to safe footing and the area around the crane before proceeding to remove or install the superstructure.



Remove the superstructure slowly and lower onto the 4 jacks safely. Maintain good visibility of the machine at all times during the lift. And continuously check that the machine is level.



Figure 6 Removal, lifting superstructure (1)



Service Information Document Title: Superstructure, installing



Function Group: 710



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Superstructure, installing Op nbr 710-002



WARNING



1.



Risk of personal injury. Very heavy object.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



WARNING Never lift the machine with a person in the cab.



WARNING Always use classified cables, lifting straps, shackles and hooks with sufficient lifting capacity. Hold the superstructure with wire ropes (cables). Check the superstructure weight. See 710 Machine weight, specifications. Wire ropes length (cables). Refer to the operators manual for further operation or cab in lifting machine decal. See Operating instructions, Transporting machine, Lifting machine.



Figure 1 Lifting superstructure 1. 2. 3.



Wire rope (cable) Superstructure Undercarriage



Figure 2 Lifting points NOTE! As shown in the decal for lifting, connect lifting wire ropes (cables) or slings with sufficient strength for the machine weight at the lifting points correctly.



After installation of all hoisting equipment, lift the machine a little to check its balance, if satisfactory, lift it slowly and evenly. 2. Thoroughly clean the mounting surface. Before replacing the superstructure, apply sealing compound to the mounting surface. NOTE! If impurities remain, adhesion with bond agent is not good.



Figure 3 Clean the mounting surface 1. 2.



3.



Clean the mounting surface Sealing compound



WARNING



The superstructure is heavy. Pay attention to safe footing and the area around the crane before proceeding to remove or install the superstructure. Lift the superstructure and install it to the swing ring gear. Maintain good visibility of the machine at all times during the lift. And continuously check that the machine is level. NOTE! Match the “S” mark (soft zone position) on inner race and the plug on outer race.



Figure 4 Installation, superstructure 1. 2. 3. 4.



Superstructure Swing ring gear “S” mark inner race (soft zone position) Plug outer race



4. Install the superstructure mounting screws from the swing ring gear. 492 Swing ring gear, description. Apply Loctite #277 or equivalent locking fluid.



Figure 5 Installation, superstructure mounting screws



Tightening



torque.



See



1. 2.



Superstructure mounting screw Swing ring gear



5. Remove the wire rope (cable) at the lifting points. Install the seal covers, seal cover fixing screws, stopper screw, clamp and hydraulic oil hoses from center passage. Tightening torque, seal cover fixing screw: 22.6 ±1.96 Nm (2.3 ±0.2 kgf m) (16.6 ±1.4 lbf ft) Apply Loctite #277 or equivalent locking fluid.



Figure 6 Installation, hydraulic hoses 1. 2. 3. 4. 5.



Hydraulic oil hoses Stopper screw: 242.2 ±24.5 Nm (24.7 ±2.5 kgf m) (178.3 ±18 lbf ft) Seal cover fixing screw Seal cover Stopper screw: 15 mm (0.59 inch)



6. Install the two lifting points covers 716 Counterweight, tightening torques.



from



the



top



of



counterweight.



See



Figure 7 Installation, lifting points covers (1) 7. Check the operation of the swing, hydraulic oil hoses and swing ring gear mounting screws.



tightening



torque.



Service Information Document Title: Tightening specifications



Function Group: torque, 715



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Tightening torque, specifications Protection plates



Figure 1 Machine view, protecting plate Tightening torque: Nm (kgf m) (lbf ft) No.



Items



Weight: kg (lbs)



Tightening torque: Nm (kgf m) (lbf ft)



1



Track motor protection cover (LH, RH)



LH: 19 (42) RH: 19 (42)



700 Undercarriage, tightening torque



2



Undercover heavy duty (mud) Apply Loctite #277 a: 30 (66) or equivalent locking fluid b: 37 (82)



265 ±29 (27 ±3) (195 ±22)



3



Retractable protection plates (LH, RH)



LH: 40 (88) RH: 40 (88)



4



Undercover standard (mud) Apply Loctite #277 or 27 (60) equivalent locking fluid



Service Information Document Title: Tightening specifications



Function Group: torque, 715



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Tightening torque, specifications Side impact protection, Demolition standard



Figure 1 Machine view, side impact protecting Tightening torque No. 1



Items



Weight: kg (lbs)



Tightening torque Nm (kgf m) (lbf ft)



Side (RH) impact protection



73 (161)



262 ±26 (26.7 ±2.7) (193 ±19)



2 3



73 (161) Side (LH) impact protection



4 5



53 (117) 53 (117)



Step-cabin



11 (25)



111 ±11 (11.3 ±1.1) (82 ±8)



Service Information Document Title: Tightening specifications



Function Group: torque, 715



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Tightening torque, specifications Boom cylinder protecting guard, Demolition standard



Figure 1 Boom cylinder protecting guard Tightening torque No.



Items



Weight: kg (lbs)



Tightening torque Nm (kgf m) (lbf ft)



1



Boom cylinder protecting guard



79.7 (175.7)



–



2



Clamp-lower



1.4 (3.1)



–



3



Clamp-upper



8.2 (18.1)



–



4



Mounting screws



8 EA



262 ±26.5 (26.7 ±2.7) (193 ±19.5)



5



Mounting screws



8 EA



a



435 mm (17.13 inch)



b



735 mm (28.94 inch)



c



318 mm (12.52 inch)



NOTE! Mounting screws. Apply Loctite #277 or equivalent locking fluid.



Service Information Document Title: Tightening specifications



Function Group: torque, 715



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Tightening torque, specifications Bucket cylinder protecting guard, Demolition standard



Figure 1 Protecting guard, bucket cylinder Gap and shims Items



Gap clearances: mm (inch)



Thick shims (1.0 t)



Thick shims (0.5 t)



Position



Minimum



Maximum



Quantity



Quantity



GAP 1



+0.5 (0.01969)



+2.5 (0.09843)



2



–



GAP 2



+2.0 (0.07874)



+3.0 (0.11811)



2



–



GAP 3



+0.5 (0.01969)



+1.5 (0.05906)



–



1



GAP 4



+0.5 (0.01969)



+1.5 (0.05906)



–



1



A



111 ±11 Nm (11.3 ±1.1 kgf m) (82 ±8 lbf ft)



B



262 ±26 Nm (26.7 ±2.7 kgf m) (193 ±19 lbf ft)



C



511.9 ±51 Nm (52.2 ±5.2 kgf m) (377 ±38 lbf ft)



NOTE! The item #4 and #5 before assembly coated grease on the hole inside.



Service Information Document Title: Function Group: Boom cylinder protecting 715 guard, removal



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Boom cylinder protecting guard, removal Op nbr 715-019 1. Park the machine in the service position B, see 091 Service positions.



Figure 1 Position, boom cylinders 1. Boom cylinders 2. Sling guard 2. Raise boom cylinders, to Vertical position and stop engine. 3. Install the I-bolt and sling guard securely with a hoist. NOTE! Guard weight. See 715 Tightening torque, specifications.



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 4. Remove the screws and guard.



Date: 2014/7/15



Figure 2 Remove, guard (2) and screws (3) 5. Remove the screws and clamps.



Figure 3 Remove, clamp (5) and screws (4)



Service Information Document Title: Function Group: Boom cylinder protecting 715 guard, installation



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Boom cylinder protecting guard, installation Op nbr 715-020 1. Park the machine in the service position B, see 091 Service positions.



Figure 1 Marking, clamp position a. b.



XXX mm (XX inch) XXX mm (XX inch)



NOTE! See 715 Tightening torque, specifications. 2. Raise boom cylinders, to Vertical position and stop engine. 3. Mark clamp location on each the boom cylinder. 4. Install the screws and clamps, don't over tighten the clamps.



Date: 2014/7/15



Figure 2 Install, clamp 2. Clamps 3. Screws 5. Sling guard securely with a hoists and install the screws.



Figure 3 Install, guard 4. Sling guard 5. Screws NOTE! Apply loctite on screws (5). NOTE! Guard weight and tightening torque. See 715 Tightening torque, specifications.



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 6. Before installing screws apply loctite.



Figure 4 Install, clamp screw (6) NOTE! Tightening torque. See 715 Tightening torque, specifications. 7. Check for interference of guard by operating the boom cylinders.



Service Information Document Title: Function Group: Bucket cylinder protecting 715 guard, removal



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Bucket cylinder protecting guard, removal Op nbr 715-023 1. Park the machine in the service position A, see 091 Service positions.



Figure 1 Remove, cover 2. Install I-bolts and sling guard (1) securely with a hoist. Remove screws (2) and cover (3). 3. Remove screws (6) and guard (5).



Figure 2 Remove, guard



WARNING The parts are heavy. Take appropriate safety cautions when handling them. NOTE! Guard (5) weight: 185 kg (408 lbs) 4. Remove screws (6), collars (7) and links (8).



Date: 2014/7/15



Figure 3 Remove, links 5. Remove screws (9) and plates (10).



Figure 4 Remove, plates 6. Remove screws (11) and clamp (12).



Figure 5 Remove, clamp



Service Information Document Title: Function Group: Bucket cylinder protecting 715 guard, installation



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Bucket cylinder protecting guard, installation Op nbr 715-024 1. Park the machine in the service position A, see 091 Service positions.



Figure 1 Install, clamp 2. Install clamp (1) and screws (2). NOTE! Apply loctite #277 on screws



Tightening torque: 111 ±11 Nm (11.3 ±1.1 kgf m) (82 ±8 lbf ft) 3. Install plates (3) and screws (4).



Figure 2 Install, plates NOTE! Apply loctite #277 on screws



Date: 2014/7/15



Tightening torque: 111 ±11 Nm (11.3 ±1.1 kgf m) (82 ±8 lbf ft) 4. Install links (7), collars (6) and screws (5). Protecting guard shims, see 715 Tightening torque, specifications.



Figure 3 Install, links 5. Install I-bolts and sling guard (8) securely with a hoist.



Figure 4 Install, guard Install guard (8) and screws (9). NOTE! Guard weight: 187 kg (412 lbs)



Tightening torque: 262 ±26 Nm (26.7 ±2.7 kgf m) (193 ±19 lbf ft)



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 6. Install cover (10), screws (11) and check for interference of guard by operating the bucket cylinder.



Figure 5 Install, cover NOTE! Tightening torque: 262 ±26 Nm (26.7 ±2.7 kgf m) (193 ±19 lbf ft)



Service Information Document Title: Function Group: Counterweight, description 716



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Counterweight, description Fabrication type The counterweight is a counterbalancing weight that is located at the rear of the machine. The counterweight is designed in order to give the machine extra weight in the back end in order to counter the weight that is located at the front of the machine, in particular the boom and dipper arm.



Figure 1 Counterweight, structure 1 Body



2 Plate



3 Reflector



4



Cover



5 Stopper



6 Base



7 Side plate



8



Under cover



Service Information Document Title: Support information



Function Group: 716



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Support information Removal counterweight support, description



Figure 1 Removal counterweight support 1



Removal counterweight support (Weight: 820 kg, 1808 lbs)



2



Removal counterweight cylinder



3, 4



Support mounting screws Tightening torque: 1324 ±49 Nm (135 ±5 kgf m) (975 ±36 lbf ft)



5



GAP: LH and RH 12.5 mm (0.492 inch)



Date: 2014/7/15



Service Information Document Title: Function Group: Removable counterweight 716 cylinder, specifications



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Removable counterweight cylinder, specifications



Figure 1 Removal counterweight cylinder Item Removal cylinder



Quantity



Unit



Specifications



EA



1



Bore (a) × rod (b) × stroke mm (inch) (c) Center to center distance Full retracted (A) of pins Full extended (B)



φ160 × φ80 × 3421.5 (φ6.30 × φ3.15 × 134.7) 6832 (269) 1025 (40.4)



Cushion



EA



–



Operating pressure



31.4 MPa (320 kgf cm2) (4552 psi) (313.8 bar)



Weight



170 kg (374.8 lbs)



Service Information Document Title: Function Group: Removable counterweight 716 cylinder, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Removable counterweight cylinder, description



Figure 1 Removal counterweight cylinder, sectional view 1



Tube



7



Back-up ring



13



Piston seal



19



Pin bush



2



Rod assembly



8



Buffer ring



14



Wear ring



20



Dust wiper



3



Gland



9



Bushing



15



O-ring



21



Screw



4



Dust wiper



10



O-ring



16



Back-up ring



22



Spring washer



5



Retaining ring



11



Back-up ring



17



Piston lock nut



23



Grease nipple



6



Rod seal



12



Piston nut



18



Set screw



23



2-PF 1/4 O-ring boss



Tightening torque, unit: Nm (kgf m) (lbf ft) No. 12



No. 17



Piston nut, to tighten turn clockwise



Piston (lock) nut, to tighten turn counterclockwise



1078.7 ±98.1 (110 ±10) (794 ±72)



1078.7 ±98.1 (110 ±10) (794 ±72)



No. 18



No. 20



Set-screw



Screw



49 ±4.9 (5 ±0.5) (36 ±3.6)



226 ±20 (23 ±2) (166 ±15)



NOTE! Apply Loctite #277 or equivalent locking fluid to the thread on rod for piston and lock nut before tightening. Volume of oil leakage



Oil leakage Volume of internal oil leakage 5.4 cc (0.33 cu in) or less/10 minimum Wear limits



Figure 2 Maintenance standards Wear limits, unit: mm (inch) Standard value



Tolerance Shaft



Standard clearance



Clearance limit



Hole



No. 1 80 (3.15)



Clearance between -0.036 ~ -0.090 piston rod and bushing (-0.0014 ~ -0.0035)



+0.195 ~ +0.060



0.096 ~ 0.285



(+0.0076 ~ +0.0023)



(0.0037 ~ 0.0112)



0.585 (0.023)



No. 2 85 (3.35)



Clearance piston rod bushing



between -0.036 ~ -0.090 pin and (-0.0014 ~ -0.0035)



+0.226 ~ +0.036



0.072 ~ 0.316



1.0 (0.039)



(+0.0089 ~ +0.0014)



(0.0028 ~ 0.0124)



No. 3 85 (3.35)



Clearance between rear -0.036 ~ -0.090 end pin and bushing (-0.0014 ~ -0.0035)



+0.226 ~ +0.036



0.072 ~ 0.316



(+0.0089 ~ +0.0014)



(0.0028 ~ 0.0124)



1.0 (0.039)



Service Information Document Title: Counterweight, removing



Function Group: 716



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Counterweight, removing Fabrication type Op nbr 716-001



WARNING The counterweight is heavy. Take care in performing removal. To lift the counterweight, use certified wire ropes in good condition, of adequate load rating and length.



WARNING Heavy lift. Make sure that no persons are under the counterweight when it is lifted. 1. Position the machine on flat, firm and level ground, free from any obstructions or interference. Position the boom and arm with the bucket on the ground. Park the machine in the service position B. See 091 Service positions. 2. Remove the plugs on the top surface of the counterweight and install eye bolts. 3. Attach wire slings to eye bolts and lift until there is no slack in the wire ropes. NOTE! Recommendation length of wire slings to keep counterweight level.



A = 2100 mm (82.7 inch), B = 2050 mm (80.7 inch)



Figure 1



1



Wire slings



6



Screw



2



Eye bolts



7



Screw



3



Screws



8



Washer



4



Counterweight



9



Washer



5



Spacer



4. Remove the engine room under cover then remove the screw, spring washer and plain washer. 5. Remove the screw , spacer. 6. Lift the counterweight just a little, and after confirming safety all around, lift it up and out. 7. Remove the counterweight and securely support the counterweight. 8. Install the engine room under cover.



Service Information Document Title: Counterweight, fitting



Function Group: 716



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Counterweight, fitting Fabrication type Op nbr 716-002



WARNING Lift the counterweight just a little, and after confirming safety and horizontal position, proceed to install it. 1. Position the machine on flat, firm and level ground, free from any obstructions or interference. Position the boom and arm with the bucket on the ground. Park the machine in the service position B. See 091 Service positions.



Figure 1



1



Wire slings



4



Counterweight



7



Screws



2



Eye bolts



5



Spacer



8



Washer



3



Screws



6



Screws



9



Washer



2. Engage the control lockout lever securely. 3. Clean the surfaces of counterweight mounting before fitting. 4. Remove the engine room under cover. NOTE! Recommendation length of wire slings to keep counterweight level.



A = 2100 mm (82.7 inch), B = 2050 mm (80.7 inch) 5. Lower the counterweight to the mounting face at the rear of the superstructure. 6. Match the screw hole. Insert spacer (5) and tighten mounting screw (6). NOTE! Apply Loctite #277 or equivalent locking fluid 7. Install the plain washer, spring washer and tighten screw then install engine room under cover. NOTE! Apply Loctite #277 or equivalent locking fluid 8. Remove the eye bolts and install the plugs. Tightening torque No.



Specifications



Screw (6)



See 716 Counterweight, tightening torques.



Screw (7) NOTE! Keep Top, bottom, left and right clearance to be equal. (A = 10 ~ 15 mm, 0.4 ~ 0.6 inch)



Figure 2



Service Information Document Title: Function Group: Removable counterweight, 716 removing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Removable counterweight, removing Op nbr 716-006



WARNING The counterweight is heavy. Take care in performing removal. To lift the counterweight, use certified wire ropes in good condition, of adequate load rating and length. 1. Park the machine in the service position C. See 091 Service positions. 2. Remove the mounting screws first, and then remove the mounting screws.



Figure 1 Removal, screws (1)



Figure 2 Removal, screws (2) 3. Open the side door on the right side of the machine. 4. Open the shut off valve.



Figure 3



1. 2.



Position 0: Close valve Position 1: Open valve



5. Turn on the solenoid valve control switch.



Figure 4



1. 2.



Position 0: Turn OFF Position 1: Turn ON



6. Operate directional control lever to the downward position slowly and smoothly to lower the counterweight onto the ground.



Figure 5



1. 2. 3.



Solenoid valve control switch Directional control lever Shut-off valve



7. Slowly lower the counterweight on firm and flat ground.



Figure 6



8. Remove the pin snap from the pin and then remove pin from the yoke.



Figure 7



1. 2.



Pin Pin snap



9. Separate the counterweight from the support link.



Figure 8



1. 2. 3.



Counterweight Yoke Support link



10. Remove the counterweight and securely support the counterweight. 11. Lift the support link to the upper frame by operating the counterweight control lever.



Figure 9



Service Information Document Title: Function Group: Removable counterweight, 716 installing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Removable counterweight, installing WARNING Lift the counterweight just a little, and after confirming safety and horizontal position, proceed to install it.



WARNING Heavy lift. Make sure that no persons are under the counterweight when it is lifted. Op nbr 716-007 1. Park the machine in the service position C. See 091 Service positions. 2. Place the counterweight on firm and flat ground.



Figure 1



3. Open the side door on the right side of the machine. 4. Open shut-off valve, turn on solenoid valve control switch and then operate directional control lever to the downward position slowly and smoothly to lower the support link.



Figure 2



1. 2. 3.



Solenoid valve control switch Directional control lever Shut-off valve



5. Adjust yoke hole and counterweight lifting hole and then assemble counterweight to support link.



Figure 3



1. 2. 3.



Counterweight Yoke Support link



6. Insert pin to the holes and secure snap pin when the holes are centered.



Figure 4



1. 2.



Pin Pin snap



7. Initially secure nut adjusting the protruded length of the yoke shaft to approximately 80 ±2 mm (A).



Figure 5



1. 2.



Nut Yoke



8. Slowly lift the counterweight, and then check the relative position of holes for inserting bolts.



Figure 6



9. To keep the center on right and left side, adjust stopper bolt and tighten the bolt when it makes symmetry.



Figure 7



10. If the holes are not centered, lower the counterweight onto the ground and adjust the nut of the yoke shaft again.



11. When the counterweight hole is higher than the inside nut, decrease the protruded length of the yoke shaft, then lift the counterweight again and check holes. 12. If there is any interference between the counterweight boss and frame, lower the counterweight onto the ground, increase the protruded length of the yoke shaft, then lift counterweight again and check the holes. 13. When the hole and nut are centered, lower the counterweight onto the ground and tighten the nut securing the yoke for keeping the protruded length. 14. Lift the counterweight slowly 15. Insert mounting screws for each side and mounting screws, and then tighten up according to specified torque.



Figure 8



Figure 9



No.



Specifications



Screw (1)



See 716 Counterweight, tightening torques.



Screw (2) 16. Turn the solenoid valve control switch to off position. 17. Turn the shut-off valve lever to close position. NOTE! Clearance between upper frame and counterweight should be 13 mm.



Figure 10



Service Information Document Title: Undercarriage, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Undercarriage, description Undercarriage consists of idlers, spring package, top and bottom rollers, sprockets, track links, track frame and track guards.



Figure 1 Undercarriage A



Track motor



F



Track chain



B



Track gear box



G



Top roller



C



Sprocket



H



Track tension valve



D



Step



I



Recoil spring



E



Track guard



J



Bottom roller



K



Idler



Lower frame



Figure 2 Foot steps: foldable type 1



Weight: 6032 kg (13298 lbs)



2



Foot step mounting screws. See 700 Undercarriage, tightening torque.



Retractable - variable (additional) lower frame (foot steps: center type)



Figure 3



1



See 700 Undercarriage, tightening torque.



2



Weight: 6820 kg (15035 lbs)



3



Foot step mounting screws. See 700 Undercarriage, tightening torque.



NOTE!



When tightening the bolts, use the dedicated tool as an optional equipment.



Track retracting and extending. See operation manual.



Service Information Document Title: Undercarriage, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Undercarriage, description Undercarriage consists of idlers, spring package, top and bottom rollers, sprockets, track links, track frame and track guards.



Figure 1 Undercarriage A



Track motor



F



Track chain



B



Track gear box



G



Top roller



C



Sprocket



H



Track tension valve



D



Step



I



Recoil spring



E



Track guard



J



Bottom roller



K



Idler



Lower frame



Figure 2 Foot steps: welded type 1



Weight: 6041 kg (13318 lbs)



2



Welded foot step type



Service Information Document Title: Selection of track shoes



Function Group: 775



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Selection of track shoes Choose suitable track shoes to match the ground conditions. Method of selecting shoes Confirm the category from the list of uses in the "Category" table then use the "Selection" table to select the shoe. Categories “B” and “C” are wide shoe, so there are restrictions on their use. Therefore, before using, check the restrictions and consider carefully the conditions of use before selecting a suitable shoe width. If necessary, give the customer guidance in their use. When selecting the shoe width, select the narrowest possible within the range that will give no problem with flotation and ground pressure. If a wider shoe than necessary is used, there will b e a large load on the shoe, and this may lead to bending of the shoe, cracking of the links, breakage of the pins, loosening of the shoe screws, or other problems. Category, track shoes Category



Use



Precautions when using



A



Rocky ground, Travel in low speed when traveling on rough ground with obstacles such as large normal soil boulders and fallen trees.



B



Soft ground



C



Extremely ground ground)



Travel in high speed only on flat ground. When it is impossible to avoid traveling over obstacles, lower the travel speed to approximate half of low speed. NOTE! Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. soft Use only for ground where “A” and “B” are impossible to use. (swamp Travel in high speed only on flat ground. When it is impossible to avoid traveling over obstacles, lower the travel speed to approximate half of low speed. NOTE! Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees.



Selection, track shoes Track shoes type



Category



600 mm (23.6 inch) triple grouser



A



600 mm (23.6 inch) double triple grouser



A



700 mm (27.6 inch) triple grouser



B



800 mm (31.5 inch) triple grouser



B



900 mm (35.4 inch) triple grouser



C



NOTE! See 7753 Track, adjusting track sag.



For ground contact pressure. See the operator's manual. Specifications, Ground pressure, Ground pressure.



Service Information Document Title: Idler, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Idler, description



Figure 1 Structure, idler 1



Idler wheel



4



Support



7



Pin



2



Shaft



5



Seal



8



Plug



3



Bushing



6



O-ring (shaft)



* Idler type: welding type and casting type NOTE! To carry about idling more than 10 times after filling oil. (filling oil and oil speciation. See operator's manual)



Service Information Document Title: Function Group: Idler, measurement of wear



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Idler, measurement of wear 11712316 Inspection tool



Figure 1



Wear limit, unit: mm (inch) No.



Check item



Standard size



Allowable limits



Remedy



1



Outside diameter of flange



674 (26.5)



–



2



Outside diameter tread



630 (24.8)



618 (24.3)



Rewelding replacing



2-1



Depth of tread



22 (0.87)



28 (1.10)



3



Width of flange



101 (3.98)



91 (3.6)



4



Total width of tread (casting)



204 (8.0)



-



Total width of tread (welding)



200 (7.8)



-



Width of tread (casting)



51.5 (2.03)



-



Width of tread (casting)



50 (2.0)



-



5



Wear limit, unit: mm (inch) No.



Check item



Tolerance limits Shaft



6



Clearance between 0 ~ -0.035 shaft and bushing (0 ~ -0.0013)



Allowable limits, Hole +0.42 ~ +0.37 (+0.0165



Standard



Remedy Limits



+0.455 ~ +0.37 1.5 ~ (+0.0179 ~ +0.0146) (0.059)



or



7



Standard size: 95 (3.7)



+0.0146)



Clearance between +0.179 ~ +0.144 idler and bushing (+0.007 ~ +0.0057) Standard size: 103 (4.1)



+0.054 ~ 0 (+0.0021 ~ 0)



-0.09 ~ -0.179 (-0.0035 ~ -0.007)



Tread and flange, measurement of wear Tread, measurement of wear 1.



2.



3. 4.



Clean the surface of tread and flange of the idler.



Figure 2 Measurement, tread wear a: Tread b: Flange 2-1: Depth e: Depth gauge Set a scale on the surface of flange horizontally. Measure the depth between surface of flange and surface of tread using depth gauge. - Tools: Depth gauge (150 mm, 5.9 inch) Measure 3 places to take average value. Measure right and left alternately. Repair or replace if necessary.



Flange, measurement of wear 1.



Clean the surface of measurement of the idler.



2.



Figure 3 Measurement, flange wear 1: Vernier calipers Measure the width of the flange between (c) and (d) using vernier calipers. - Tools: Vernier calipers (200 mm, 7.8 inch) Measure 3 places to take average value. Measure right and left alternately. Repair or replace if necessary.



3. 4.



0 (0)



–



Service Information Document Title: Front idler, removal



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Front idler, removal Op nbr 775-009 14548448 Pump 14560748 Track pin press 14566479 Pin kit



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Remove the track. See 7753 Track chain assembly, removing 2. Push the idler assembly out of the track frame using a pry bar.



Figure 1 Front idler (1) 3. Install an eye bolt onto the track recoil spring assembly.



Figure 2 Install, eye bolt (1) and wire rope (2) 4. Remove the idler and track recoil spring using a lifting device.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 3 Removal, idler (1) and track recoil spring (2) 5. Support it on a workbench. Remove screws connecting the idler and track recoil spring. Replace the idler unit and install the complete assembly.



Figure 4 Removal, connecting screws 1. 2. 3.



Idler unit connecting screws Track recoil spring Idler unit



Service Information Document Title: Front idler, installation



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Front idler, installation Op nbr 775-010 14548448 Pump 14560748 Track pin press 14566479 Pin kit



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Support it on a workbench. Install the idler, track recoil spring and screws connecting . Replace the idler unit and install the complete assembly.



Figure 1 Installation, connecting screws 1. 2. 3.



Idler unit connecting screws Track recoil spring Idler unit







Tightening torque for connecting screws: See 700 Undercarriage, tightening torque.



NOTE! Be careful of offset direction of recoil spring when assemble the spring package.



Apply Loctite #277 or equivalent locking fluid 2. Install the idler and track recoil spring using a lifting device.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 2 Installation, idler (1) and track recoil spring (2) 3. Remove an eye bolt onto the track recoil spring assembly.



Figure 3 Removal, eye bolt (1) and wire rope (2) 4. Push the idler assembly in of the track frame using a pry bar.



Figure 4 Installation, front idler 5. Install the idler and recoil spring assembly to the track frame. NOTE! Confirm that the boss at the piston end of the track recoil spring is in the track frame hole.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 5 Installation, idler and recoil spring assembly 6. Install the track. See 7753 Track chain assembly, installing



Service Information Document Title: Front idler, replacing one



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Front idler, replacing one Op nbr 775-011 14548448 Pump 14560748 Track pin press 14566479 Pin kit



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Remove the track. See 7753 Track chain assembly, removing 2. Push the idler assembly out of the track frame using a pry bar.



Figure 1 Front idler (1) 3. Install an eye bolt onto the track recoil spring assembly.



Figure 2 Install, eye bolt (1) and wire rope (2) 4. Remove the idler and track recoil spring using a lifting device.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 3 Removal, idler (1) and track recoil spring (2) 5. Support it on a workbench. Remove screws connecting the idler and track recoil spring. Replace the idler unit and install the complete assembly.



Figure 4 Removal, connecting screws 1. 2. 3.



Idler unit connecting screws Track recoil spring Idler unit







Tightening torque for connecting screws: See 700 Undercarriage, tightening torque.



NOTE! Be careful of offset direction of recoil spring when assemble the spring package.



Apply Loctite #277 or equivalent locking fluid 6. Install the idler and recoil spring assembly to the track frame. NOTE! Confirm that the boss at the piston end of the track recoil spring is in the track frame hole.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 5 Installation, idler and recoil spring assembly 7. Install the track. See 7753 Track chain assembly, installing



Service Information Document Title: Idler, disassembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Idler, disassembly Tools: 11712326 Prepare the following tools for disassembly and assembly. The numbers in parentheses following each part name in the text correspond to those in figure. 1.



Remove the screws, and remove the track spring.



Figure 1 Removal, spring package A. B. 2.



Remove the plug to drain oil. 



3.



Screw Spring package



Tool : Allen wrench (6 mm)



Put the pin jig on pin, and force out the pin by lightly tapping the jig with a hammer.



Figure 2 Removal, pin



4.



7



Pin



8



Plug



d



Pin jig



Place idler on idler support block, put shaft removal the jig on shaft and force out the shaft using press.



Figure 3 Push with a press



5. 6.



1



Idler



a



Press



2



Shaft



f



Block



g



Jig



Remove the seal ring and O-ring from idler wheel and support, respectively. Remove the O-ring from shaft.



Figure 4 Removal, seal and sealing



7.



1



Idler wheel



5



Seal ring



2



Shaft



6



O-ring



4



Support



9



O-ring



Place the idler on idler support jig, put bushing pressure jig on bushing and bushing removal the jig, and drive out the bushing by lightly tapping the jig.



Figure 5 Removal, bushing 1



Idler



e



Jig



3



Bushing



f



Support jig



4



Jig



g



Pressure jig



Inspection after disassembly



Figure 6 Inspection, parts 1



Idler 1. 2. 3.



4



Bushing



Confirm that there is no damage or rust on the sealing face of seal. Confirm that any wear of idler is within the allowable range. Confirm that any wear of shaft or bushing is within the allowable range.



Service Information Document Title: Idler, assembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Idler, assembly Tools: 11712326 The numbers in parentheses following each part name in the text correspond to those in figure. Assemble in the reverse order of disassembly. 1.



Place the bushing on idler wheel, and using jig, force fit with press.



Figure 1 Assembly, bushing



2.



1



Idler wheel



a



Press



3



Bushing



h



Jig



6



O-ring



Install the O-ring on shaft.



Figure 2 Assembly, O-ring and etc. 2



Shaft



3. 4.



Apply a thin coat of grease to inner side of support, install the shaft, and insert pin. In this case, take care not to damage O-ring. Insert seal ring and O-ring to the support and idler wheel, respectively.



Figure 3 Assembly, shaft



5.



1



Idler wheel



6



O-ring



2



Shaft



7



Pin



4



Support



9



O-ring



5



Ring



Install the shaft, and support assembly to idler. Lightly coat engine oil on seal ring contact face.



Figure 4 Assembly, shaft and support



6.



1



Idler



2



Shaft



4



Support



5



Ring



Install the support with seal ring, O-ring and shaft O-ring. Install the support assembly to idler. Lightly coat engine oil on seal ring contact face.



Figure 5 Assembly, support



7.



1



Idler



5



Seal ring



2



Shaft



6



O-ring



4



Support



9



O-ring



Insert the spring pin with hammer.



Figure 6 Assembly, spring pin



8.



7



Pin



k



Hammer



Prior to filling with oil perform a pressure leak test.  



9. 10.



Fill with engine oil: 460 cc (28.1 cu in) Install the plug with teflon tape and tighten securely. 



11.



Attach a pressure regulated air line to the oil fill port, then completely immerse the assembly in water. Under a pressure of 2 ~ 3 kgf cm2 (28 ~ 43 psi), air bubbles must not form for 15 seconds.



Tool : Allen wrench (6 mm, 0.236 inch)



Confirm that there are no oil leaks around seals and plug.



Figure 7 Assembly, idler and track spring



12. 13.



A



Screw



5



Seals



B



Spring package



6



Seals



8



Plug



End play must be within specifications: 0.23 ~ 1.33 mm (0.01 ~ 0.052 inch) Assemble the idler assembly and track spring. After assembling, manually confirm that idler (1) rotates to the extent you can rotate it despite the resistance. (More than 10 times). Tightening torque. See 700 Undercarriage, tightening torque. Apply loctite 277 to the screws.



Service Information Document Title: Tools & equipment



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Tools & equipment Sprocket wear gauge, tools Sprocket wear gauge, tools Sprocket wear gauge tools kit part number: 14623167 Sprocket wear gauge Sprocket wear gauge tools part number:



Machine



14516698



EC55B, EC55C, EC60C ECR58



14527913



ECR88



14516699



EC135B, EC140B, EC140C ECR145C, ECR145D EC140D



14516700



EC240B FX: Machine serial number 10001 – EC140B LCM, EC160B, EC180B, EC200B, EC210B, EC240B EC140C LCM, EC160C, EC180C, EC210C, EC240C EC160D, EC180D, EC250D, EC220D ECR235C, ECR235D FC2121C, FC2421C



14516701



EC240B FX: Machine serial number 80361 – EC290B FX: Machine serial number 10001 – 17000 EC290B FX: Machine serial number 80001 – 81228 EC290B EC235C, EC290C, FC2924C EC300D, EC235D



14516702



EC290B FX: Machine serial number 17001 – EC290B FX: Machine serial number 80001 – EC330B, EC360B EC330C, EC360C, ECR305C, FC3329C, EC360C HR EC340D, EC380D PL3005D



14516703



EC460B EC460C, EC460C HR, FB2800C, FBR2800C EC480D PL4608, PL4611, PL4808D



14537336



EC700B, EC700B HR EC700C



Service Information Document Title: Function Group: Sprocket, measurement of wear



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Sprocket, measurement of wear Tools: Sprocket wear gauge tools kit part number and part number. See 7752 Tools & equipment.



Figure 1 Sprocket NOTE! When installing the sprocket, place "X" side of the sprocket outside. Wear limit, unit : mm (inch) Symbo Item l



Specifications



Remedy



A



Wear limit of sprocket tooth profile



6.0 (0.236)



Replace



B



Width of sprocket tooth



Standard value



88 ±2 (3.46 ±0.079)



–



Allowable value



76 (2.99)



Replace



23 EA



–



No. of tooth Measuring of sprocket tooth profile   



Black line (2) of the gauge shows the original sprocket tooth profile. Sprocket tooth profile is worn in the direction of red line (3) of the gauge. Sprocket tooth profile is worn irregularly and not as regular as red line (3) of the gauge.



1. 2. 3.



Clean the measuring faces of the sprocket. Put the worn sprocket tooth profile between black line (2) and red line (3) of the gauge and move the measuring gauge. Stop measuring gauge on the location which is the most similar to black line (2) and red line (3) formation on sprocket tooth profile. Stop and put the gauge at the point that NOTE! If the sprocket tooth profile is worn slightly, it would be closer to the black line (2).



If the sprocket tooth profile is worn havily, it would be closer to the red line (3). 4. 5. 6.



Measure the value of P1, P2, P3 of the sprocket gauge and find the average value. Sprocket tooth profile has to be measured more then twice at different points. Replace the sprocket as a new one if the sprocket tooth profile is below the red line (3) of the measuring gauge. NOTE! Sprocket tooth profile that has been measured below the red line (3) of the gauge will continue to wear rapidly.



Measuring of tooth width



Figure 3 Measurement, sprocket wear A



Vernier calipers



B



Wear of tooth width 1. 2. 3. 4.



Clean the sprocket. Measure the width of the sprocket using vernier calipers. Measure 2 places to take average value. If the measuring value is over wear limit, replace the sprocket.



Service Information Document Title: Sprocket, removal



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Sprocket, removal Op nbr 775-022 14560748 Track pin press 14548448 Pump 14566479 Pin kit



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Remove the track. See 7753 Track chain assembly, removing 2. Raise the track and sprocket using boom down operation and insert the block between track frame and link for safety measure.



Figure 1 The above illustration explains the case of the EC480D. 1. 2. 3. 4.



Track frame Sprocket Mounting screw Track link



3. Remove the mounting screws on sprocket. 4. Remove the sprocket carefully using a lifting device.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 2 The above illustration explains the case of the EC480D. 1. 2.



Sprocket Mounting screw



Service Information Document Title: Sprocket, installation



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Sprocket, installation Op nbr 775-023 14560748 Track pin press 14548448 Pump 14566479 Pin kit



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Raise the track and sprocket using boom down operation and insert the block between track frame and link for safety measure. 2. Install the sprocket carefully using a lifting device.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 1 The above illustration explains the case of the EC480D. 1. 2.



Sprocket Mounting screws



3. Install the sprocket and tighten screws in several stages.



Figure 2 The above illustration explains the case of the EC480D. 1. 2. 3. 4.



Track frame Sprocket Mounting screw Track link







Tightening torque for mounting screws: See 700 Undercarriage, tightening torque.



NOTE! Apply Loctite #277 or equivalent locking fluid 4. Install the track. See 7753 Track chain assembly, installing



Service Information Document Title: Sprocket, replacing one



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Sprocket, replacing one Op nbr 775-021 14548448 Pump 14560748 Track pin press 14566479 Pin kit



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Remove the track. See 7753 Track chain assembly, removing 2. Raise the track and sprocket using boom down operation and insert the block between track frame and link for safety measure.



Figure 1 The above illustration explains the case of the EC480D. 1. 2. 3. 4.



Track frame Sprocket Mounting screw Track link



3. Remove the mounting screws on sprocket. 4. Remove the sprocket carefully using a lifting device.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 2 The above illustration explains the case of the EC480D. 1. 2.



Sprocket Mounting screw



5. Install a new sprocket and tighten screws in several stages. 



Tightening torque for mounting screws: See 700 Undercarriage, tightening torque.



NOTE! Apply Loctite #277 or equivalent locking fluid 6. Install the track. See 7753 Track chain assembly, installing



Service Information Document Title: Track chain, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track chain, description



Figure 1 Structure, track chain 1



Seal



5



Regular pin



9



Screw



2



Link (right)



6



Master bushing



10



Nut



3



Link (left)



7



Master pin



11



Shoe



4



Regular bushing



8



Spacer



Service Information Document Title: Track link, dimension



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track link, dimension



Figure 1 Dimension, track link No.



Specifications, mm (inch)



No.



Specifications, mm (inch)



D1



146.05 ±0.25 (5.75 ±0.010)



F



φ24.3 +0.3/0 (0.96 +0.012/0)



D2



184.15 ±0.25 (7.25 ±0.010)



G



φ71.4 (φ2.81)



D3



76.2 (3)



H



φ47.71 (φ1.88)



D4



64 (2.52)



g



φ71.4 (φ2.81)



D5



75.7 (2.98)



h



φ47.21 (φ1.86)



Service Information Document Title: Track, adjusting track sag



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track, adjusting track sag 1.



Swing the superstructure to the side, and raise the track using boom down operation.



2.



Figure 1 Raising the track Slowly turn the track in forward and reverse direction several times. Stop the track while moving in the reverse direction. Measure the track slack at the center of track frame between track shoe and track roller mounting surface.



3.



Figure 2 Measurement, track slack (A)



WARNING High pressure grease in track adjuster cylinder. Do not remove grease fitting or nut and valve assembly to release grease. 4.



To decrease track sag, add multi-purpose grease to track adjuster cylinder through grease nipple using a grease gun with a maximum capacity 690 bar (10000 psi). To increase track sag, loosen valve assembly one turn so that grease in the track adjuster cylinder can be drained through rod hole. Tighten the valve assembly when track sag is correct. NOTE! If the piston in track adjuster cylinder does not move, replace the valve assembly, repair or replace the cylinder.



Figure 3 Adjusting, track sag



A. B. C. D. E. 5.



Valve tightening torque. See 700 Undercarriage, tightening torque. Grease nipple Drained through rod hole Screws Brake



Adjust the track sag according to soil condition of work site.



Recommended track tension Working condition



Clearance (A) (mm) (inch)



General soil



340 - 360 (13.4 - 14.2)



Rocky ground



320 - 340 (12.6 - 13.4)



Moderate soil like gravel, sand, snow, and so on.



360 - 380 (14.2 - 15.0)



Service Information Document Title: Function Group: Track chain, measurement of wear



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track chain, measurement of wear 14566479 Pin kit



Figure 1 Track chain Wear limit, unit: mm (inch) No.



Check item



Standard size



Repair limit



Remedy



1



Link pitch



215.9 (8.5)



221.2 (8.71)



Turn or replace



2



Outer diameter of bushing



71.4 (2.81)



66.4 (2.62)



3



Height of grouser - Double



49.5 (1.95)



27.5 (1.08)



Height of grouser - Triple



36 (1.42)



22 (0.87)



Height of link



129 (5.07)



119 (4.69)



4



Lug welding Repair or replace



Wear limit, unit: mm (inch) No. Check item



Tolerance limits Shaft



5



Clearance of bushing Standard size: 71 .4 (2.81)



link



and +0.05 ~ -0.05 (+0.002 ~ -0.002)



Allowable limits



Remedy



Hole



Clearance



Repair limit



-0.33 ~ -0.43 (-0.013 ~ -0.017)



-0.28 ~ -0.48 (-0.011 ~ -0.019)



0.1 (0.004)



–



6



Clearance of link and pin Standard size: 47.71 (1.88)



+0.05 ~ -0.05 (+0.002 ~ -0.002)



-0.34 ~ -0.41 (-0.013 ~ -0.016)



-0.29 ~ -0.46 (-0.011 ~ -0.018)



0.15 (0.006)



–



7



Clearance of link matching 0 ~ 1.5 (0 ~ 0.0591) surface



One side



8



Tightening torque of shoe See 700 Undercarriage, tightening torque. screw size



Tighten



Track link pitch, measurement of wear 1. 2. 3.



4.



Put pin between sprocket and track link, and then drive the machine slowly backward to tighten the track link. - Tools: 14566479 Pin kit Measure dimension of four links, at three links away from master pin. - Tools: Tape measure Measure 2 places to take average value. Measure right and left alternately. - Tools: Tape measure If the measuring value is over wear limit, repair or replace the track link.



Figure 2 Measurement, track link pitch wear 1



Dimension of four links



3



Pin



2



Master pin



4



Tape measure



Bushing outer diameter, measurement of wear 1.



Clean the bushing.



Figure 3 Measurement, bushing outer diameter wear



2. 3.



4.



1



Pin



4



Vernier calipers



2



Bushing



5



Link



3



Shoe



Measure at direction of D1 and D2, and determine the small value between two dimension (D1 and D2). - Tools: Vernier calipers Measure 2 places to take average value. Measure right and left alternately. - Tools: Vernier calipers If the measuring value is over wear limit, repair or replace the bushing.



link height, measurement of wear 1. 2.



Clean the link. Measure the height of link using vernier calipers. NOTE! Measure the height of link at the center of link.



3.



Measure 2 places to take average value. Measure right and left alternately. If the measuring value is over wear limit, repair or replace shoe plate.



4.



Figure 4 Measurement, link height wear 1



Shoe plate



2



Link



3



Vernier calipers



Shoe grouser height, measurement of wear 1.



Clean the shoe grouser.



Figure 5 Measurement, shoe grouser height wear 1. 2. 3. 4. 2. 3. 4.



Link Shoe plate Depth gauge Height of shoe grouser



Measure the height of shoe grouser using depth gauge. Measure 2 places to take average value. Measure right and left alternately. If the measuring value is over wear limit, repair or replace shoe plate.



Clearance of link matching surface (left and right), measurement of wear NOTE! Measure at direction of idler or sprocket. 1. 2. 3. 4.



Clean the link. Measure the clearance of between inner link and outer link using thickness gauge. Measure 2 places to take average value. Measure right and left alternately. If the measuring value is over wear limit, repair or replace the link.



4



Height of link



Figure 6 Measurement, clearance of link matching surface (left and right) wear 1. 2. 3. 4. 5. 6.



Thickness gauge Inner link Outer link Clearance between links Idler Sprocket



Service Information Document Title: Track chain removing



Function Group: assembly,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track chain assembly, removing Op nbr 775-034 14548449 Track pin press 14548448 Pump 14548450 Pin kit



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Place the machine in the service position F, on a level surface with adequate space for rolling out the tracks. See 091 Service positions 2. Reduce the track tension by draining the grease through nipple in the tensioning cylinder. Put a piece of cardboard under the nipple to catch the grease that drains out. After slackening the track-tighten the grease nipple.



Figure 1 Track tension grease nipple (1) NOTE! Do not loosen the valve more than 1 turn. If loosened more than 2 turns, the valve and grease will be ejected with tremendous force. 3. Raise the undercarriage/track off the ground using the digging equipment. Run the track until the master pin is over the idler. And then lower the undercarriage/track.



Figure 2 Master pin 4. Remove the track shoes on both sides of the master pin.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 3 Removal, track shoe 5. Raise the machine, run the track slowly until the master pin is past the idler, then place a wood block onto the track frame.



Figure 4



6. Use the special tool (14548449 Track pin press) for removing the master pin. See special tool instruction, “TRACK PIN PRESS” that accompanies the press equipment. Press out the master pin.



WARNING Do not get near the idler as the track assembly may fall on your feet.



Figure 5 Removal, master pin 7. Raise the undercarriage/track using the digging equipment, and run the track to remove track chain assembly.



Figure 6 Removal, track chain (1)



Service Information Document Title: Track chain installing



Function Group: assembly,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track chain assembly, installing Op nbr 775-035 14548449 Track pin press 14548448 Pump 14548450 Pin kit



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. NOTE! Pay attention to the assembly direction of the track shoe. 1. Place the machine in the service position F, on a level surface with adequate space for rolling out the tracks. See 091 Service positions



Figure 1



A. B.



Track motor side Front idler side



2. Raise the undercarriage to barely take the machine weight off the track using the digging equipment. 3. Install the links bushing the inside link.



Figure 2



1. 2.



Bushing Links



4. While an assistant operates the machine, insert a extra pin into the spacer pin bore located at the track end, and help the track engage the drive sprocket tooth. Guide the track until the spacer pin bore is close to the idler. 5. Run the track slowly and place a wood block onto the track frame.



Figure 3



1. 2. 3.



Forcing pin Wire rope Wood block



6. Use the special tool (14548449 Track pin press) for fitting the spacer pin. See special tool instruction, “TRACK PIN PRESS” that accompanies the press equipment. Press in the spacer pin.



Figure 4 Spacer pin installation 7. Remove the wood block.



8. Reinstall the track shoes and tighten the screws. 



Tightening torque for mounting screws: See 700 Undercarriage, tightening torque.



NOTE! Tighten the screws in the order as shown in the figure.



Figure 5



9. Figure 6 Measurement, track slack (A) Tension the track by pumping grease through the grease nipple on the tensioning cylinder. 10. Distribute the tension equally by running the track back and forth a few times in both directions. 11. Measure the slack between track shoe and track roller mounting surface. Measure where the slack is the greatest. NOTE! Adjust the track tension according to the soil characteristics.



See 7753 Track, adjusting track sag.



Service Information Document Title: Track shoe, replacing one



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track shoe, replacing one Op nbr 775-032



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Place the machine in the service position F, on a level surface with adequate space for rolling out the tracks. See 091 Service positions 2. Raise the undercarriage/track off the ground using the digging equipment. Run the track so that the track shoe to be replaced is over the idler. Then lower the undercarriage/track to the ground.



Figure 1 Track shoe 3. Remove the track shoe and replace with a new one.



Figure 2 Track shoe removal 



Track shoe bolt tightening torque. See 700 Undercarriage, tightening torque.



NOTE! Tighten the bolts in the order as shown in the figure.



Service Information Document Title: Top roller, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Top roller, description



Figure 1 Structure, top roller 1



Roller



6



Cover



11



Shaft



2



Bearing



7



Plate



12



O-ring



3



Screw



8



Plug



13



Seal ring



4



O-ring



9



Screw



14



Collar



5



Washer



10



Lock plate



15



O-ring



16



Snap ring



NOTE! Tightening torque. See 700 Undercarriage, tightening torque.



Service Information Document Title: Function Group: Top roller, measurement of wear



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Top roller, measurement of wear 11712316 Inspection tool



Figure 1 Dimension, top roller Wear limit, unit : mm (inch) No.



Check item



Standard size



Repair limit



Remedy



1



Outside diameter of flange



197 (7.76)



–



2



Outside diameter of tread



168 (6.61)



150 (5.91)



Repair replace



3



Width of flange



95 (3.74)



83 (3.27)



Wear limit, unit: mm (inch) No.



Check item



Tolerance limits Shaft



Allowable limits, Hole



+0.30 ~ 0.40 ~ (+0.0118 ~ 0.0158)



Repair limit



4



Clearance between 0 ~ -0.03 shaft and bearing (0 ~ -0.0012) Standard size: 50 (1.97)



5



Clearance between +0.132 ~ +0.102 +0.046 ~ 0 roller shell and (+0.005 ~ +0.0040) (+0.0018 ~ 0) bearing Standard size: 82 (3.23)



-0.056 ~ -0.132 (-0.002 ~ -0.0052)



6



Screw torque



64 ±6.9 Nm (6.5 ±0.7 kgf m) (47 ±5.1 lbf ft)



7



Mounting



screw A: Fixed (M24)



+0.35 ~ +0.30 (+0.0138 +0.0118)



Clearance



Remedy 1.5 (0.059)



–



0 (0)



–



See 700 Undercarriage, tightening torque.



or



torque



B: Retractable (variable) (M20)



See 700 Undercarriage, tightening torque.



Roller tread diameter, Measurement of wear 1. 2. 3. 4.



Clean the top roller. Measure the outer diameter of top roller tread using outside calipers . - Tools: Outside calipers (200 mm, 7.8 inch) Read the values of vernier calipers. - Tools: Vernier calipers (200 mm, 7.8 inch) Measure right and left alternately. If the measuring value is over wear limit, repair or replace the top roller.



Figure 2 Measurement, top roller tread outer diameter wear 1. 2. 3.



Outside calipers Outer diameter of top roller tread Vernier calipers



Measuring of top roller flange width wear 1.



Clean the top roller.



Figure 3 Measurement, top roller flange width wear 1. 2. 2. 3.



Top roller flange width Vernier calipers



Measure the width of top roller flange using vernier calipers. - Tools: Vernier calipers (200 mm, 7.8 inch) Measure right and left alternately. If the measuring value is over wear limit, repair or replace the top roller.



Service Information Document Title: Top roller, replacing one



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Top roller, replacing one Op nbr 775-051



Removal



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Place the machine in the service position F, on a level surface with adequate space for rolling out the tracks. See 091 Service positions 2. Reduce the track tension by draining the grease through the nipple on the tensioning cylinder. Put a piece of cardboard under the nipple to catch the grease that drains out. After slackening the track-tighten the grease nipple.



Figure 1 Track tension grease nipple (1) NOTE! Do not loosen the valve more than 1 turn. If loosened more than 2 turns, the valve and grease will be ejected with tremendous force. 3. Raise the track off the top roller using a lifting device. Increase the track sag and position blocks between the track chain and the undercarriage. Lower the track onto the blocks.



Figure 2 Lifting up track



1. 2. 3.



Wire rope Blocks Top roller



4. Remove the top roller mounting screws at the bracket of the top roller.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 3 Removal, top roller 1. 2.



Mounting screws Top roller



Installation 5. Replace the top roller with a new one. Remove the wood blocks. Align the center of the track link and top roller. 



Tightening torque screws. See 700 Undercarriage, tightening torque.



NOTE! Apply Loctite #277 or equivalent locking fluid 6. Tension the track by pumping grease through the grease nipple on the tensioning cylinder. 7. Distribute the tension equally by running the track back and forth a few times in both directions. 8. Raise the track using boom down operation and measure the slack between track shoe and track roller mounting surface. Measure where the slack is the greatest. NOTE! Adjust the track tension according to the soil characteristics.



Refer to the (Track sag according to soil condition) operator's manual track unit, checking tension.



Figure 4 Measurement, track slack (A)



Service Information Document Title: Bottom roller, description



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Bottom roller, description



Figure 1 Structure, bottom roller 1



Support



6



Shaft



2



Seal ring



7



O-ring



3



O-ring



8



Pin



4



Roller shell



9



Plug



5



Bushing



NOTE! Oil filling specification. ISO VG 220 EP oil. 500 ±10 cc (30.5 ±0.61 cc.in)



Bottom roller mounting screws. See 700 Undercarriage, tightening torque.



Date: 2014/7/15



Service Information Document Title: Function Group: Bottom roller, measurement of wear



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Bottom roller, measurement of wear 11712316 Inspection tool



Figure 1 Dimensions, bottom roller Wear limit, unit: mm (inch) No.



Check Item



Standard value



Allowable limits



Remark



1



Flange outside diameter



246 (9.69)



–



2



Tread outside diameter



200 (7.87)



182 (7.17)



Reweld replace



3



Flange width



33 (1.30)



29 (1.14)



Wear limit, unit: mm (inch) No.



Check item



Tolerance limits Shaft



Allowable limits,



Remedy



Hole



Clearance



Repair limit



4



Clearance between 0 ~ -0.035 shaft and bushing (0 ~ -0.001) Standard size: 85 (3.35)



+0.42 ~ +0.37 (+0.017 ~ +0.015)



+0.455 ~ +0.37 (+0.018 ~ +0.015)



1.5 (0.059)



–



5



Clearance between +0.159 ~ +0.124 roller shell and (+0.006 ~ +0.005) bushing Standard size: 93 (3.66)



+0.035 ~ 0 (+0.001 ~ 0 )



-0.089 ~ -0.159 (-0.0035 ~ -0.0063)



–



–



6



End play



0.21 ~ 1.37 (0.008 ~ 0.054)



2.5 (0.098)



Replace bushing



or



Roller tread diameter, measurement of wear 1. 2. 3. 4.



Clean the bottom roller. Measure the outer diameter of bottom roller tread using outside calipers. - Tools: outside calipers (200 mm, 7.8 inch) Read the values of vernier calipers. - Tools: vernier calipers (200 mm, 7.8 inch) Measure right and left alternately. If the measuring value is over wear limit, repair or replace the roller.



Figure 2 Measurement, bottom roller tread outer diameter wear 1. 2. 3.



Outside calipers Outer diameter of bottom roller tread Vernier calipers



Roller flange width, measurement of wear 1.



Clean the bottom roller.



Figure 3 Measurement, roller flange width wear 1. 2. 2. 3.



Bottom roller flange width Vernier calipers



Measure the width of bottom roller flange using vernier calipers. - Tools: vernier calipers (150 mm, 5.9 inch) Measure right and left alternately. If the measuring value is over wear limit, repair or replace the roller.



Service Information Document Title: Bottom roller, one



Function Group: replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Bottom roller, replacing one Op nbr 775-061 11712316 Inspection tool



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Place the machine in the service position F, on a level surface with adequate space for rolling out the tracks. See 091 Service positions 2. Reduce the track tension by draining the grease through the nipple on the tensioning cylinder. Put a piece of cardboard under the nipple to catch the grease that drains out. After slackening the track-tighten the grease nipple.



Figure 1 Track tension grease nipple (1)



WARNING Recoil spring cylinder is filled with pressurized grease. When adjusting the track tension or loosening the track, pay special attention. Keep face, hands and body away from the nipple and valve. NOTE! Do not loosen the valve more than 1 turn. If loosened more than 2 turns, the valve and grease will be ejected with tremendous force. 3. Remove the four mounting screws of the bottom roller.



Figure 2 Removal, mounting screws 1. 2.



Mounting screws Bottom roller



4. Raise the undercarriage/track off the ground using boom down operation and pull out the bottom roller.



Figure 3 Removal, bottom roller (1) 5. Set a new roller in place, lower the undercarriage to a position about 5 ~ 10 mm above the roller end caps. Align the screw holes and install the screws. 



Tightening torque for mounting screws: See 700 Undercarriage, tightening torque.



NOTE! Apply Loctite #277 or equivalent locking fluid 6. Tension the track by pumping grease through the grease nipple on the tensioning cylinder. 7. Distribute the tension equally by running the track back and forth a few times in both directions. 8. Measure the slack between track shoe and track roller mounting surface. Measure where the slack is the greatest. NOTE! Adjust the track tension according to the soil characteristics.



Refer to the (Track sag according to soil condition) operator's manual track unit, checking tension.



Figure 4 Measurement, track slack (A)



Service Information Document Title: Bottom roller, seal



Function Group: replacing



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Bottom roller, replacing seal Op nbr 775-066 1. Remove the bottom roller, see 7756 Bottom roller, replacing one. 2. Open the oil plug and drain oil. NOTE! Prepare container for collecting oil.



Figure 1 Plug (1) 3. Remove the pins form the support.



Figure 2 Pins (2) 4. Remove the shaft form the roller.



Date: 2014/7/15



Figure 3 Shaft (3) 5. Remove the supports form the roller.



Figure 4 Supports (4) 6. Clean impurities around seal groove and seal groove. Replace the with a new seals (apply grease to the seals). Repeat the same work for the opposite side. NOTE! Assembly at clean condition.



Do not reuse removed seal.



Be care full not to damage assembling seal.



Figure 5 Seals (5) 7. Install the support at the shell. NOTE! Be care full not to damage seal assembling support.



Figure 6 Support (4) 8. Install the shaft, pin and fill bottom roller oil.



Figure 7 Pin (2) and shaft (3) ISO VG 220 EP oil Filling oil: cc (cu in) 9. Install the support and pin at the shell. NOTE! Be care full not to damage seal assembling support.



500 ±10 (30.5 ±0.6)



Figure 8 Pin (2) and support (4) 10. Check the operation of the bottom roller.



Figure 9



11. Install the bottom roller. See 7756 Bottom roller, replacing one.



Service Information Document Title: Track guards



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Track guards Track guards, description



Figure 1 Standard (1) and Heavy duty full track guards (2) NOTE! Tightening torque screws, see 700 Undercarriage, tightening torque.



Apply loctite #277 to track guards mounting screws.



Weight: Standard track guards 44 kg (97 lbs)



Date: 2014/7/15



Weight: Heavy duty full track guards 119 kg (263 lbs)



Service Information Document Title: Track guard, replacing one



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track guard, replacing one Op nbr 775-071



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Place the machine in the service position F, on a level surface with adequate space for rolling out the tracks. See 091 Service positions 2. Reduce the track tension by draining the grease through nipple on the tensioning cylinder. Put a piece of cardboard under the nipple to catch the grease that drains out. After slackening the track-tighten the grease nipple.



Figure 1 Track tension grease nipple (1) NOTE! Do not loosen the valve more than 1 turn. If loosened more than 2 turns, the valve and grease will be ejected with tremendous force. 3. Remove the four track guard mounting screws.



Figure 2 Removal, track guide mounting screws 1. 2.



Mounting screws Track guide



4. Raise the undercarriage/track off the ground using boom down operation and pull out the track guard. 5. Replace the track guide with a new one. 



Tightening torque for connecting screws: See 700 Undercarriage, tightening torque.



NOTE! Apply Loctite #277 or equivalent locking fluid 6. Tension the track by pumping grease through the grease nipple on the tensioning cylinder. 7. Distribute the tension equally by running the track back and forth a few times in both directions. 8. Measure the slack between track shoe and track roller mounting surface. Measure where the slack is the greatest. NOTE! Adjust the track tension according to the soil characteristics.



Refer to the (Track sag according to soil condition) operator's manual track unit, checking tension.



Figure 3 Measurement, track slack (A)



Service Information Document Title: Function Group: Full track guard, installing new



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Full track guard, installing new Op nbr 775-902 11712316 Inspection tool



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Park the machine in the service position F, on a level surface with adequate space for rolling out the tracks. See 091 Service positions.



2.



NOTICE Do the work in an environmentally safe manner. Reduce the track tension by draining the grease through nipple on the tensioning cylinder. Put a piece of cardboard under the nipple to catch the grease that drains out. After slackening the track-tighten the grease nipple.



Figure 1 Track tension grease nipple (1)



WARNING Recoil spring cylinder is filled with pressurized grease. When adjusting the track tension or loosening the track, pay special attention. Keep face, hands and body away from the nipple and valve. NOTE! Do not loosen the valve more than 1 turn. If loosened more than 2 turns, the valve and grease will be ejected with tremendous force. 3. Insert the wooden block under the full track guard. Remove the track guard mounting screws.



Figure 2 Removal, track guard mounting screws 1. 2. 3.



Track guard Wooden block Mounting screws



4. Hold the track guard with hoist and remove the track guard.



Figure 3 Removal, track guard 5. Install the new track guide.



Figure 4 Installation, track guard 



Tighten torque. See 700 Undercarriage, tightening torque.



NOTE! Apply Loctite #277 or equivalent locking fluid



6. Tension the track by pumping grease through the grease nipple on the tensioning cylinder. 7. Distribute the tension equally by running the track back and forth a few times in both directions. 8. Measure the slack between track shoe and track roller mounting surface. Measure where the slack is the greatest. NOTE! Track sag according to soil condition. See 7753 Track, adjusting track sag



Service Information Document Title: Function Group: Spring package, assembly dimension



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Spring package, assembly dimension Spring package, standard



Figure 1 Dimension No.



Specification



Remark



A



1010 mm (39.76 inch)



Assembled length



B



683 mm (26.89 inch)



Installed load: 28070 kg



C



68.6 ±2.5 Nm (7 ±0.25 kgf m) (50.5 ±1.8 lbf ft)



Valve tightening torque



D



Apply Loctite #277 or equivalent locking fluid



K



Maximum 8 mm (0.32 inch)



Bend limit (X X side)



KS



Bend limit (Y Y side)



Service Information Document Title: Function Group: Spring package, assembly dimension



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Spring package, assembly dimension Sand protection, option



Figure 1 Dimension No.



Specification



Remark



A



1010 mm (39.76 inch)



Assembled length



B



683 mm (26.89 inch)



Installed load: 28070 kg



C



68.6 ±2.5 Nm (7 ±0.25 kgf m) (50.5 ±1.8 lbf ft)



Valve tightening torque



D



Apply Loctite #277 or equivalent locking fluid



K



Maximum 8 mm (0.32 inch)



KS



Bend limit (X X side) Bend limit (Y Y side)



Service Information Document Title: Function Group: Track recoil spring (tensioner) assembly, replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Track recoil spring (tensioner) assembly, replacing Op nbr 775-081 14548448 Pump 14560748 Track pin press 14566479 Pin kit



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Remove the track. See 7753 Track chain assembly, removing 2. Push the idler assembly out of the track frame using a pry bar.



Figure 1 Front idler (1) 3. Install an eye bolt onto the track recoil spring assembly.



Figure 2 Install, eye bolt (1) and wire rope (2)



4. Remove the idler and track recoil spring using a lifting device.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 3 Removal, idler (1) and track recoil spring (2) 5. Support it on a workbench. Remove screws connecting the idler and track recoil spring. Replace the track recoil spring and install the complete assembly.



Figure 4 Removal, connecting screws 1. 2. 3.



Track recoil spring connecting screws Track recoil spring Idler unit







Tightening torque for connecting screws: See 700 Undercarriage, tightening torque.



NOTE! Be careful of offset direction of recoil spring when assemble the spring package.



Apply Loctite #277 or equivalent locking fluid 6. Install the idler and recoil spring assembly to the track frame. NOTE! Confirm that the boss at the piston end of the track recoil spring is in the track frame hole.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 5 Installation, idler and recoil spring assembly 7. Install the track. See 7753 Track chain assembly, installing



Service Information Document Title: Function Group: Recoil spring cylinder seal kit, replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Recoil spring cylinder seal kit, replacing Op nbr 775-082 14548448 Pump 14560748 Track pin press 14566479 Pin kit



WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Remove the track chain assembly. See 7753 Track chain assembly, removing. 2. Remove the track recoil spring (tensioner) assembly. See 7758 Track recoil spring (tensioner) assembly, replacing 3. Remove the plate mounting screw and plate.



Figure 1



1. 2. 3.



4.



Plate mounting screw Plate Track tension cylinder (piston)



Figure 2



1. 2.



Air hole Track tension cylinder (piston)



Remove the track tension cylinder (piston). NOTE! Put pump air into a track tension cylinder (piston) air hole.



5. Figure 3



1. 2. 3.



Packing and back-up ring Dust seal Track tension cylinder (piston)



Exchange sealing for a new dust seal, packing and back-up ring. Replace the track tension cylinder (piston) with a new one.



6. Figure 4



1. 2. 3.



Plate mounting screw Plate Track tension cylinder (piston)



Install the plate and plate mounting screw. 7. Install the track recoil spring (tensioner) assembly. See 7758 Track recoil spring (tensioner) assembly, replacing. 8. Install the track chain assembly. See 7753 Track chain assembly, installing.



Service Information Document Title: Spring disassembly



Function Group:



Information Type: Service Information



package,



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Spring package, disassembly Op nbr 00000 14525310



WARNING A great force is applied to the spring package. Pay special attention when disassembling. 1. Remove the screw, plate, and grease valve from the piston, in order.



Figure 1 Removal, grease valve 4



Grease valve



13



Lubricating nipple piston



11



Plate



14



Washer



12



Screw



2. Remove the piston, dust seal, back-up ring, and packing from the cylinder, in order.



Figure 2 Removal, piston



1



cylinder



9



Back-up ring



3



Piston



10



Dust seal



8



Packing



WARNING A great force is applied to the spring package. Pay special attention when disassembling.



WARNING Use special tools for safety.



WARNING While compressing or releasing the spring by press, take care that the spring does not slip out. 3. Prepare a press with a capacity of more than 30 tons. 4. Slowly compress spring with press. Remove screw, lock plate and nut. 5. Remove the yoke and spring while releasing the load applied to spring.



Figure 3 Removal, screw and lock plate A



Screw bar (Minimum M30 and tensional strength 35 kgf mm2) 1



Body cylinder



B



Nut



2



Spring



C



Plate (Minimum thickness 40 mm)



5



Yoke



D



Press (30 ton class)



6



Nut



15



Lock plate



7



Stopper



16



Screw



17



Rod



6. Remove the lock screw and rod.



Figure 4 Removal, screw and rod 1



Cylinder



17



Rod



18



Screw



Inspection after disassembly  



Confirm that there is no damage or rust on the inner side of the cylinder and the outer side of the piston. Replace the packing and dust seal.



Service Information Document Title: Spring package, assembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Spring package, assembly Op nbr 00000 14525310



WARNING A great force is applied to the spring package. Pay special attention when disassembling. Assemble in the reverse order of disassembly. 1. Install the rod to cylinder. Align the screw hole of rod and cylinder, and tighten screw. NOTE! To drill No. 18 tap and tighten No. 18 hex screw after assembling rod and cylinder, body.



Apply Loctite #277 or equivalent locking fluid



No. 18 Tightening torque screw: 176 ±18 Nm (17.9 ±1.8 kgf m) (129 ±13 lbf ft)



Figure 1 Assembly, rod and cylinder 1



Cylinder



17



Rod



18



Screw



WARNING Use special tools for safety.



WARNING Take care that the spring not does slip out during installation. 2. Push stopper, spring and yoke onto cylinder on which rod is installed. Slowly compress spring until the rod thread is exposed. Install nut, lock plate and screw, in order.



Installed length and load of the spring Installed length, mm (inch)



683 (26.9)



Installed load, kg (lbs)



28070 (61883)



Figure 2 Assembly, spring A



Screw bar (Minimum M30 and tensional strength 35 kgf mm2)



1



Body cylinder



B



Nut



2



Spring



C



Plate (Minimum thickness 40 mm)



5



Yoke



D



Press (30 ton class)



6



Nut



15



Lock plate



7



Stopper



16



Screw



17



Rod



3. Install the packing, back-up ring, and dust seal to cylinder. 4. Fill cylinder with grease and push piston in. Release the air from the cylinder.



Figure 3



Assembly, seal 1



Cylinder



9



Back-up ring



4



Grease valve



10



Dust seal



8



Packing



5. Install the grease valve, plate, and screw to piston. 6. Tightening torque (grease valve). See 700 Undercarriage, tightening torque.



Figure 4 Assembly, grease valve 4



Grease valve



13



Piston



11



Plate



14



Washer



Thank you for your purchase. Have a nice day.



file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/7/15 9:05:16]



Service Information Document Title: VCADS Pro, Operations



Function Group: 800



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



VCADS Pro, Operations The following VCADS Pro operations are available for function group 3. Operations used when changing or working on components are mandatory. Tests Operation



Application



87373-3 ECC Input and Output signals Used when there is a suspicion of fault and/or at abnormal values/readings. status, test 87374-3 Air mix door actuator, test



Used when there is a suspicion of fault and/or at abnormal values/readings.



87376-3 Sensor values, ECC, check



Used when there is a suspicion of fault and/or at abnormal values/readings.



Calibrations Operation



Application



–



–



Programming Operation



Application



87371-3 MID 146 ECU, programming



When changing E-ECU or only reprogramming. 870 ECC, MID 146, changing non-programmed ECU



87372-3 MID 146 Control unit, campaign



See



Service Information Document Title: Cab, removing



Function Group: 810



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Cab, removing Op nbr 810-001 1. Park the machine in the service position A, see 091 Service positions 2. Turn battery disconnect switch to off position.



Figure 1



3. Disconnect wire harness of the front left extra light and remove the light. This step is needed for attaching wire ropes to the lifting shackles on the cab. 4. Attach wire ropes to the lifting shackles on the cab, and raise the hoist until there is no slack in the wire ropes.



Figure 2



Figure 3



5. Remove the footrest and floor mat.



Figure 4 Footrest and floor mat, removing 1. 2. 3. 4.



Footrest rubber cover Footrest Screw Floor mat



6. Move the operator's seat to the front position and fold the backrest forward. 7. Remove plastic casing over the cab fan.



Figure 5



1.



Plastic casing



8. Remove two screws fixing the radio cover.



Figure 6



1.



Screw



9. Disconnect wire harness connector and antenna cable from radio. Take out radio cover.



Figure 7



1. 2.



Connector Antenna cable



10. Disconnect the connector of auxiliary heater. (option)



Figure 8



1.



Connector



11. Disconnect the connectors of voltage converter and wiper motor controller.



Figure 9



1. 2.



Connector Connector



12. Remove screw fixing the voltage converter support.



Figure 10



1.



Screw



13. Remove the steel bar.



Figure 11



1.



Bar



14. Disconnect the main wire harness and cab wire harness in the right hand cab wall.



Figure 12 1. Wire harness 15. Remove air ducts (1) and put the defrost duct aside from fan motor.



Figure 13



1.



Air duct



16. Disconnect 2 wiring harness connectors from the V-ECU.



Figure 14



1.



Connector



Figure 15 NOTE! Concerning JA connector, 70 pins, pull up the locking device to disconnect it. NOTE! Concerning JB connector, 16 pins, pull out the red locking device to disconnect it. 17. Remove 2 screws at the upper side of V-ECU, and loosen 2 screws at the bottom side of V-ECU.



Figure 16



1.



Screw



18. Remove the ground cable from the cab left wall, and separate the windshield washer hose from the nozzle.



Figure 17



1. 2.



Ground cable Washer nozzle



19. Remove the connectors of Care track.



Figure 18



1.



Connector



20. Remove the mounting screws and ROPS screws located at the bottom plate of the cab. NOTE! Before lifting the cab, be sure to lock the open door to the latch.



Figure 19 Cab 1. 2. 3. 4.



Screws: torque 261.8 ±26.4 Nm, 192.7 ±19.4 lbf ft Screws: torque 261.8 ±26.4 Nm, 192.7 ±19.4 lbf ft Screws: torque 261.8 ±26.4 Nm, 192.7 ±19.4 lbf ft Nuts



21. Lift the cab just a little, and after confirming safety all around lift up and out. NOTE! One person controls the lift and one person watches the cab lifting condition for safety. 22. Lower the cab to the ground.



Service Information Document Title: Cab, installing



Function Group: 810



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Cab, installing Op nbr 810-002 1. Park the machine in the service position A, see 091 Service positions 2. Attach wire ropes to the lifting shackles of the cab, and raise the hoist until there is no slack in the wire ropes.



Figure 1



Figure 2



3. Lift the cab using crane and fit it to the mounting plate. 4. Tighten the screws and ROPS screws to fix the cab on the bottom plate.



Figure 3 Cab 1. 2. 3. 4.



Screws: torque 261.8 ±26.4 Nm, 192.7 ±19.4 lbf ft Screws: torque 261.8 ±26.4 Nm, 192.7 ±19.4 lbf ft Screws: torque 261.8 ±26.4 Nm, 192.7 ±19.4 lbf ft Nuts



5. Install the ground cable and washer nozzle hose and the 4 ducts.



Figure 4



1. 2.



Ground cable Washer nozzle



6. Install the V-ECU and connect the wiring harness connectors.



Figure 5



1.



Screw



Figure 6



1.



Wiring harness connector



7. Connect the connectors of Care track.



Figure 7



1.



Connector



8. Connect the main wire harness and I-ECU wire harness.



Figure 8



1.



Wire harness



9. Install the air ducts.



Figure 9



1.



Air duct



10. Install the steel bar.



Figure 10



1.



Steel bar



11. Install the screw fixing the voltage converter support.



Figure 11



1.



Screw



12. Connect the connectors of voltage converter and wiper motor controller.



Figure 12



1. 2.



Connector Connector



13. Connect the wire harness connector and antenna cable from radio.



Figure 13



1. 2.



Connector Antenna cable



14. Connect the connector of auxiliary heater. (option)



Figure 14



1.



Connector



15. Install the screws fixing the radio cover.



Figure 15



1.



Screw



16. Install the plastic casings over radio and fan.



Figure 16



1.



Plastic casing



17. Return the operator's seat to the original position. 18. Fit floor mat and assemble the footrest.



Figure 17 Footrest and floor mat 1. Footrest rubber cover 2. Footrest 3. Screw 4. Floor mat



19. Remove the wire ropes. 20. Install the extra light of the cab front. 21. Switch on battery disconnect switch. 22. Check the machine operation and all equipment.



Service Information Document Title: Function Group: Cab suspension, description 818



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Cab suspension, description The bottom plate of the cab is mounted on the four suspension, and then assembled to the superstructure. The cab suspension is designed to absorb vibration generated when operating the machine. Silicon oil and spring inside the suspension absorbs extreme shock impact. NOTE! If the cab suspension is dropped or impacted, silicon oil may be leaked and lower the performance. NOTE! The cab suspension exterior is natural rubber with low oil resistance. Avoid contact with grease and oil.



Figure 1 Cab suspension, position 1. Screw (flange) , torque : (33.2 ±3.6 lbf.ft), (45.1 ± 4.9 N.mt) (4.6 ± 0.5 kg.m)



Service Information Document Title: Engine hood, replacing



Function Group: 821



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Engine hood, replacing Op nbr 821-005



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 1. Open the engine hood.



Figure 1



1.



Engine hood



2. Hold engine hood with hoist.



Figure 2



1. 2. 3.



Hoist Screw Nut



3. Remove the screws fixing the engine hood. 4. Remove the nut supporting the engine hood.



5. Put the engine hood down on the ground.



Figure 3



6. Remove latch assemble, brackets and sponges.



Figure 4



1. 2. 3.



Latch assemble Bracket Sponge



7. Replace the engine hood with a new one. The installation procedure is the reverse order of removal. Tightening torque screws (5): 39.2 ±3.9 Nm, 28.8 ±2.8 lbf ft. 8. Check the hood latch.



Service Information Document Title: Tool box replacing



Function Group: assembly, 827



Profile: EXC, EC480D L [GB]



Tool box assembly, replacing Op nbr 827-091 1. Remove screws from electrical box cover. 2. Remove electrical box cover.



Figure 1



1. 2.



Screws Electrical box cover



3. Remove screws from bracket.



Figure 2



1. 2.



Screws Bracket



4. Remove two brackets. 5. Remove screws from rear-view mirror bracket.



Information Type: Service Information



Date: 2014/7/15



Figure 3



1. 2.



Screws Bracket



6. Remove rear-view mirror bracket from toolbox. 7. Open the toolbox door.



Figure 4



1.



Screws



8. Remove 4 screws from tool box. 9. Close toolbox door.



Figure 5



1. 2.



Eye bolt Anti slip plate



10. Attach hoist slings to the eye bolts. 11. Remove the toolbox. 12. Remove the screws from anti slip plate.



13. Install the new toolbox. NOTE! The installation procedure is the reverse order of removal.



Toolbox mounting screws, tightening torque: 39.2 ±3.9 Nm, 28.8 ±2.8 lbf ft 14. To see the rear side from operator's seat adjust the mirror angle.



Service Information Document Title: Door, replacing



Function Group: 831



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Door, replacing Op nbr 831-004 1. Park the machine in the service position B, see 091 Service positions.



Removing the door 2. Open the door. 3. Secure the door with lifting slings.



Figure 1



1.



Lifting sling



4. Remove the snap rings from the upper and lower hinges.



Date: 2014/7/15



Figure 2



1.



Snap ring



5. Knock off the pins in the upper and lower hinges.



Figure 3



1.



Pin



6. Lift off the door.



Figure 4



Installing the door 7. Check the hinge pins and snap rings and replace them if they are damaged. 8. Align the door towards the hinges so that the holes for the hinge pins are straight. 9. Knock the hinge pins into the hinges. 10. Install the snap rings fixing the pins. 11. Check the door operation.



Service Information Document Title: Function Group: Rear-view mirror, changing 841



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Rear-view mirror, changing Op nbr 841-061 1. Remove the screws.



Figure 1



1. 2. 3.



Screws Mirror Bracket



2. Remove the mirror. 3. Install the new mirror. 4. Install the screws. 5. To see rear side from operator's seat adjust the mirror angle.



Date: 2014/7/15



Service Information Document Title: Windows, general



Function Group: 843



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Windows, general Windows There are 8 window panes in the cab; the windscreen comprises one large pane connected to two smaller panes on either side. Both the windscreen upper pane and lower pane are made with laminated glass while the other panes are made with tempered glass. Windows, replacing Use clean tools and protective gloves when replacing windows since residue and grease can affect the adhesive capacity. The adhesive curing process, which is contingent on temperature and humidity, is indicated in this section with a curing time based on a temperature of approximately 23° C (73° F) and normal humidity. A longer curing time is required during other weather conditions with freezing temperatures and low humidity. NOTE! The panes should not come in contact with metal or welded joints. Use rubber spacers and follow the instructions and steps for replacing window panes. T-red T-red is specially - developed cleaning agent and adhesive fluid used fro contact surface pre - treatment before glue adhesive application. SimsonPrimer M SimsonPrimer M is a transparent, moisture-inhibiting, low viscosity primer specially developed for use on contact surfaces before polyurethane adhesive application. SimsonPrimer M is used on window panes without a composite moulding (the black impregnation around the window pane edges) in order to protect the adhesive form UV radiation or when the contact surface is newly surface coated. In both cases, the surface must be cleaned with T-red cleaning agent. Simson IRS 70 - 08 Simson IRS 70 - 08 is one-part adhesive and sealing compound which cures on exposure to atmospheric moisture to form a permanent elastomer. To ensure the best treatment properties, the cartridges should maintain room temperature.



Service Information Document Title: Windscreen, replacing



Function Group: 843



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Windscreen, replacing Op nbr 843-002 Tools: 88830060 Disassembly tool 88830062 Wire unvinding device 88890051 Dispensing gun 1. Park the machine in the service position A, see 091 Service positions



Disassemble front screen 2. Disconnect the wires on both sides of the windscreen. Open the window to almost open position for easy access to the wire. Unhook the wire from the window. One person holds the window from inside and one person removes the wire from the front.



Figure 1



Attach the wire to the latch pin.



Figure 2



NOTE! Be careful during this operation as the wire is spring loaded and can cause personal injury if not handled correctly. Do NOT fully close the window when the wires are attached to the latch pin. This will damage the wires. 3. Remove the screws fixing the cover.



Figure 3



4. Remove the blind if fitted.



Figure 4



5. Position the front window to almost closed position. Do not force the window to lock position as this will damage the wires. Unscrew the step bolt.



Figure 5



Remove the carrier plate.



Figure 6



NOTE! Be careful during this operation as the window can drop down with the carrier plate removed. 6. Disassemble front window. Position the front window at about 45°. Unhook right side upper rollers. Tilt front window as shown in the picture. Now both lower rollers will come out of the rails.



Figure 7



Move the front window into the cab and down to the ground.



Figure 8



7. Remove all screws fixing the handles and locking assembly.



Figure 9



8. Remove the weatherstrip rail from the glass using a soft faced mallet or hammer and soft block.



Figure 10 Cut away remnants of any sealing compound from the joints. Remove any remaining adhesive from the internal channel of the weatherstrip rail after disassembly.



Figure 11



9. Remove all three cover plates 1,2 and 3.



Figure 12



10. Remove the glass from frame complete with glazing rubber and bottom seal.



Figure 13



1. 2. 3.



Outer frame Glass Glazing rubber-notched



Retain glazing rubber for re-use.



Assemble front screen 11. Assemble glazing rubber around glass.



Figure 14



1. 2.



Glass Glazing rubber-notched



12. Slide the glass with glazing rubber mounted into the frame assembly.



Figure 15



13. Insert both tapped strips with connecting rods into the left and right channels.



Figure 16



1. 2.



Side tapped strip Connecting rod assembly



Typical Section through frame showing tapped strip with connecting rod assembled into outer frame. 14. Assemble the left and right clamping strips.



Figure 17 Rotate both clamping strips onto outer frame. Left hand – assembled in Clockwise direction. Right hand – assembled in anticlockwise direction.



Figure 18 Left hand clamping strip shown in assembled position. 15. Assemble all screws. NOTE! Loosely assemble all hardware on both sides.



Figure 19



16. Moisten the edge of the glass prior to fitting weatherstrip (The adhesive requires some moisture to cure).



Figure 20



1. 2.



Top section Bottom surface



Apply a small bead of adhesive (loctite MS393) along the full length of the weatherstrip channel prior to fitting onto the glass. Assemble bottom seal to glass panel edge and ensure that the weatherstrip is centred on the glass. Top section to be in line with this the surface of the bottom roller carrier. Trim back if required. Bottom surface to be in line with the edge of the glass. Trim back if required. 17. Torque all screws to 6Nm and then re-tighten to 12Nm.



Figure 21



18. Attach the tape (1). Apply Simon IRS 70–08 windscreen adhesive compound along the glass edges. In order to maintain the correct compound height, apply as shown using the proper glue gun angle. Rub the adhesive compound gently with water. And then remove the tape. NOTE! Do not apply adhesive below 5°C (41°F).



NOTE! Allow six hours for the sealing compound to cure at 20°C (68°F).



Figure 22



Figure 23



Figure 24



19. Move the windscreen to the cab.



Figure 25



20. Position front window to tilted position and both lower rollers inside the pillar tracks, then tilt the widow a level position.



Figure 26



Lift the window up and hook RH upper rollers in the channel.



Figure 27



NOTE! Be careful during this operation as the window can drop down with the carrier plate removed. 21. Attach left carrier plate. Position the front window to almost closed position. Do not force the window to locked position as this will damage the wires.



Figure 28



Screw in the step bolt. Tighten to 20 Nm. Position the front window at about 45°. Attach lock nut on carrier plate step bolt. Tighten to 48±8 Nm.



Figure 29



22. Install the blind if fitted.



Figure 30



23. Install the screws fixing the cover.



Figure 31



24. Attach lift wires on both sides.



Figure 32 Open the window to almost full open position for easy access to the wire hook. Unhook the wire from the latch pin. One person holds the window from inside and one person removes the wire from the front. Attach the wire to the hook on front window. NOTE! Be careful during this operation as the wire is spring loaded and can cause personal injury if not handled correctly.



Service Information Document Title: Side window, replacing



Function Group: 843



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Side window, replacing Op nbr 843-013 88830060 Disassembly tool 88830062 Wire unvinding device 88890051 Dispensing gun NOTE! Allow six hours for the sealing compound to cure at 20 ° C ( 68 ° F), during which time the machine must not be driven.



Do not sealing work at below 5° C (41° F).



Operate machine 24 hours later after sealing work. 1. Fold bucket and arm and lower boom maximum to the ground. 2. Remove the screws fixing work light bracket to the cab, and remove the bracket of beacon light and antenna and cushion. 3. Remove the screws fixing cab cover on the cab roof, then remove the cover.



Figure 1



A. B. C.



Antenna Cab cover Screw



WARNING Risk of cuts! Wear safety glasses and use protective gloves. 4. Cover the body surfaces around the window pane with masking tape to protect the painted surfaces during continued work.



5. Cut away old sealing compound remnants from the joints. Make a hole in the compound in order to thread in a metal wire.



Figure 2



6. Thread in a metal wire which has been wound securely around an appropriate handle. Using the wire and a knife, cut around the entire window glass until the glass loosens.



Figure 3 Cutting out window glass 7. Remove the window glass using a suction cup holder. 8. Use a sharp knife to level off the old adhesive compound, leaving a surface 1–2 mm ( 0.039 – 0.079 inch) thick.



Figure 4



9. Clean the window frame with T-red on a lint-free rag, wiping in one direction to avoid smearing any residue back



and forth.



Figure 5



10. To repair any paint damage that has been caused by the work, apply the SimsonPrimer M on the contact surface of the painted cab structure.



Figure 6 Painting the damaged area by work NOTE! When opening of new SimsonPrimer M make three small holes in the foil.



After wetting of piece of rag, put back the cover to the can. 11. Fit 3 mm thick rubber spacers and support blocks as required on the metal flange as shown.



Figure 7 Preparation A. B.



Spacer Support block



12. Clean the edge of the window glass with T-red using a lint-free rag.



Figure 8 Cleaning window glass 13. Apply the Simson IRS 70–08 windscreen adhesive compound along the glass edges. In order to maintain the correct compound height, apply as shown using the proper glue gun angle.



Figure 9 Applying adhesive



Figure 10



14. Using two suction cup holder lift up window glass and fit the window glass into the cab frame and press the window glass against cab frame for 5 minutes.



Figure 11 The substrate must be pretreated with T-red. In other words, the substrate must be clean, dry and free from oil and grease.



Service Information Document Title: Rear window, replacing



Function Group: 843



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Rear window, replacing Op nbr 843-012 88830060 Disassembly tool 88830062 Wire unvinding device 88890051 Dispensing gun NOTE! Allow six hours for the sealing compound to cure at 20 °C ( 68 °F), during which time the machine must not be driven.



Do not sealing work at below 5 °C (41 °F).



Operate machine 24 hours later after sealing work.



WARNING Risk of cuts! Wear safety glasses and use protective gloves. 1. Cover the body surfaces around the window pane with masking tape to protect the painted surfaces during continued work.



2. Figure 1 1. Metal wire Cut away old sealing compound remnants from the joints. Make a hole in the compound in order to thread in a metal wire.



3. Figure 2 Cutting out window glass Thread in a metal wire which has been wound securely around an appropriate handle. Using the wire and a knife, cut around the entire window glass until the glass loosens. 4. Remove the window glass using a suction cup holder.



5. Figure 3 Use a sharp knife to level off the old adhesive compound, leaving a surface 1–2 mm ( 0.039 – 0.079 inch) thick.



6. Figure 4 Clean the window frame with T-red on a lint-free rag, wiping in one direction to avoid smearing any residue back and forth.



7. Figure 5 Painting the damaged area by work To repair any paint damage that has been caused by the work, apply the SimsonPrimer M on the contact surface of the painted cab structure. NOTE! When opening of new SimsonPrimer M make three small holes in the foil.



After wetting of piece of rag, put back the cover to the can.



8. Figure 6 Preparation A. B.



Spacer Support block



Fit 3 mm thick rubber spacers and support blocks as required on the metal flange as shown.



9. Figure 7 Cleaning window glass



Clean the edge of the window glass with T-red using a lint-free rag.



10. Figure 8 Applying adhesive Apply the Simson IRS 70–08 windscreen adhesive compound along the glass edges. In order to maintain the correct compound height, apply as shown using the proper glue gun angle.



Figure 9



11. Figure 10 Using two suction cup holder lift up window glass and fit the window glass into the cab frame and press the



window glass against cab frame for 5 minutes. The substrate must be pretreated with T-red. In other words, the substrate must be clean, dry and free from oil and grease.



Service Information Document Title: Door window, replacing



Function Group: 843



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Door window, replacing Op nbr 843-048 1. Open the door window (1).



Figure 1



1. 2. 3. 4. 5.



Door window Window latch Window sliding guard Locking pins Cab



2. Press the lock pins and remove them from window sliding guards. 3. Remove the door window (1) from cab.



Figure 2



4. Remove window latch (2) and window sliding guard (3), (6) install them to the new door window.



Figure 3



5. The installation procedure is the reverse order of removal. 6. Check the door window operation.



Service Information Document Title: Seat, replacing



Function Group: 852



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Seat, replacing Op nbr 852-008 1. Pull slide adjustment lever up, and move the operator's seat forward.



Figure 1 Operator's seat 1. 2. 3. 4. 5. 6. 7.



Supporter Screw Stopper Screw Screw Seat assembly Bottom plate



2. Disconnect heater wiring of seat. (option) 3. Loosen mounting screw at the rear of operator's seat. 4. Pull slide adjustment lever up, and move the operator's seat backward.



Date: 2014/7/15



5. Loosen front mounting screw of operator's seat. 6. Disassemble operator's seat from machine. 7. Assemble new operator's seat to machine. 8. Tighten mounting screw at front of operator's seat. Torque: 21.5 ±1.9 N m (2.2 ±0.2 kgf m) (15.8 ±1.4 lbf ft) 9. Pull slide adjustment lever up and move the operator's seat forward. 10. Tighten mounting screw at the rear of operator's seat. Torque: 21.5 ±1.9 N m (2.2 ±0.2 kgf m) (15.8 ±1.4 lbf ft) 11. Connect seat heating cable. (option) 12. Adjust operator's seat to comfort work position.



Service Information Document Title: Seat support, replacing



Function Group: 852



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Seat support, replacing Op nbr 852-091



Removal



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 1. Open the cab door and fix it. 2. Move the operator's seat to the front position and fold the backrest forward. 3. Remove seat cushion, see: 852 Seat cushion, replacing 4. Remove 4 screws (1) fixing the seat assembly and put the seat assembly away.



NOTICE All adjusting screws and lock nuts must be secured with locking fluid ("medium", Loctite type) when assembling.



Figure 1



5. Remove 4 screws (1) fixing the support assembly and put the support assembly away.



NOTICE All adjusting screws and lock nuts must be secured with locking fluid ("medium", Loctite type) when assembling.



Figure 2



6. Loosen 2 screws (1) and put the handrail away.



Figure 3



7. Loosen the screw fixing the LH console cover.



Figure 4



8. Loosen 2 screws (1), (2) and put the LH console aside for making a work space.



Figure 5



Figure 6



9. Loosen screw (1) and nut (2).



Figure 7



10. Remove the RH console and take the support assembly out from the cab.



Figure 8



11. Remove cable bracket (1), by pushing bracket on both sides downward.



Figure 9 NOTE! Mark position of cable bracket on the seat frame. 12. Remove cable (2) of longitudinal adjustment lever (1).



Figure 10



13. Remove 4 screws (1) fixing isolator (2).



NOTICE All adjusting screws and lock nuts must be secured with locking fluid ("medium", Loctite type) when assembling.



Figure 11



14. Turn support assembly upside down. 15. Remove 4 screws (1, 2) fixing the slide rail.



NOTICE All adjusting screws and lock nuts must be secured with locking fluid ("medium", Loctite type) when assembling.



Figure 12



16. Remove rubber suspension cover (3).



Installing 17. The installing procedure is the reverse order of removal. 18. Check the seat operation.



Service Information Document Title: Function Group: Electronic climate control 870 unit ECC, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Electronic climate control unit ECC, description Concerning the description of Electronic 3002 Electronic climate control unit ECC, description.



climate



control



unit



ECC,



see



Service Information Document Title: Function Group: Electronic climate control 870 unit ECC, specification



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Electronic climate control unit ECC, specification Concerning the specifications of Electronic 3002 Electronic climate control unit ECC, specification.



climate



control



unit



ECC,



see



Service Information Document Title: Wiring diagram



Function Group: 870



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Wiring diagram Concerning the wiring diagram of Electronic climate control, see 370 Wiring diagram SCH10.



Service Information Document Title: HVAC system



Function Group: 870



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



HVAC system HVAC, Heating, Ventilation , air-conditioning The machine can be equipped with different kind of system, for example, with air conditioning unit or heater with air conditioning unit.



Figure 1



A



Time



E



Air flow direction



B



Air conditioner mode



F



Air flow circulation



C



Temperature



G



Air-conditioning status



D



Fan speed



Button function Button



Digit



Description



Button



Digit



Description



1



Fan speed control +



-



HVAC system on/off



2



Temperature control +



0



Arrow up, Browse upwards



3



Air flow direction



-



Rear view camera



4



Fan speed control –



-



Previous screen or escape



5



Temperature control –



-



Arrow down, Browse downwards



6



Air flow circulation



-



Selection, Acknowledge



7



Automatic mode selection



-



Automatic idling



8



Air conditioner



-



Overload warning



9



Defrost selection



-



Buzz stop



-



ECO mode



-



Hammer/shear selection



Fan speed control Press buttons 1 or 4 to increase or decrease the fan speed. When pressing any of them, automatic mode will be switched automatically to manual mode. Temperature control Press buttons 2 or 5 to raise or lower the temperature. Default setting value is 22 °C (71.6 °F) and setting range is 16 °C ~ 32 °C. If the temperature sensor in cabin is malfunction, automatic mode shall be turned OFF. Air flow direction Press button 3 to select the direction of the air flow. When pressing the button, automatic mode will be changed to manual mode automatically. Air flow circulation Press button 6 to select the circulation of the air flow ; recycle the air inside the cab or draw fresh air from outside into the cab. When the defrost mode is activated, the fresh air mode is selected automatically. Automatic mode Press button 7 to select the Automatic mode for temperature setting. Required temperature can be changed with buttons 2 or 5. Air conditioner Press button 8 to activate the air conditioning. Defroster Press button 9 to select to activate the defroster. The fresh air mode is selected automatically. In automatic mode, if this button is pressed, mode shall be changed to manual mode. HVAC system ON/OFF Press button 10 to turn the HVAC system ON or OFF. All settings remain if the system is turned OFF. Even if HVAC system is turned OFF, when ECC (electronic climate controller) gets auxiliary heater signal, ECC turns ON the cooling fan setting 1st step in manual mode.



Service Information Document Title: Air conditioning description



Function Group: unit, 870



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Air conditioning unit, description The advanced integrated air conditioning system, with the heating and the cooling system installed in a single unit is designed to provide a comfortable indoor environment in all seasons. The integrated system is ergonomically designed for the most efficient air flow distribution. According to the indoor and outdoor air condition, indoor or outdoor air circulation can be selected. All fresh air is drawn through the air filter installed between the duct and the cab vent. Air cooling type The air cooling type is used only for cooling. If heating is required, use the integrated system with heating and cooling systems. Air conditioning (AC), basic principles The AC unit conducts heat away from the cab air to the surrounding atmosphere. At the same time as the temperature is lowered, the air is also dehumidified as the moisture in the air condenses on the cold fins while it passes through the evaporator. In order to conduct heat away from the cab air, a medium with a lower temperature than the air is required, since heat always moves from a warmer object to a colder one. If water is heated to 100 °C (212 °F), it begins to boil since the water has reached its limit for storing heat. If you continue to heat the water, it must release an amount of heat equal to the heat that is added. This is accomplished by boiling which means that some of the water is converted to steam. The steam carries excess heat with it as it leaves the water. However, the boiling point of water is too high to be used in an AC unit. A liquid that is converted into gas at a considerably lower temperature is required. This liquid, so called refrigerant, must also fulfill other requirements in addition to converting to a gas at a low temperature. Refrigerant R134a fulfills these requirements. NOTE! Use only refrigerant R134a. R134a has a constant pressure-temperature ratio. This means that when the temperature is increased or decreased, the pressure also either increases or decreases. Likewise, if the pressure is increased or decreased, then the temperature is either increased or decreased. At normal atmospheric pressure, R134a boils at 26 °C (79 °F). Somewhat simplified, the AC unit can be said to consist of two heat exchangers, one (evaporator) being located in the cab and the other (condenser) located next to the engine radiator or separately. Both heat exchangers are connected with hoses to a system. The system is charged with refrigerant, R134a, which is pumped through the system by the compressor. The cab fan circulates the cab air through the evaporator where the heat from the air is transferred to the refrigerant. The compressor pumps refrigerant to the condenser, where the heat is dissipated to the outdoor air which is blown through the condenser by the engine radiator fan or a separate fan.



Figure 1 Diagram, air conditioning system 1



Engine



7



2



Compressor



7-1 Cooling position



Heater core



B



Outdoor air



3



Condenser



7-2 Heating position



C



Face



4



Filter



8



Door



D Foot



5



Blower motor



9



Diesel heater (option)



E



6



Evaporator



Air conditioning unit, related components



A Indoor air



Defrost



Figure 2 Location of components A



Ambient temperature sensor



E



Ambient Filter



I



Compressor



B



Recirculation air sensor



F



Condenser



J



Inlet hose



C



Air conditioning unit



G



Heater hose (to air conditioning unit)



K



Charging hose



D



Keypad



H



Heater hose (to engine block)



L



Intake hose



NOTE! The above illustration explains as an example. Regarding the ports for heater supply and return, please see Section 2 Engine. Components of the air conditioning unit The air conditioning unit components, with their hose connections, make up a closed system where the refrigerant is circulated by a compressor. The cooling process operates continuously, with the refrigerant alternating between gaseous and liquid states, depending on the temperature and the pressure changes.



Figure 3 Refrigerant flow 1



Air conditioning unit



9



Evaporator



17



Receiver drier



2



Blower motor



10



Air mix driver



18



Compressor



3



Relay



11



Heater core



19



Electromagnetic clutch



4



Water temperature sensor



12



Battery



20



Service valve



5



Duct temperature sensor



13



Electronic climate controller



21



I-ECU



6



Expansion valve



14



Engine



22



Keypad



7



Recirculation air sensor



15



Condenser



8



Ambient temperature sensor



16



Dual switch



NOTE! The above illustration explains as an example. Regarding the ports for heater supply and return, please see Section 2 Engine. The air conditioning unit is of the compressor type, that is, the refrigerant is circulated by a compressor. The air conditioning unit consists of the following main components: 1.



Air conditioning unit Air conditioning unit consists of a evaporator, a heater core, an expansion valve, a blower motor, actuators, relays and sensors.



2.



3. 4.



5.



6.



7.



8.



9.



10.



11. 12. 13. 14.



15. 16.



17.



18.



19. 20.



21. 22.



Blower motor The blower motor circulates the air in the cab where indoor and outdoor air is transferred to the cab. Outlet air flow regulated by the motor speed. Relay The relay is located outside the air conditioning unit and is driven the blower motor and electromagnetic clutch. Coolant temperature sensor When coolant temperature is over 25 °C (77 °F), air conditioner is activated automatically if cab auxiliary heater is equipped. Duct temperature sensor The duct temperature sensor is installed in the evaporator core at intervals of 5 mm. NOTE! If the sensor is out of order, the air conditioning switch turns off the compressor clutch. Thermostatic expansion valve Controls the quantity of refrigerant supplied to the evaporator. The valve is directly connected to the inlet pipe on the evaporator. Recirculation air temperature sensor Recirculation air temperature sensor is installed at the right sides the driver's seat. The sensor controls the open and shut angle of the mixing door, the speed of blowing motor, and setting temperature of compressor with sensing the setting temperature on gauge, inner and outer temperature of cab. Ambient temperature sensor The ambient temperature sensor is located in the tool box. This sensor has compressor on/off by sensing the difference between inner and outer temperature of cab. Evaporator Transfers the heat, from the cab air and the outdoor air supplied to the cab, to the refrigerant. The evaporator is located in the air conditioning unit in front of or in parallel with the heater core, and consists of a coiled pipe with fins for heat absorption. To prevent ice formation in the evaporator, there is a switch which interrupts the power supply to the compressor's magnetic clutch when the temperature becomes too low. Air mix door driver (actuator) The air mix door (actuator) is located at the air conditioning unit and regulates the opening/closing angle of the mix door according to the system conditions (ambient, indoor and setting temperature). Heater core Always hot coolant flows through the heater core and gives off heat before returning to the engine. Battery The battery supplies the power to the air conditioning system. Electronic climate control unit Engine The air compressor is installed to the engine. The engine also provides hot coolant to the heater core. The engine cooling fan draws air through the condenser core which cools the refrigerant. Condenser Transfers heat to the outdoor air. Located next to the engine radiator, using the radiator fan for air flow. Dual switch A dual switch is fitted to the high pressure line of receiver drier top side. Its function is to protect the system by interrupting the power to the compressor's magnetic clutch if the pressure should become too high or too low. Receiver drier Contains a filter and a desiccant which absorbs any moisture in the system. Also serves as a reservoir for the refrigerant and is located on the front side of condenser. Compressor Circulates the refrigerant in the system. Located beside the engine and is driven by V belt from the engine crankshaft pulley. An electromagnetic clutch on the compressor pulley connects or disconnects the compressor drive. Electromagnetic clutch An electromagnetic clutch on the compressor pulley connects or disconnects the compressor drive. Service valve The service valve is installed into the hose, which is mounted to the compressor. This valve provides a way to check the pressure and supply refrigerant. I-ECU Keypad



Service Information Document Title: Air conditioning maintenance



Function Group: unit, 870



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Air conditioning unit, maintenance Periodic inspection 



During the off - season operate the air conditioner 2 ~ 3 times per month for 5 ~ 10 minutes to lubricate the compressor components.



Check item Proper refrigerant handling Worldwide environmental protection regulations prohibit the discharge of any refrigerant into the atmosphere, and require that refrigerant be recovered using the approved recovery equipment.



NOTICE Use correct refrigerant recovery, recycling and charging stations, DO NOT use refrigerant, hoses, fittings, components or refrigerant oils intended for use with other refrigerants. Recovery, recycling and charging stations for R134a and other refrigerants MUST NOT be interchanged. Systems containing other refrigerants use a different oil than systems using R134a. Certain seals are not compatible with both types of refrigerants. R134a refrigerant precautions



WARNING Do not allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. Repair and refilling of the refrigerant system must only be done by trained personnel. Contact your authorized Volvo Construction Equipment workshop. If liquid refrigerant contacts eyes or skin, do not rub the area. Splash large amounts of cool water on affected area. Go to a physician or hospital immediately for treatment. Do not allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials. Do not heat refrigerant over 52 °C (125 °F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. do not handle a damp refrigerant container with your bare hands. Skin may freeze to the container. Wear gloves. If skin freezes to the container, pour cool water over container to free the skin. Go to a physician or hospital immediately for treatment. Check method Check for gas leakage on refrigerant hose joint.  



When oil is found on the pipe joint, gas leakage could be occurring. Check the union and tighten to the proper torque.



Check the tension of V-belt for driving compressor.



Figure 1 Check, belt looseness A. B.



Compressor Crank pulley







Check the belt for looseness by pressing with your fingers. When a force of approximately 10 kg is applied to the belt center, allowable limit is 8 ~ 10 mm. After about 40 hours, recheck the belt tension.



Check the compressor. 



After operating air conditioner for 5 ~ 10 minutes, check the high pressure pipe and low pressure pipe by hand. In normal condition the high pressure pipe is hot and low pressure is cold.



Check the condenser. 



When the condenser is contaminated, the radiating efficiency is lowered significantly. Clean the condenser to improve cooling.



NOTICE DO NOT use steam to clean the condenser core. The refrigerant can overheat! When cleaning with water, protect the electrical components.



Service Information Document Title: Function Group: ECC, MID 146, changing 870 pre-programmed ECU



Information Type: Service Information



Profile: EXC, EC480D L [GB]



ECC, MID 146, changing pre-programmed ECU Op nbr 870-010 1. Park the machine in the service position A, see 091 Service positions. 2. The new control unit has basic settings for parameters for the machine. 3. Turn OFF battery disconnect switch. 4. Move the operator's seat to the front position, and fold the backrest forward. 5. Remove the screws and covers.



Figure 1



1. 2. 3.



Screw Cover Cover



6. Disconnect wire harness connector from the ECC.



Date: 2014/7/15



Figure 2



1.



ECC Connector



7. Remove two screws at the upper side of ECC, and loosen a screw at the bottom side of ECC.



Figure 3



8. Lift off the ECC and replace it with a new one. 9. Install three screws for fixing ECC to the air conditioner unit. 10. Connect the wire harness to the ECC. 11. Fit the plastic casing over the cab fan.



Figure 4



12. Return the operator's seat to the original position. 13. Check the air conditioner working after turning on the battery disconnect switch.



Service Information Document Title: Function Group: ECC, MID 146, changing 870 non-programmed ECU



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



ECC, MID 146, changing non-programmed ECU Op nbr 870-011 1. Park the machine in the service position A, see 091 Service positions. 2. Connect VCADS Pro and perform the operation 87371-3 MID 146 ECU, programming. 3. Turn OFF battery disconnect switch. 4. Move the operator's seat to the front position, and fold the backrest forward. 5. Remove the screws and covers.



Figure 1



1. 2. 3.



Screw Cover Cover



6. Disconnect wire harness connector from the ECC.



Figure 2



1.



ECC Connector



7. Remove two screws at the upper side of ECC, and loosen a screw at the bottom side of ECC.



Figure 3



8. Lift off the ECC and replace it with a new one. 9. Install three screws for fixing ECC to the air conditioner unit. 10. Connect the wire harness to the ECC. 11. Fit the plastic casing over the cab fan.



Figure 4



12. Return the operator's seat to the original position. 13. Finish VCADS Pro operation 87371-3 MID 146 ECU, programming. 14. Check the air conditioner working after turning on the battery disconnect switch.



Service Information Document Title: Function Group: Air distribution, description 872



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Air distribution, description The machine is equipped with a climate control system where the fan can maintain a permanent excess pressure in the cab to keep out pollutants. In addition, all air will be filtered, i.e. even the recirculating air. As standard the cab is equipped with a heater unit, but air conditioning (AC) is also available as optional equipment.



Figure 1 Air flow A. B. C. D. E.



Foot Defrost Air intake from outdoor Air intake from indoor Face



The air which is drawn into the cab first passes through air intake. From there the air passes on through a washable prefilter, which is accessible via a cover on the rear side of the cab. After the air has passed the cab filter it is sucked, via evaporator, into fan and is then forced on through heating unit and distributed throughout the cab. The air is distributed through air outlets, which are individually adjustable and which also can be closed. The air in the cab is discharged through a one-way outlet fitted with slats and placed in the cab door. To open the slats a certain excess pressure is required in the cab. This excess pressure helps to keep the air in the cab as clean as possible.



Service Information Document Title: Cab filter, replacing



Function Group: 872



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Cab filter, replacing Op nbr 872-001



Outside filter 1. Park the machine in the service position A, see 091 Service positions 2. Loosen the screw.



Figure 1



3. Pull filter case cover and remove filter.



Figure 2



1. 2.



filter case Filter



4. Replace with a new one. 5. Close the filter case cover and tighten the screws.



Date: 2014/7/15



Inside filter 6. Move the operator's seat to the front position, and fold the backrest forward. 7. Remove the plastic casing over the cab fan.



Figure 3 Cab fan casing, removal 8. Disconnect wire harness of the air conditioner actuator.



Figure 4



1. 2.



Actuator Cover



9. Open the upper cover of the air conditioner. 10. Take out old filter and replace with a new one.



Figure 5 Filter, inside



6. filter, inside 11. Close the upper cover of the air conditioner and fit ducts. 12. Connect wire harness of the air conditioner actuator. 13. Reinstall the plastic casing over the cab fan. 14. Return the operator's seat to the original position.



Service Information Document Title: Heating description



Function Group: system, 873



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Heating system, description With the engine running, the heat is transmitted to the heater core via the hot coolant circulating between the engine block and heater core. The blower motor transfers heat from the heater core by moving the indoor/outdoor air through the heater core transferring it to the cab. The air mix door is installed in the air conditioning unit in order to regulate the indoor temperature according to the setting temperature.



Figure 1 Heating unit, principle illustration 1



Blower motor



6



Mix door lever



11



Outdoor air



2



Foot



7



Face door actuator



12



Intake door actuator



3



Heater hose



8



Mix door actuator



13



Hot water port (to heater)



4



Heater hose



9



Face



14



Cool water port (from heater)



5



Heater core



10



Indoor air



NOTE! The above illustration explains as an example, regarding the ports for heater supply and return, see Section 2, Engine.



Service Information Document Title: Fan motor, replacing



Function Group: 873



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Fan motor, replacing Op nbr 873-006 1. Park the machine in the service position A, see 091 Service positions 2. Move the operator's seat to the front position, and fold the backrest forward. 3. Remove the plastic casing over the cab fan.



Figure 1



4. Disconnect wire harness of the actuator.



Figure 2



1. 2.



Upper cover Wire harness



5. Open the upper cover of the air conditioner. 6. Take out the filter.



Date: 2014/7/15



Figure 3



1.



Filter



7. Remove screws fixing fan motor and protecting cover.



Figure 4



1. 2.



Screw Wire harness connector



8. Disconnect the wire harness connector of the fan motor and remove motor from plastic case.



9. Replace with a new fan motor and tighten the screws. 10. Reinstall the fan motor protecting cover. 11. Reconnect the wire harness and install grommet. 12. Reinstall the filter and air conditioner cover.



13. Connect actuator connector. 14. Fit the plastic casing over the cab fan. 15. Return the operator's seat to the original position. 16. Check the air conditioner operation.



Service Information Document Title: Heater core, replacing



Function Group: 873



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Heater core, replacing Op nbr 873-004



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 1. Move the operator's seat to the front position, and fold the backrest forward. 2. Remove the screws and covers.



Figure 1



1. 2. 3.



Cover Cover Cover



3. Remove the wire harness connector and cover.



Figure 2



1. 2.



Cover Wire harness connector



4. Remove the filter.



Figure 3



1.



Filter



5. Remove the screws (5EA), ECC connector and wire harness connector.



Figure 4



1. 2. 3. 4.



Screws ECC connector Wire harness connector Motor case



6. Remove the motor case. 7. Remove the screw and duct.



Figure 5



1. 2.



Screw Duct



8. Remove the screws (12EA), main connector, bracket of CareTrack and ambient sensor.



Figure 6



1. 2. 3. 4. 5.



Screw Main connector Bracket Case Ambient sensor



9. Put the start switch ON position, place the mode changing switch to the heater (Maximum). Put the start switch OFF position. 10. Open the lock lever, and remove the latch.



Figure 7



1. 2. 3. 4. 5.



Wire harness Screw Valve actuator Latch Lock lever



A. B. C.



Cooling unit Lock lever close Lock lever open



Remove the wire harness, screws and valve (mix) actuator. 11. Take out the case. 12. Remove the heater hose clamp and take out the heater core.



Figure 8



1.



Heater core



13. Replace with a new heater core. 14. Reassemble the air conditioner unit. 15. Check the heater operation.



Service Information Document Title: Function Group: Cooler and Heater 874 assembly, replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Cooler and Heater assembly, replacing Op nbr 870-001 1. Park the machine in the service position E. See 091 Service positions



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 2. Open the engine hood. 3. The service valve (G) is installed into the hose, which is mounted to the compressor. Drain the refrigerant.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite.



Figure 1



A. B. C. D. E. F. G.



Low pressure hose High pressure hose Low pressure gauge (blue) High pressure gauge (red) Center filler hose Compressor Service valve



4. Remove the screws fixing the under cover.



Figure 2



1.



Under cover



5. Remove the screws of suction and liquid hose.



Figure 3



1. 2. 3.



Screw Coolant flow Screw



6. Block the coolant flow flyer and remove the screws of the heater hose and separate the hoses.



7. Move the operator's seat to the front position, and fold the backrest forward. 8. Remove the plastic casing over the cab fan and cassette cover and plastic separator.



Figure 4



1. 2. 3.



Cab fan casing Cassette cover Plastic separator



9. Remove the screws fixing the radio support.



Figure 5



1.



Screw



10. Disconnect the connectors and antenna cable.



Figure 6



1. 2.



Connector Cable



11. Disconnect the connectors of voltage converter and wiper motor controller.



Figure 7



1. 2.



Connector Connector



12. Remove the screw fixing the voltage converter supporter.



Figure 8



1. 2.



Screw Steel bar



13. Remove the steel bar.



14. Take out two face ducts, one air intake duct, two foot ducts and one defrost duct.



Figure 9



1. 2. 3. 4.



Face duct Air intake duct Foot duct Defrost duct



15. Disconnect the wire harness of the air conditioner from main harness.



Figure 10



1.



Wire harness



16. Remove the bracket of CareTrack (option).



Figure 11



1.



Bracket



Put them away. 17. Remove the screws mounting the unit, then remove cooler and heater assembly unit.



Figure 12



1.



Screw



18. Replace with a new unit. 19. Reassemble the parts disassembled. 20. Supply refrigerant. The service valve (G) is installed into the hose, which is mounted to the compressor.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite.



Figure 13



A. B. C. D. E. F. G.



Low pressure hose High pressure hose Low pressure gauge (blue) High pressure gauge (red) Center filler hose Compressor Service valve



21. Check the heater and air conditioner operation.



Service Information Document Title: Function Group: Compressor, replacing incl 874 draining and filling



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Compressor, replacing incl draining and filling Op nbr 874-006 1. Park the machine in the service position A see 091 Service positions.



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 2. Open the engine hood.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite. 3. Install the Gauge set to the Service valve and drain the refrigerant.



Figure 1



A. B. C. D. E. F. G.



Low pressure gauge (blue) High pressure gauge (red) Low pressure hose (blue) High pressure hose (red) Center filler hose (yellow) Compressor Service valve



For detailed information, see the refrigerant extracting and filling procedure in the air conditioning component manual. NOTE! The service valve is installed into the hose, which is mounted to the compressor. 4. Remove the compressor belt.



Figure 2



1.



Compressor belt



5. Remove two hoses.



Figure 3



1.



Hoses



6. Remove harness connector and four compressor mounting screws.



Figure 4



1. 2.



Harness connector Mounting screw



7. Replace with a new compressor assembly. 8. Reassemble the parts disassembled. 9. Supply refrigerant. The service valve (G) is installed into the hose, which is mounted to the compressor.



Figure 5



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite.



10. Reinstall the guard and close the engine hood. 11. Check the air conditioner and heater operation.



Service Information Document Title: Receiver, replacing draining and filling



Function Group: incl 874



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Receiver, replacing incl draining and filling Op nbr 874-011 1. Park the machine in the service position A. See 091 Service positions.



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 2. Open the engine hood.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite. 3. The service valve (G) is installed into the hose, which is mounted to the compressor. Drain refrigerant.



Figure 1



A. B. C. D. E. F. G.



Low pressure hose High pressure hose Low pressure gauge (blue) High pressure gauge (red) Center filler hose Compressor Service valve



4. Open the left side door behind the cab. 5. Remove the hoses from condenser.



Figure 2



1. 2.



Hose Sensor



Remove the sensors. 6. Remove the screws fixing the condenser.



Figure 3



1.



Screw



7. Remove the ring of receiver drier.



Figure 4



1.



Ring



Figure 5



8. Install the new receiver drier. The installation procedure is the reverse order of removal. 9. The service valve (G) is installed into the hose, which is mounted to the compressor. Supply refrigerant.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite.



Figure 6



A. B. C. D. E. F. G.



Low pressure hose High pressure hose Low pressure gauge (blue) High pressure gauge (red) Center filler hose Compressor Service valve



10. Close the engine hood. 11. Check the air conditioner and heater operation.



Service Information Document Title: Function Group: Condenser, replacing incl 874 draining and filling



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Condenser, replacing incl draining and filling Op nbr 874-010 1. Park the machine in the service position A. See 091 Service positions.



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 2. Open the engine hood.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite. 3. The service valve (G) is installed into the hose, which is mounted to the compressor. Drain refrigerant.



Figure 1



A. B. C. D. E. F. G.



Low pressure hose High pressure hose Low pressure gauge (blue) High pressure gauge (red) Center filler hose Compressor Service valve



4. Open the left side door behind the cab. 5. Remove the hoses from condenser.



Figure 2



1. 2.



Hose Sensor



Remove the sensors. 6. Remove the screws fixing the condenser.



Figure 3



1.



Screw



7. Install the new condenser. The installation procedure is the reverse order of removal. 8. The service valve (G) is installed into the hose, which is mounted to the compressor. Supply refrigerant.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite.



Figure 4



A. B. C. D. E. F. G.



Low pressure hose High pressure hose Low pressure gauge (blue) High pressure gauge (red) Center filler hose Compressor Service valve



9. Close the engine hood. 10. Check the air conditioner and heater operation.



Service Information Document Title: Function Group: Evaporator, replacing incl 874 draining and filling



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Evaporator, replacing incl draining and filling Op nbr 874-012 1. Park the machine in the service position E. See 091 Service positions.



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 2. Open the engine hood. 3. The service valve (G) is installed into the hose, which is mounted to the compressor. Drain refrigerant.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite.



Figure 1



A. B. C. D. E. F. G.



Low pressure hose High pressure hose Low pressure gauge (blue) High pressure gauge (red) Center filler hose Compressor Service valve



4. Remove the screws (1), cover (2) and cover (3).



Figure 2



5. Remove the screws fixing the radio support.



Figure 3



1.



Screw



6. Disconnect the connectors and antenna cable.



Figure 4



1. 2.



Connector Cable



7. Remove the steel bar.



Figure 5



1.



Steel bar



8. Remove the wire harness and cover.



Figure 6



1. 2.



Wire harness Cover



9. Remove the filter.



Figure 7



1.



Filter



10. Remove the wire harness connector and screws (5 EA).



Figure 8



1. 2. 3.



Wire harness connector Screw Motor case



11. Remove the motor case. 12. Remove the screw and duct.



Figure 9



1. 2.



Screw Duct



13. Remove the screws (12EA), main connector, bracket of CareTrack and ambient sensor.



Figure 10



1. 2. 3. 4. 5.



Screw Main connector Bracket Case Ambient sensor



14. Put the start switch ON position, place the mode changing switch to the heater (Maximum). Put the start switch OFF position. 15. Open the lock lever, and remove the latch.



Figure 11



1. 2. 3.



Valve actuator Latch Lock lever



A. B. C.



Cooling unit Lock lever close Lock lever open



16. Take out the case. 17. Remove the screws and sensor.



Figure 12



1. 2. 3.



Screws Sensor Evaporator



18. Remove the evaporator.



19. Install the new evaporator. 20. The installation procedure is the reverse order of removal. 21. The service valve (G) is installed into the hose, which is mounted to the compressor. Supply refrigerant.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite.



Figure 13



A. B. C. D. E. F. G.



Low pressure hose High pressure hose Low pressure gauge (blue) High pressure gauge (red) Center filler hose Compressor Service valve



22. Check the air conditioner and heater operation.



Service Information Document Title: Function Group: Expansion valve, replacing 874 incl draining and filling



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Expansion valve, replacing incl draining and filling Op nbr 874-013 1. Park the machine in the service position E. See 091 Service positions.



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 2. The service valve (G) is installed into the hose, which is mounted to the compressor. Drain refrigerant.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite.



Figure 1



A. B. C. D. E. F. G.



Low pressure hose High pressure hose Low pressure gauge (blue) High pressure gauge (red) Center filler hose Compressor Service valve



3. Remove the screws and covers.



Figure 2



1. 2. 3.



Screw Cover Cover



4. Remove the screws fixing the radio support.



Figure 3



1.



Screw



5. Disconnect the connectors and antenna cable.



Figure 4



1. 2.



Connector Cable



6. Remove the steel bar.



Figure 5



1.



Steel bar



7. Remove the wire harness and cover.



Figure 6



1. Harness 2. Cover



8. Remove the filter.



Figure 7



1. Filter 9. Remove the wire harness connector and screws (5 EA).



Figure 8



1. Wire harness connector 2. Screw 3. Motor case 10. Remove the motor case. 11. Remove the screw and duct.



Figure 9



1. Screw 2. Duct 12. Remove the screws (12 EA), main connector, bracket of CareTrack and ambient sensor.



Figure 10



1. 2. 3. 4. 5.



Screw Main connector Bracket Case Ambient sensor



13. Put the start switch ON position, place the mode changing switch to the heater (Maximum). Put the start switch OFF position. 14. Open the lock lever, and remove the latch.



Figure 11



1. 2.



Valve actuator Latch



3.



Lock lever



A. B. C.



Cooling unit Lock lever close Lock lever open



15. Remove the case. 16. Remove the screws.



Figure 12



1. 2.



Screws Expansion valve



17. Remove the expansion valve.



18. Install the new expansion valve. 19. The installation procedure is the reverse order of removal. 20. The service valve (G) is installed into the hose, which is mounted to the compressor. Supply refrigerant.



WARNING Always wear protective gloves and use safety glasses for all work with refrigerant. Risk of frostbite.



Figure 13



A. B. C. D. E. F. G.



Low pressure hose High pressure hose Low pressure gauge (blue) High pressure gauge (red) Center filler hose Compressor Service valve



21. Check the air conditioner and heater operation.



Service Information Document Title: Vent actuator, replacing



Function Group: 874



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Vent actuator, replacing Op nbr 874-094



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 1. Remove the screws (1) and cover (2). Remove the screws (3) and cover (4).



Figure 1



2. Remove the wire harness (5), screws (6) and vent actuator (7).



Figure 2 A: Cooling unit 3. Install the new vent actuator. The installation procedure is the reverse order of removal. 4. Check the machine operation.



Service Information Document Title: Mode (foot) replacing



Function Group: actuator, 874



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Mode (foot) actuator, replacing Op nbr 874-095



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 1. Remove the screws (1) and cover (2). Remove the screws (3) and cover (4).



Figure 1



2. Remove the wire harness (5), screws (6) and mode (foot) actuator (7).



Figure 2 A: Cooling unit 3. Install the new mode (foot) actuator. The installation procedure is the reverse order of removal. 4. Check the machine operation.



Service Information Document Title: Intake actuator, replacing



Function Group: 874



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Intake actuator, replacing Op nbr 874-096



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 1. Remove the screws (1) and cover (2). Remove the screws (3) and cover (4).



Figure 1



2. Remove the wire harness (5), screws (6) and intake actuator (7).



Figure 2 A: Cooling unit 3. Install the new intake actuator. The installation procedure is the reverse order of removal. 4. Check the machine operation.



Service Information Document Title: Air mix door replacing



Function Group: actuator, 874



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Air mix door actuator, replacing Op nbr 873-011



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 1. Remove the screws (1) and cover (2). Remove the screws (3) and cover (4).



Figure 1



2. Put the start switch ON position, place the mode changing switch to the heater (Maximum). The start switch OFF position. 3. Open the lock lever (9), and remove the latch (8). Remove the wire harness (5), screws (6) and valve (mix) actuator (7).



Figure 2



A. B. C.



Cooling unit Lock lever close Lock lever open



4. Install the new valve (mix) actuator. The installation procedure is the reverse order of removal.



5. Check the machine operation.



Service Information Document Title: Function Group: Compressor, replacing 874 magnetic clutch (compressor removed)



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Compressor, replacing magnetic clutch (compressor removed) NOTE! This procedure describes the steps for replacing the magnetic clutch after the compressor has been removed from the machine. For removal and installation of the compressor refer to 874 Compressor, replacing incl draining and filling.



The clutch may also be replaced in frame, without disconnecting the cooling lines or removing the compressor, by loosening the compressor mounting bolts and removing the compressor drive belt. Op nbr 874-016



Removing the clutch 1. Place the compressor assembly on a clean work surface. 2. Remove three screws fixing the clutch cover.



Figure 1



1. 2.



Screw Clutch cover



3. Remove the nut.



Figure 2



1.



Nut



4. Remove the outer drive flange with a small screwdriver.



Figure 3



1.



Outer drive flange



5. Remove the cap.



Figure 4



1.



Cap



6. Remove the snap ring.



Figure 5



1.



Snap ring



7. Remove the clutch drive pulley with bearing from the drive shaft.



Figure 6



1. 2.



Clutch drive pulley Bearing



8. Remove the screw fixing the wire.



Figure 7



1.



Screw



9. Remove the snap ring. Then, remove the magnetic clutch from the compressor.



Figure 8



1. 2.



Snap ring Magnetic clutch



Installing the clutch 10. Install the magnetic clutch to the compressor and snap ring. NOTE! Locate the wire behind the tab on the magnet.



Figure 9



1. 2.



Magnetic clutch Snap ring



11. Install the pulley with bearing so it is seated fully onto the clutch shaft and secure it in place with the snap ring. 12. Install the outer clutch drive flange with the nut and cover. 13. Check the compressor clutch operation.



Service Information Document Title: Auxiliary description



Function Group: heater, 875



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Auxiliary heater, description The diesel coolant heater is used for heating the engine coolant by a fuel combustion unit while the engine is stopped. It consists of the fuel pump, the water pump, the timer and the heating unit. The heating unit has the control unit, the electric motor, the glow plugs, the fuses and the sensors in it. The diesel coolant heater facilitates the engine start and heating the cab in severe cold weather. Diesel coolant heater, related components



Figure 1 Diesel coolant heater, component A



Exhaust



V



Combustion air



B



Fuel



WA



Water oulet



WE



Water inlet



NOTE! The above illustration explains as an example. Regarding the ports for heater supply and return, please see Section 2 Engine. Diesel coolant heater operation Switching on When the heater is turned on, the control lamp in the switch or in the automatic heater switch lights up. The combustion-air fan and the water pump start up and the heater plug's preheating phase commences. Start-up After the preheating phase of approx. 60 seconds, the feeder pump starts up and fuel is supplied to the combustion chamber. Ignition follows. Then the combustion-air fan speeds up infinitely along with the feeder pump's impulse frequency to the "POWER" stage with 9500 watts to achieve the required temperature in the combustion chamber. The time-controlled heater plug is switched off. A second start commences when the flame sensor does not recognize a flame. The heater with after-running switches to fault when a flame is not recognized during the second phase. Control in heating mode When the heater is first started up after switch-on, or during normal operation, it works in the "POWER" setting 9500 watts



until • either the water temperature exceeds the switch-over threshold "POWER" / "LARGE" (e.g. 72 °C), • or the maximum operating time of two hours for this stage is exceeded. Depending on the amount of heat extracted, the Depending on the amount of heat extracted, the heater switches to one of the "POWER – LARGE – MEDIUM – SMALL – OFF" stages. If the cooling water temperature reaches 55 °C temperature reaches a maximum of 85 °C in the individual control stages. • The heater switches to "POWER" mode when the heat extracted equals or exceeds 9500 watts. • The heater will switch between "POWER and LARGE" when heat extraction is between 9500 and 8000 watts. • The heater will switch between "LARGE and MEDIUM" when heat extraction is between 8000 and 3500 watts. • The heater will switch between "MEDIUM and SMALL" when heat extraction is between 3500 and 1500 watts. • The heater operates in the "SMALL" stage when heat extraction is 1500 watts or less. The heater will switch from "SMALL" into the heater will switch from "SMALL" into the stage is so low that the cooling water temperature reaches 85 °C. It will follow the after-running of 210 seconds. The water pump continues until the heater is restarted. The heater starts in "MEDIUM" when the cooling water has cooled down to 70 °C (as an example). Control and safety equipment The flame is monitored by the flame sensor, the maximum permissible temperature by the overheating sensor. Both affect the control unit which switches the heater off when faults occur. • The start will be repeated if the heater doesn't ignite within 105 seconds after fuel has started to be supplied. The heater will be switched off if it doesn't ignite within 75 seconds after fuel has started to be supplied with the second start. After a certain number of unsuccessful starting attempts, a fault cutout is triggered.* • A new start will be triggered if the flame extinguishes itself during operation. The heater The heater will be switched off if it does not ignite within 105 seconds after fuel has started to be supplied. Switch the heater on and off again to cancel deactivation due to faults. • The overheating sensor is triggered by over heating,** which will result in the fuel supply being interrupted. The heater will then be switched off. Once the cause of overheating has been remedied, the heater can be restarted by switching on and off again***. After a certain number of cutouts caused by overheating have occurred, a fault cutout is triggered.* • If the voltage drops below the lower limit or rises above the upper limit, a fault cutout is triggered. • The heater will not start if the heater plug is faulty and the electric line to the feeder pump has been interrupted. • The speed-regulated combustion motor is permanently monitored. In the event of a fault, if it doesn't start, is blocked or when its speed falls below 40 % of the desired revolutions, the heater will switch to fault after a delay of 60 seconds. You can repair the following faults yourself If the control unit detects a fault at start-up of the diesel heater or while the diesel coolant heater is in operation, it is indicated on the timer module display within 15 seconds in the form of a fault code (F + 2 digit number). Safety devices If the heater does not start after being switched on: 1. 2.



Check the heater plug and change if necessary. Switch the heater off. and back on again.



Service Information Document Title: Auxiliary heater, principles



Function Group: 875



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Auxiliary heater, principles



Figure 1 Diesel coolant heater, structure 1



Combustion motor



10 Water pump



W Water inlet E



2



Flame sensor



11 Exhaust silencer



W Water outlet A



3



Combustion chamber



12 Combustion air silencer



V



Combustion air



4



Control unit



13 Fuel feeder pump



B



Fuel



5



Heater plug



14 Fuel branch piece



A



Fumes



6



Temperature sensor



15 Cable tree



7



Flame tube



16 Fuse bracket



8



Heat exchanger



17 Relay for switching vehicle's fan



9



Overheating switch



18 Timer



on



the



Timer The timer controls the diesel coolant heater, and displays the operating status. The functions the timer displays current date, current time and operating time. It also controls the manual operation, the reserved operation and the ON/OFF function of the diesel heater. Fuel feeder pump The fuel feeder pump supplys the diesel coolant heater with the fuel from the tank. Water pump The water pump is located between the diesel coolant heater and the engine block, and supplys the Diesel coolant heater with the coolant from the engine block. Heating unit



The heating unit raises the temperature of the coolant using the fuel combustion unit, consists of the glow plug, the thermostats, the flame sensor, the controller, the electric motor and the fuse. The case of the unit has the fuel supplying port, the coolant inlet/outlet port, the air inlet port and the exhaust port.



Service Information Document Title: Troubleshooting (10kw)



Function Group: 875



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Troubleshooting (10kw) First check for the following if faults occur     



Check the fuel level. Mechanical damage of components. When making transition to winter operation: Is there still summer diesel in the fuel line? Check the exhaust and combustion air pipes. Check fuses.



Fault diagnosis with timer module



Figure 1 Fault codes on timer module 1. 2. 3. 4. 5. 6.



Time Preselect Heat Back Forward Display



If the control unit detects a fault when the diesel heater is switched on or while the diesel coolant heater is in operation, the timer module indicates this using an error code comprising the letter F and as a 2-figure number within 15 seconds. Reading on Display e. g. 64 (current fault) + flashing heating symbol Interrogating the fault memory in the control unit using the timer module The electronic control unit can store up to 5 faults which can be read out and displayed with the timer module. The current fault is always written to memory location F1. Preceding faults are transferred to memory location F2 - F5. The contents of memory location F5 is overwritten if necessary. The errors stored in memory locations F1 to F5 can be called up using the button No. 4 and button No. 5. Interrogating the fault memory Condition :The diesel coolant heater is switched off. Press the button No. 3 on the module - the heater is switched on - then press the button No. 1, hold it down and then press the button No. 2 within 2 seconds. The heating symbol flashes and the current error is indicated. The errors stored in memory locations F1 to F5 can be called up using the button No. 4 and button No. 5. Troubleshooting



Fault code Description



Remarks - Remedial action



010



Overvoltage cut-out



Check to see if voltage between 13 and 14 of control unit (external plug) is greater than 15 V or 30 V



011



Undervoltage cut-out



Check to see if voltage between 13 and 14 of control unit (external plug) is less than 10 V or 20 V



012



Overheat



Over temperature sensor signals temperature of greater than 115 °C (239 °F). Impedance at over temperature sensor < 400 ohms. Ventilate heater (water level too low). Open the heater slide valve. Check water throughflow and sensor. Check the impedance at the control unit (internal plug). For this purpose, dismantle the control unit, disconnect the internal plug from the control unit and measure the impedance between 5 and 8. Over temperature sensor values: 150 ohms at – 25 °C / 10 ohms at + 25 °C



013



Excess temperature at flame sensor



Flame sensor signals temperature of greater than 700 °C (1292 °F). Impedance at flame sensor > 3400 ohms. Check the impedance at the control unit (internal plug). For this purpose, dismantle the control unit, disconnect the internal plug from the control unit and measure the impedance between 10 and 12. Flame sensor values: 900 ohms at – 25 °C (-13 °F) / 1100 ohms at + 25 °C (77 °F)



014



Difference between overheat and Temperature difference between measurements of over temperature water temperatue too large sensors is greater than 70 K. Ventilate heater (water level too low). Open the heater slide valve and check water throughflow. Check the over temperature sensor. Check the impedance between 5 and 8 at the control unit (internal plug). Over temperature sensor values: 150 ohms at – 25 °C (-13 °F) / 10 ohms at + 25 °C (77 °F)



015



Too many overheats



The control unit is interlocked after three successive overheats (error codes 012, 013 and 014). Eliminate the case of the overheat. Unlocking by deleting the error memory with diagnosis unit/PC or plus signal for 0.5 to 5 sec. on connection 7 (0.5 v) on the control unit (ext. plug) with heater switched on.



020 021



Glow plug interruption Short-circuit at glow plug



Check glow plug (nominal value: approx. 2 ohms), replace it if necessary. Check terminal 4 (1.5 white) on the control unit (internal plug) leading to glow plug to terminal 3 (1.5 brown) for continuity/ short-circuit. If O.K. - replace control unit.



033



Burner motor or speed controller Speed deviation for longer than 60 seconds. Nominal values: 7300 rpm defective, speed deviation (POWER), 5700 rpm (HIGH), 3600 rpm (MEDIUM), 2000 rpm (LOW). - Check burner motor: apply supply voltage to motor. Connect + to 1.5 black and to 1.5 orange. Motor does not turn replace burner motor with integrated sensor. - Check sensor supply. Switch on heater and measure voltage between output 13 (0.25 red) and 14 (0.25 green) at the control unit (internal plug). Nominal value: 8 V. If deviation replace control unit. - Check sensor: Measure voltage between terminal 15 (0.25 violet) and 14 (0.25 green) with an analog voltmeter when the blower is running. Nominal value: 4 V (+/0.3 V) aver- age value (8 V square-wave signal). If deviation replace motor with integrated sensor. If sensor signal is O.K



037



Water pump is not working



Check water pump (driven externally)



042



Short-circuit at water pump output



Test connection 6 (0.5 swrt) on the control unit (int. plug) for short circuit. Test water pumps and cables



043



Short-circuit at external components Check terminal 2 (1 green) of control unit (external plug) for shortcircuit. Check connected components (maximum current 6 A), replace them if necessary.



047



Short-circuit of metering pump



Check terminal 1 (1 blue) of control unit (external plug) and leads up to metering pump for short-circuit/interruption.



048



Metering pump interruption



Check the metering pump. Nominal value: approx. 20 ohms. Replace if necessary.



050



Too many failed starts



The control unit is interlocked after it has been switched on 10 times in succession (= 20 failed starts) without flame detection (fault code 052). Check the fuel supply, glow plug, exhaust piping, combustion air piping and flame sensor. Unlocking by deleting the error memory with diagnosis unit/ PC or plus signal for 0.5 to 5 sec. on connection 7 (0.5 v) on the control unit (ext. plug) with heater switched on.



051



Flame message is displayed



Flame sensor signals a temperature of greater than 80 °C (176 °F) when heater is switched on despite 4 minutes of cooling with cold air. Impedance at flame sensor >1300 ohm. If no combustion takes place check the flame sensor, replace it if necessary. Flame sensor values: 900 ohms at -25 °C (-13 °F) / 1100 ohms at +25 °C (77 °F)



052



Safety time exceeded



No flame was detected during the start-up phase. Flame heater does not start sensor value of less than 80 °C (176 °F) (1310 ohms). Check the fuel supply, glow plug, exhaust piping, combustion air piping and flame sensor. Flame sensor values: 900 ohms at -25 °C (-13 °F) / 1100 ohms at +25 °C (77 °F)



053 054 055 056



Flame loss in Power setting Flame loss in High setting Flame loss in Medium setting Flame loss in Low etting



Flame loss in Power setting Heater has started (flame detected) and indicates flame loss in a power setting. Check fuel flow rate, blower speed, fuel supply, exhaust pipe and combustion air piping. If combustion is O.K. check flame sensor, replace if necessary. Flame sensor values: 900 ohms at -25 °C (-13 °F) / 1100 ohms at +25 °C (77 °F)



059



Water temperatur rises too quickly



Check water circulation (012) and temperature control sensor (060/061)



060 061



Temperature control sensor For this purpose, dismantle the control unit, disconnect the internal interruption plug from the control unit and measure the impedance between 9 and Short circuit in temperature control 11. Impedance between terminals 9 and 11 of the control unit (internal sensor plug): greater than 10 ohms (in the event of interruption) less than 100 ohms (in the event of short-circuit) Temperature sensor values: 650 ohms at -25 °C (-13 °F) / 1000 ohms at +25 °C (77 °F)



064 065



Flame sensor interruption Short circuit in flame sensor



Flame sensor signals temperature value outside measurement range. Check the connecting leads (0.35 green). Impedance between terminals 10 and 12 of the control unit (internal plug): greater than 50 ohms (in the event of interruption) less than 100 ohms (in the event of shortcircuit) Flame sensor values: 900 ohms at -25 °C (-13 °F) / 1100 ohms at +25 °C (77 °F)



071 072



Overheat sensor interruption Short circuit in overheat sensor



Overheat sensor signals temperature value outside measu-rement range. Check the connecting leads (0.35 blue). Im-pedance between terminals 5 and 8 of the control unit (internal plug): greater than 700 ohms (in the event of interruption) less than 100 ohms (in the event of short-circuit) Overheat sensor values: 150 ohms at -25 °C (-13 °F) / 10 ohms at +25 ° C (77 °F)



090 093 094 097



Control unit defective (internal Internal control unit error in microprocessor/memory detected. reset) Replace control unit Control unit defective (RAM fault) Control unit defective (EPROM fault) Control unit defective (general fault)



Figure 2 Circuit diagram of diesel coolant heater Mark



Description



Mark



Description



Mark



Description



1



Glow plug



9



Vehicle blewer relay



sw



black



2



Safety thermal cutout switch



10



Switch-over relay for water ws circulation system, to be fitted by customer if required



white



3



Water pump



11



Main fuse (24 volt = 15 A)



rt



red



4



Temperature sensor



12



Fuse for vehicle blower 25 A



ge



yellow



5



Flame sensor



13



Fuse for control switch 5 A



br



brown



6



Burner motor



14



Battery



gr



grey



7



Control unit



gn



green



bl



blue



8



Fuel metering pump



vi



violet



li



purple



Service Information Document Title: Function Group: Instrument panel, replacing 881 (left)



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Instrument panel, replacing (left) Op nbr 881-003



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 1. Open the cab door (1) and fix it.



Figure 1



2. Remove the screws (2) and open the cover.



Figure 2



A.



Instrument panel (left)



3. Disconnect the wire harness (4) from remote controller for radio and CD switch (5).



Figure 3



4. Remove the screw (6), and remove cover (7).



Figure 4



5. Remove the screws (8), and open the panel (9).



Figure 5



6. Disconnect connectors (10), and remove panel (9).



Figure 6



7. Disconnect connectors switch (11).



Figure 7



8. Install the new instrument panel (12). The installation procedure is the reverse order of removal. 9. Check the machine operation.



Service Information Document Title: Function Group: Instrument panel, replacing 881 (right)



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Instrument panel, replacing (right) Op nbr 881-005



WARNING Turn off the battery disconnect switch and remove the start key before starting to work. 1. Open the cab door (1) and fix it.



Figure 1



2. Remove the screws (2) and open the cover (3).



Figure 2 Instrument panel, right 3. Disconnect the wire harness (4), and remove cover (3).



Figure 3



4. Remove the screw (5), and remove cover (6).



Figure 4



5. Remove the screws (7), and open the panel (8).



Figure 5



6. Disconnect connectors (9), and remove panel (10).



Figure 6



7. Disconnect connectors switch (11), and install new instrument panel.



Figure 7



8. Install the new instrument panel. The installation procedure is the reverse order of removal. 9. Check the machine operation.



Thank you for your purchase. Have a nice day.



file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/7/15 9:13:27]



Service Information Document Title: Description, general



Function Group: 900



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Description, general The machine is equipped with a negative flow control system with variable flow. With this system, the working pump can deliver flow according to demand. A variable flow from the pump allows precision work even with high engine speed. The hydraulic system, also known as the “Automatic Sensing Work Mode,” is designed for high-productivity, high-digging capacity, high-manoeuvring precision and excellent fuel economy. The summation system, boom, arm and swing priority along with boom and arm regeneration provides optimum performance. The following important functions are included in the system:       



Summation system: Combines the flow of both hydraulic pumps to ensure quick cycle times and high productivity. Boom priority: Gives priority to the boom operation for faster raising when loading or performing deep excavations. Arm priority: Gives priority to the arm operation for faster cycle times in leveling and for increased bucket filling when digging. Swing priority: Gives priority to swing functions for faster simultaneous operations. Regeneration system: Prevents cavitation and provides flow to other movements during simultaneous operations for maximum productivity. Power boost: All digging and lifting forces are increased. Holding valves: Boom and arm holding valves prevent the digging equipment from creeping.



The following functions are included in the main control valve:      



Boom Dipper arm Bucket Slew Travel Optional equipment, X1



The optional control valve has the following functions:  



Optional equipment, X3 Line rupture for boom and arm



Service Information Document Title: Hydraulic description



Function Group: system, 900



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic system, description The machine's hydraulic system is divided into two subsystems - the working hydraulic system and servo hydraulic system. All power transmission is via hydraulic oil in the working hydraulic system. A working pump supplies the main valve block with oil. The main valve block distributes the oil to the digging equipment's four (five split boom) hydraulic cylinders and the two hydraulic motors for travel and slew. The flow of oil to the different movements is controlled with valve spools in directional valves. The servo hydraulic system is used for control. A servo pump supplies the control levers and pedals with servo pressure. When the machine is operated, the control pressure valves reduce the servo pressure to a control pressure, which activates the directional valves.



Service Information Document Title: Hydraulic oil, description



Function Group: 900



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic oil, description The oil contains selected additives that provide good oxidation stability, corrosion protection and good lubricating characteristics as well as compatibility with bearings containing lead alloys. The ester base gives the oil a very high viscosity index and good characteristics at low temperatures.



Service Information Document Title: VCADS Pro, Operations



Function Group: 900



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



VCADS Pro, Operations The following VCADS Pro operations are available for function group 9. Operations used when changing or working on components are mandatory. Tests Operation



Application



91003-3 Cooling fan control, test



Used when there is a suspicion of fault and/or at abnormal values/readings.



91303-3 Proportional valve changing, amperage, test 91401-3 Solenoid valves, test



for



power Used when there is a suspicion of fault and/or at abnormal values/readings. Used when there is a suspicion of fault and/or at abnormal values/readings.



Service Information Document Title: Function Group: Hydraulic system, repair of 900 hydraulic components in workshop



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic system, repair of hydraulic components in workshop  



 



    



Always wear clean coveralls and be strict about personal cleanliness. Work on hydraulic components should be performed separate from other work in a so-called "clean room". The room must have good ventilation and the floor must be coated with a binding material. Machining, grinding and similar work is not allowed in the "clean room". The workplace must be equipped with thoroughly cleaned tools and suitable containers for cleaning hydraulic components. Containers for cleaning hydraulic components must not be used for other cleaning. The containers must be cleaned frequently and filled with new fluid. The containers must be equipped with a removable grating on the bottom, which separates the component from any sludge on the bottom. Always clean components that are going to be handled in the "clean room". If an alkaline detergent is used, it should contain anti-corrosion agent. Always plan work on the hydraulic system so that it can be completed without any longer interruptions. When cleaning during repairing – use dry and clean compressed air for drying, do not use cotton waste or rags. Always plug a component when work is completed, use clean plastic plugs of the correct dimensions, and pack the component. When cleaning in the "clean room" – use methods that do not stir up dust or dirt.



Service Information Document Title: Function Group: Hydraulic oil, storage and 900 handling



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic oil, storage and handling    



Hydraulic oil should be stored in tightly sealed tanks or barrels. Only containers used for transporting hydraulic oil should be used for this purpose. Oil should be stored under cover or in temperature-controlled premises. If oil is stored outdoors, the barrels should be stored horizontally so that water cannot enter and the barrel markings are not eradicated. Oil must not be stored at temperatures exceeding 60 °C, or be exposed to direct sunlight or freezing temperatures.



Service Information Document Title: Function Group: Hydraulic system, 900 cleanliness when handling hydraulic components



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic system, cleanliness when handling hydraulic components WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries



NOTICE It is very important to keep the hydraulic system free from any impurities, as these can cause abnormal wear and may lead to expensive downtime. Greatest possible cleanliness should be maintained during all handling of hydraulic components and hydraulic oil. NOTE! A vacuum pump should be used for work on the hydraulic system, see 900 Vacuum pump, connection.



Service Information Document Title: Function Group: Hydraulic components, 900 storage and transport



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic components, storage and transport   



All hydraulic components must be stored in plastic bags or film and they must be plugged. The packaging must not be opened before use of the component. Service vehicles should be equipped with an interior which facilitates good order and cleanliness. Each service vehicle should carry a roll of plastic film, plastic plugs of the most common sizes and plastic containers for components. Plugs and film should be of the disposable type.



Service Information Document Title: Hydraulic system, instructions



Function Group: work 910



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic system, work instructions      







Always wear clean coveralls and be strict about personal cleanliness. Perform thorough troubleshooting to avoid unnecessary repair work. If necessary, move the machine, to as dust-free an environment as possible. If possible, do not dismantle components in the field. Use exchange components. Protect both replaced components and components that are to be reused by wrapping them in plastic film. If the tank is to be drained, and the oil has been found to be free of discolouration and impurities – drain the oil into clean containers, and seal securely. Refilling of this oil or filling of new oil should always be performed by removing the hydraulic oil filter cap and then filling through the filter. Use a suitable fluid when cleaning and pour it into a thoroughly cleaned container.



Service Information Document Title: Function Group: Hydraulic components, 910 description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic components, description This machine incorporates the features and functions described below in its hydraulic diagram in order to provide easier operation, greater safety, higher productivity, and better fuel economy. Function of components Purpose



Component



Ease of Travel operation and safety



Function



Feature







Controlled pressure







Straight travel during simultaneous operations







Straight travel







Low speed, Low/High automatic shift



speed







Automatic shifting between low and high speed.







Slew priority diagram (during simultaneous slew and arm in)







Easier digging due to the use of simultaneous slew and arm in







Automatic slew parking brake







Delayed slew parking brake application during slew to allow for inertia







Rebound damping function







Damping by rebound valve







Controlled pressure







Fine operation



 



Boom regenerating diagram Arm regenerating diagram







Changing the balance between boom, arm and bucket functions







Holding valve (boom, arm lock)







Decreasing the amount of natural fall of boom/arm when the boom/ arm are at rest



by



servo



hydraulic



Slew



damping



Digging units by



servo



hydraulic







Heavy lift and heavy–duty digging







Increasing the working pressure by increasing the pressure of main relief valve







Closed and semi automatically pressurized hydraulic tank







Contamination of hydraulic oil prevented, suction ability of pump improved







Suction strainer







Damage of hydraulic components prevented







Return line : filter and drain filter







Contamination prevented







Servo hydraulic diagram : line filter







Servo hydraulic-operated diagram failure prevented







Hydraulic oil cooled by oil cooler







Deterioration prevented







Emergency diagram







If engine stopped, boom movable by weight of attachments







Full horsepower control







Effective use of engine horsepower through action of two variable displacement pumps







2–speed auto shift by the 2–speed track motor







Low speed/High propel torque. High speed/Low propel torque







Conflux for boom raising







Faster boom raising







Conflux diagram for arm in







Faster arm in







Regeneration diagram for boom down, arm in







Faster boom down, arm in







Regeneration diagram for arm in







Faster arm in







Conflux diagram for arm out







Faster arm out



Others



Productivity increased



of



of



hydraulic



hydraulic



oil



oil



Pump



Travel



Digging units



Fuel economy







Conflux diagram for bucket







Faster bucket in/out







Pressure increasing diagram for heavy load







Improved digging, lifting under heavy load







Negative flow control







Flow minimized when in neutral







Mode select switch changeover







Selecting an effective engine rpm suited for the amount of work, fuel consumption and fine control







Auto idling







Engine speed decelerated during waiting periods for reduced fuel cost and less noise.



Pump



Controller



Service Information Document Title: Hydraulic schematic



Function Group: diagram, 910



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic diagram, schematic The mechanical power from the engine is converted to hydraulic power by the main pumps. Hydraulic power from the main pumps goes to the track motors, slew motor and hydraulic cylinders via the control valve, where it is converted back to mechanical power, which actuates the travel action, slew action and attachments.



Figure 1 Hydraulic diagram 1



Quickfit cylinder



27



Main control valve



2



Quickfit valve



28



Shuttle valve block



3



X1 (hammer)



29



Control pattern change valve



4



X1 preset proportional relief valve left)



30



Remote control valve (lever)



5



3 way selector valve



31



Shuttle valve



6



X1 preset proportional relief valve (right)



32



Remote control valve (straight travel)



7



Arm cylinder



33



Remote control valve (travel)



8



Line rupture valve (arm cylinder)



34



Remote control valve (X1)



9



Bucket cylinder



35



Proportional valve (X1)



10



3 way non leak valve



36



Solenoid valve (hammer and scissors)



11



Removal counterweight cylinder



37



Servo hydraulic block



12



Slow return valve



38



Servo hydraulic block



13



Removal counterweight valve



39



Solenoid valve (5 serial)



14



Boom cylinder



40



Drain oil filter



15



Line rupture valve (left boom cylinder)



4 1 Hydraulic oil tank



16



Boom float position valve (with line rupture valve)



42



Check valve (3.0 kgf/cm2)



17



Line rupture valve (right boom cylinder)



43



Check valve (1.5 kgf/cm2)



18



Boom float position valve (with out line rupture valve)



44



Hydraulic oil cooler



19



Boom float position solenoid valve



45



Hydraulic oil cooling fan motor



20



X3 (rotator)



46



Accumulator and block



21



X3 (rotator valve)



47



Removal counterweight solenoid valve



22



Proportional valve (X3)



48



X1 pump control proportional valve



23



Track drive unit (left)



49



Main pump



24



Center passage



50



Gear pump (servo, cooling and X3)



25



Track drive unit (right)



51



Engine



26



Slew drive unit



Service Information Document Title: Function Group: Hydraulic system, position 910 of main components



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Hydraulic system, position of main components



Date: 2014/7/15



Figure 1 Hydraulic system's main components



1



Remote control valve (X1 pedal)



32



Bucket cylinder



2



Remote control valve (travel)



33



Boom cylinder



3



Remote control valve (straight travel )



34



Line rupture valve (boom cylinder)



4



Servo hydraulic block



35



Non leak valve



5



Hammer & Shear solenoid valve



36



Overload warning pressure switch



6



Remote control valve (left lever)



37



Boom float position valve (with out hose rupture valve)



7



X1 single acting solenoid valve



38



Boom float position valve (with hose rupture valve)



8



Remote control valve (right lever)



39



X3 control valve



9



Boom float position solenoid valve



40



X3 solenoid valve



10



Servo hydraulic block



41



3-way selector valve



11



Center passage



42



X3 proportional solenoid valve



12



X1 return filter



43



X1 pre pressure proportional relief valve (right)



13



X1 pre pressure proportional relief valve (left)



44



Slew drive unit



14



Hydraulic oil cooler



45



Servo hydraulic block



15



Hydraulic oil cooling proportional relief valve



46



Main control valve



16



Hydraulic oil cooling fan motor



47



Hydraulic oil tank



17



Quickfit valve



48



Air breather



18



Shuttle valve



49



Solenoid valve



19



Control pattern change valve



50



Oil level gauge



20



X1 double acting control solenoid valve



51



X1 pump flow control proportional solenoid valve



21



Shuttle valve



52



Gear pump (Servo and cooling)



22



X1 1 switch control solenoid valve



53



Gear pump (servo, cooling and x3)



23



X1 2 switch control solenoid valve



54



Accumulator block



24



X1 proportional solenoid valve



55



Accumulator



25



Track drive unit



56



Track drive unit



26



Shuttle valve



57



Main pump



27



Check valve (1.5k)



58



Drain filter



28



Check valve (3.0k)



59



Removal counterweight control valve



29



Stop valve



60



Servo hydraulic oil filter



30



Line rupture valve (arm cylinder)



61



Slow return valve



31



Arm cylinder



62



Removal counterweight cylinder



Service Information Document Title: Hydraulic oil description



Function Group: tank,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic oil tank, description



Figure 1 Structure, hydraulic oil tank 1 O-ring



6 Spring washer



11 Strainer



16 Breather-strainer



2 Shim



7 Plain washer



12 Spring



17 Air breather



3 O-ring



8 Screw



13 Bypass valve



18 Element



4 Copper gasket



9 Screw



14 Drain valve



19 Strainer assembly



15 Hydraulic oil tank



20 Level gauge



5 Spring washer



10 Plug



Tightening torque, : unit : kgf·m (lbf·ft) No.



Tightening torque



No.



Tightening torque



8



52.2 ± 5.2 (377 ± 38)



14



4.5 ± 0.5 (32 ± 4)



9



6.5 ± 0.7 (47 ± 5)



20



1.5 ± 0.2 (11 ± 1.4)



NOTE! When mounting the tank, make the bottom level with frame by use of shim (2).



Maintain the clearance



Front, rear, left, bottom : 10 mm.



Right : 5 mm Hydraulic oil level   



To check the oil level, park on a level surface, retract the arm cylinder, extend the bucket cylinder, lower the bucket to the ground and stop the engine. Operate each control lever (for digging unit and travel) to its full stroke to release the residual pressure. The center line of the sight gauge is normal. Add oil when required. – Bypass valve set pressure: 1.5 ± 0.3 kgf/cm2 (21 ± 4 psi) – Air breather : 1) Relief set pressure : 0.5 ± 0.1 kgf/cm2 (7 ± 0.7 psi) 2) Suction set pressure : 0.05 ± 0.01 kgf/cm2 (0.7 ± 0.07 psi)



Figure 2 Oil level sight gauge Oil filter bypass valve When the filter is clogged Bypass valve (1) is opened and the oil returns directly to the tank without passing through the filter.



Figure 3 Oil flow, when the filter is clogged 1.



From main control valve



NOTE! Bypass valve set pressure : 1.5 ± 0.3 kgf/cm2 (21.33 ± 4.3 psi)



Service Information Document Title: Air breather, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Air breather, description



Figure 1 Structure, air breather 1 Breather assembly



5 Inlet valve



9 Retaining ring



13 Spring



2 Key



6 Inlet valve



10 Cover assembly



14 Spring



3 Mounting screw



7 Packing



11 Filter element



15 Valve assembly



4 Hydraulic oil tank



8 Body



12 Outlet valve



Operation Preventing negative pressure inside the tank The tank is a pressurized sealed type, so negative pressure is formed inside the hydraulic tank when the oil level drops during operations. When this happens, the difference in pressure between the tank and the outside atmospheric pressure opens the poppet in the breather, and air from the outside is let into the tank to prevent negative pressure. At that time filter (11) prevents contamination from entering the tank.



Figure 2 Operation, air breather 1 Preventing excessive pressure inside the tank When the hydraulic actuators are operated, the oil level in the hydraulic system increases as temperature rises. If the hydraulic pressure rises exceeding the set pressure, the breather is actuated to release the hydraulic pressure inside the tank.



Figure 3 Operation, air breather 2 Hydraulic tank pressurizing The hydraulic tank is pressurized to create a positive pressure at the hydraulic pump inlet to prevent cavitation. If the tank cap assembly does not function or seal properly, the hydraulic pump could be damaged. To pressurize the tank, raise the boom to maximum height, extend the arm and bucket cylinders, then lower the boom to the ground. To prevent hydraulic oil ejection due to the tank internal pressure while hydraulic system maintenance, press the cap (3) several times to release the pressure until the air is all out.



Figure 4 Operation, air breather 3



Service Information Document Title: Function Group: Hydraulic oil tank, vacuumpumping, connecting and disconnecting pump



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump Op nbr 911-040 14 360 000 Vacuum pump



NOTICE Connection of the vacuum pump must be performed with the diesel engine off. The air filter is placed above the filtered hydraulic oil. Therefore, carefully clean the surfaces closest to the filter. Do not leave the connection to the filter open for longer than it takes to fit the adapter. NOTE! There is always a risk of air entering the hydraulic system when using a vacuum pump. NOTE! See : 9111 Breather, replacing 1. Place the vacuum pump on the hydraulic oil tank. 2. Remove the air breather and immediately install the adapter.



Figure 1 Connection of vacuum pump 1. 2. 3.



Hose Adapter Air breather (Air filter)



Connect the hose to the adapter. 3. Connect the plug to the 24 V socket behind the operator's cab.



4. Start the vacuum pump.



Figure 2 Vacuum pump 1.



Adjusting knob



5. Run the pump for 2–3 minutes until a negative pressure reading of –30 kPa (–4.35 psi) is obtained. 6. Adjust the vacuum pressure with the adjusting knob so that oil leakage will not occur during work on the hydraulic system. IMPORTANT! The pressure must not fall below –30 kPa (–4.35 psi), as otherwise there is a risk of damage to the hydraulic oil tank. 7. Turn off the electric power to the vacuum pump. 8. Remove the plug from the 24V socket. 9. Remove the hose from the adapter.



Figure 3 Disconnection vacuum pump 1. 2. 3.



Hose Adapter Air breather (Air filter)



10. Remove the adapter and immediately fit the air breather. 11. Turn off the electric power to the vacuum pump. 12. Remove the plug from the 24V socket. 13. Remove the hose from the adapter.



14. Remove the adapter and immediately fit the air breather.



Service Information Document Title: Oil level gauge, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Oil level gauge, replacing Op nbr 911-015 14360000 Vacuum pump / 24V



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1. Place the machine in the service position D. See 091 Service positions 2. Press the air breather cap on the hydraulic tank to release the residual pressure. 3. Connect the vacuum pump on the hydraulic 9111 Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump 4. Remove mounting screws (2) and level gauge (1).



Figure 1



5. Install the new level gauge with a new O-ring and tighten screws (2). Tightening torque : 1.5 ±0.2 kgf m (11 ±1.4 lbf ft) 6. Refill hydraulic oil.



oil



tank,



see



Service Information Document Title: Breather, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Breather, replacing Op nbr 911-051 1. Release the internal pressure in the hydraulic oil tank via the breather. 2. Align the locking hole to horizontal using a (-) screwdriver (1) and remove breather cap (2).



Figure 1



3. Remove breather mounting screws (1).



Figure 2



4. Remove breather body (2) and rubber packing (3) 5. Install the new breather body with new rubber packing. NOTE! Observe torque when install the breather. Tighten torque : 2.94 N m (2.17 lbf ft) ~ 5.88 N m (4.33 lbf ft) 6. Install breather cover assembly.



Service Information Document Title: Hydraulic oil replacing



Function Group: tank,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic oil tank, replacing Op nbr 911-038



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! Oil that drains from hoses and connections must be collected in a suitable container. Disconnected hoses and connections must be plugged. NOTE! Container capacity : 400 liters



Drain hose : The hose for engine oil draining can be used. 1. Place the machine in the service position D. See 091 Service positions.



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping.



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 2. Press the air breather cap on the hydraulic tank to release the residual pressure.



WARNING When the last bolt has been removed, the cover plate falls down. 3. Remove the screws and the under cover.



Figure 1



1.



Screw



2.



Under cover



4. Connect the drain hose supplied with the machine to the drain valve and drain the hydraulic oil into an oil barrel. Disconnect the drain hose, after draining hydraulic oil and install valve cab.



Figure 2



1. 2.



Drain valve Drain hose



5. Remove the plug and drain the hydraulic oil into an oil barrel. Fit the plug, after draining hydraulic oil.



Figure 3



1.



Plug



NOTE! Container capacity : 120 litres 6. Remove the screws and the main control valve cover.



Figure 4



1. 2.



Screw Cover



7. Remove clamp screw. Disconnect the servo hydraulic hoses. Remove return block screws.



Figure 5



1. 2. 3. 4.



Clamp screw Return block screw Return block screw Hose



8. Remove the screws and the hydraulic oil level gauge.



Figure 6



1. 2.



Level gauge mounting screw Level gauge



9. Disconnect the hydraulic oil temperature sensor wire harness. Disconnect the hoses.



Figure 7



1. 2. 3. 4.



Hose Hose Hydraulic oil temperature sensor wire harness Hose



10. Remove the hydraulic oil temperature sensor. Remove the fitting.



Figure 8



1. 2. 3. 4.



Fitting Fitting Hydraulic oil temperature sensor Fitting



11. Loosen the clamps and move the hose right side.



Figure 9



1. 2. 3.



Hose clamp Hose Hose clamp



12. Remove the hydraulic oil tank mounting screws.



Figure 10



1.



Screw



13. Install the eye bolts and hold the hydraulic oil tank with hoist. Remove the hydraulic oil tank



Figure 11



1.



Eye bolt



14. Transfer the hydraulic oil tank composition parts (air breather, strainer, bypass valve, return filter, suction pipe, covers, fittings nonslip plate) to the new hydraulic oil tank from old hydraulic oil tank. 15. Install the eye bolts and hold hydraulic oil tank with hoist and hydraulic oil tank.



Figure 12



1.



Eye bolt



16. Install the hydraulic oil tank and tighten the hydraulic oil tank mounting screws. 512 ±51 N m (377 ±37 lbf ft) (52.2 ±5.2 kgf m)



Figure 13



1.



Screw



NOTE! When mounting the tank, level the bottom to the frame by use of shims.



Maintain the clearance and tighten torque, see 9111 Hydraulic oil tank, description 17. Install the suction hose and tighten the clamps securely. NOTE! Tightening torque: 10.7 ±1 N m (7.9 ±0.7 lbf ft) (1.1 ±0.1 kgf m)



a. 60 mm (Do not paint)



b. 9 mm



c. 25 mm



Figure 14 1. Clamp 2. Suction hose 18. Install the hydraulic oil level gauge and tighten screws. Tighten torque: 14.7 ±2 N m (10.8 ±1.4 lbf ft) (1.5 ±0.2 kgf m)



Figure 15



1. 2.



Level gauge mounting screw Level gauge



19. Install the fittings and the hydraulic oil temperature sensor. NOTE! Tightening torque: N m (lbf ft) (kgf m) 1. 2. 3. 4.



81.4 ±8.1 N m 59.9 ±5.8 lbf ft) (8.3 ±0.8 kgf m) 141.2 ±13.7 N m (104 ±10.1 lbf ft) (14.4 ±1.4 kgf m) 11.7 N m ((8.6 lbf ft) (1.2 kgf m) 347.1 ±34.3 N m (255.5 ±25.3 lbf ft) (35.4 ±3.5 kgf m)



Figure 16



1. 2. 3. 4.



Fitting Fitting Hydraulic oil temperature sensor Fitting



20. Connect the hoses with O-rings and the hydraulic oil temperature sensor wire harness.



Figure 17



1. 2. 3. 4.



Hose Hose Hydraulic oil temperature sensor wire harness. Hose



21. Tighten the clamp screw. Tighten torque: 14.7 ±1.5 N m (11 ±1 lbf ft) (1.5 ±0.15 kgf m) Install return blocks and tighten screws with O-ring. Tightening torque: 111 ±11 N m (81.6 ±8 lbf ft) (11.3 ±1.1 kgf m) Connect the servo hydraulic hoses with O-ring.



Figure 18



1. 2. 3. 4.



Clamp screw Return block mounting screw Return block mounting screw Hose



22. Install the cover and tighten the screws.



Figure 19



1. 2.



Screw Cover



23. Install the hydraulic oil tank under cover and tighten screws.



Figure 20



1. 2.



Screw Under cover



24. Remove the plug. Fill the hydraulic oil tank with hydraulic oil through the return filter.



Figure 21



1.



Plug



NOTE! Check the hydraulic oil level. See 9111 Hydraulic oil tank, description 25. Start the engine. Check any leaks and repair if needed.



Service Information Document Title: Shock reducing description



Function Group: valve,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Shock reducing valve, description Function The shock reducing valves installed in the servo hydraulic lines at the main control valve prevent shock loads at the end of cylinder rod movement by restricting return servo hydraulic flow of the main control valve spool, thereby controlling spool return speed from an operating to neutral position. Circuits: See 990 Hydraulic diagram, arm in conflux Structure The structure of this valve is as shown in the figure. Spool (103) and spring (105) are equipped in casing (101), and spool (102), spring (106) are equipped in spool (103). Fixed diaphragm (1) is installed at the center of spool (102), and diaphragm (4) is installed at the side of spool (103).



Figure 1 Structure, shock reducing valve Tightening torque (T): 7 ~ 8 kgf·m (50 ~ 58 lbf·ft) Specifications Max. pressure: 50 kgf/cm2(711 psi) Max. oil flow: 20 l /min (B → A, free flow direction) Control oil flow: 2.0 l /min: KFR 6A-10/2.0 (A → B) Oil temperature: -20 ~ 90°C (-4 ~ 194°F) Operation A → B (Controlled oil flow direction) As the oil flow from port A increases, the resistance against fixed orifice (1) also increases, and the pressure in chamber (2) rises. When the oil flow in port A is over setting flow, the right directional force by the difference of pressure between chamber (2)



and (3) is stronger than spring (106) force, spool (102) is full stroke, and orifice (4) is closed. When this happens, the pressure in chamber (3) rises, and the difference of pressure between chamber (2) and (3) is kept to setting pressure. Oil flow passing fixed orifice (1), i.e. oil flow from port A, is kept to setting flow, regardless of the pressure of port A or port B.



Figure 2 Controlled oil flow direction B → A (Free flow direction) When the oil flows from port B, spool (103) is full stroke, oil flows into chamber (6) through outline of spool (103) from chamber (5), and into chamber (2) from sectional slit of spool (103), then into port A.



Figure 3 Free flow direction Troubleshooting Troubleshooting Trouble



Cause



Remedy



Oil flow (A → B) over setting flow. Spool (102) sticks, spool (103) sticks. (Shock is considerable as actuator stopping.) Oil flow (A → B) is less than setting flow. Spool (102) sticks. (It takes a long time to stop the Control diaphragm actuator.) clogged. Oil flow (A → B) is low. (It takes a long time to start actuator.)



Spool (103) sticks.



of



spool



Polish minor scratches and nicks with extra fine emery cloth.



Disassemble, (102) reassemble.



clean



and



polish,



Polish minor scratches and nicks with extra fine emery cloth.



Service Information Document Title: Servo hydraulic block



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Servo hydraulic block Servo hydraulic block, description Ports connection See 990 Hydraulic diagram, with option components to item number 40.



Figure 1 Servo hydraulic block Ports connection See 990 Hydraulic diagram, with option components to item number 86.



Date: 2014/7/15



Figure 2 Servo hydraulic block



Service Information Document Title: Shuttle valve description



Function Group: block,



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Shuttle valve block, description Shuttle valve (attachment) , description Ports connection See 990 Hydraulic diagram, with option components to item number 26.



Figure 1 Shuttle valve, attachment 1. 2.



Nut, tightening torque : 73.55 ±6.86 Nm (7.5 ± 0.7 kgf·m) (54.2 ± 5 lbf·ft) Screw, tightening torque : 63.74 ±6.37 Nm (6.5 ± 0.65 kgf·m) (46.93 ± 4.69 lbf·ft)



Shuttle valve (track - straight travel), description Ports connection See 990 Hydraulic diagram, with option components to item number 91.



Date: 2014/7/15



Figure 2 Shuttle valve, track 1.



Shuttle cartridge, tightening torque : 73.55 ±6.86 Nm (7.5 ± 0.7 kgf·m) (54.2 ± 5 lbf·ft)



Service Information Document Title: Check valve, description



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Check valve, description Creates a back pressure to prevent reverse flow in the return circuit. Hydraulic oil cooler directions: 147.1 kPa (1.5 kg/cm2) (21.3 psi) (1.47 bar) Hydraulic oil cooler directions: 294.2 kPa (3.0 kg/cm2) (42.7 psi) (2.94 bar)



Figure 1 Structure, check valve 1



Screw



6



Spring



2



Screw guide



7



Spring holder



3



O-ring



8



Spring guide



4



Check valve body



9



Nut



5



Valve seat



10



Lock nut



Check valve mounting position



Date: 2014/7/15



Figure 2 Check valve mounting position 1



Hydraulic cooler



5



Check valve (1.5 k) Main control valve → Oil cooler → Oil tank



2



Fan motor



6



Check valve (3.0 k) Main control valve → Oil tank



3



Proportional relief valve



7



Hydraulic oil tank



4



Main control valve



NOTE! When replacing and re-assembling, the check valve must be installed to open in the direction of the flow. If installed in the reverse direction, excessive back pressure will build in the return circuit.



Service Information Document Title: Function Group: Oil cooler line bypass valve (check valve), replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Oil cooler line bypass valve (check valve), replacing Op nbr 911-033



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1. Place the machine in the service position B. See 091 Service positions



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container. 2. Press the air breather cap on the hydraulic tank to release the residual pressure.



WARNING The parts are heavy. Take appropriate safety precautions. 3. Remove screws (1) and main control valve upper cover (2). Remove screws (3) and pipe clamp.



Figure 1 Removal cover 4. Remove screws (1) and check valve (2) from the pipe.



Figure 2 Removal check valve (1.5k) 5. Install check valve (2) with new O-rings and tighten screws (1). NOTE! Tightening torque: N m (lbf ft) (kgf m) 1.



49 ±4.9 (36.1 ±3.6) (5 ±0.5)



NOTE! When replacing, use the same specifications as old bypass valve.



When replacing, the bypass valve must be installed to open in the direction of the flow. If installed in the reverse direction, excessive back pressure will build in the return circuit.



Figure 3 Removal check valve (1.5k) 6. Install pipe clamp and tighten screws (3) Install main control valve upper cover (2) and tighten screws (1). NOTE! Tightening torque: N m (lbf ft) (kgf m) 1. 2.



110 ±11 (81.6 ±8) (11.3 ±1.1) 262 ±26 (192.7 ±19.4) (26.7 ±2.7)



Figure 4 Install cover 7. Refill hydraulic oil and test machine.



Service Information Document Title: Function Group: Pump suction hose and pipe, replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Pump suction hose and pipe, replacing Op nbr 911-005



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container.



Container capacity : 400 litres



Drain hose : The hose for engine oil draining can be used. 1. Park the machine on a level surface and place the machine in the service position B. Turn clockwise 30° and lower the bucket to the ground and stop the engine.



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. 2. Press the air breather cap on the hydraulic tank to release the residual pressure.



WARNING When the last bolt has been removed, the cover plate falls down. 3. Remove screws (1) and cover (4). Remove screws (2) and cover (5). Remove screws (3) and cover (6).



Figure 1



4. Connect hose (2) to drain valve (1) and drain the hydraulic oil into an oil container.



Figure 2



5. Drain the hydraulic oil via plug (1) in the hydraulic oil pump suction tube. NOTE! Container capacity : 120 lires



Figure 3



6. Loosen hydraulic pump suction hose clamps (1) and remove hose (2).



Figure 4



7. Install new suction hose (2) and tighten clamps (1) securely. NOTE! Tightening torque: N m (lbf ft) (kgf m) 1.



10.7 ±1 (7.9 ±0.7) (1.1 ±0.1)



a. b. c.



60 mm (Do not paint) 9 mm 25 mm



Figure 5



8. Install cover (6) and tighten screws (3). Install cover (5) and tighten screws (2). Install cover (4) and tighten screws (1). NOTE! Tightening torque: N m (lbf ft) (kgf m)



110 ±11 (81.6 ±8) (11.3 ±1.1)



Figure 6



9. Refill hydraulic oil. 10. Start the engine and check for oil leakage and operation.



Service Information Document Title: Function Group: Hydraulic oil cooling system, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic oil cooling system, description The hydraulic oil cooler consists of a steel frame with cells and tanks made of aluminium. The cells contain turbulators, which create turbulence in the oil so it makes maximum contact with the cell walls. The oil is cooled by a hydraulically driven cooler fan. The oil flow to the cooler is regulated by a proportional relief valve. The maximum flow through the cooler is approximately 300 l/min.



Figure 1



Hydraulic oil cooling system 1



Hydraulic cooler



oil 8



2



Fan motor



3



Main control valve 10



Check valve (3.0 17 kgf cm2)



Pipe



4



Proportional relief 11 valve



Pipe



18



Hose



5



Pipe



12



Hose



19



Pipe



6



Hose



13



Pipe



20



Coupling



7



Pipe



14



Hydraulic oil tank



21



Pipe



9



Check valve (1.5 15 kgf cm2)



Pipe



Pipe



Coupling



16



No



Name



Unit



Tightening torque



5, 15 (a)



Screws



N m (lbf ft) (kgf m)



64 ±6.9 (47.4 ±5.1) (6.53 ±0.7)



6, 12, 18 (a)



Hose clamp



N m (lbf ft) (kgf m)



10~12 (7.4~8.9) (1.0~1.2)



6, 12, 18 (b)



Hose clamp



N m (lbf ft) (kgf m)



Until no deformation rubber hose



8, 10 (a)



Check valve mounting screw



N m (lbf ft) (kgf m)



49 ±4.9 (36.2 ±3.6) (5 ±0.5)



16, 20 (a)



Coupling screw



N m (lbf ft) (kgf m)



10.5~13.0 (1.07~1.3)



of



(7.8~9.6)



After getting a signal like hydraulic oil temperature, the V-ECU controls fan speed with the control relief valve, which is necessary at fixed pump and motor application, depending on the setting demand for each machine. Check valve could be set to prevent hydraulic motor cavitation.



Figure 2 Hydraulic oil cooling system 1. 2. 3. 4. 5. 6. 7. 8.



Hydraulic oil temperature Fan pump Proportional valve Check valve Fan motor Fan Coolant temperature Charge air temperature



Hydraulic oil cooling system, reversible type The cooling is driven by hydraulic motor, and fan rotation is reversed by reversible solenoid valve, which can divert oil flow



direction to hydraulic motor.



Figure 3 Hydraulic oil cooling system, reversible type 1



Hydraulic pump



oil



2



Fan speed switch



3



V-ECU



4



Hydraulic sensor



5



Check valve



cooling



fan 6



auto/manual 7 8



oil



temperature 9 10



Proportional relief valve Reversible solenoid valve Direction change valve Hydraulic motor



oil



cooling



fan



Hydraulic oil cooling fan



Fan speed control curve Basic speed control concept depending on some temperature is as the following diagram. Here, K ≤ 0 nᵐ K ≥ 1 nᵐᵃ 0 < K ≤ 1 nᵐ + k (nᵐᵃ - nᵐ ) If operator requests air conditioning [ON] and the required fan speed, of which minimum speed shall be determined later, is higher than the fan control speed according to the basic concept above, the required fan speed for air conditioning takes the first priority. Fan speeds are converted to the working pressure of the fan motor.



Figure 4 Fan speed control curve A. B. C.



Fan speed Hydraulic oil temperature Maximum fan speed



Service Information Document Title: Hydraulic oil description



Function Group:



Information Type: Service Information



cooler,



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic oil cooler, description The hydraulic oil cooler is a plate fin type. Air is drawn into the engine compartment passing through the radiator and the hydraulic oil cooler as the fan rotates. The hydraulic oil cooler is installed to the radiator frame. Structure



Figure 1 Hydraulic oil cooler 1



Net



7



Fan



2



Sponge



8



Fan motor



3



Condenser



9



Guard



4



Stay



10



Shroud



5



Oil cooler



11



Holder



6



Oil out



12



Oil in



Service Information Document Title: Fan pump, description



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Fan pump, description See 9143 Servo pump, description Fan pump, principle of operation 



The fan pump is a gear pump attached to the main pump of the engine.



Date: 2014/7/15



Service Information Document Title: Fan motor, description



Function Group:



Profile: EXC, EC480D L [GB]



Fan motor, description



Figure 1 Structure, fan motor A: Normal type



Information Type: Service Information



Date: 2014/7/15



B: Reversible type Rotational direction Inlet



Outlet



View from shaft end



Pin



Pout



Clockwise



Figure 2 Sectional view, fan motor A: Normal type B: Reversible type 1



Case



14 Retainer plate



32 Spring



2



Shaft



15 Piston assembly



33 Plug



3



Ball bearing



16 Valve plate



34 O-ring



4



Oil seal



17 Pin



35 Pin



5



Swash plate



18 Ball bearing



36 Plug (for shipping)



6



Pin



19 O-ring



40 Spring seat



7



Cylinder block



20 Rear cover



41 O-ring



8



Spring seat



21 Screw



42 Backup ring



9



Spring



22 Name plate



43 Plug



10 Washer



23 Drive screw



44 Set screw



11 Snap ring



24 Snap ring



45 Nut



12 Pin



28 Plug (for shipping)



13 Retainer holder



31 Check valve



Fan motor, principle of operation Hydraulic motor The cylinder block incorporates 9 pistons, and at one end it is connected to the port block, and acts as a distributing valve, via 2 half-moon shaped ports, B and C. Torque generating principle: When oil at high pressure (pressure P) is supplied to port B, the pistons push against the swash plate, each exerting a force of F (F = P × A, where A = cross sectional area of piston). The pistons are then subject to a corresponding reaction force from the swash plate, so that a rotational direction component, Ft, is generated for each piston. Together, these Ft components generate a force which rotates the cylinder block. The torque is transmitted to the shaft via the spline, and the shaft rotates. The oil, having performed its designated function, is expelled from port C. Conversely, if oil at high pressure is supplied to port C, the shaft will rotate in the opposite direction.



Figure 3 Operation, fan motor 1. 2. 3. 4. 5.



Port block Cylinder block Piston assembly Swash plate Shaft



Check valve The check valve helps to avoid cavitation while decelerating, to supply oil from outlet port to inlet port. The motor outlet oil flows from Pout port, (when machine circuit stops oil supply) to Pin port. Then the motor works as a pump because the component which is driven by motor has inertia. To stop motor completely, it needs oil supply from Pin port. During deceleration, Pin port pressure is less than that of Pout. This pressure balance makes the check valve open. Then the oil can return to Pin port through the check valve.



Figure 4 Check valve A.



Check valve



General precautions Operating oil 1.



2.



Appropriate operating oil The operating oil has a critical role to play in transmitting motive power and lubricating hydraulic components. Oil selection and handling therefore have a critical bearing on the performance and life of the hydraulic components. You must use an extremely good quality oil, which has excellent lubricating, oxidizing stability, corrosion resistance and floating resistance properties. Also, it must not soak into packing / sealing materials. We recommend the oil shown in the table below for this motor. Do not mix other types of operating oil with it. Item



In cold regions



In warm/hot regions



Outside temperature



10 ~ 25 °C



0 ~ 35 °C



Hydraulic operating oil



ISO VG 32



VG 56



Usage viscosity range for operating oil Item



Viscosity (cSt)



Oil temperature (°C) ISO VG 32



VG 56



Temperature range



20 ~ 100



15 ~ 45



27 ~ 57



Working range



20 ~ 500



-3 ~ 50



5 ~ 63



If it is used below the "working viscosity range" bottom limit, you must carry out unloaded warming-up prior to usage. For continuous operation: Install cooler or heater, as required, to keep it within the appropriate viscosity range. 3.



Oil temperature control 







Circuit oil temperature range: Normal usage oil temperature range



20 ~ 60 °C



Permitted oil temperature range



-20 ~ 80 °C



The extent to which you can control the circuit oil temperature is extremely important. If it is too high, the oil oxidizes more quickly and degenerates faster. If it is too low, the viscosity is too high, causing increased motor friction loss and reducing mechanical efficiency. Hence you should take the following measures: 



Start-up oil temperature



 



If the motor is operated at below 10 °C, either carry out warming-up or use a heater to get it above 10 °C before usage. Normal usage oil temperature Ideally it should be kept within 20 ~ 60 °C. Oil temperature range limits The upper limit for the circuit oil temperature is 80 °C. This limit has been determined based on the effect of oil temperature on the viscosity/oxidizing resistance of the oil, and deterioration of the O-rings and seals. Using it at above 80 °C will shorten the life of the motor and the operating oil.



Filters 







The motor is comprised of precision components with extremely small clearances, so it is particularly susceptible to contamination (sludge, iron powder, corrosion, filings, grinding dust etc.). Preventing contamination will enable you to keep motor performance reduction (lock characteristics) and sliding component friction to a minimum. You need to maintain the cleanliness of the oil in the hydraulic system. This will allow you to use the motor for a long time with minimal repairs and checks.



Piping   



You must flush the pipes out before fitting them. Make sure you remove all scale etc. inside the piping. When fitting the pipes, take care not to allow ingress of contamination via motor ports. When you have finished fitting the pipes, use a flushing pump to thoroughly clean out the whole circuit.



Shaft coupling method  



The motor shaft and slave shaft should be centred to within φ 0.1. Please treat the center of the motor shaft and the center of the mounting flange as being one and the same. When fitting/removing the coupling, use the screw at the tip of the shaft or the centre hole to make sure you do not subject it to thrust load or shock.



Starting up   



Fill the motor case with clean operating oil (minimum volume 150 cc) before starting the motor up. Bleed all air from the piping. First run it at low speed and check for abnormal noises / vibration. Then increase it to the specified speed and apply the load.



Service Information Document Title: Function Group: Fan motor, troubleshooting



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Fan motor, troubleshooting Troubleshooting Phenomenon



Cause



Remedy



Does not rotate.



A hydraulic pump other than the motor, or a Check that the specified oil pressure is being pressure control valve / direction change valve supplied at the motor inlet, then check each is malfunctioning. component and repair if necessary. Hydraulic pressure is being lost due to Replace worn components, then thoroughly abnormal wear of sliding components. clean all components. Remove any scratches / burring, and reassemble, taking care to prevent ingress of contamination. Malfunction caused by damage to the main Dismantle it and replace damaged part of the motor. If this is the cause, the motor components, then thoroughly clean all itself will make an abnormal noise. components. Remove any scratches / burring, and reassemble, taking care to prevent ingress of contamination. The load on the motor is excessive, with the Check loading mechanism. Use a load result that the relief valve is operating. appropriate for the relief valve pressure setting. Check valve can not close, in circuit.



Disassemble and inspect the check valve, if there is some contamination remove it.



Does not rotate quickly The correct oil flow rate is not being supplied Check that the specified oil pressure is being enough. to the motor because of a problem with a supplied at the motor inlet, then check each hydraulic pump or pressure control valve. component and repair if necessary.



Oil leak



Oil pressure is dropping significantly due to wear on motor sliding components, and rpm falls off sharply when large amounts of oil leak via the drain port. Alternatively, the bearing is worn.



Dismantle it, replace any worn components, then thoroughly clean all components. Remove any scratches / burring, and reassemble, taking care to prevent ingress of contamination.



Contamination at check valve



Disassemble and inspect the check valve, if there is some contamination remove it.



O-rings or seals are damaged.



Replace damaged O-rings or seals with new ones. Take care not to scratch lip when inserting seals. Also, remember that the maximum usage temperature for seals and O-rings is 80 °C, so check the temperature of the oil in the motor. If it is above 80 °C, you need to take countermeasures, for example, fitting a cooler within the hydraulic oil circuit.



The pressure inside the motor case increases, Repair the motor and replace the seals with seals are damaged, and oil leaks (Seal new ones. Take care not to scratch lip when withstand pressure = 1 kgf/cm2). inserting seals. Negative pressure may have built up (because drainage pipe is clogged), causing damage to seals and leakage. (Seal withstand pressure = 1 kgf/cm2)



Clean out clogged drainage pipe to reduce resistance within. Make sure that these measures reduce the pressure on the seals to less than 1 kgf/cm2. Replace the seals with new ones. Take care not to scratch lip when inserting seals.



Service Information Document Title: Function Group: Proportional relief valve, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Proportional relief valve, description Series DBVSA-1LG inverse-proportional pressure relief valves are two stage, spool-type units. They limit the inlet pressure in port P to a value that is inversely proportional to the solenoid current. The valves are screw-in cartridges and the mounting thread is the well known 3/4"-16 UNF pattern. All exposed steel parts are corrosion protected to ISO 4042, grade A3C, and the valves are suitable for use in the harshest operating environments. The coils slide onto the core tubes and hydraulic envelop, even when the valve is under pressure. Coils turn through 360° and lock at any angle.



Figure 1 Structure, proportional relief valve (normal type) Description



Tightening torque: N m (lbf Size (mm) ft) (kgf m)



1



Protective cap



-



-



2



Adjust screw



-



4



3



Lock nut



10



13



4



Air bleed screw



1



2



5



Nut



2.7



27



6



40



24



Proportional relief valve Proportional relief valve, air bleeding 1. 2. 3. 4. 5.



Remove the protective cap Slacken the air bleed screw approximately 2 turns. Switch the pressure relief valve ON/OFF several times unit no more air bubbles escape. Tighten the air bleed screw. Fit the protective cap.



Figure 2 Structure, proportional relief valve (reversible type) Description



Tightening torque: N m (lbf Size (mm) ft) (kgf m)



1



Protective cap



-



-



2



Adjust screw



-



4



3



Lock nut



10



13



4



Air bleed screw



1



2



5



Nut



2.7



27



60



27 8



6 Proportional relief valve 7



Locking screw



55



8



Check valve



60



9



Reversible solenoid valve



40



24



10



Locking screw



50



8



24



Proportional relief valve characteristic curve



Figure 3 Characteristic curve Temperature 60 °C 90 °C



Unit



Specifications



Speed



rpm



750



Current



mA



580



Speed



rpm



1450



Current



mA



330



Service Information Document Title: Oil cooler, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Oil cooler, replacing Op nbr 911-011 14360000 Vacuum pump / 24V



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container. 1. Park the machine on a level surface and place the machine in the service position B. Turn counterclockwise 30° and lower the bucket to the ground and stop the engine.



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. 2. Press the air breather cap on the hydraulic tank to release the residual pressure.



WARNING When the last bolt has been removed, the cover plate falls down. 3. Remove screws (1) and main control valve under cover (2)



Figure 1



4. Connect the vacuum pump on the hydraulic 9111 Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump 5. Remove plug (1) at the return pipe (2) and drain hydraulic oil.



oil



tank,



see



Figure 2 NOTE! Drain the oil into a suitable container (120 litres). 6. Loosen hose clamps (1) and remove hose (2).



Figure 3



7. Remove mounting screws (1, 2) and covers (3, 4).



Figure 4



8. Remove air condenser mounting screws (1). NOTE! Do not remove the hoses for air conditioner condenser NOTE! After removing mounting screws of air conditioner condenser, carefully place the air conditioner condenser on the track shoe to avoid damage.



Figure 5



9. Remove screws and bracket (1) Remove stay screws (2). Loosen hose clamps (5) and remove pipe mounting screws (3) on hose and pipe (4).



Figure 6



10. Disconnect oil cooler fan motor hoses (1).



Figure 7



11. Remove screws (1) and hydraulic oil cooler under cover (2).



Figure 8



12. Loosen clamp screws (1) and move coupling (2) to the tube side.



Figure 9



13. Remove hydraulic oil cooler mounting screws (1).



Figure 10



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 14. Hold bracket with hoist (2) and remove hydraulic oil cooler (1).



Figure 11



15. Remove support bracket screws (1) and fan shroud screws (2). Remove the fan motor and fan shroud (3) from hydraulic oil cooler.



Figure 12



16. Remove screws (2 ) and nets (1).



Figure 13



17. Install the nets and the screws. 18. Install fan motor and fan shroud (3) on the hydraulic oil cooler. Tighten screws (1, 2) NOTE!



Tightening torque: 39.2 ±3.9 N m (28.9 ±2.9 lbf ft) (4 ±0.4 kgf m)



Figure 14



19. Hold bracket with hoist (2) and assemble hydraulic oil cooler (1).



Figure 15



20. Tighten hydraulic oil cooler mounting screws (1). NOTE! Tightening torque: 64 ±6.9 N m (47.3 ±5.1 lbf ft) (6.5 ±0.7 kgf m)



Figure 16



21. Install coupling (2) and tighten screws (1). NOTE! Tightening torque: 11 N m (8.1 lbf ft) (1.13 kgf m)



Figure 17



22. Install air condenser (2) and tighten screws (1). NOTE! Tightening torque: 24.5 N m (18 lbf ft) (2.5 kgf m)



Figure 18



23. Connect hoses (1).



Figure 19



24. Install bracket (1) tighten screw. Tighten stay bar screws (2). Install pipe and hose (4) and tighten clamps (5). NOTE! Tightening torque See : 9113 Hydraulic oil cooling system, description



Figure 20



25. Install covers (3) and tighten screws (1). Install covers (4) and tighten screws (2). NOTE! Tightening torque: 110.8 ±10.8 N m (81.6 ±7.9 lbf ft) (11.3 ±1.1 kgf m)



Figure 21



26. Install hose (2) and tighten hose clamps (1). NOTE! Tightening torque: 5.9 ~ 6.9 N m (4.3 ~5.1 lbf ft) (0.6 ~ 0.7 kgf m)



Figure 22



27. Tighten plug (1).



Figure 23



28. Install main control valve under cover and tighten screws (1). NOTE! Tightening torque: 110.8 ±10.8 N m (81.6 ±7.9 lbf ft) (11.3 ±1.1 kgf m)



Figure 24



29. Install hydraulic oil cooler under cover (2) and tighten screws (1). NOTE! Tightening torque: 110.8 ±10.8 N m (81.6 ±7.9 lbf ft) (11.3 ±1.1 kgf m)



Figure 25



30. Refill the hydraulic oil tank with hydraulic oil. Start the engine. Check for leaks and aeration.



Service Information Document Title: Function Group: Fan pump, parts inspection Profile: EXC, EC480D L [GB]



Fan pump, parts inspection See : 9143 Servo pump, parts inspection



Information Type: Service Information



Date: 2014/7/15



Service Information Document Title: Fan pump, disassembly



Function Group:



Profile: EXC, EC480D L [GB]



Fan pump, disassembly See : 9143 Servo pump, disassembly



Information Type: Service Information



Date: 2014/7/15



Service Information Document Title: Fan pump, assembly



Function Group:



Profile: EXC, EC480D L [GB]



Fan pump, assembly See : 9143 Servo pump, assembly



Information Type: Service Information



Date: 2014/7/15



Service Information Document Title: Oil cooler fan replacing



Function Group: pump,



Profile: EXC, EC480D L [GB]



Oil cooler fan pump, replacing Op nbr 911-035 1. See : 9143 Servo pump, replacing



Information Type: Service Information



Date: 2014/7/15



Service Information Document Title: Fan motor, tools Profile: EXC, EC480D L [GB]



Fan motor, tools Special tools Special tools Description & Part no. Jig for seal (17) assembly



Part no.: 14514415



Function Group:



Information Type: Service Information



Date: 2014/7/15



Service Information Document Title: Fan motor, disassembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Fan motor, disassembly Precautions   



Thoroughly clean the motor prior to removal from the machine. Use a proper bench for working, spread a paper or rubber mat on the bench, and disassemble the motor on it. Do not reuse the O-rings, seal and gasket.



Disassembly procedure 1.



Fix the motor in a vise and remove screws (18).



2.



Figure 1 Removal, screws Remove recover (20).



3.



Figure 2 Removal, rear cover Remove O-ring (19) from cylinder block (7).



Figure 3 Removal, O-ring NOTE! O-ring is never used again. Change it at every disassembling. 4.



Remove valve plate (16). The valve plate could be on the rear cover.



Figure 4 Removal, valve plate NOTE! Take care not to scratch the valve plate. If it has any damage, replace with a new one. 5.



Remove cylinder block assembly. – Cylinder block assembly consists of: – Cylinder block (7) x 1 – Spring seat (8) x 1 – Spring (9) x 1 – Washer (10) x 1 – Snap ring (11) x 1 – Pin (12) x 3 – Retainer holder (13) x 1 – Retainer plate (14) x 1 – Piston assembly (15) x 1



Figure 5 Removal, cylinder block assembly NOTE! Do not lose pin (12), they are small and can easily fall out.



Any damage is not allow on mating surfaces.



When it is needed, cylinder block assembly must be changed as an assembly. 6.



Remove shaft (2) with bearing (3) and swash plate (5). In case the shaft does not come out, hit the end of shaft with a hammer as shown in the picture below.



7.



Figure 6 Removal, shaft with bearing and swash plate Remove seal (4) by pushing it from mounting flange face shown in the picture below.



8.



Figure 7 Removal, seal Remove snap ring (24) if it is needed.



9.



10.



Figure 8 Removal, snap ring Remove plug (33) on rear cover. Then spring (32) and check valve (31) can be disassembled. Rear cover (20) has bearing (18). If it is needed to change bearing (18), disassemble it from rear cover (20).



Figure 9 Removal, plug, spring and check valve Disassemble shaft (20) with bearing (3) from the swash plate.



Figure 10 Removal, shaft with bearing



Service Information Document Title: Fan motor, assembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Fan motor, assembly Precautions     



Wash all parts with treated oil and blow off oil completely. Be sure that the washed parts are free of dust and other foreign matter. Handle them with care so that they will not be scratched or damaged. Always replace seals and bearings with new ones. Tighten all the tightening areas to the specified torque. Apply grease to the oil seals and the O-rings in advance. (In particular, the oil seal lips must be oiled.)



Assembly procedure 1.



Install check valve (31) and spring (32) into rear cover (20) then install plug with O-ring. 



Tightening torque: 4 ± 0.2 kgf·m (29 ± 1.5 lbf·ft)



Figure 1 Installation, check valve and spring NOTE! O-ring must be replaced to new one every disassembling. 2.



Install snap ring (24)



3.



Figure 2 Installation, snap ring Install oil seal (4). This part must be changed every disassembling to prevent oil leakage. Prior to install, put enough grease on the oil seal and rear cover (Outer and internal diameter, also housing bore). The position of oil seal must be as shown. A : Grease before assembling



Figure 3 Installation, oil seal NOTE! Recommended grease: SHELL ALVANIA GREASE–2 4.



Install shaft (2) with bearing (3) into the case.



5.



6.



7.



Figure 4 Installation, shaft with bearing Install swash plate (5) into the case. Swash plate must be pushed at the end of motor case.



Figure 5 Installation, swash plate Install cylinder block assembly. The consistence of cylinder block assembly is referred in assembling procedure. Prior to installing, all parts are oiled. Pin (12) is easy to drop. Take care not to lose it. This part is important for motor working.



Figure 6 Installation, cylinder block assembly Install O-ring (19). This part must be changed every disassembling.



8.



9.



Figure 7 Installation, O-ring Put rear cover (20) which is equipped with check valve and valve plate. Take care not to drop valve plate. Greasing between valve plate and rear cover will help to assemble. Prior to the installing, put oil into each hole of cylinder block (7). (total 9 holes)



Figure 8 Installation, rear cover Tighten screws (18). 



10.



Tightening torque: 6.25 ± 0.25 kgf·m (45 ± 1.8 lbf·ft)



Reassembled motor must start slowly to confirm corrective assembling.



Service Information Document Title: Oil cooler fan replacing



Function Group: motor,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Oil cooler fan motor, replacing Op nbr 911-034



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! Clamps around hoses and lines must be removed. Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container. 1. Park the machine on a level surface and place the machine in the service position B. Turn counterclockwise 30° and lower the bucket to the ground and stop the engine. 2. Press the air breather cap on the hydraulic tank to release the residual pressure.



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. 3. Loosen hose clamps (1) and remove hose (2).



Figure 1 Removal, hose 4. Remove mounting screws (1, 2) and covers (3, 4).



Figure 2 Removal, cover 5. Remove screws and bracket (1). Remove stay screws (2). Loosen hose clamps (5) and remove pipe mounting screws (3) on hose and pipe (4).



Figure 3 Removal, hose and pipe 6. Remove screws (1) and fan guard (2)



Figure 4



7. Disconnect oil cooler fan motor hoses (1).



Figure 5



8. Remove screw (1) with washers (3, 4) and cooler motor fan (5) from cooler fan motor (8). Remove screws (2), nuts, washers (6, 7, 9) and cooler fan motor from bracket (10).



Figure 6



9. Transfer the fittings with new O-rings to a new oil cooler fan motor. NOTE! Tightening torque: N m (lbf ft) (kgf m) 1. 2. 3.



47 ±4.9 (34.6 ±3.6) (4.8 ±0.5) 81.4 ±7.8 (59.9 ±5.8) (8.3 ±0.8) 81.4 ±7.8 (59.9 ±5.8) (8.3 ±0.8)



Figure 7



10. Install oil fan motor (8) to bracket (10) and tighten screws (2) with washer (7, 9). Install cooing fan (5) to oil cooler fan motor and tighten screws (1) with washer (3, 4). NOTE! Tightening torque: N m (lbf ft) (kgf m) 1. 2.



63.7 ±6.8 (46.9 ±5) (6.5 ±0.7) 81.4 ±7.8 (59.9 ±5.8) (17.9 ±1.8)



Figure 8



11. Connect oil cooler fan motor hoses (1).



Figure 9



12. Install fan guard and Tighten screws (1). NOTE! Tightening torque: 23.5 ±1.9 N m (17.3 ±1.4 lbf ft) (2.4 ±0.2 kgf m)



Figure 10



13. Install stay (2). Install hose and pipe (4) and tighten screws (3) and hose clamps (5). Install bracket and the screws. NOTE! Tightening torque See 9113 Hydraulic oil cooling system, description



Figure 11



14. Install covers (3, 4) and tighten screws (1, 2). NOTE! Tightening torque: 110.8 ±10.8 N m (81.6 ±7.9 lbf ft) (11.3 ±1.1 kgf m)



Figure 12



15. Install hose (2) and tighten hose clamps (1). NOTE! Tightening torque: 5.9 ~ 6.9 N m (4.3 ~5.1 lbf ft) (0.6 ~ 0.7 kgf m)



Figure 13



16. Start the engine. Check for leaks and repair if needed.



Service Information Document Title: Hydraulic diagram, ports



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic diagram, ports Port connection, component Port name



Description



Port name



Description



P1



Inlet port from P1 Pump



5pa5



Arm in servo hydraulic signal port



P2



Inlet port from P2 Pump



5B5



Arm out port



4A1



Left track motor port (Forward)



5pb5



Arm out servo hydraulic signal port



4pa1



Left travel servo hydraulic port (Forward)



pc



Pressure boost servo hydraulic signal port (main)



4B1



Left track motor port (Reverse)



4pc1



Boom holding valve release servo hydraulic signal port



4pb1



Left travel servo hydraulic port (Reverse)



4pc2



P2 pump flow summation port



4A2



Boom raise port



4pc4



Arm parallel conflux change over servo hydraulic signal port



4pa2



Boom raise servo hydraulic port



4pc5



Boom lower regenerating servo hydraulic signal port



4B2



Boom lower port



5pc1



Arm holding valve release servo hydraulic signal port



4pa2



Boom raise servo hydraulic port



5pc2



P1 pump flow summation port



4A3



Bucket curl port



5pc3



Boom raise conflux shut off servo hydraulic signal port



4pa3



Bucket curl servo hydraulic port



5pc4



Slew priority servo hydraulic signal port



4B3



Bucket dump port



5pc6



P1 pump flow summation port



4pb3



Bucket dump servo hydraulic signal port



dr1



Drain port



4A4



Close



dr2



Boom holding valve drain port



4pa4



Arm out conflux servo hydraulic signal port



dr3



Arm holding valve drain port



4B4



Close



dr4



Drain port



4pb4



Arm in conflux servo hydraulic signal port



dr5



Drain port



5A1



Right track motor port (Forward)



dr6



Drain port



5pa1



Right travel servo hydraulic signal port (Forward) dr7



Drain port



5B1



Right track motor port (Reverse)



2-steps relief valve signal port



5pb1



Right travel servo hydraulic signal port (Reverse) 4pf



Negative control signal port (P2 pump)



5A2



Close



5pf



Negative control signal port (P1 pump)



5pa2



Drain port



pp



Pressure source for straight travel and Auto deceleration signal port (attachment, travel)



5B2



Close



4pp



Boom holding valve release signal pressure source



5pb2



Boom raise conflux servo hydraulic signal port



5pp



Arm holding valve release servo hydraulic signal port



5A3



Slew port (Left) (A)



Pg



Quickfit pressure source port



5pa3



Slew servo hydraulic signal port (Left)



Px



Auto deceleration (Attachment)



5B3



Slew port (Right) (B)



Py



Auto deceleration pressure switch port (Travel)



Pd



pressure



switch



port



5pb3



Slew servo hydraulic signal port (Right)



Pz



Arm regenerating servo hydraulic signal port



5A4



Option port for X1



R1



Hydraulic tank return line



5pa4



Option servo hydraulic signal port



R2



Close (return port)



5B4



Option port for X1



Rs1



Close



5pb4



Option servo hydraulic signal port



Rs2



Slew motor boost port



5A5



Arm in port



Service Information Document Title: Main control description



Function Group: valve,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Main control valve, description This control valve consists of two 5-spool blocks connected by screws, main spool, main relief valve, port relief valves, arm holding valve, arm regenerating valve, arm parallel valve, boom priority logic valve, foot relief valve, straight travel valve, center bypass valve, and various check valves such as arm parallel conflux check, back pressure check, load check etc.



Figure 1 Main control valve



Figure 2 Main control valve, parts



Figure 3 Main control valve, parts



Figure 4 Main control valve, parts 1



Foot relief valve



32 Check valve



2



Arm 1 spool



33 Check valve



3



Optional spool



34 Check valve



4



Slew spool



35 Boom conflux shut-off valve



5



Boom 2 spool



36 Boom holding valve



6



Left track spool



37 Check valve



7



Arm out port relief valve



38 Port relief valve



8



Check valve



39 Make-up valve



9



Arm 2 spool



40 Check valve



10 Bucket spool



41 Port relief valve



11 Boom 1 spool



42 Check valve



12 Right track spool



43 Port relief valve



13 Straight travel spool



44 Check valve



14 Foot relief valve



45 Port relief valve



15 Check valve



46 Check valve



16 Arm regulating valve



47 2 stage port relief valve



17 Boom boost check valve



48 Check valve



18 Main relief valve



49 Arm semi-parallel changeover valve



19 Option flow summation check valve



50 Check valve



20 Arm parallel conflux check valve



51 Make-up valve



21 Boom servo hydraulic check valve



52 Arm holding valve



22 Check valve



53 Check valve



23 Screw



54 Slew priority valve



24 Plug



55 Check valve



25 Plug



56 Check valve



26 Screw



57 Port relief valve



27 O-ring



58 Center bypass valve



28 O-ring



59 Center bypass valve



29 Screw



60 Foot relief valve (flow sensing valve)



30 Cap



61 Foot relief valve (flow sensing valve)



31 Port relief valve



62 Port relief valve



Service Information Document Title: Function Group: Main control valve, port size and tightening torque



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Main control valve, port size and tightening torque Port size and tightening torque: N m (lbf ft) (kgf m Port name



Port size



Connector



Tee



P1, P2



-



175.5 ±17.6 (129.2 ±13) (17.9 ±1.8)



175.5 ±17.6 (129.2 ±13) (17.9 ±1.8)



R1



-



-



63.7 ±6.9 (46.9 ±5.1) (6.5 ±0.7)



Rs1, Rs2



G1



205.9 ±20.6 (151.6 19.6 ±11.8 (88.1 ±15.2) (21 ±2.1) ±8.7) (12.2 ±1.2)



-



Flange screw



Hose



4Pa1, 4Pa2, 4Pa3, 4Pb1, 4Pb3, G3/8 4Pb4, 5Pa1, 5Pa2, 5Pa3, 5Pa4, 5Pb1, 5Pb2, 5Pb3, 5Pb4, 5Pb5



73.5 ±7.8 (54.2 ±5.8) (7.5 ±0.8)



-



36.3 ±3.9 (26.7 ±2.9) (3.7 ±0.4)



4Pb2, 5Pa5



G3/8



73.5 ±7.8 (54.2 36.3 ±3.9 (26.7 ±5.8) (7.5 ±0.8) ±2.9) (3.7 ±0.4)



36.3 ±3.9 (26.7 ±2.9) (3.7 ±0.4)



4Pa4



G3/8



49 ±4.9 (36.1 ±3.6) (5 ±0.5)



-



36.3 ±3.9 (26.7 ±2.9) (3.7 ±0.4)



4Pc2, 4Pp



G1/4



49 ±4.9 (36.1 ±3.6) 25.5 ±2.9 (18.8 (5 ±0.5) ±2.2) (2.6 ±0.3)



25.5 ±2.9 (18.8 ±2.2) (2.6 ±0.3)



4Pc5, 5Pc2, 5Pc3, 5Pc4, 5Pc6, G1/4 5Pp, 4Pf, 5Pf, Pc, Pp



49 ±4.9 (36.1 ±3.6) (5 ±0.5)



-



25.5 ±2.9 (18.8 ±2.2) (2.6 ±0.3)



Pd



G1/4



49 ±4.9 (36.1 ±3.6) 25.5 ±2.9 (18.8 (5 ±0.5) ±2.2) (2.6 ±0.3)



36.3 ±3.9 (26.7 ±2.9) (3.7 ±0.4): Pd → X1 logic Pi 25.5 ±2.9 (18.8 ±2.2) (2.6 ±0.3): Pd → Sol B



4Pc2, 4Pp



G1/4



49 ±4.9 (36.1 ±3.6) 25.5 ±2.9 (18.8 (5 ±0.5) ±2.2) (2.6 ±0.3)



25.5 ±2.9 (18.8 ±2.2) (2.6 ±0.3)



Px, Py, Pz,



G1/4



49 ±4.9 (36.1 ±3.6) 25.5 ±2.9 (18.8 (5 ±0.5) ±2.2) (2.6 ±0.3)



25.5 ±2.9 (18.8 ±2.2) (2.6 ±0.3)



C1, C2



G1/2



107.9 ±10.8 (79.4 ±7.9) (11 ±1.1)



-



119.6 ±11.8 (88.1 ±8.7) (12.2 ±1.2)



4A1, 4B1, 4A2, 4B2, 4A3, 4B3, 4A4, 4B4, 5A1, 5B1, 5A2, 5B2, 5A3, 5B3, 5A4, 5B4, 5A5, 5B5



-



-



175.5 ±17.6 (129.2 ±13) (17.9 ±1.8)



5B4HF, 5B4PC



-



-



-



175.5 ±17.6 (129.2 ±13) (17.9 ±1.8)



5AB3BC



-



-



-



63.7 ±6.9 (46.9 ±5.1) (6.5 ±0.7)



dr1, dr2, dr3, dr4, dr5, dr6



G1/4



49 ±4.9 (36.1 ±3.6) 25.5 ±2.9 (18.8 (5 ±0.5) ±2.2) (2.6 ±0.3)



25.5 ±2.9 (18.8 ±2.2) (2.6 ±0.3)



dr7



G1/8



24.5 ±2 (18.1 ±1.4) (2.5 ±0.2)



25.5 ±2.9 (18.8 ±2.2) (2.6 ±0.3)



-



T



-



-



-



-



347.1 ±34.3 (255.6 ±25.3) (35.4 ±3.5)



T1



-



-



-



-



54.9 ±5.9 (40.4 ±4.3) (5.6 ±0.6)



T2



-



-



-



-



250.1 ±25.5 (184.1 ±18.8) (25.5 ±2.6)



T3



-



-



-



-



119.6 ±11.8 (88.1 ±8.7) (12.2 ±1.2)



Figure 1 Tightening torque



Service Information Document Title: Pressure relief troubleshooting



Function Group: valve,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Pressure relief valve, troubleshooting     



If an abnormal condition is detected, determine if the malfunction is in the control valve, main pump, servo hydraulic pump or the circuit components such as: remote control valve, motor, or the center passage. Check the main relief, port relief, and servo hydraulic relief pressure. Check the P1/P2 pump flow rate. Check the hoses and piping for damage. Check the filters and hydraulic oil for contamination.



Troubleshooting Phenomenon



Cause



Remark



Pressure does not rise.  



Main poppet of relief valve is sticking and valve is open. There is contamination on the poppet or seat.



  



Check for contamination on the poppet. Confirm that each component slides smoothly. Clean all the components thoroughly.



Damaged main poppet seat or servo hydraulic poppet seat of relief valve. Main poppet is sticking.



 



Replace damaged component. Clean all the components thoroughly.



Wear due to foreign matter. Damaged pilot seat due to foreign matter. Loosened lock nut or adjusting screw.



 



Disassemble and clean the valve. Adjust the relief pressure.



Damaged main poppet seat or pilot poppet seat due to foreign matter. Worn O-ring. Sticking component due to foreign matter.







Replace damaged or worn component. Confirm that each component operates smoothly before reassembling. Confirm that there are no scratches, nicks, or contamination present before reassembling.



Unstable relief pressure. 



 Relief pressure incorrect.



is   



Oil leak   







Service Information Document Title: Main control troubleshooting



Function Group: valve



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Main control valve troubleshooting If an abnormal condition is noticed, check to see if the problem is in the control valve itself, one of the main pumps, the servo hydraulic pump, or a circuit. To this end, you will need to measure servo hydraulic pressure, pump delivery pressure, load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and reassembly procedures in this manual. Dirt is the enemy of hydraulic components. Pay strict attention to protection from dirt. If any part of the system is to be disassembled, take preventative measures beforehand. Moving parts must be handled with care. If they are damaged smooth the nicks or scratches with #2000 sand paper. Take care not to damage the sealing face of o-rings. A damaged sealing face will certainly cause oil leaks. Troubleshooting, control valve Phenomenon



Cause



Remark



Travel does not Malfunctioning main relief valve. Measure main relief valve pressure. occur. Slow to start up (sluggish). Slow  Contamination between main poppet  Disassemble and clean. If damaged, response. valve and seat. replace the assembly as a unit.  



Contamination between servo hydraulic poppet and seat. Sticking main poppet.



  



Broken or fatigued spring. Clogged main poppet orifice. Loosened adjusting screw.







Same as above.







Smooth sticking poppet with crocus cloth.



  



Replace spring. Remove contamination. Readjust, and tighten lock nut to the specified torque.



Clogged orifice in servo hydraulic circuit. Remove contamination. Machine does not Malfunctioning straight travel valve. travel straight during simultaneous  Sticking spool. travel and  Broken or fatigued spring. attachment  Excessive clearance between operation. block and spool.



Measure servo hydraulic pressure.



casing



Malfunctioning track motor relief valve.



  



Smooth sticking spool with crocus cloth. Replace spring. Replace spool.



See “Track motor”.



Excessive drift of Excessive clearance between casing and spool. Replace control valve section. Measure primary, cylinder in neutral Spool is not completely in neutral position. secondary servo hydraulic pressure. position.   



Contamination between casing spool, or sticking spool. Broken or fatigued spring. Clogged servo hydraulic circuit.



and  



Disassemble, clean, and smooth sticking part with crocus cloth. Replace spring.



Malfunctioning port relief valve. Malfunctioning anti–cavitation check valve.







Remove contamination.



Measure port relief valve pressure.  



Contamination between poppet and casing. Broken or fatigued spring.



When extending Malfunctioning load check valve. cylinder, at first it retracts.  Contamination between poppet and casing.  Sticking poppet.  Broken or fatigued spring.







Disassemble and clean.







Replace spring.







Disassemble and clean. If damaged, replace. Smooth sticking poppet with crocus cloth. Replace spring.



 



Bucket, boom or Malfunctioning main spool. Measure primary, secondary servo hydraulic arm alone does pressure. not operate. Slow to start up  Excessive clearance between casing and  Replace control valve section. (sluggish). Slow spool. response.  Contamination between casing and  Disassemble and clean. spool.  Smooth sticking spool with crocus cloth.  Sticking spool.  Replace spring.  Broken or fatigued return spring.  Remove contamination.  Clogged servo hydraulic circuit. Measure main relief valve pressure. Measure port Malfunctioning main relief valve. Malfunctioning relief valve pressure. Measure servo hydraulic port relief valve. Malfunctioning servo hydraulic pressure. Clean filter screen. relief valve. Clogged screen filter of control lever. Slew priority Incorrect orifice. function does not hydraulic circuit. occur. Slew does occur.



Clogged



orifice



in



servo Check orifice size and replace with correct one. Remove contamination.



not Malfunctioning main spool   



See previous content.



Excessive clearance between casing and spool. Contamination between casing and spool. Sticking spool.



Relief valve pressure is low  



Contamination at seat surface Broken or fatigued spring.



Despite lever Malfunctioning flow sensing valve. Measure flow sensing valve pressure. being in neutral, negative control  Contamination between poppet and  Disassemble and clean. If damaged, does not occur, seat. replace the assembly as a unit.  and fails to Replace spring. minimize flow.  Broken or fatigued spring.  Disassemble and clean. Remove  Clogged poppet orifice. contamination.  Disassemble and clean. Replace filter  Clogged filter. screen. Disassemble and clean. Sticking spool.



Service Information Document Title: Control valve, inspection



Function Group: part



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Control valve, part inspection Parts inspection Part



Remark



Housing 











If there are score marks, rust and corrosion, correct with #2000 sand paper and crocus cloth.







If there is damage that can"t be repaired, replace with a new component.



Valve housing is a non–serviceable part. If there is damage, replace the control valve assembly.







Housing bore : Spool and sliding parts. Especially around the pressure holding areas as applied to : Seat : Seat of check valve. Port seal : o-ring contact surface. Seal : Main relief, port relief bore contact surface.



Check for nicks, scratches, rust, and corrosion on the outer diameter. If a flaw is found on the outer diameter, check the relevant housing bore. Insert the spool into its bore and operate forward/ reverse while rotating. Check if there is a flaw on the check valve seat and the check valve, inside the spool. Insert the check valve into the spool, and operate it forward/reverse. Check the spring.











If there are nicks, scratches, rust and corrosion, correct with #2000 sand paper and crocus cloth. The spool is a non-serviceable part. If damaged replace the control valve assembly. If it binds slightly try polishing the spool with crocus cloth. If there is a flaw or a partial contact trace on the seal face seat, replace the valve. If it sticks, replace it.







If there is damage or heat discoloration replace it.







If there is wear or damage, replace the part.



If there is a flaw or partial contact trace on the seat, replace the part. If there is damage replace it.



Check for flaws, cracks and corrosion, and check for hidden cracks by use of various detection methods. i.e. magnaflux, or dyes.



Spool      



  



Return spring, rear side. 



Check the spring, spring guide, spool cap and cover for rust, corrosion, wear, and damage.



Load check valve. 



Check the seat of check valve.











Check the spring.







Orifice 



Check if the flow sensing valve orifice is clogged.







If clogged, bore with wire.



NOTE! Do not distort or change the orifice size. Boom holding valve, servo hydraulic logic valve 



Check the poppet seat for flaws.











Insert the poppet, and operate it forward/reverse.







If there is a flaw or partial contact trace on the seat, replace the part. If it sticks replace it.



Main relief, port relief valve. 



Check the seat for flaws.







   



Check if the orifice is clogged. Insert the poppet, and move it forward/reverse. Check the spring. It is difficult to judge the relief valve for damage by eye, therefore check the operating condition carefully.



  



If there is a flaw or partial contact trace on the seat, replace it. If clogged, bore with wire. If it sticks replace it. If there is damage or heat discoloration, replace it.



Service Information Document Title: Main relief description



Function Group: valve,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Main relief valve, description Normal pressure Py servo hydraulic signal : OFF Hydraulic oil supplied from the pump flows to chamber (3) through orifice (2) of main poppet A.



Figure 1 Main relief valve A Main poppet



D Piston



B Servo hydraulic poppet



P From pump port



C Spring



T Tank passage



As section area d1> d2, main poppet A will not move. If the pressure reaches set value of spring C, servo hydraulic poppet B will open so that the oil flows to tank passage(5) through hole (4). The pressure in chamber (3) will be lowered.



Figure 2 Main relief valve The oil supplied when servo hydraulic poppet B is opened (the pressure of chamber (3) is low) creates a pressure differential between front and rear of orifice (2), so the “pressure of chamber (1) × d2” becomes larger than “pressure of chamber (3) × d1”. The circuit pressure is controlled to constant level as main poppet A opens to allow hydraulic oil flow to tank passage.



Figure 3 Main relief valve High pressure Py servo hydraulic signal : ON Servo hydraulic pressure moves piston D and the set pressure of spring C is increased, so pressure setting is raised.



Figure 4 Main relief valve



Service Information Document Title: Main relief disassembly



Function Group: valve,



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Main relief valve, disassembly Op nbr 00000



1. Loosen cap (1), and remove cartridge complete.



Figure 1 Removal, cap etc 



Tools: Spanner 41 mm



2. Loosen nut 2 



Tools: Spanner 41 mm



3. Loosen nut 3 



Tools: Spanner 30 mm



Figure 2 Removal, sleeve etc 4. Pull off sleeve (4), and take off Main poppet (5), spring (6) and orifice (7).



Date: 2014/7/15



Figure 3 Removal, sleeve etc NOTE! The servo hydraulic seat (12) should not be removed because it is press-fitted into the cap. 5. Remove adjustment screw (8), and take off piston (9), spring (10) and servo hydraulic poppet (11). 



Tools: Spanner 22 mm



Figure 4 Removal, sleeve etc Provisional fitting / setting 1. 2.



3.



Tighten up adjustment screw (1) until piston (A) comes into contact with the Z surface of sleeve (3). Check that the pressure setting is at ‘0’. With the adjustment screw side facing downwards, loosen sleeve (3), and then tighten the adjustment screw again until servo hydraulic poppet (B) comes into contact with the seat. In other words, provisionally set it at the point where the pressure- regulating spring (C) starts to have an effect. Fit the provisionally-assembled cartridge onto the main body of the valve and tighten cap (5). NOTE! Cap (5) tightening torque : 10 kgf·m (72 lbf·ft)



Figure 5 Provisional adjustment



Assembly (for assembly, reverse disassembly procedure)



Service Information Document Title: Port relief description



Function Group:



Information Type: Service Information



valve,



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Port relief valve, description Overload operation(for boom, arm, bucket and option) Hydraulic oil from cylinder port (P) flows through the orifice of piston A to chamber (2). As section area d1 > d2, main poppet B will not move.



Figure 1 Port relief valve A



Piston



C



Spring



B



Main poppet



D



Servo hydraulic poppet



If the pressure reaches set value of spring C, servo hydraulic poppet D will open so that the oil flows to tank through lateral hole(4) and circular passage(5), so the pressure in chamber (2) will be lowered.



Figure 2 Port relief valve The oil supplied when servo hydraulic poppet D is opened (the pressure of chamber (2) is low) creates a pressure differential between front and rear of orifice in piston A (chamber (1) and (2)), so piston A moves to the right side and stops at the end of servo hydraulic poppet D.



Figure 3 Port relief valve The oil in chamber (1) flows to tank passage through the orifice of piston A, through the lateral hole and circular passage. As the pressure is lowered front and rear of the orifice in servo hydraulic poppet D, “pressure of chamber (1) × d2” will be higher than “pressure of chamber(2) × d1”. Therefore, poppet B opens and hydraulic oil from the cylinder port flows directly to tank passage.



Figure 4 Port relief valve Anti–cavitation operation Section area of poppet B is larger than d1, and since pressure in the cylinder port is usually higher than pressure in the tank port, the valve is closed. However if the pressure in the cylinder port decreases lower than the tank port (near to negative pressure), poppet B is opened by tank pressure by as much as the area difference of d1 and d2. Then the tank passage return oil will flow to the cylinder port to prevent cavitation.



Figure 5 Port relief valve



Service Information Document Title: Function Group: Port relief valve, disassembly and assembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Port relief valve, disassembly and assembly (For assembly, reverse disassembly procedure) Op nbr 00000 NOTE! When disassembling, mark each part to make assembling easier. NOTE! Do not disassemble pressure adjusting section. 1. Remove sleeve (1) and remove cartridge. Tools : Spanner 41 mm Tightening torque : 10 kgf·m (72.5 lbf·ft) NOTE! Set pressure is different according to position. Be sure to assemble it to its original position.



Figure 1 Removal, sleeve 2. Remove cap (2) and pull out spring (3) and servo hydraulic poppet (4). Tools : Socket, Spanner 32 mm Tightening torque : 10 kgf·m (72.5 lbf·ft)



Figure 2 Removal, spring etc 3. Remove servo hydraulic seat (5) and pull out spring (6, 7), piston (8) and main poppet (9).



Figure 3 Removal, main poppet etc



Service Information Document Title: Function Group: 2 stage port relief valve, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



2 stage port relief valve, description Overload operation (for option) When the high pressure setting is used [Pl servo hydraulic signal: OFF] Piston (E) moves to the right due to the action of spring (F).



Figure 1 2 stage port relief valve A. B. C. D. E. F.



Piston Main poppet Spring Servo hydraulic poppet Piston Spring



Pressure oil from the cylinder port goes through orifice (3) in piston (A), and enters chamber (2). Because d1>d2, the main poppet (B) remains securely seated. When the pressure oil exceeds the pressure set by spring (C), servo hydraulic poppet (D) opens, and oil flows through passages (4) and (5) to the tank passage.



Figure 2 2 stage port relief valve Due to the oil flow past poppet (D), the pressure drops before and after orifice (3) in piston (A). The piston moves to the left, into its seat at the tip of the servo hydraulic poppet (D). Oil from chamber (1) flows through orifice (3) in piston (A), through side hole (4) and passage (5), to the tank passage.



Figure 3 2 stage port relief valve The pressure drops before and after orifice (6) in servo hydraulic poppet (D). When the following condition: Chamber (1) pressure x d2 surface area > chamber (2) pressure x d1 surface area, is achieved, main poppet (B) opens, and pressure oil from the cylinder port flows to the tank passage, protecting the actuator.



Figure 4 2 stage port relief valve When the low pressure setting is used [Pl servo hydraulic signal: ON] Piston (E) moves to the right because Pl servo pressure compresses spring (F), the pressure set by spring (C) decreases, and the low pressure setting condition is achieved.



Figure 5 2 stage port relief valve Anti–cavitation operation Because d1>d2, the cylinder port pressure is normally greater than the tank pressure, and the main poppet (B) remains securely seated. When the cylinder port pressure falls below the tank pressure (close to negative pressure), the main poppet (B) comes under pressure corresponding to the difference between the surface areas of d1/d2, and opens. Oil flows from the tank passage to the cylinder port, preventing cavitation.



Figure 6 2 stage port relief valve



Service Information Document Title: Function Group: 2 stage port relief valve, disassembly and assembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



2 stage port relief valve, disassembly and assembly (For assembly, reverse disassembly procedures) When disassembling, mark each part to make assembling easier. NOTE! It is difficult to adjust the pressure when this component is located on the machine, so do not dismantle the pressure adjustment section.



Figure 1 2 stage port relief valve 1.



Loosen sleeve (1), and remove cartridge completely.  



2. 3.



Loosen nuts (3 and 4) with spanner 32 mm. Loosen cap (2), and remove subassembly completely. Remove spring (5) and servo hydraulic poppet (6).  



4. 5.



Tools: Spanner 32 mm Tightening torque: 147 Nm (108 lbf ft)



Tools: Spanner 32 mm Tightening torque: 98 Nm (72 lbf ft)



Remove servo hydraulic seat (7), and springs (8, 9), piston (10) and main poppet (11). Remove adjusting screw (12), and piston (13).



Service Information Document Title: Function Group: Boom and arm holding valve (Boom-1, Arm-1), description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom and arm holding valve (Boom-1, Arm-1), description Spool in neutral L servo hydraulic signal : OFF Piston A is in the position shown in the drawing, and servo hydraulic pressure H is being blocked. As a result, piston B and poppet C are also in the positions shown in the drawing, and passages 5 and 6 are blocked by poppet C, passage 7 is blocked by check valve E. Also, because chamber 1 is connected with chamber 2 (Pc) orifice 4, the pressure there is 2 (Pc). Because d1>d2, poppet C is in its seat, completely blocking chambers 2 (Pc) and 3 (Pv).



Figure 1 Boom holding valve, spool in neutral A Piston



F Blocked



B Piston



G To piston chamber



C Poppet



H Servo pressure (4pp, 5pp)



D Poppet



I Drain port (dr2, dr3)



L Servo signal port (4pc1, 5pc1) PL Spool P High pressure supply passage T Tank passage



E Check valve



J Port to boom cylinder piston side



Spool operating Boom raising [2 (Pc) < 3 (Pv)] (L servo hydraulic signal : OFF) The spool moves to the right, and oil from the high pressure supply passage enters chamber 3 (Pv). Chamber 1 is connected with chamber 2 (Pc) via orifice 4, so the pressure there is 2 (Pc). Poppet D opens under pressure 3 (Pv), and oil from the high pressure supply passage is supplied to the boom cylinder piston side.



Figure 2 Boom holding valve, spool operating A Piston



F Blocked



B Piston



G To piston chamber



C Poppet



H Servo pressure



D Poppet



I Drain port



E Check valve



J Port to boom cylinder piston side



L Servo signal port PL Spool P High pressure supply passage T Tank passage



Boom lowering [2 (Pc) > 3 (Pv)] (L servo hydraulic signal : ON) The spool moves to the left, and chamber 3 (Pv) is connected with the tank passage. Also, the spool operating pressure acts on port L, so that piston A moves to the left and the servo hydraulic pressure enters Piston B chamber. Piston B and poppet C move to the right, and passage 7 is connected with the tank passage via passages 5 / 6 and check valve E. As a result, the pressure in chamber 1 is low, and the difference in the surface areas of d1 and d2 / pressure Pc come into play, opening poppet D. Oil returning from the boom cylinder piston side flows into the tank passage.



Figure 3 Boom holding valve, lowering A Piston



F Blocked



B Piston



G To piston chamber



C Poppet



H Servo pressure



D Poppet



I Drain port



E Check valve



J Port to boom cylinder piston side



L Servo signal port PL Spool P High pressure supply passage T Tank passage



Service Information Document Title: Function Group: Boom and arm holding valve (Boom-1, Arm-1), disassembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom and arm holding valve (Boom-1, Arm-1), disassembly Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



When disassembling, mark each part to make assembling easier. Main body check valve 1. Remove screw (1) and remove cover assembly 



Tool : Allen wrench 12 mm Tightening torque : 18 kgf·m (130.6 lbf·ft)



NOTE! When reassembling, make sure that the o-ring is installed on housing inlet before assembling the cover.



Figure 1 Disassembling, boom holding valve 2. Pull out spring (2) and poppet (3).



Figure 2 Removal, spring and poppet Cover 3. Remove cap (4) and pull out piston (6) and spring (5). 



Tool : Allen wrench 19 mm Tightening torque : 3 kgf·m (21.8 lbf·ft)



Figure 3 Removal, cap 4. Remove cap (7) and pull out spring (8) and check poppet (9). 



Tool : Allen wrench 6 mm Tightening torque : 3 kgf·m (21.8 lbf·ft)



Figure 4 Removal, cover assembly 5. Remove cap (10) and pull out piston (11). 



Tool : Allen wrench 10 mm Tightening torque : 6 kgf·m (43.3 lbf·ft)



Figure 5 Removal, cap 6. Remove poppet (12) and pull out spring (13) and poppet (14). 



Tool : Allen wrench 8 mm Tightening torque : 5 kgf·m (36.1lbf·ft)



Figure 6 Removal, cap NOTE! Sometimes, if the components have been in use for a long time, poppet (14) will not come off, it sticks on the edge of the seat of the sleeve. Do not use excessive force to dismantle it. 7. Lightly tap out sleeve (15) using a pipe (inner dia. φ6, outer dia. φ10) to the right side of the cover.



Figure 7 Removal, cap



Service Information Document Title: Function Group: Boom 2 conflux shut-off valve, disassembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom 2 conflux shut-off valve, disassembly Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



1. Remove screw (1) and cover (2). 



Tool : Allen wrench : 10 mm Tightening torque : 10 kgf·m (72.2 lbf·ft)



Figure 1 Removal, cover NOTE! When you re-assemble it, before refitting the cover ensure that an o-ring has been fitted in the entrance of the housing. 2. Remove cap (3), spool (4), spring holder (5) and spring (6). 



Tool : Spanner : 27 mm Tightening torque : 5 kgf·m (36 lbf·ft)



Figure 2 Removal, spool



Service Information Document Title: Function Group: Boom boost check valve, disassembly



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Boom boost check valve, disassembly Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



1. Remove cap (1). 



Tool : Spanner : 46 mm Tightening torque : 18 kgf·m (130 lbf·ft)



Figure 1 Removal, cap 2. Remove cap (1), spring (2) and poppet (3). 



Tool : Spanner : 46 mm Tightening torque : 18 kgf·m (130 lbf·ft)



Figure 2 Removal, poppet



Date: 2014/7/15



Service Information Document Title: Function Group: Cover assembly (for preventing Boom-1 spool rotation), disassembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Cover assembly (for preventing Boom-1 spool rotation), disassembly Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



1. Remove cap (1) and cover (2). 



Tool : Socket wrench : 10 mm Tightening torque : 10 kgf·m (72.2 lbf·ft)



Figure 1 Removal, cap NOTE! When you re-assemble it, before refitting the cover ensure that an o-ring has been fitted in the entrance of the housing.



Also, line up key groove of spool with tip of plug. 2. Remove plug (3). 



Tool : Socket wrench : 19 mm Tightening torque : 8 kgf·m (57.8 lbf·ft)



Figure 2 Removal, cap



Service Information Document Title: Boom servo check valve



Function Group: hydraulic



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom servo hydraulic check valve Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



1. Loosen sleeve (1), and remove cartridge complete (2). 



Tool : Spanner : 46 mm Tightening torque : 18 kgf·m (130 lbf·ft)



Figure 1 Removal, cartridge 2. Remove cap (2), spool (3), spring (4). 



Tool : Spanner : 36 mm Tightening torque : 10 kgf·m (72.2 lbf·ft)



Figure 2 Removal, spool 3. Using a round bar with an outer diameter of ø3.5, gently tap sleeve (5) out from the left, and take off piston (6), spring (7) and check (8).



Figure 3 Removal, piston NOTE! Take care not to scratch edge of inside of sleeve (Inside diameter at seat = ø9).



Service Information Document Title: Arm regenerating description



Function Group:



Information Type: Service Information



valve,



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Arm regenerating valve, description Arm regenerating valve, description Servo pressure 5pa5 (arm in) moves the spool to the right blocking the centre bypass passage, then main pump pressurized oil opens the load check valve and flows via the u-shaped path, circular notch of the spool, to port PA on the cylinder piston side.



Figure 1 Arm regenerating valve A



Check



E



Center bypass passage



B



Piston



P



High pressure supply passage



C



Spool



Pz



Servo hydraulic signal



D



Piston



T



Tank passage



Pressure on rod side is high [PB>PA] Return oil from port PB, flows via the spool circular notch to a small bore hole left of passage 3, as a result oil pressure increases moving spool C to the left, opening a narrow passage to check valve A in the main spool, When the check valve open the return oil flows via the path in the spool to merge with the supply flow through port PA. This prevents cylinder cavitation during arm in operation.



Figure 2 Arm regenerating valve A



Check



E



Center by-pass passage



B



Piston



P



High pressure supply passage



C



Spool



Pz



Servo hydraulic signal



D



Piston



T



Tank passage



Pressure on piston is high [PA>PB] When the pressure at PA is greater then PB, check valve A closes. The pressurized oil acts against piston B, When it exceeds the spring force, piston B and spool C move to the right and passage 2 opens fully. The return oil flows via unrestricted passages 1 and 2 to tank. When servo pressure is applied to port Pz, piston D moves to the left, servo pressure × piston D surface area is added to the spring force and moves spool C to the left closing passage 2. As the return oil pressures increases, the regeneration process starts again and volume of return oil corresponding to the servo pressure is recycled to the cylinder piston side.



Figure 3 Arm regenerating valve A



Check



E



Center by-pass passage



B



Piston



P



High pressure supply passage



C



Spool



Pz



Servo hydraulic signal



D



Piston



T



Tank passage



Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



When disassembling, mark each part to make assembling easier.



Figure 4 Disassembling, cartridge complete 1. Remove cap (1) and spring (2) and spool (3). 



Tool : Spanner : 46 mm Tightening torque : 18 kgf·m (130 lbf·ft)



Figure 5 Removal, cap 2. Using removing tool, pull off sleeve (4) and remove piston (5), spring (6) and spool (7).



Figure 6 Removal, cap 3. Remove cap (8), piston (9) and spring (10). 



Tool : Spanner : 30 mm Tightening torque : 8 kgf·m (57.8 lbf·ft)



Figure 7 Removal, cap



Service Information Document Title: Arm parallel changeover disassembly



Function Group: conflux valve,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Arm parallel conflux changeover valve, disassembly Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



1. Remove screws (1), and take off cover assembly. 



Tool : Allen wrench : 8 mm Tightening torque : 6 kgf·m (43 lbf·ft)



NOTE! Before you re-assemble it, make sure that an o-ring has been fitted into the cover mating surface.



Figure 1 Removal, cover 2. Remove cap (2), take out spool (4) and spring (3). 



Tool : Spanner : 41 mm Tightening torque : 10 kgf·m (72.5 lbf·ft)



Figure 2 Removal, spool



Service Information Document Title: Function Group: Check valve (for arm parallel conflux, slew priority), disassembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Check valve (for arm parallel conflux, slew priority), disassembly Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



1. Remove cap (1), and take out spring (2) and check (3). 



Tool : Allen wrench : 12 mm Tightening torque : 8 kgf·m (57.8 lbf·ft)



Figure 1 Removal, cap



Service Information Document Title: Function Group: Arm conflux check valve, disassembly



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Arm conflux check valve, disassembly Disassembly (for assembly, reverse disassembly procedure) When disassembling, mark each part to make assembling easier. Op nbr 00000



1. Remove cap (1) and pull out spring (2), check (3). 



Tool : Socket wrench, spanner 41 mm Tightening torque : 18 kgf·m (129.6 lbf·ft)



Figure 1 Disassembling, arm conflux check valve



Date: 2014/7/15



Service Information Document Title: Option confluence check



Function Group:



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Option confluence check Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



1. Remove cap (1), and take out spring (2) and check (3). 



Tool : Spanner : 41 mm Tightening torque : 18 kgf·m (130 lbf·ft)



Figure 1 Removal, cap 2. Remove nut (4), take off adjustment screw (5) and spring (3). 



Tool : Spanner : 19 mm



Figure 2 Removal, adjustment screw NOTE! Tighten up adjustment screw, then remove to left. 3. Adjustment Method







Option is not fitted:



Date: 2014/7/15



a. Tighten adjustment screw up to end of check. Tightening torque: 0.3 kgf·m (2.2 lbf·ft) b. Tighten hexagonal nut. Tightening torque: 3.2 kgf·m (23.2 lbf·ft) 



Option is fitted: a. Tighten adjustment screw up to end of check. Gradually loosen it, and adjust to appropriate speed. b. Tighten hexagonal nut. Tightening torque: 3.2 kgf·m (23.2 lbf·ft)



Service Information Document Title: Slew priority disassembly



Function Group: valve,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Slew priority valve, disassembly Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



1. Remove screw (1), and take off cover (2) assembly. 



Tool : Allen wrench : 8 mm Tightening torque : 6 kgf·m (43 lbf·ft)



NOTE! Before refitting cover, make sure that an o-ring has been fitted into cover mating surface.



Figure 1 Removal, cover 2. Remove cap (2), take out spool (4) and spring (3). 



Figure 2



Tool : Spanner : 41 mm Tightening torque : 10 kgf·m (72.5 lbf·ft)



Removal, spool



Service Information Document Title: Function Group: Check valve (for straight travel changeover valve), disassembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Check valve (for straight travel changeover valve), disassembly Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



1. Remove cap (1) and pull out spacer (2) and spring (3) and check (4). 



Tool : Allen wrench, spanner 5 mm Tightening torque : 2 kgf·m (14.4 lbf·ft)



Figure 1 Disassembling, straight travel valve



Service Information Document Title: Function Group: Foot relief valve (flow sensing valve), description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Foot relief valve (flow sensing valve), description Oil from the center by-pass passage flows through orifice A in the poppet, into the tank passage. The pressure (fp), which corresponds to the flow rate through the orifice, is fed back to the pump regulator, controlling its output volume.



Figure 1 Foot relief valve A. B. C. D. E.



Poppet (Orifice A) From center bypass passage Spring Negative control signal port to pump Tank passage



If, due to pump response delay, the flow rate is excessive, when pressure (fp) reaches the level set by spring C, poppet A opens and pressure oil flows to the tank; it therefore acts as a relief valve.



Figure 2 Foot relief valve Disassembly (for assembly, reverse disassembly procedure) Op nbr 00000



1. Remove cap (1), and take off spring (2) and poppet (3). 



Tools: Spanner 36 mm



Tightening torque: 25.9 kgf·m (187 lbf·ft)



Figure 3 Removal, cap and spring



Service Information Document Title: Function Group: Center bypass valve, disassembly and assembly



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Center bypass valve, disassembly and assembly Disassembly (for assembly, reverse disassembly procedure) When disassembling, mark each part to make assembling easier. Op nbr 00000



1. Remove cap (1) and pull out spool (3) and spring (2). 



Tool : Socket wrench, spanner 46 mm Tightening torque : 25 kgf·m (180 lbf·ft)



Figure 1 Removal, cap



Date: 2014/7/15



Service Information Document Title: Function Group: Center bypass valve (for bucket conflux), disassembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Center bypass valve (for bucket conflux), disassembly Disassembly (for assembly, reverse disassembly procedure) When disassembling, mark each part to make assembling easier. Op nbr 00000



1. Remove cap (1) and pull out spool (3) and spring (2). 



Tool : Socket wrench, spanner 46 mm Tightening torque : 25 kgf·m (180 lbf·ft)



Figure 1 Removal, cap 2. Remove cap (4) and piston (5). 



Tool : Socket wrench, spanner 46 mm Tightening torque : 25 kgf·m (180 lbf·ft)



Figure 2 Removal, cap



Service Information Document Title: Function Group: Make up valve, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Make up valve, description Make up valve, description Pressure oil from the cylinder port enters chamber 2 via the tip of poppet A. Because d1>d2, poppet A sits securely in its seat.



Figure 1 Make up valve A. B. C. D.



Poppet From cylinder port Tank passage To cylinder port



When the cylinder port oil pressure falls below the tank pressure (close to negative pressure), poppet A opens as it comes under tank pressure corresponding to the difference between the surface areas of d1 and d2. Oil flows from the tank passage to the cylinder port, preventing cavitation.



Figure 2 Make up valve A. B. C. D.



Poppet From cylinder port Tank passage To cylinder port



Disassembly (for assembly, reverse disassembly procedure)



Op nbr 00000



When disassembling, mark each part to make assembling easier. 1. Loosen sleeve (1) and remove cartridge complete. 



Tool : Spanner : 41 mm Tightening torque : 10 kgf·m (72.2 lbf·ft)



Figure 3 Disassembling, cartridge complete 2. Remove cap (2), spring (3) and poppet (4). 



Tool : Spanner : 36 mm Tightening torque : 10 kgf·m (72.2 lbf·ft)



Figure 4 Removal, cap



Service Information Document Title: General, precautions



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



General, precautions Removal, precautions     



Thoroughly clean the control valve prior to removal from the machine. Tag all hoses prior to disconnecting from the control valve. Cap all hoses and plug all ports to prevent contamination from entering. Use eye bolts to lift the control valve. Do not sling on the relief valves or spool caps. The control valve is heavy. Take appropriate safety precautions when handling.



Disassembly, precautions     



Do not use excessive force, sharp or high-hardness tools to disassemble the control valve. Handle the components carefully, protect the highly polished precision finish. If the surface is damaged it will cause internal oil leakage and malfunction. Match mark the parts to indicate original location and position during reassembly. Take care not to mix the parts of the various check valves and flow valves. Inspect and analyze all failures. – Determine the root cause!



Assembly, precautions      



Clean all parts with cleaning solvent and dry with compressed air. Rework damaged parts, polish minor burrs, nicks, score marks or sharp edges with fine emery and crocus cloth. Prepare all replacement parts. Coat the sliding parts with clean hydraulic oil. Replace the seals, O-rings and back-up rings. Use a torque wrench to tighten the screws and plugs to the specified torque. Take care not to interchange the spools.



Service Information Document Title: General, tools



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



General, tools Before disassembling or assembling the valve, prepare the following tools : Tools No.



Tool



Size



Quantity



1



Vise



2



Socket



27, 32, 41, 46 mm



1



3



Allen wrench



4, 5, 6, 8, 10, 12, 14, 17, 19 mm



1



4



Torque wrench



75 ~ 4000 kgf·cm (5 ~ 300 lbf·ft)



Various



5



Loctite



# 262



1



1



Prepare the following tools, also :   



M6 screw, (To remove cut–off valve, conflux flow valve, travel priority valve). Magnet bar, (To remove shuttle valve ball, negative control relief valve). Holder for main spool, (To protect the spool when clamped in the vise).



Holder Material : brass



Figure 1 Holder Holder, dimensions



1



Holder



φD



L



B



H



Application



36



96



50



25



Main spool



2



Removing arm regenerating valve sleeve



Service Information Document Title: Function Group: Main control valve, disassembly and assembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Main control valve, disassembly and assembly Op nbr 00000



Disassembly 1. Remove screws (1, 2, and 3) and separate the slew-side valve.



Figure 1 Main control valve 2. Remove screws (4 and 5) and separate bucket side valve. 



Tool : Allen wrench 14 mm



Assembly (reverse disassembly procedure) 3. With fitting surface flat, first couple bucket side valve with manifold and tighten screws to specified torque. Then couple slew-side valve. 



Tool : Allen wrench 14 mm Tightening torque : 25 kgf·m (180.5 lbf·ft)



NOTE! Make sure that all the o-rings have been fitted in the manifold mating surface. Disassembly (for assembly, reverse disassembly procedures) When disassembling, mark each part to indicate original location and position during assembly.



Main spool 4. Remove screw (1), and remove cover (2). 



Tool : Allen wrench 10 mm Tightening torque : 10 kgf·m (72.2 lbf·ft)



Figure 2 Disassembling, main spool NOTE! When assembling, make sure that the o-ring is installed before assembling the cover. 5. Pull out the spool sub–assembly.



Figure 3 Disassembling, main spool NOTE! Pull out the spool slowly confirming the housing condition. 6. Hold spool with holder (A) and vise, and loosen spool cap (3).



Figure 4 Loosen spool cap Tool : Allen wrench 8 mm Tightening torque : 10 kgf·m (72.2 lbf·ft) NOTE! Remove oil from spool and holder. When assembling, note spring guide direction. 7. Remove spool cap (3) and remove spring guide (4), (7), spring (5) and spacer (6).



Figure 5 Removal, spool cap etc 8. Only for arm and boom spool, remove cap (7) and pull out spring (9) and check valve (10). Tool : Allen wrench 10 mm Tightening torque : 10 kgf·m (72.2 lbf·ft)



Figure 6 Removal, cap 1



Boom-1 spool



2



Arm-1 spool



Service Information Document Title: Main relief adjustment



Function Group: valve,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Main relief valve, adjustment Adjustment of the limiting pressure Measuring condition     



Place the machine in the service position B. See 091 Service positions Hydraulic oil temperature : 50 ±5°C (122 ±41°F) Working mode: “P” mode ( North America : H mode ) Measuring location : P2 gauge ports at hydraulic main pump At full stroke end of bucket in/out (at 1 pump flow condition)



NOTE! Adjustment temperature should be kept within 50 ±5°C (122 ±41°F), as unnecessary relief (valve loading) causes rapid temperature rise.



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries



WARNING Leaking high-pressure hydraulic hoses may cause severe injuries. Fine jets have high penetrating capacity on bare skin. Measurement    



Connect oil pressure gauge (600 kgf/cm2, 8530 psi) to the quick coupler. Start the engine, set to “ P ” mode, and measure the main pressure with the engine at high idle. Operate the bucket cylinder to the end of its stroke to check the low/high relief pressures. Operate the switch on the upper part of operating lever (right) to measure the boost pressure.



Hydraulic pressure See 9121 Main control valve, specifications



Figure 1 Pressure measuring port of hydraulic pump



1



Quick coupler



2



Hose (pressure gauge)



3



Pressure gauge



4



Cap



NOTE! Adjustment temperature should be kept within 50 ~ 60 °C (122 ~ 140 °F), as unnecessary relief (valve loading) causes rapid temperature rise. * Operate the bucket cylinder to the end of its stroke to check the Low / High relief pressures.



Figure 2 Main relief valve 1 Screw (low pressure)



A Piston



2 Lock nut



B Servo hydraulic poppet



3 Screw (high pressure) 4 Lock nut



C Regulating spring



5 Cartridge



Z Surface



NOTE! If the relief valve pressure setting is wrong, hydraulic devices may be damaged, and the result could be dangerous. NOTE! Make absolutely sure that the pressure setting is not higher than specified. High pressure adjustment : 350 kgf/cm 2 (4980 psi) 1. 2. 3.



Remove the servo hydraulic hose connected to the relief valve, and plug the hose end. Loosen lock nut (2), and turn adjusting screw (1) clockwise until fully seated (Z). Loosen lock nut (4), and turn adjusting screw (3) as follows. To increase pressure, turn clockwise. To decrease pressure, turn counterclockwise. NOTE! 1/4 rotation will change it by about 46 kgf/cm2 (652 psi).



4.



Hold adjusting screw (3) securely and tighten lock nut (4). NOTE! Tightening torque : 10 kgf·m (72.2 lbf·ft)



5. 6.



Readjust the low pressure setting to specifications. Reconfirm the high/low pressure settings.



Low pressure adjustment : 320 kgf/cm2 (4550 psi) 1. 2.



3.



4.



Remove the servo hydraulic hose connected to the relief valve, and plug the hose end. Loosen lock nut (2), and turn adjusting screw (1) as follows. To increasepressure, turn clockwise. To decrease pressure, turn counterclockwise. Hold adjusting screw (1) securely and tighten lock nut (2). NOTE! Lock nut (2) tightening torque : 6 kgf·m (43.3 lbf·ft) Reinstall the relief valve servo hydraulic hose.



NOTE! Reconfirm the low pressure setting, then check the high pressure setting using the power boost function. Do not try to adjust the high pressure setting without proper gauges.



Service Information Document Title: Function Group: Main pressure relief valve, replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Main pressure relief valve, replacing Op nbr 912-067 1. Park the machine on a level surface and place the machine in the service position B.



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. 2. Remove screws (1) for main control valve cover (2).



Figure 1 Removal, main control valve cover 3. Remove main pressure relief valve (1).



Figure 2 Removal, main pressure relief valve 4. Fit the main relief valve. NOTE! Tightening torque : 117.6 ~ 137.2 N m (87 ~ 102 lbf ft)



5. Adjust main pressure and test machine . See : 9121 Main relief valve, adjustment 6. Install main control valve cover screws.



Service Information Document Title: Function Group: Port relief valve pressure, measuring and adjusting



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Port relief valve pressure, measuring and adjusting Measuring condition    



Place the machine in the service position B. See091 Service positions Hydraulic oil temperature : 50 ±5°C (122 ±41°F) Working mode: “F3” mode Main relief valve pressure : 44.1 MPa (450 kgf/cm2) (6400 psi) (441.3 bar) NOTE! Do not adjust the main relief pressure when adjusting the slewing relief pressure only.



NOTE! Adjustment temperature should be kept within 50 ±5°C (122 ±41°F), as unnecessary relief (valve loading) causes rapid temperature rise.



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries



WARNING Leaking high-pressure hydraulic hoses may cause severe injuries. Fine jets have high penetrating capacity on bare skin. Measurement   



Connect oil pressure gauge (600 kgf/cm2, 8530 psi) to the P1/P2 gauge ports. Start the engine. Condition of digging unit to be measured.    



For the working equipment, set each cylinder to the end of its stroke. For slewing, put the bucket against an immovable object or put it in a trench. For travel, fit a pin between the sprocket and frame to lock the sprocket against the frame. Operate the switch on the upper part of operating lever (right) to measure the boost pressure.



Hydraulic pressure See 9121 Main control valve, specifications. Primary pump supply to each actuator and test port location. Port connections Plug



Pump



Actuator (test port)



1



P1 pump



Slew motor (on the motor head), Option attachment Arm cylinder, Right track motor (on the motor head)



2



P2 pump



Boom cylinder, Bucket cylinder, Left track motor (on the motor head)



Pressure measuring port of hydraulic pump



Figure 1 Pressure measuring port of hydraulic pump 1



Quick coupler



2



Hose (pressure gauge)



3



Pressure gauge



4



Port relief valve pressure, adjustment (For boom, arm, bucket)



Figure 2 Port relief valve, adjustment 1



Adjusting screw



2



Lock nut



NOTE! Do not adjust the port relief valve unnecessarily. Symptoms of faulty port relief valve : 



Main relief valve high/low pressures can not be adjusted.



3



Cartridge



Cap







Attachment hoses rupture repeatedly.



NOTE! Adjustment temperature should be kept within 50 ±5 °C (122 ±41 °F), unnecessary relief valve loading causes rapid temperature rise. * Operate the hydraulic cylinder of the circuit to be measured to the end of its stroke. 1. 2. 3.



4. 5.



Decrease the displacement of the pump. Increase the main relief valve pressure to exceed 450 kgf/cm2 (6525 psi), approximately 1 turn. Loosen lock nut (2), and turn adjusting screw (1) as follows. To increase pressure, turn clockwise. To decrease pressure, turn counterclockwise. Hold adjusting screw (1) securely and tighten lock nut (2). After completion of adjustment, reset the main relief valve high/low pressures to specifications.



Track motor port relief valve pressure, adjustment See 4411 Track motor, description Slew motor port relief valve pressure, adjustment See 4412 Slew motor, adjustment Port relief valve pressure, adjustment (When installing or dismantling the line rupture valve See 9123 Port relief valve pressure, adjustment (when installing or dismantling the line rupture valve).



Service Information Document Title: Function Group: 2 stage port relief valve, adjustment



Information Type: Service Information



Profile: EXC, EC480D L [GB]



2 stage port relief valve, adjustment (For option) See 030 Main control valve, specifications. See 9121 Port relief valve pressure, measuring and adjusting.



Figure 1 Port relief valve, adjustment 1



Adjusting screw (Low pressure)



2



Lock nut



Date: 2014/7/15



3



Adjusting screw (High pressure)



4



Lock nut



5



Cap



X



Piston surface



Y



Screw (high pressure) surface



High pressure adjustment 1. 2. 3.



4.



5.



Remove the servo hydraulic hose connected to the relief valve, and plug the hose end. Loosen lock nut (2), and turn adjusting screw (1) clockwise until fully seated (X, Y). Loosen lock nut (4), and turn adjusting screw (3) as follows. To increase pressure, turn clockwise. To decrease pressure, turn counterclockwise. Hold adjusting screw (3) securely and tighten lock nut (4). NOTE! Tightening torque: 98 Nm (72 lbf ft) Readjust the low pressure setting to specifications.



Low pressure adjustment 1. 2.



3.



Connect the servo hydraulic hose connected to the relief valve. – Pl servo hydraulic signal: ON Loosen lock nut (2), and turn adjusting screw (1) as follows: To increase pressure, turn clockwise. To decrease pressure, turn counterclockwise. Hold adjusting screw (1) securely and tighten lock nut (2). NOTE! 1/4 rotation will change it by about 5.8 MPa (839 psi) (58 bar). NOTE! Lock nut (2) tightening torque: 98 Nm (72 lbf ft)



NOTICE Reconfirm the low pressure setting, then check the high pressure setting using the power boost function. Do not try to adjust the high pressure setting without proper gauges.



Service Information Document Title: Control valve, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Control valve, replacing Op nbr 912-001 14360000 Vacuum pump / 24V



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. NOTE! Draining oil must be collected in a barrel. Plug all hoses/lines and connections when these have been disconnected or removed. NOTE! Any work on the hydraulic system requires great demands on cleanliness. Even very small particles can cause damage or clog up the system. therefore, wipe areas clean before any work is carried out. 1. Connect the vacuum pump on the hydraulic 9111 Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump



oil



tank,



see



2. Place the machine in the Service position B, See 091 Service position 1 3. Remove screws (1, 2) and main control valve under covers (3, 4).



Figure 1 Removal, cover 4. Disconnect wire harness (1) and hoses (2). NOTE! When a hose or pipe has been disconnected, plug both the hose/pipe and the connection immediately. The hoses should be marked for correct connection.



Figure 2 Disconnection, hoses 5. Remove screws (1) and main control valve upper cover (2).



Figure 3 Removal, cover 6. Remove drain pipe (1) with hoses (3). Remove hoses/pipes flange screws (5, ) and the pipes/hoses. Remove bracket (4). Remove screws (7) and hose. NOTE! When a hose or pipe has been disconnected, plug both the hose/pipe and the connection immediately. The hoses should be marked for correct connection.



Figure 4 Removal, hoses 7. Disconnect servo hydraulic hoses (1).



Figure 5 Removal, hoses 8. Remove inlet block (1) mounting screws and screws (2) Remove hoses/pipes mounting screws (3) and pipe clamp screw (4). Disconnect hoses (5, 6).



Figure 6 Removal, hose 9. Remove main control valve mounting screws (1).



Figure 7 Removal, screws 10. Remove main control valve (2) using a lifting device (1).



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 8 Removal, main control valve 11. Transfer the fittings and elbows from old main control valve to new control valve. NOTE! When assembling, make sure that the O-ring is installed before connector and elbow.



Tightening torque See 9121 Main control valve, port size and tightening torque



Figure 9 Transfer, connector 12. Install main control valve (2) using a lifting device (1).



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 10 Installation, main control valve 13. Tighten main control valve mounting screws (1). NOTE! Apply Loctite # 277 onto the threads of screws (1).



Tightening torque: 511.9 ±51 N m (376.9 ±37.5 lbf ft) (52.2 ±5.2 kgf m)



Figure 11 Tighten, screws 14. Connect wire harness (1) and hoses (2). NOTE! When connecting, make sure that the O-ring is installed before hose NOTE! When connecting, make sure that the O-ring is installed before hoses.



Tightening torque See 9121 Main control valve, port size and tightening torque



Figure 12 Connection, hoses 15. Install main control valve under covers (3, 4) and tighten screws. NOTE! Tightening torque: 110.8 ±10.8 N m (81.6 ±7.9 lbf ft) (11.3 ±1.1 kgf m)



Figure 13 Installation, covers 16. Install inlet block (1) with hose and tighten screws (2) Install hoses/pipes with flange and tighten screws (3) and tighten screw (2) with plate Connect hoses (5, 6) and servo hydraulic hoses. Tighten screw (4) with clamp. NOTE! When installing and connecting, make sure that the O-ring is installed before pipe and hose



Tightening torque See 9121 Main control valve, port size and tightening torque



Figure 14 Installation, hose 17. Connect servo hydraulic hoses 1). NOTE! When connecting, make sure that the O-ring is installed before hose



Tightening torque See 9121 Main control valve, port size and tightening torque



Figure 15 Connection, hose 18. Install hoses/pipes with flange and tighten screws (5). Connect servo hydraulic hoses and drain pipe (1) with hoses (3). Tighten screws with bracket (4). Install hose with flanges and tighten screws (7). NOTE! When installing and connecting, make sure that the O-ring is installed before pipe and hose



Tightening torque See 9121 Main control valve, port size and tightening torque



Figure 16 Connection, hoses 19. Install main control valve upper cover (2) and tighten screws (1). NOTE! Tightening torque: 110.8 ±10.8 N m (81.6 ±7.9 lbf ft) (11.3 ±1.1 kgf m)



Figure 17 Installation, cover 20. Refill hydraulic oil. 21. Start the engine, test machine and check main relief/port relief pressure. See : 9121 Main relief valve, adjustment 9121 Port relief valve pressure, measuring and adjusting9121 Main control valve, specifications



Service Information Document Title: Function Group: Line rupture valve (boom), description



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Line rupture valve (boom), description



Figure 1 Line rupture valve RH (boom) 1



Body assembly



13



Spring



2



Spool



14



Spring



3



Plug



15



O-ring



4



O-ring



16



Retainer



5



Back-up ring



17



Retainer



6



Check valve



18



Name plate



7



Logic valve



19



Screw



8



Spring



20



Shim



9



Relief valve



21



Plug



Date: 2014/7/15



10



Screw



22



Plug



11



Cap



23



Plug



12



Plug



The boom line rupture valve connected between the boom cylinder and the main control valve consists of a servo hydraulic valve, logic valve, check valve, pressure relief valve and a housing. The line rupture valve function is to prevent an accident caused by a sudden dropping of the boom when a pipe or hose ruptures. It also prevents boom cylinder creep caused by internal leakage of the main control valve. Neutral position When the remote control valve is in neutral position, spring (8) pushes the poppet of check valve (6) forward blocking the passage to port P1. The oil flow from P4 & P5 normally connected through orifice (a) is blocked by servo hydraulic valve spool (2) at position (b). The spring force combined with the oil pressure acting on the sectional area difference between f & e of logic valve (7) pushes the poppet forward blocking passage P2. With the boom / attachment off the ground the weight pressurizes the oil on the boom cylinder piston side, the flow connected via passage P2 is blocked by the poppet of check valve (6) and logic valve (7), trapping the oil in the hydraulic cylinder preventing the boom from dropping.



Figure 2 Line rupture valve RH (boom), neutral position Boom raising (P1 → P2) When operating the remote control valve (lever) to raise the boom, servo hydraulic valve spool (2) and logic valve (7) are in the neutral position. Pressurized oil from the main control valve is routed through P1 port, pushes open check valve (6), then flows via P2 to the piston side of the hydraulic cylinder raising the boom. When the boom is raised and the (lever) is returned to neutral position (P1 = P2), as described above check valve (6) poppet blocks the passage and the pressurized oil on the boom piston side is trapped in the cylinder preventing the boom from dropping. When a pipe or hose ruptures during boom raising, pressurized oil flow will be cut off to passage P1. As a result the pressure in passage P1 drops quickly and the poppet of check valve (6) will be pushed forward by its spring blocking passage P1, and pressurized oil flow from the piston side of the boom cylinder is blocked.



Figure 3 Line rupture valve RH (boom), boom raising Boom lowering (P2 → P1) When operating the remote control valve (lever) to lower the boom, servo (servo hydraulic) hydraulic oil is supplied to passage Pi and pushes servo hydraulic valve spool (2) upward against springs (13, 14). As spool (2) moves, passage T3 aligns with position b, and the oil in the spring chamber of logic valve (7) drains to the hydraulic tank through passage P4 and P5. The pressure difference of area e and f causes logic valve (7) to open and the oil from P2 flows past the poppet of logic valve (7) to servo spool (2). The return oil from the piston side of the boom cylinder will flow from passage P2 → P6 → P1 → main control valve → tank. The oil passage opening from P6 to P1 will be varied because of the area of notch (c), which controls the return oil flow rate (speed) from the boom cylinder. When a pipe or hose ruptures during boom lowering, the pressure at port P1 will be lower than passage P6, P2, so the poppet of logic valve (7) will be pushed forward by its spring blocking passage P6, and return oil flow from the boom cylinder is blocked. When the remote control valve (lever) is released to neutral position, servo hydraulic pressure at Pi is cut off, and springs (13, 14) move spool (2) downward blocking passage P3.



Figure 4 Line rupture valve RH (boom), boom lowering Overload relief valve Normally the hydraulic oil from port P2 flows through g , d, h. If the pressure of the boom cylinder reaches the set value, the pressure in chamber h will open poppet and the oil from port P2 flows to T1 through g. So the pressure in the boom cylinder will be lowered.



Figure 5 Line rupture valve RH (boom), overload relief valve



Service Information Document Title: Function Group: Line rupture valve pressure, checking and adjusting



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Line rupture valve pressure, checking and adjusting NOTE! For the correct setting of the relief pressure of the valve, connect the hoses, and follow the procedures for adjusting the pump displacement. NOTE! Do not adjust the relief valve unnecessarily. Symptoms of faulty port relief valve :   



Main relief valve’s high/low pressures can not be adjusted. Port relief valve pressures can not be adjusted. Attachment hoses rupture repeatedly.



NOTE! Adjustment temperature should be kept within 50 ~ 60 °C (122 ~140 °F), unnecessary relief valve loading causes rapid temperature rise. If pump displacement is not decreased, the relief valve will open at lower pressure than specified. Line rupture relief valve (boom) position See 9123 Line rupture valve (boom), description. Operate the hydraulic cylinders to be measured to the end of its stroke (boom raise or arm out).     



Increase the main relief valve and port relief valve pressure to reach 380 kgf/cm2 (5405 psi), approximately 1/3 turn. Decrease the displacement of the pump. Loosen lock nut(2), and turn adjusting screw (1) as follows : To increase pressure, turn clockwise. To decrease pressure, turn counterclockwise. Hold adjusting screw (1) securely and tighten lock nut (2). After completion of adjustment, reset the main relief valve’s high/low and port relief valve pressures to specification.



Figure 1 Line rupture valve relief pressure, adjustment Hydraulic pressure



See 9123 Line rupture valve (boom), specifications. See 9123 Line rupture valve (arm), specifications. See 9121 Main control valve, specifications. See 9123 Port relief valve pressure, adjustment (when installing or dismantling the line rupture valve).



Service Information Document Title: Function Group: Port relief valve pressure, adjustment (when installing or dismantling the line rupture valve)



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Port relief valve pressure, adjustment (when installing or dismantling the line rupture valve) NOTE! If the line rupture valve is installed, the machine may cause some strange noises while the boom is raising or the dipper arm is extracting. The reason of the phenomenon is the pressure difference between the relief pressure of the line rupture valve and the port relief valve for the boom raise or the arm out operation. In that case, adjust the port relief valve pressure for those operations at the main control valve. So if you hear the noise or install the line rupture valve newly, adjust the port relief pressure. In case of removal the line rupture valve, never forget to adjust the port relief pressure to prevent the hydraulic circuit from causing the unusual high pressure. NOTE! Regarding the detailed procedure for adjusting the port relief pressure, see Port relief valve pressure, adjustment.



Figure 1 Port relief valve, adjustment 1. 2.



Lock nut Adjusting screw



3. 4. 5.



Port relief valve Boom raise port relief valve Arm out port relief valve



NOTE! Do not adjust the relief valve unnecessarily. When adjustment line rupture relief valve (boom raise or arm out):   



When installing the line rupture valve newly. When hearing the noise. When dismantling the line rupture valve.



When installing the line rupture valve 



Hold adjusting screw (2) securely, loosen lock nut (1) counterclockwise, approximately 1 turn. 







Turn adjusting screw (2) to increase pressure clockwise, approximately 1/2 turn. 







Tools Adjusting screw (2): Allen wrench 6 mm Lock nut (1): spanner 22 mm



Tools: Allen wrench 6 mm



Holding adjusting screw (2) securely, tighten lock nut (1). 



Tightening torque (1): 3 kgf·m (22 lbf·ft)



NOTE! The port relief pressure on main control valve is about 455 kgf/cm2 after the adjusting work. When dismantling the line rupture valve After removing the line rupture valve from the machine, adjust the port relief pressure for the boom raise or the arm out operation to 375 kgf/cm2 (5337 psi).



Service Information Document Title: Function Group: Line rupture valve (boom), air breathing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Line rupture valve (boom), air breathing WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1.



Start the engine at low rpm. Operate boom down until the attachment is on the ground.



Figure 1 2.



Loosen the hose fitting on port Pi (about 2~3 turns to check that oil comes out from the hose's swivel nut).



Figure 2



1.



Hose on port Pi



3.



Operate the RCV-lever to boom down (approx. 1/5 of full stroke). NOTE! Do not operate the lever at full stroke to avoid an oil jet.



4. 5.



Operate repeatedly until no more bubbles come out of the hose. When no more bubbles come out, tighten the fitting and hose with the specific torque. Tightening torque: 3.7 ±0.4 kgf m (26.7 ±2.9 lbf ft) (36.3 ±3.9 Nm)



Service Information Document Title: Function Group: Disassembly and assembly, general



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Disassembly and assembly, general General, precautions  



Thoroughly clean the valves prior to removal from the machine. Cap all hoses and plug all ports to prevent contamination from entering.



Disassembly, precautions   



Do not use excessive force, sharp or high hardness tools to disassemble the valves. Handle the components carefully, protect the highly polished precision finish. If the surface is damaged it will cause internal oil leakage and malfunction. Match mark the parts to indicate original location and position during reassembly.



Assembly, precautions     



Clean all parts with cleaning solvent and dry with compressed air. Rework damaged parts, polish minor burrs, nicks, score marks or sharp edges with fine emery and crocus cloth. Prepare all replacement parts. Coat the sliding parts with clean hydraulic oil. Replace the seals, o-rings and back-up rings. Use a torque wrench to tighten the screws and plugs to the specified torque.



Service Information Document Title: Function Group: Line rupture valve (boom), troubleshooting



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Line rupture valve (boom), troubleshooting Troubleshooting Phenomenon 1



Excessive oil leakage in the passage P2 → P1.



Cause 



Contamination between the check valve and seat. Contamination between the logic valve and seat. Oil leakage of the servo hydraulic valve. Oil leakage of the relief valve.







Disassemble and clean. If damaged, replace.







Sticking spool of the servo hydraulic valve.







Disassemble and clean. If damaged, replace.







Damaged seals.







Replace damaged or worn component.







Clogged orifice in the logic valve. Clogged port T in the servo hydraulic valve.







Disassemble and clean. If damaged, replace.



   2



3



4



Boom lowering (or arm in) does not occur.



Remark



External oil leakage.



Slow response in boom lowering (or arm in).







Service Information Document Title: Function Group: Line rupture valve (arm), description



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Line rupture valve (arm), description



Figure 1 Line rupture valve (arm) 1



Body assembly



16



Retainer



2



Spool



17



Retainer



3



Plug



18



Plug



4



O-ring



19



O-ring



5



Back-up ring



20



Shim



6



Check valve



21



Cover



7



Logic valve



22



O-ring



8



Spring



23



Spring



Date: 2014/7/15



9



Relief valve



24



Seat spring



10



Screw



25



O-ring



11



Cap



26



Back-up ring



12



Screw



27



Flange



13



Spring



28



Plug



14



Spring



29



Spring washer



15



O-ring



The arm line rupture valve (antidrop valve) connected between the arm cylinder and the main control valve consists of: a servo hydraulic valve, logic valve, check valve, pressure relief valve and a housing. The line rupture valve function is to prevent an accident caused by a sudden dropping of the arm when a pipe or hose ruptures. It also prevents arm cylinder creep caused by internal leakage of the main control valve. Neutral position When the remote control valve is in neutral position, spring (23) pushes the poppet of check valve (6) forward blocking the passage to port P1. The oil flow from P4 & P5 normally connected through orifice (a) is blocked by servo hydraulic valve spool (2) at position (b). The spring force combined with the oil pressure acting on the sectional area difference between f & e of logic valve (7) pushes the poppet forward blocking passage P6. With the arm in position / attachment off the ground, the weight pressurizes the oil on the arm cylinder rod side, the flow connected via passage P2 is blocked by the poppet of check valve (6) and logic valve (7), trapping the oil in the hydraulic cylinder preventing the arm from dropping.



Figure 2 Line rupture valve (arm), neutral position Arm out (P1 → P2) When operating the remote control valve (lever) to arm out, servo hydraulic valve spool (2) and logic valve (7) are in the neutral position. Pressurized oil from the main control valve is routed through P1 port, pushes open check valve (6), then flows via P2 to the rod side of the hydraulic cylinder moving the arm out. When the arm is out and the remote control valve (lever) is returned to neutral position (P1 = P2), as described previously check valve (6) poppet blocks the passage and the pressurized oil on the arm rod side is trapped in the cylinder preventing the arm from dropping. When a pipe or hose ruptures during arm out, pressurized oil flow will be cut off to passage P1. As a result the pressure in passage P1 drops quickly and the poppet of check valve (6) will be pushed forward by its spring blocking passage P1, and pressurized oil flow from the rod side of the arm cylinder is blocked.



Figure 3 Line rupture valve (arm), arm out Arm in (P2 → P1) When operating the remote control valve (lever) to arm in (lower the arm), servo hydraulic oil is supplied to passage Pi and pushes servo hydraulic valve spool (2) to the left against springs (13, 14). As spool (2) moves, passage T2 aligns with position b, and the oil in the spring chamber of logic valve (7) drains to the hydraulic tank through passage P4 and P5. The pressure difference of area e and f causes logic valve (7) to open and the oil from P2 flows past the poppet of logic valve (7) to servo spool (2). The return oil from the rod side of the arm cylinder will flow from passage P2 → P6 → P1 →main control valve → tank. The oil passage opening from P6 to P1 will be varied because of the area of notch (C), which controls the return oil flow rate (speed) from the arm cylinder. When a pipe or hose ruptures during arm lowering, the pressure at port P1 will be lower than passage P6, so the poppet of logic valve (7) will be pushed forward by its spring blocking passage T3, and return oil flow from the arm cylinder is blocked. When the remote control valve (lever) is released to neutral position, servo hydraulic pressure at Pi is cut off, and springs (13, 14) move spool (2) to the right blocking passage P6.



Figure 4 Line rupture valve (arm), arm in Overload relief valve Normally the hydraulic oil from port P2 flows through g , d, h. If the pressure of the arm cylinder reaches the set value, the pressure in chamber h will open poppet and the oil from port P2 flows to T1 through g. So the pressure in the arm cylinder will be lowered.



Figure 5 Line rupture valve (arm), overload relief valve



Service Information Document Title: Function Group: Line rupture valve (arm), air breathing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Line rupture valve (arm), air breathing WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1.



Start the engine at low rpm. Operate arm in until the arm is at end-position.



Figure 1



1. 2.



Arm cylinder, piston rod



Loosen the hose fitting on port Pi (approx. 2~3 turns to check that oil comes out from the hose's swivel nut).



Figure 2



1.



Hose fitting



3.



Operate the RCV-lever to arm in (approx. 1/5 of full stroke). NOTE! Do not operate the lever at full stroke to avoid an oil jet.



4.



Operate repeatedly until no more bubbles come out of the hose.



5.



Tighten the hose with specific torque. Tightening torque: 3.7 ±0.4 kgf m (26.7 ±2.9 lbf ft) (36.3 ±3.9 Nm)



Service Information Document Title: Function Group: Line rupture valve (arm), troubleshooting



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Line rupture valve (arm), troubleshooting See 9123 Line rupture valve (boom), troubleshooting.



Date: 2014/7/15



Service Information Document Title: Rupture valve, (boom cylinder)



Function Group: replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Rupture valve, replacing (boom cylinder) Op nbr 912-071



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1. Place the machine in the service position B. See : 091 Service positions 2. Press the air breather cap on the hydraulic tank to release the residual pressure.



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container.



WARNING Loosen carefully. There may be hot/high-pressure oil in the line. 3. Remove hoses (1).



Figure 1 Replacing, rupture valve 4. Turn the connector to remove hose.



Figure 2 Replacing, rupture valve 1.



Spanner



5. Remove hose (2) using spanner (1). Remove screws (3, 5), cover (6) and rupture valve (4).



Figure 3 Replacing, rupture valve 6. Remove the connectors from the old rupture valve. 7. Transfer the connectors with new O-rings to the new rupture valve. 8. Install rupture valve (4), cover (6) with new O-ring and screws (5) on the cylinder. 9. Fit the pipe with O-ring and tighten screws (3). 10. Connect hose (2) using spanner. NOTE! O-rings disassembled should be replaced with new ones.



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



WARNING When the last bolt has been removed, the cover plate falls down. 11. Connect hoses (1).



Figure 4 Replacing, rupture valve 12. Refill hydraulic oil and test the machine.



Service Information Document Title: Function Group: Line rupture valve (boom), disassembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Line rupture valve (boom), disassembly Op nbr 00000



Tools      



L wrench: 4, 6, 10 and 14 mm Spanner: 32 mm Torque wrench: 1 ~ 20 kgf·m (7.2 ~ 144 lbf·ft) Socket wrench: 32 mm Hammer Rod: φ 10, 100 mm 1. Remove relief valve (9) from the line rupture valve. 



Tools: Spanner 32 mm



NOTE! Do not disassemble the pressure adjusting parts.



2. Remove plug (3) of the logic valve, and pull out o-ring (4), spring and logic valve (7). 



Tools: Allen wrench 14 mm



3. Remove plug (3) of the check valve, and pull out o-ring (4), spring (8) and check valve (6). 



Tools: Allen wrench 14 mm



4. Remove screw (10) of the cover (11), and pull out o-ring (15). 



Tools: Allen wrench 6 mm



5. Pull out springs (13, 14), Retainer (16, 17). 6. Remove plug (3), and pull out o-ring (4). 



Tools: Allen wrench 14 mm



7. Remove spool (2). 8. Remove plug (12). 



Tools: Allen wrench 4 mm



9. Remove plugs (21, 22 & 23).



Service Information Document Title: Function Group: Line rupture valve (boom), assembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Line rupture valve (boom), assembly Op nbr 00000



Tightening torque Tightening torque No.



Screw size



Tightening torque, kgf·m (lbf·ft)



Tools size (mm)



3



M 33 × 1.5



20 ± 2 (144 ± 14)



14 (Allen wrench)



9



M 27 × 1.5



6 ± 0.6 (43 ± 4.3)



32 (Spanner)



10



M 8 × 35



3 ± 0.3 (22 ± 2)



6 (Allen wrench)



12



NPTF 1/16



1.2 ± 0.1 (8.7 ± 0.7)



4 (Allen wrench)



21



3/4 UNF



Plastic plug



22



9/16 UNF



Plastic plug



23



7/8 UNF



Plastic plug



1. Assemble plug (12) with seal tape to the valve body. 



Tools: Allen wrench 4 mm



2. Assemble plastic plugs (21, 22 & 23) to the valve body. 3. Assemble the servo hydraulic valve parts.  







Assemble plug (3) with o-ring (4) to the valve body. – Tools: Allen wrench 14 mm Assemble spool (2) to the valve body. NOTE! Ensure that the spool moves smoothly. Assemble retainer (16, 17) and springs (13, 14) to the valve body in this order, and assemble cap (11) with o-ring (15). – Tools: Allen wrench 6 mm



4. Assemble check valve (6), spring (8) and plug (3) with o-ring (4). 



Tools: Allen wrench 14 mm



NOTE! If you replace check valve (6) with a new one, press-fit with a driver and hammer. 5. Assemble logic valve (7), spring and plug (3) with o-ring (4). 



Tools: Allen wrench 14 mm



NOTE! If you change logic valve (7) with a new one, press-fit with a driver and hammer. 6. Assemble relief valve (9). 



Tools: Spanner 32 mm



Service Information Document Title: Function Group: Rupture valve, replacing (dipper arm cylinder)



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Rupture valve, replacing (dipper arm cylinder) Op nbr 912-073



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1. Place the machine in the service position D. See : 091 Service positions 2. Press the air breather cap on the hydraulic tank to release the residual pressure.



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container.



WARNING Loosen carefully. There may be hot/high-pressure oil in the line. 3. Remove hoses (1).



Figure 1



4. Remove screws (4). 5. Remove screws (2) and rupture valve (3).



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



WARNING When the last bolt has been removed, the cover plate falls down. 6. Remove the connectors and flange from the old rupture valve. NOTE! O-rings disassembled should be replaced with new ones. 7. Transfer the flange and connectors with new O-rings to the new rupture valve. 8. Install rupture valve (3) with a new O-ring on the cylinder and tighten screws (2). 9. Fit the pipe with a new O-ring and tighten screws (3). 10. Connect hoses (1). 11. Refill hydraulic oil and test the machine.



Service Information Document Title: Function Group: Line rupture valve (arm), disassembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Line rupture valve (arm), disassembly Op nbr 00000



Tools      



Allen wrench: 4, 6, 8 and 14mm Spanner: 32 mm Torque wrench: 1 ~ 20 kgf·m (7.2 ~ 144 lbf·ft) Socket wrench: 32 mm Hammer Rod: φ10,100 mm 1. Remove relief valve (9) from the line rupture valve. 



Tools: Spanner 32 mm



NOTE! Do not disassemble the pressure adjusting parts.



2. Remove plug (3) of the logic valve, and pull out o-ring (4), spring (8) and logic valve (7). 



Tools: Allen wrench 14 mm



3. Remove screw (12), flange (27) of the check valve (6), and pull out o-ring (25), spring (23) and check valve (6). 



Tools: Allen wrench 8 mm



4. Remove screws (10), cover (11), o-ring (15), springs (13, 14), retainer (16, 17). 



Tools: Allen wrench 6 mm



5. Remove plug (18), and pull out o-ring (19). 



Tools: Allen wrench 6 mm



6. Remove cover (21) and o-ring (22). 7. Remove spool (2) 8. Remove plugs (28). 



Tools: Allen wrench 4 mm



Service Information Document Title: Function Group: Line rupture valve (arm), assembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Line rupture valve (arm), assembly Op nbr 00000



Tightening torque Tightening torque No.



Screw size



Tightening torque, kgf·m (lbf·ft)



Tools size (mm)



3



M 33 × 1.5



20 ± 2 (144 ± 14)



14 (Allen wrench)



9



M 27 × 1.5



6 ± 0.6 (43 ± 4.3)



32 (Spanner)



10



M 8 × 35



3 ± 0.3 (22 ± 2)



6 (Allen wrench)



12



M 10 × 35



5 ± 0.5 (36 ± 3.6)



8 (Allen wrench)



18



PF 1/4



3 ± 0.3 (22 ± 2)



6 (Allen wrench)



28



NPTF 1/16



1.2 ± 0.1 (8.7 ± 0.7)



4 (Allen wrench)



1. Assemble plug (28) with seal tape to the valve body. (6 places) 



Tools: Allen wrench 4 mm



2. Assemble spool (2) to the valve body. NOTE! Ensure that the spool moves smoothly. 3. Assemble cover (21) with o-ring (22) to the valve body. 4. Assemble plug (18) with o-ring (19) to the valve body. 



Tools: Allen wrench 6 mm



5. Assemble retainer (16, 17) and springs (13, 14) to the valve body in this order, and assemble cover (11) with o-ring (15). Install screws (10). 



Tools: Allen wrench 6 mm



6. Assemble check valve (6), spring (23) and flange (27) with o-ring (25). 



Tools: Allen wrench 8 mm



NOTE! If you replace check valve (6) with a new one, press-fit with a driver and hammer. 7. Assemble logic valve (7), spring (8) and plug (3) with o-ring (4). 



Tools: Allen wrench 14 mm



NOTE! If you replace logic valve (7) with a new one, press-fit with a driver and hammer. 8. Assemble relief valve (9). 



Tools: Spanner 32 mm



Service Information Document Title: Hydraulic description



Function Group: pump, 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic pump, description Model code Model code Code



Description



K*V



Series



Remarks



***



Size (Displacement : cm3 / rev)



DT



S : Single pump DT : Tandem type double pump



H



– : Standard H : With impeller



***



Design series number



R L



Shaft rotation view from shaft end



R : Clock wise L : Counter clockwise



****



Regulator type



For more details, see the section for the regulator.



V



O-ring material



Fluoro-RUBBER



Port connection Port



Port name



port



Port name



A1, A2



Delivery



Psv1, Psv2



Power shift pressure



B1



Suction



a1, a2, a3, a4, a5



Gauge port



Dr1, Dr2, Dr3, Dr4



Drain



PB



Gauge port



Pi1, Pi2



Negative pilot pressure signal



Pump, structure



Figure 1 Main pump, structure Sectional view



Figure 2 Main pump, sectional view 012



Cylinder block



311



Valve cover (Front)



717



O-ring



101



Sub plate



312



Valve cover (Rear)



719



O-ring



111



Driving shaft (Front)



313



Valve plate (Right)



724



O-ring



113



Driving shaft (Rear)



314



Valve plate (Left)



725



O-ring



114



Spline coupling



401



Screw



728



O-ring



123



Roller bearing



402



Screw



732



O-ring



124



Needle bearing



406



Screw



774



Oil seal



127



Bearing spacer



407



Screw



789



Back-up ring



130



Impeller



466



Vp plug



792



Back-up ring



151



Piston



468



Vp plug



808



Nut



152



Shoe



490



Plug



824



Snap ring



153



Set plate



492



Plug



885



Valve plate pin



156



Spherical bushing



531



Tilting pin



886



Spring pin



157



Cylinder spring



532



Servo piston



901



Eye bolt



211



Shoe plate



534



Stopper (Long)



953



Set screw



212



Swash Plate



535



Stopper (Short)



954



Set screw



214



Tilting bushing



548



Feedback pin



956



Set screw



251



Swash plate support



702



O-ring



981



Name plate



261



Seal cover (Front)



706



O-ring



983



Pin



263



Seal cover (Rear)



707



O-ring



271



Pump casing



710



O-ring



Figure 3 Main pump, exploded view Pump, principle of operation 



This pump assembly consists of two pumps connected by spline coupling (114). The two pumps are driven simultaneously as the engine rotation is transmitted to the front drive shaft (111). The suction and delivery ports are integrated at the connecting section of the two pumps, in valve block (312). The common suction port serves both the front and rear pump. Structure and operating principle of front and rear pump is the same so front pump only will be explained. The pump consists of rotary group, swash plate group and valve block group.







The rotary group consists of front drive shaft (111), cylinder block (141), piston and shoe (151, 152), set plate (153), spherical bushing (156), and cylinder spring (157). The drive shaft is supported by bearings (123, 124). The shoe is caulked to the piston to form a spherical coupling. It has a pocket to relieve thrust force generated by loading



pressures and create a hydraulic balance so that it slides lightly over shoe plate (211). The sub group composed of a piston and a shoe is pressed against the shoe plate by the action of the cylinder spring through the set plate and spherical bushing. Similarly, the cylinder block is pressed against valve plate (313) by the action of the cylinder spring. 



The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bushing (214), tilting pin (531) and servo piston (532). The swash plate is supported by a cylindrical part on the opposite side of its sliding surface and swash plate support (251). The servo piston moves to the right and the left as hydraulic oil controlled by the regulator flows to a hydraulic chamber located on both sides of the servo piston. The force exerted on the tilting pin by the servo piston causes the swash plate to slide on support (251) to change the tilting angle (α).



Figure 4 Swash plate group 



The valve block group consists of valve cover (311), valve cover (312), valve plate (313, 314), spline coupling (114), impeller (130) and valve plate pin (885). The valve plate which has two crescent ports is attached to the valve block to feed oil to and collect oil from the cylinder block. The oil discharged via the valve plate is routed to an external pipe line by way of the valve block.



Figure 5 Valve block group 



The pump shaft driven by the engine, rotates the cylinder block via the splined bore. If the swash plate is tilted the pistons arranged in the cylinder block make a reciprocating motion with respect to the cylinder block, while they revolve with the cylinder block. A single piston will perform a 180° motion away from the valve plate (oil suction stroke) and then make another 180° motion towards the valve plate (oil discharging stroke) as the cylinder block rotates. When the swash plate tilting angle is zero, the piston does not stroke or discharge oil.



Figure 6 Moving, swash plate 1. 2.



Servo piston Tilting pin



Adjustment of maximum flow Adjust it by loosening hexagon nut (808) and by tightening (or loosening) adjusting screw (954). Only the maximum flow is adjusted without changing other control characteristics. 



For the location of adjusting screw and nut.



See 913 Hydraulic pump, description.



Figure 7 Adjustment of maximum flow X



Servo hydraulic pressure Pi



Y



Delivery flow, Q



Adjustment of minimum flow Adjust it by loosening hexagon nut (808) and by tightening (or loosening) adjusting screw (953). Similar to the adjustment of the maximum flow, other characteristics are not changed. However, if tightened too much, the required horsepower for the maximum delivery pressure (or for relief) may increase.



Figure 8 Adjustment of minimum flow X



Servo hydraulic pressure Pi



Y



Delivery flow, Q



Service Information Document Title: Pump, troubleshooting



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Pump, troubleshooting Overload of engine Cause



Remedy



Remark



Revolution and pressure are higher Set to specification. than set values. Regulator torque is set higher than Readjust regulator. normal.



See the regulator section.



Regulator is operating abnormally. Pump internal parts are seized or Replace faulty parts. broken.



Check filter and drain oil to see if abnormal wear particles are present.



Pump oil flow is extremely low and discharge pressure is not raised Cause



Remedy



Remark



Regulator is faulty.



Repair regulator.



See the regulator section.



Pump internal parts are seized or Replace damaged parts. broken.



Check filters and drain oil.



Auxiliary pump is faulty.



Replace auxiliary pump.



Remove Auxiliary pump and check shaft coupling.



Servo hydraulic relief valve is faulty.



Check servo hydraulic relief valve. Particularly poppet, seat and spring.



See the servo hydraulic relief valve section.



Abnormal noises and abnormal vibrations Cause



Remedy



Cavitation



Prevent cavitation. Check if hydraulic oil is cloudy.



Remark    



Hydraulic oil is insufficient. Auxiliary pump is damaged. Suction pipe is drawing air. Suction ports are blocked.



Caulked part of shoe is broken.



Replace piston assembly and shoe plate.



Cylinder is cracked.



Replace cylinder.



Pump is installed improperly.



Correct installation.



Regulator is hunting.



Repair regulator.



See the regulator section.



Servo hydraulic relief valve is hunting.



Repair/replace valve.



See the servo hydraulic relief valve section.



Service Information Document Title: Regulator, description



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Regulator, description model code Model code Code



Description



KR3



Regulator for series pump



Remarks



*



Size (Displacement : cm3/ rev)



K : K5V200



*



Type of horsepower control



1 : Rated horsepower control 2 : Total cumulative horsepower control 3 : Pressure cut - off control 5 : Rated horsepower control + Pressure cut - off control 6 : Total cumulative horsepower control + Pressure cut - off control 9 : Total cumulative horsepower control + Power shift control



*



Type of flow control



O : No flow control N : – flow control P : + flow control M : Manual flow control E : Electric flow control C : Flow control (Max. flow cut control) D : + flow control (Flow cut control attach)



**



Regulator design series number



V



O-ring material



Fluoro-RUBBER



Port connection Port name



Port size



Psv



Negative servo hydraulic pressure signal port



PF 1/4



P2



Companion pump servo hydraulic pressure port



PF 1/4



Pf



Secondary servo hydraulic pressure port on proportional solenoid valve



PF 1/4



Tightening torque Tightening torque No.



Size



Tightening torque N·m



kgf·cm



lbf·ft



412, 413



M8



29



296



21.4



407, 408, 436, 438



M6



12



122



8.8



482



G 1/4



36



367



26.3



496



NPTF 1/16



8.8



90



6.5



630



M30 x 1.5



160



1633



118



801



M8



16



163



11.8



Regulator, Sectional view



Figure 1 Regulator, sectional view 407 Screw



611 Feedback lever



628 Adjusting screw (C)



654 Return spring



408 Screw



612 Lever (1)



629 Cover (C)



655 Adjusting spring



412 Screw



613 Lever (2)



630 Lock nut



697 Check valve plate



413 Screw



614 Center plug



631 Pf sleeve



699 Valve casing



436 Screw



615 Adjust plug



641 Servo cover



708 ~ 763 O-ring



438 Screw



621 Compensator piston



643 Servo piston



801 Nut



482 Plug



622 Piston case



644 Spring seat (Q)



814 Snap ring



496 Plug



623 Compensator rod



645 Adjusting ring (Q)



836 Snap ring



541 Seat 1



624 Spring seat (C)



646 Servo spring



858 Snap ring



543 Stopper 1



625 Outer spring



651 Sleeve



874 ~ 898 Pin



545 Ball



626 Inner spring



652 Spool



924 Set screw



601 Casing



627 Adjusting stem (C)



653 Spring seat



925 Adjusting screw (Q1)



Regulator, exploded view



Figure 2 Regulator, exploded view Regulator, principle of operation Schematic In-line type axial piston pump regulator consists of following controllers. Horsepower control As the delivery pressure of the pump P1 and mate pump P2 are raised, the delivery flow rate will be reduced automatically, so the input torque will be regulated to a certain value. (When the rpm is constant, the input horsepower will become constant also.) The regulator is the total cumulative horsepower type, that operates by the sum of load pressures of the two pumps in the tandem double pump system. Therefore the engine can be automatically prevented from being overloaded regardless of the loading conditions on the two pumps. Power shift control The horsepower setting will be changed by changing the instruction current of the proportional solenoid valve attached to the regulator. Only one proportional solenoid valve is provided. However, secondary pressure Pf (power shift pressure) flows into the horsepower control portion of each pump regulator through an inner passage, and shifts it to same horsepower setting, respectively. Delivery flow rate of the pump can be changed, so the proper power level suitable for the work conditions can be acquired. Negative flow control Delivery rate of the pump can be controlled by varying the servo hydraulic pressure Pi. This regulator is the negative flow control type that reduces delivery rate Q according to the increase of servo hydraulic



pressure Pi. As the servo hydraulic pressure corresponds to the flow required for the work designated, the pump will deliver only the required oil so unnecessary power consumption will be prevented. This regulator has 3 control functions, however when different control functions act at the same time, low oil flow instruction will have priority by the mechanical operation.



Figure 3 Structure, regulator X Large end part



612 Lever-1



626 Inner spring



654 Return spring



Y Small end part



613 Lever-2



643 Servo hydraulic piston



875 Pin



531 Tilting pin



621 Compensating piston



646 Servo hydraulic spring



897 Pin



548 Feedback pin



623 Compensating rod



651 Sleeve



898 Pin



611 Feedback lever



625 Outer spring



652 Spool



Regulator, negative flow control According to the change of the servo hydraulic pressure Pi, the delivery flow is regulated, as shown. The regulator is negative flow control type, so the delivery flow Q decreases as the servo hydraulic pressure Pi increases. As the servo hydraulic pressure corresponds to the flow required for the work commanded, the pump discharges the required flow only, so it does not consume power needlessly.



Figure 4 Negative flow control chart X



Servo hydraulic pressure Pi



Y



Delivery flow, Q



Flow reducing function As the servo hydraulic pressure Pi rises, servo hydraulic piston (643) moves right to a position where the force of servo hydraulic spring (646) is balanced with the hydraulic force. Groove “A” in the servo hydraulic piston is fitted with pin (875) that is fixed to lever 2 (613). Therefore, when the servo hydraulic piston moves, lever 2 rotates around the fulcrum of point “B” [Fixed by fulcrum plug (614) and pin (875)]. Since the large hole section “C” of lever 2 contains protruding pin (897) fixed to feedback lever (611), pin (897) moves to the right as lever 2 rotates. Since the opposed flat section “D” of the feedback lever is fitted with pin (548) fixed by the tilting pin (531) that slews the swash plate, the feedback lever rotates around the fulcrum of point “D”, as pin (897) moves. Since the feedback lever is connected with spool (652) through pin (874), the spool moves to the right. The movement of the spool causes the delivery pressure P1 to flow to port (C l) through the spool and be admitted to the large-diameter section of the servo piston. The delivery pressure P1 that is constantly admitted to the small diameter section of servo piston moves the servo piston right due to the area difference, resulting in a decrease of the tilting angle. When the servo piston moves to the right, point “D” also moves right. The spool is fitted with return spring (654) and is tensioned to the left at all times, so pin (897) is pressed against the large hole section “C” of lever 2. Therefore, as point “D” moves, the feedback lever rotates around the fulcrum of point “C”, and the spool is shifted to the left. This causes the opening between sleeve (651) and spool (652) to close slowly, and the servo piston stops when it is closed completely. Flow increasing function As the servo hydraulic pressure Pi decreases, servo hydraulic piston (643) is moved to the left by the action of servo hydraulic spring (646), and lever 2 (613) is rotated around the fulcrum of point “B”. Since pin (897) is pressed against the large hole section “C” of lever 2 by the action of the return spring (654) through spool (652), pin (874), and feedback lever (611), the feedback lever rotates around the fulcrum of point “D” as lever 2 rotates, and shifts the spool to the left. As the spool moves, port (C l) opens a path to the tank port. This cuts off the pressure to the large diameter section of the piston, and the servo piston shifts left due to delivery pressure P1 on the small diameter section, resulting in an increase of the flow rate. As the servo piston moves, point “D” also moves to the left, the feedback lever rotates around the fulcrum of point “C”, and the spool moves right until the opening between the spool and sleeve is closed. Regulator, total horsepower control The regulator decreases the swash plate tilting angle (delivery flow) when the load pressure is increased to prevent engine overload. Since this regulator is the total cumulative horsepower type, it controls the tilting angles (displacement volumes) of the two pumps to the same value as represented by the following equation: Tin = P1 x Q/2p + P2 x Q/2p = (P1 + P2) x Q/2p The horsepower control function is the same as the flow control function and is summarized as follows: (For details of respective parts, see the section on flow control.)



Figure 5 Total horsepower control chart X



Delivery pressure, (P1 + P2)



Y



Delivery flow, Q



Overload preventive function When the pump delivery pressure P1 or the mate pump delivery pressure P2 rises, it acts on the stepped part of compensating piston (621). It presses compensating rod (623) to the right till the force of outer spring (625) and inner spring (626) is balanced with the hydraulic force. The movement of the compensating rod is transmitted to lever 1 through pin (875), and lever 1 rotates around pin (875) “E” fixed to casing (601). Since the large hole section “F” of lever 1 contains protruding pin (897) fixed to feedback lever (611), the feedback lever rotates around the fulcrum of point “D” as lever 1 rotates, and spool (652) is shifted to the right. As the spool moves, delivery pressure P1 flows to the large-diameter section of the servo piston through port (C l), the servo piston is moved to the right, the pump delivery flow rate is reduced, and the engine is prevented from being overloaded. The movement of the servo piston is transmitted to the feedback lever through point “D”. Then the feedback lever rotates around the fulcrum of point “F” and the spool moves to the left until the opening between the spool and sleeve (651) is closed completely. Flow reset function As the pump delivery pressure P1 or the mate pump delivery pressure P2 decreases, compensating rod (623) is pushed back by the action of springs (625, 626) and lever 1 is rotated around the fulcrum of point “E”. Rotation of lever 1 causes the feedback lever to rotate around the fulcrum of point “D” and the spool moves to the left. As a result, port (C l) opens a path to the tank port, and the servo piston moves left as the pressure to the large diameter section is released, resulting in an increase of the pump delivery rate. The movement of the servo piston is transmitted to the spool by the action of the feedback mechanism till the opening between the spool and sleeve is closed. Regulator, low tilting angle (low flow) command priority function As mentioned, the tilt angle commands of flow control and horsepower control are transmitted to the feedback lever and the spool through the large hole sections “C”, “E” of levers 1 and 2, respectively. However, since sections “C” and “E” have the pins (ø4) protruding from the large hole (ø 8), the lever contacts pin (897) only when the tilt angle is lessened. If the tilt angle command is greater the lever doesn’t contact pin (897) in the large hole (ø8). Such a mechanical selection method permits priority of the low tilt angle commands of flow control and horsepower control. Regulator, power shift control The power shift pressure Pf controls the set horsepower of the pump to a desired level, as shown in the figure. As the power shift pressure Pf rises, compensating rod (623) moves right through pin (898) and compensating piston (621). This decreases the pump tilting angle and the set horsepower in the same way as explained in the overload preventive function of the horsepower control. On the contrary, the set horsepower rises as power shift pressure Pf falls.



Figure 6 Power shift control chart X



Delivery pressure, (P1 + P2)



Y



Delivery flow, Q



Service Information Document Title: Function Group: Proportional solenoid 913 valve, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Proportional solenoid valve, description Model code



Figure 1 Model code Model code Cord



Description



KDRDE



Electric proportional pressure reducing valve



5



Nominal designation



K



Cartridge type



20



Series number



40



Maximum setting secondary pressure (40 kgf/cm2)



C



Solenoid specifications



L



Electrical connection



The proportional solenoid valve regulates secondary pressure (pressure in port A) to be proportional to the current applied to the solenoid coil. If solenoid (801) is energized, spool (311) is pushed to the right, and oil flows from P to A. The pressure in port A affects the spring of spool (311). If the pressure reaches the set value of the solenoid, the spool moves left and reduces the flow from P to A. 



  



When selecting a mode by turning the engine rpm control rotary switch, the controller outputs a current value (adequate for the pertinent mode) to the proportional solenoid valve to regulate the servo hydraulic pressure to the hydraulic pump regulator. The valve regulates the secondary servo hydraulic pressure to the hydraulic pump regulators to control the swash plate angle and allowable pump output. The secondary servo hydraulic pressure varies in proportion to the current value at the proportional solenoid valve. The proportional solenoid valve spool vibrates continuously to maintain the secondary servo hydraulic pressure, and is very sensitive to contamination due to the close tolerances of the spool/valve body. In the event of a malfunction, always inspect the valve for contamination before replacing it.



Notes on operation Solenoid wiring Solenoid has no polarity. Input current Never add more than 0.7A to the solenoid coil. Adjusting screw Factory adjusted at shipment. Port A pressure increases when the adjusting screw is turned clockwise.



Figure 2 Proportional solenoid valve 450



Tools: spanner 32 mm



IC



Input current



Tightening torque: 450 kgf·cm



SP



Secondary pressure



725



Proportional solenoid valve secondary pressure measuring port



HC



Hydraulic circuit



OR



O-ring



Tightening torque Tightening torque No.



Item



Thread size



Tightening torque (kgf·cm)



079



Proportional valve



M22 × 1



450 ± 50



311



Spool



324



Spring



351



Orifice



M3



6 ± 1 (Loctite # 24)



361



O-ring



362



O-ring



363



O-ring



407



Screw



M6



120



408



Screw



M6



120



482



Plug



G 1/4



370



496



Plug



NPTF 1/16



90



699



Valve case



755



O-ring



802



Seal nut



M6



75 ± 5



901



Name plate



Inspection method  



Connect the adapter cable for testing between proportional solenoid valve connectors as shown. Start engine and measure the current value.



Figure 3 Connection, proportional solenoid valve 1



Black with red stripe



3



Tester



2



White



4



Red



5



Black



Service Information Document Title: Function Group: Proportional solenoid 913 valve, troubleshooting



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Proportional solenoid valve, troubleshooting Troubleshooting Phenomenon



Cause



Remedy



Pressure does not rise or vary.



Error in wiring. Damage of solenoid. Stuck piston or spool. Damage of amplifier.



Correct wiring. Replace the solenoid. Remove, clean and polish. Repair or replace the controller.



Pressure does not vary smoothly. Incorrect dither adjustment.  



Pressure is unstable.



Dither frequency is high. Dither amplitude is low.



Stuck piston or spool.



Remove, clean and polish.



Incorrect dither adjustment.



Readjust.



  Slow response



Readjust.



Dither frequency is low. Dither amplitude is high.



Servo hydraulic primary pressure is low.



Readjust.



Service Information Document Title: Function Group: Pump, maintenance 913 standard



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Pump, maintenance standard Precautions for usage Precautions Item



Description



• Long term storage    



Long term storage of more than 1 year is not recommended. If installed in a machine, operate it occasionally. If in stock inventory, rotate the pump shaft occasionally. If in storage more than 1 year consider overhaul.







Rotating direction of pump is depicted on the name plate.



• Rotating direction



Lubrication and air purging Precautions Item



Cautions



• Lubrication  



Fill the pump casing through P1, P2 delivery ports with the specified hydraulic oil. Following repair or replacement of the pump it is necessary to pre-lubricate the internal components to prevent scoring, scuffing, seizure of the bearing and sliding parts.







Following hydraulic system repairs, purge the air from the pump circuit by loosening the upper plug in the pump casing.



• Air purging



Start-up       



Check that there is no contamination in the ports or plumbing before connecting to the pump. Check the direction of rotation and the suction/delivery direction. Check the oil level in the hydraulic tank. At initial start-up run the engine at idle to purge the air in the circuit. Check for oil leakage on the pump assembly. Check for abnormal sound or vibration. Check for any abnormal temperature increase after running for a short time.



General precautions    



Determine the nature of the abnormality, before disassembling. Especially, check if the problem is in the circuit, or caused by the regulator, auxiliary valves, defective pump, or motor. Read the maintenance manual thoroughly before disassembling, and then follow the procedures carefully. When any section is to be disassembled, pay attention not to allow contamination into the pump. Since the parts are precision finished, handle them carefully to prevent damage.



Check of pump for abnormalities



The pump is usually fitted with a regulator, auxiliary valves or an auxiliary pump, so it may be difficult to find the cause of failure. Check the following principal items, to identify the abnormality. Check of filter and drain oil Check the filter elements for abnormal impurities. As the shoes and cylinder wear, a small quantity of metal particles may be detected. However, if a considerable amount of metal particles are found, the shoes may be damaged. Similarly, check the drain oil in the pump casing. Check of abnormal sound or vibration Check the pump for abnormal sound and vibration. If any, check if it is a noise of regular frequency, such as hunting of the regulator or the relief valve. If it is an abnormal vibration or sound, it may result from cavitation or damage inside the pump. Check of circuit where two pumps are used For the circuit with two single pumps or a tandem double pump, exchange the piping of one pump with that of the other one. With the results of this exchange, it will be determined if the trouble is with the pump or a component downstream of the pump. Pressure measurement at various points If the failure is a problem in control, do not overhaul the pump needlessly, but measure pressures at various points in the circuit. Standard for parts service and replacement When a part exceeds any of the following criteria, replace or readjust it. However, when a part is damaged seriously in appearance, replace it without fail. Standard wear limit, unit: mm (inch) Part name inspection item



and Standard dimension / Recommended replacement value



Remedy



Pump type K3V63



K3V112



K3V140



Clearance between 0.028/0.056 piston and cylinder (0.0011/0.0022) bore (D-d)



0.039/0.067 (0.0015/0.0026)



0.043/0.070 0.0375/0.078 (0.0017/0.0027) (0.0015/0.0031)



Replace piston cylinder.



Play between piston 0.1/0.3 and shoe caulking (0.004/0.012) section (d)



0.1/0.3 (0.004/0.012)



0.1/0.3 (0.004/0.012)



0.1/0.35 (0.004/0.014)



Replace piston and shoe assembly.



Thickness of shoe (t)



3.9/3.7 (0.153/0.146)



4.9/4.7 (0.192/0.185)



5.4/5.0 (0.212/0.197)



5.4/5.0 (0.212/0.197)



Replace piston and shoe assembly.



Free height of cylinder 31.3/30.5 spring (L) (1.232/1.200)



41.1/40.3 (1.618/1.586)



47.9/47.1 (1.886/1.854)



40.9/40.1 (1.610/1.578)



Replace spring.



Assembled height of 19.0/18.3 set plate and spherical (0753/0.72) bushing (H-h)



23.0/22.0 (0.91/0.87)



23.8/22.8 (0.94/0.90)



23.8/22.8 (0.94/0.90)



Replace set plate or spherical bushing.



Figure 1



K3V180 K5V200 or



cylinder



Wear limit of parts D d



- Clearance between piston and cylinder bore



δ



Play between piston and shoe



t



Thickness of shoe



L H h



Free height of cylinder spring - Assembled height of set plate and spherical bushing



Repair standards for cylinder, valve plate and swash plate Repair standards Surface roughness of cylinder, valve plate Surface roughness requiring correction and swash plate Standard surface roughness (correction value)



3Z 0.4Z max. (lapping)



NOTE! Lap the cylinder and valve plate together to correct the surface roughness. Tightening torque Tightening torque, unit: N m (kgf cm) (lbf ft) Description



Size



Tightening torque



B (mm)



Tool



Screw



M5 M6 M8 M 10 M 12 M 14 M 16 M 18 M 20



6.9 (70) (5.1) 12 (120) (8.7) 29 (300) (22) 57 (580) (42) 98 (1000) (72) 160 (1600) (120) 240 (2400) (170) 330 (3400) (250) 430 (4400) (320)



4 5 6 8 10 12 14 14 17



Allen wrench



PT plug NOTE! Apply loctite # 577



PT 1/16 PT 1/8 PT 1/4 PT 3/8 PT 1/2 NPTF 1/16



6.9 (70) (5.1) 10 (105) (7.6) 17 (175) (13) 34 (350) (25) 49 (500) (36) 11 (1.12) (8.2)



4 5 6 8 10



PO plug



PF 1/4 PF 1/2 PF 3/4 PF 1 PF 1 1/4 PF 1 1/2



29 (300) (22) 98 (1000) (72) 150 (1500) (110) 190 (1900) (140) 260 (2700) (190) 270 (2800) (200)



6 10 14 17 17 17



Service Information Document Title: Pump, disassembly



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Pump, disassembly Op nbr 00000



Tools The tools necessary to disassemble/reassemble the pump is shown in the following list. The sizes of the screws and plugs depend on the pump type. Tools Tool name & size



Part name



Name



B mm



Screw



PT plug (PT thread)



Screw



Allen wrench



4



M5



BP - 1/16



M8



5



M6



BP - 1/8



M 10



6



M8



BP - 1/4



M 12, M 14



8



M 10



BP - 3/8



M 16, M 18



17



M 20, M 22



BP - 1



–



Name



B



Screw



Nut



VP plug (PF thread)



Box end spanner Socket wrench Open end spanner



19



M 12



M 12



VP - 1/4



24



M 16



M 16



–



27



M 18



M 18



VP - 1/2



30



M 20



M 20



–



36



–



–



VP - 3/4



Adjustable wrench



Medium size, 1 set



Screwdriver



Blade type screwdriver, medium size, 2 sets



Hammer



Plastic hammer, 1 set



Pliers



For snap ring, TSR-160



Brass bar



Approximately 10 x 8 x 200 mm



Torque wrench



Capable of tightening to the specified torques



Precautions      



Thoroughly clean the pump assembly prior to disassembly. Select a clean work area. Match mark the pump casing parts and the regulators to indicate proper positioning during reassembly. Take care not to mix the parts of the front pump with the parts of the rear pump. Thoroughly clean all parts and the inside of the casing. Inspect and analyze all failures. Determine the root cause!



Disassembly 1. Select a place suitable for disassembly.



NOTE! Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged. 2. Remove dust, rust, etc., from pump surfaces with cleaning solvent. See sectional and exploded view of main pump. 913 Hydraulic pump, description 3. Remove drain port plug (468) and drain oil from the pump casing. NOTE! For tandem type pump, remove plugs from the front and the rear pumps. 4. Remove screws (412, 413) and remove the regulator and PTO subassembly. NOTE! Refer to regulator section for disassembly. NOTE! Refer to PTO section for disassembly. NOTE! Mark each regulator to match the pump.



Figure 1 Removal screws and regulator 5. Remove set screws (956). 6. Loosen screws (401) which hold swash plate supports (251), pump casing (271) and valve cover (311). NOTE! If a gear pump is fitted to the rear face of the pump, remove it before starting this work. 7. Remove set screws (956). 8. Loosen screws (402) which hold swash plate supports (251), pump casing (271) and valve cover (312). 9. Place the pump level on the workbench with the surface of the regulator mounting facing down, and then remove the fastening screws (401) and (402). NOTE! When the regulator mounting surface is facing down, be sure to lay down a rubber mat, etc. on the workbench to avoid damaging the mounting surface. 10. Separate the front side pump casing (271) and the valve cover (311).



Figure 2 Removal, casing and valve block 11. Separate valve cover (311) and the valve (312), and then remove the booster (130) and the spline coupling (114) that are connected to the drive shaft. 12. Separate the rear side pump casing (271) and the valve cover (312). Carefully take out the cylinder (012) from the pump casing by pulling straight along the drive shaft (113). Remove the piston (151), pressure plate (153), spherical bushing (156) and cylinder spring (157) all at once. NOTE! Take care not to damage sliding surfaces of the cylinder, spherical bushing, shoes and swash plate, etc. NOTE! Mark the pistons and respective cylinder bores. Pistons must be installed into the same bores because of wear pattern.



Figure 3 Removal, cylinder 13. Remove screws (406) and front seal cover (261). NOTE! Fit screws into pull out tapped holes (M 8) of front seal cover, so it can be removed easily.



Since a seal is fitted to the front seal cover, take care not to damage it during disassembly.



Figure 4 Removal, screws and seal cover 14. Remove screws (406) and rear cover (263). 15. Tap lightly the flange section of swash plate support (251) on the pump casing side to separate swash plate support from pump casing (271).



Figure 5 Removal, swash plate support 16. Remove shoe plate (211) and swash plate (212) from pump casing (271).



Figure 6 Removal, shoe plate and swash plate



17. Tap lightly the ends of drive shafts (111, 113) with a plastic hammer to remove them from the swash plate supports (251).



Figure 7 Removal, drive shaft 18. Remove valve plates (313, 314) from valve covet (311, 312).



Figure 8 Removal, valve plate NOTE! These parts may be removed during steps 10 and 12. 19. If necessary, remove stopper (534), stopper (535), servo piston (532) and tilting pin (531) from pump casing (271), and needle bearing (124) from valve block (311, 312). NOTE! When removing the tilting pin, use a jig to prevent the pin head from being damaged.



Since loctite is applied to fitting areas of tilting pin and servo piston, take care not to damage the servo piston.



Do not remove the needle bearing except when it is to be replaced.



Do not loosen nuts (808) and set screws (953, 954). If loosened, the flow setting will be changed.



Service Information Document Title: Pump, assembly



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Pump, assembly Op nbr 00000



Tightening torque Tightening torque, unit: kgf·m (lbf·ft) Item no.



Thread size



Tightening torque



401



M 20



44 (318)



406



M8



3 (22)



466



G 1/4



3.7 (27)



468



G 3/4



17 (123)



490



NPTF 1/16



1.12 (8.2)



492



Rc 1/8



1.0 (7)



531, 532



M 30



44 (318)



808



M 20



24 (173)



Preparation       



Clean all parts with cleaning solvent and dry with compressed air. Rework damaged parts before assembling, and prepare all replacement parts. Coat the sliding parts, bearing, etc. with clean hydraulic oil. Replace the o-ring and seals. Use a torque wrench to tighten the screws and plugs to the specified torque. Take care not to mix the parts of the front pump with the parts of the rear pump. Align the match marks of the pump casing parts and the regulators.



Assembly 1. Fit swash plate support (251) to pump casing (271), tapping it lightly with a hammer. NOTE! Fit servo piston, tilting pin, stopper (534) and stopper (535) to the pump casing in advance of assembling the swash plate support (251).



In tightening servo piston and tilting pin, use a jig to prevent the tilting pin head and feedback pin from being damaged.



In addition, apply loctite (medium strength) to their threaded sections.



Figure 1 Assembly, swash plate support 2. Place pump casing on its regulator fitting surface, fit tilting bushing of swash plate to tilting pin (531), and fit swash plate (212) to swash plate support (251). NOTE! Confirm with fingers of both hands that the swash plate can be moved smoothly. NOTE! Apply grease to the sliding plate and swash plate support, so the drive shaft can be fitted easily.



Figure 2 Assembly, swash plate 3. Fit drive shaft (111) with bearing (123), bearing spacer (127) and snap ring (824) to swash plate support (251). NOTE! Do not tap the drive shaft with a hammer. Assemble the parts into support (251) by tapping the outer bearing race lightly with a plastic hammer. Fit them fully using a brass drift.



Figure 3 Assembly, drive shaft 4. Assemble front seal cover (261) to pump casing (271) and install screws (406). NOTE! Apply grease lightly to the seal in seal lip cover (F). NOTE! Assemble seal, taking care not to damage it.



Figure 4 Assembly, seal cover 5. Assemble piston cylinder block [cylinder (141), piston subassembly (151, 152), set plate (153), spherical bushing (156), and cylinder spring (157)]. Then, insert the cylinder block assembly into the pump casing. NOTE! Match the splines of spherical bushing (156) and cylinder block (141). Then match to the splines of drive shaft (111). NOTE! Ensure that the pistons are installed in their original bores.



Figure 5 Assembly, piston cylinder block 6. Fit valve plates (313) to valve cover (311) and valve plate (314) to valve cover (312) by aligning the plates with the pins. NOTE! Take care not to mistake suction/delivery ports of the valve plate.



Suction port is the long crescent slot.



NOTE! Apply grease to the valve plate fitting face to hold it to the valve block.



Figure 6 Assembly, valve plate 7. Fit valve cover (312) to pump casing (271), and then assemble the spline coupling (114) and the booster (130) to the drive shaft (113). 8. Fit valve cover (311) and tighten the screws (402) and tighten set screws (956). 9. Fit pump casing (271) ) included with drive shaft (111) to the valve cover (311), and tighten screws (401) and tighten set screws (956).



Figure 7 Assembly, valve block NOTE! Assemble (312) to the rear pump first. NOTE! Take care not to mistake the direction of valve block (312). NOTE! 



Clockwise rotation (viewed from input shaft side) Fit block with regulator up and with delivery flange left, viewed from the front side.



10. Fit feedback pin of tilting pin (531) to feedback lever of regulator. Install regulator and tighten screws (412, 413). NOTE! Take care not to interchange the front and rear pump regulators. NOTE! Align the match marks made prior to disassembly.



Figure 8 Assembly, regulator 11. Fit drain port plug (468). This is the end of reassembling procedures. NOTE! After assembling, fill with hydraulic oil to prevent corrosion. When mounting to a machine, fill with hydraulic oil and bleed the air from the pump circuit.



Service Information Document Title: Pump, installation



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Pump, installation Precautions, start–up    



Fill the pump casing (P1, P2) with hydraulic oil. Vent the air from the pump circuit. Check that all hoses and pipes are properly connected. After starting the engine, operate at low idle for a while to completely vent the air from the circuit.



NOTE! If there is air in the hydraulic system, sliding parts may be damaged. Precautions, installation    



Keep the pump shaft horizontal during installation to the pump coupling. Ensure that there is neither a radial nor thrust load on the end of the pump shaft. When centering the pump shaft and the coupling, keep the alignment within ± 0.03 mm. Use a torque wrench to tighten all screws and fittings to the specified torque.



Figure 1 Installation, pump Precautions, tightening torque Tightening torque, unit : kgf·m (lbf·ft) Symbol



Description



Tightening orque



Remark



A



M20 (10.9 and more, JIS)



44 ± 6.6 (377 ± 36)



Apply Loctite #243



B



M10 × 2.0 × 25L



6.5 ± 0.7 (47 ± 5)



C



M10 × 60L



4 ~ 4.5 (28.9 ~ 32.5)



Service Information Document Title: Regulator, maintenance



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Regulator, maintenance Fault and remedies In case a functional fault probably resulting from the regulator occurs, disassemble and inspect it, referring to the section of disassembly and assembly. Engine is overloaded Determine which is faulty, front pump or rear pump, by loading each pump independently. When both pumps are found faulty, investigate the following (1) and (2). Begin investigation with (3), when only one pump is found faulty. 1. 2.



Check the power shift signal current. Power shift pressure is low.  



3.



The compensating piston and rod are stuck. 



4.



Check the amplifier dither. Replace the proportional solenoid valve.



Disassemble and clean.



Pin (898) is stuck. 



Disassemble and clean.



Maximum flow is not available 1. 2.



Check that the servo hydraulic pressure Pi is normal. Servo hydraulic piston (643) is stuck. 



3.



Spool (652) is stuck. 



4.



Disassemble and clean the regulator.



Disassemble and clean the regulator.



Piston (621) is stuck in piston case (622). 



Disassemble and clean the regulator.



  



Replace faulty parts that are deeply scored. (1) and (2) are only for cases of the servo hydraulic control. (4) is only for cases of the maximum flow control.



Regulator, inspection and adjustment Maximum/minimum flow, horsepower control characteristics and flow control characteristics of this regulator can be adjusted by the adjusting screw. (See the specified value for the regulator adjustment) The values will be halved when only one pump is loaded. Adjustment of input horsepower Since the regulator is the total cumulative horsepower type, adjust the adjusting screws of both front and rear pumps, when



changing the horsepower set values. The pressure change values are based on two pumps pressurized at the same time. Adjustment of outer spring Adjust it by loosening hexagon nut (630) and by tightening (or loosening) adjusting screw C (628). Tightening the screw shifts the control chart to the right and increases the input horsepower as shown in the figure. Since turning adjusting screw C (628) by N turns changes the setting of inner spring, back-off adjusting screw C1 (925) by N × A turns.



Figure 1 Adjustment of input horsepower X



Delivery pressure, (P1 + P2)



Y



Delivery flow, Q



Adjustment of inner spring Adjust it by loosening hexagon nut (801) and by tightening (or loosening) adjusting screw C1 (925). Tightening the screw increases the flow and the input horsepower as shown in the figure.



Figure 2 Change of input horsepower X



Delivery pressure, (P1 + P2)



Y



Delivery flow, Q



Adjustment of flow control characteristic Loosen hexagon nut (801), and tighten (or loosen) adjusting screw (924). If the adjusting screw is tightened, the control curve will move to right as shown in the figure. Tightening the screw INCREASES the servo hydraulic flow control pressure and the pump delivery rate.



Figure 3 Change of control curve X



Servo hydraulic pressure Pi



Y



Delivery flow, Q



Change of value by adjusting regulator Specifications Item



Specifications



Hydraulic pump rotating speed



rpm



1800



Maximum flow



Turn of adjusting screw (954)



+1/4



Flow, lpm (U.S.gpm)



–7 (–1.85)



Turn of adjusting screw (953)



+1/4



Flow, lpm (U.S.gpm)



+7 (–1.85)



Minimum flow Input horsepower Adjusting spring



Adjusting spring



Flow control characteristic



Pump control curve



of



outer Turn of adjusting screw (628)



+1/4



Pressure at compensating control start, delta P kgf/ +25.6 (364.2) cm2 (psi)



of



Input torque, delta T kgf·m (lbf·ft)



+13.3 (+96.1)



A



2.17



inner Turn of adjusting screw (QI, 628)



+1/4



Flow change (lpm)



+16.1



Input torque, delta T kgf·m (lbf·ft)



+10.56 (76.3)



Turn of adjusting screw (924)



+1/4



Pressure at flow control start, kgf/cm2 (psi)



+1.33 (18.9)



lpm (U.S.gpm)



+21 (+5.5)



Figure 4 Pump control curve



Q



Flow rate (liter / min)



Pd



Delivery pressure



Tin



Input torque Tin (kgf· m)



Pi



Servo hydraulic pressure



NOTE! Actual delivery flow = Engine rpm/1800 × Q (read at curves)



Simultaneous 2-pump loading (1800 rpm)



I : Power-shift valve input current (Dither : 80 Hz, 200 mA)



Pf : Power-shift pressure (Reference)



Pi : Negative control pressure (Pi1, Pi2)



Service Information Document Title: Regulator, disassembly



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Regulator, disassembly Op nbr 00000



Precautions      



Thoroughly clean the pump prior to removing the regulators. Match mark the regulators to the pump casing. Select a clean work area. Take care not to mix the parts of the front regulator with the parts of the rear regulator. It is not necessary to loosen or remove the adjusting screws for cleaning. Replacement of the regulator as an assembly is recommended, since it consists of small precision finished parts and overhaul is rather complicated.



Tools Tools Description



Size



Allen wrench



4, 5, 6, 8 mm (B)



Socket wrench, double-ended (single-ended)



Compact (max. 36 mm)



Adjustable wrench Screwdriver-blade type Plastic hammer Torque wrench Pliers snap ring



2 Sets



Pry bar



Less than φ 4, L = 100



Tweezers Screw



M 4, L = approximately 50 mm



Tightening torque Tightening torque Description



Size



Torque kgf·cm (lbf·in)



B (mm)



Tool



Screw (material: SCM 435)



M5



70 (60)



4



Allen wrench



M6



120 (105)



5



M8



300 (260)



6



M 10



580 (500)



8



M 12



1000 (870)



10



M 14



1600 (1390)



12



M 16



2400 (2080)



14



M 18



3400 (2945)



14



M 20



4400 (3810)



17



PT plug (material: S45C) Apply loctite # 577



PO plug (material: S35C)



PT 1/16



70 (60)



4



PT 1/8



105 (90)



5



PT 1/4



175 (150)



6



PT 3/8



350 (260)



8



PT 1/2



500 (430)



10



PF 1/4



300 (260)



6



PF 1/2



1000 (870)



10



PF 3/4



1500 (1300)



14



PF 1



1900 (1650)



17



PF 1 1/4



2700 (2340)



17



PF 1 1/2



2800 (2420)



17



Allen wrench



Allen wrench



1. Select a place suitable for disassembly. NOTE! Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged. 2. Remove dust, rust, etc. from regulator surfaces with cleaning solvent. 3. Remove screws (412, 413), and remove the regulator. NOTE! Take care not to lose the o-ring.



Figure 1 Removal, screws and regulator 4. Remove screws (438), and remove cover (C) (629). NOTE! Cover (C) is fitted with adjusting screws (C), (C1) (628, 925), adjusting ring (C) (627), lock nut (630), nut (801) and adjusting screw (924). NOTE! Do not loosen these screws and nuts. If they are loosened, adjusted pressure-flow setting will be changed. NOTE! To adjust the pressure and flow, inspection and adjustment on a test bench will be necessary.



Figure 2 Removal, screws and cover 5. After removing cover (C) (629) subassembly, take out outer spring (625), inner spring (626) and spring seat (C) (624) from compensating section. Then draw out adjusting ring (Q) (645), servo hydraulic spring (646) and spring seat (644) from servo hydraulic section. NOTE! Adjusting ring (Q) (645) can be easily drawn out with a M 4 screw.



Figure 3 Removal, adjusting ring 6. Remove screws (436, 438), and remove servo hydraulic cover (641). After removing servo hydraulic cover, take out set spring (655) from the servo hydraulic section.



Figure 4



Removal, servo hydraulic cover 7. Remove snap ring (814), and take out spring seat (653), return spring (654) and sleeve (651). NOTE! Sleeve (651) is fitted with snap ring (836). When removing snap ring (814), return spring (654) may pop out. Take care not to lose it.



Figure 5 Removal, snap ring, spring seat and spring 8. Remove snap ring (858), and take out fulcrum plug (614) and adjusting plug (615). NOTE! Fulcrum plug (614) and adjusting plug (615) can be easily taken out with a M 6 screw.



Figure 6 Removal, snap ring and adjusting plug 9. Remove lever (2) (613). NOTE! Do not draw out pin (875). NOTE! Work will be promoted by using long needle nose pliers.



Figure 7 Removal, lever 10. Draw out pin (874), and remove feedback lever (611). NOTE! Push out pin (874) (4 mm in diameter) with a slender steel bar so that it does not interfere with lever (1) (612). NOTE! Note the direction of the feedback lever.



Figure 8 Removal, feedback lever 11. Remove lever (1) (612). NOTE! Do not draw out pin (875). 12. Draw out servo hydraulic piston (643) and spool (652). 13. Draw out piston case (622), compensating piston (621) and compensating rod (623). This completes the operation. NOTE! Piston case (622) can be taken out by pushing compensating rod (623) on opposite side of piston case. NOTE! Since component parts are small, take care not to lose them.



Service Information Document Title: Regulator, assembly



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Regulator, assembly Op nbr 00000



Preparation 



Clean all parts with cleaning solvent and dry with compressed air. NOTE! The parts are small and light weight. Take care not to lose them.



    



Rework scored parts before assembling, and prepare all replacement parts. Coat the sliding parts with clean hydraulic oil. Replace the o-rings and seals. Use a torque wrench to tighten the screws and plugs to the specified torque. Align the match marks of the regulator to the pump casing. 1. Put compensating rod (623) into compensating hole of casing (601). 2. Put lever (1) (612) force-fitted pin into the compensating rod groove, then fit lever (1) to the pin in the casing. 3. Fit spool (652) and sleeve (651) into the casing spool hole. NOTE! Confirm that spool and sleeve slide smoothly in casing without binding. NOTE! Pay attention to orientation of the spool.



1. 2.



Spool Feedback lever



4. Fit feedback lever (611), matching its pin hole with the hole in the spool. Then insert pin (874). NOTE! Insert pin into feedback lever a little to ease operation. NOTE! Take care not to mistake direction of feedback lever.



1. 2.



Lever (1) side Lever (2) side (Fulcrum plug of adjusting plug side)



5. Put servo hydraulic piston (643) into negative control hole of casing. NOTE! Confirm that servo hydraulic piston slides smoothly without binding. 6. Put the pin force-fitted in lever (2) (613) into the groove of the servo hydraulic piston. Then fix lever (2).



Figure 1 Assembly, lever 7. Fit fulcrum plug (614) so that the pin force-fitted in fulcrum plug (614) can be put into the pin hole of lever (2). Then fix locking ring (858).



Figure 2 Assembly, locking ring 8. Insert adjusting plug (615) and fit locking ring. NOTE! Take care not to mistake inserting holes for fulcrum plug and adjusting plug. At this point move feedback lever to confirm that it has no excess play and is free from binding. 9. Fit return spring (654) and spring seat (653) into the spool hole and attach snap ring (814). NOTE! Pay attention to the orientation of the spring seat.



Figure 3 Assembly, snap ring 10. Fit set spring (655) to spool hole and put compensating piston (621) and piston case (622) into compensating bore.



Figure 4 Assembly, spring 11. Fit servo hydraulic cover (641) and tighten it with screws (436, 438). 12. Put spring seat (644), servo hydraulic spring (646) and adjusting ring (Q) (645) into the servo hydraulic hole. Then fix spring seat (624), inner spring (626) and outer spring (625) into the compensating hole. NOTE! Pay attention to the orientation of the spring seat.



Figure 5 Assembly, spring seat and spring 13. Install cover (C) (629) fitted with adjusting screws (628) (925), adjusting ring (C) (627), lock nut (630), nut (801) and adjusting screw (924). Then install screws (438).



Figure 6 Assembly, cover



Service Information Document Title: Current/pressure, specifications



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Current/pressure, specifications See 270 Engine - Pump control, specification Pump flow control, specifications Specifications Flow control switch



Setting pump flow rate, Flow control current, Valve secondary pressure No-load, kgf/cm2 (psi) lpm (gpm) mA



9



340 (90)



300



9.2 (131)



8



310 (82)



355



11.7 (166)



7



280 (74)



380



14.0 (199)



6



240 (64)



420



17.3 (246)



5



200 (53)



455



20.3 (289)



4



160 (42)



495



23.4 (333)



3



120 (32)



535



27.0 (384)



2



80 (21)



575



30.0 (427)



1



40 (11)



630



33.2 (472)



NOTE! Valve secondary pressure at various current may differ from the specifications according to the external condition.



Service Information Document Title: Function Group: Proportional solenoid 913 valve, measuring and adjustment



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Proportional solenoid valve, measuring and adjustment Measuring condition   



Engine speed: Corresponds to working mode Working mode: Select "P" (power maximum), “H”, “G”, “F”, “I” mode in sequence. Oil temperature when measuring: 50 ~ 60 °C (122 ~ 140 °F)



Measurement 



Connect an oil pressure gauge (60 kgf/cm2, 850 psi) to the pressure checking port to measure servo hydraulic secondary pressure.



Adjustment Loosen lock nut (2) and turn screw (1) to adjust by using a blade screwdriver.  



To increase pressure, turn clockwise. To decrease pressure, turn counterclockwise.



Figure 1 Pressure checking 1. 2. 3.



Adjusting screw (1) Lock nut (2) Pressure checking port (a)



Current/pressure specifications See 270 Engine - Pump control, specification NOTE! Valve secondary pressure at various current may differ from the specifications according to the external condition.



Service Information Document Title: Function Group: Hydraulic pump (removed), 913 changing shaft seal



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic pump (removed), changing shaft seal Op nbr 913-007 1. Remove screws (1) and front seal cover (3). NOTE! Install screws (1) into tapped pull out holes (3) of front seal cover (2), so it can be removed easily.



Figure 1



2. Remove seal (1) and O-ring (3) from seal cover (2).



Figure 2



3. Install seal (1) and O-ring (3) in seal cover (2). 4. Assemble front seal cover to pump casing and install screws. NOTE! Apply grease lightly to the seal lip.



Install seal, taking care not to damage it.



Service Information Document Title: Hydraulic pump, replacing



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic pump, replacing Op nbr 913-010



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. NOTE! Oil that drains from hoses and connections must be collected in a barrel. Disconnected hoses and connections must be plugged. NOTE! Container capacity : 400 litres Drain hose : The hose for engine oil draining can be used.



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Place the machine in the service position B. See : 091 Service positions 2. Connect drain hose (3) supplied with the machine to the drain valve and drain the hydraulic oil into an oil barrel Disconnect drain hose (3), after draining hydraulic oil and fit cover (1).



NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.



WARNING When the last bolt has been removed, the cover plate falls down. 3. Remove screws (1) and cover (4). Remove screws (2) and cover (5). Remove screws (3) and cover (6).



Figure 1



4. Connect hose (2) to drain valve (1) and drain the hydraulic oil into an oil container. Disconnect hose (2) and cap the drain valve cap, after draining hydraulic oil.



Figure 2



5. Drain the hydraulic oil from the tube line at the hydraulic oil pump suction tube plug. Fit drain plug (3), after draining hydraulic oil.



Figure 3



6. Remove screws (1) and cover (3). Remove screws (2) and bracket (4).



Figure 4



7. Loosen hose clamp (2) and remove screws (1, 3).



Figure 5



8. Disconnect electric cable and fuel hose (2). Remove screws (3).



Figure 6



9. Remove wire harness and hose clamp screws (1) and disconnect wire harness connector (2).



Figure 7



10. Disconnect wire harness (6, 7), fuel hoses (1, 2) and air hose (4). Remove screw (3) and filter mounting bracket screws (5).



Figure 8



11. Remove screws (1) and rubber (2).



Figure 9



12. Remove screw (1) back side of ASU box (2).



Figure 10



13. Loosen coupling clamp screws (1).



Figure 11



14. Hold DPF (1) and mounting plate (2) with hoist (3) and remove. NOTE! Pay attention the gasket inside of the coupling.



Figure 12



15. Disconnect proportional valve wire harness (1). Remove hoses (2).



Figure 13



16. Disconnect servo hydraulic hose (1). Remove screws (2) discharge port block mounting screws (2).



Figure 14



17. Remove screws (1) and disconnect hose (2).



Figure 15



18. Install the slings, hold with hoist (1) and remove mounting screws (2).



Figure 16



19. Remove the hydraulic pump. 20. Transfer the connectors, eye bolts and elbows to the new hydraulic pump. NOTE! O-rings disassembled should be replaced with new ones. 21. Install the hydraulic pump (1) and tighten mounting screws (2). NOTE! Tightening torque: 431.5 ±43.1 N m (317.7 ±31.8 lbf ft) (44 ±4.4kgf m)



Figure 17



22. Install suction pipe and tighten screws (1). Connect hose (2). NOTE! Tightening torque: 261.8 ±26.5 N m (192.8 ±19.5 lbf ft) (26.7 ±2.7kgf m)



Figure 18



23. Install discharge port block (2) with hoses and tighten mounting screws (3). Connect hose (1). NOTE! Tightening torque: 175.5 ±17.6 N m (129.2 ±13 lbf ft) (17.9 ±1.8kgf m)



Figure 19



24. Connect hoses (2). Connect proportional valve wire harness (1).



Figure 20



25. Hold DPF (1) and mounting plate (2) with hoist (3) and install.



Figure 21



26. Install hose (4) and tighten clamp (2) and screws (1, 3). NOTE! Tightening torque (clamp) : 4.9~5.8 N m (3.6 ±4.3 lbf ft) (0.5~0.6 kgf m)



Figure 22



27. Connect electric cable and fuel hose (2). Tighten screws (3).



Figure 23



28. Install coupling with gasket and tighten clamp screws (1). NOTE! Tightening torque: 11.7 ±1 N m (8.6 ±0.7 lbf ft) (1.2 ±0.1kgf m)



Figure 24



29. Install rubber (2) and tighten screws (1) . NOTE! Tightening torque: 48 ±4.9 N m (35.4 ±3.6 lbf ft) (4.9 ±0.5kgf m)



Figure 25



30. Tighten screw (1) back side of ASU box (2).



Figure 26



31. Tighten wire harness and hose clamp screws (1) and connect wire harness connector (2). NOTE! Tightening torque: 14.7 ±1.5 N m (10.8 ±1 lbf ft) (1.5 ±0.15kgf m)



Figure 27



32. Install filter mounting bracket with filter and tighten screws (5) and screws (3). Connect fuel hoses (1, 2), air hose (4) and wire harness (3, 6). NOTE! Tightening torque: N m (lbf ft) (kgf m) 1. 2.



11.7 ±1.2 (8.6 ±0.8) (1.2 ±0.12) 44.1 ±4.9 (32.5 ±3.6) (4.5 ±0.5)



Figure 28



33. Install bracket (4) and tighten screws (2). Install cover (3) and Tighten screws (1). NOTE! Tightening torque: 110.8 ±10.8 N m (81.6 ±7.9 lbf ft) (11.3 ±1.1kgf m)



Figure 29



34. Install cover (6) and tighten screws (3). Install cover (5) and tighten screws (2). Install cover (4) and tighten screws (1). NOTE! Tightening torque: 110.8 ±10.8 N m (81.6 ±7.9 lbf ft) (11.3 ±1.1kgf m)



Figure 30



35. Remove plug (1). Fill the oil tank with hydraulic oil through the return filter. Tighten plug (1). NOTE! Tightening torque: 245.1 ±24.5 N m (180.5 ±18 lbf ft) (25 ±2.5kgf m)



Figure 31



36. Start the engine and test the machine.



Service Information Document Title: Pump regulator, replacing



Function Group: 913



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Pump regulator, replacing Op nbr 913-029



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container. 1. Disconnect hose (3) and wire harness (4).



Figure 1



2. Remove regulator mounting screws (2). See 913 Pump, disassembly 3. Remove regulator (1). 4. Transfer fitting to the new regulator. 5. Install regulator (1) with new O-rings. See 913 Pump, assembly 6. Tighten regulator mounting screws (2). 7. Connect hose (3).



Service Information Document Title: Function Group: Proportional solenoid valve 913 (power shift), replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Proportional solenoid valve (power shift), replacing Op nbr 914-041 NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container. 1. Park the machine on a level surface, lower the bucket to the ground and stop the engine. Operate each control lever (for attachment and travel) to its full stroke to release the residual pressure. 2. Press the air breather cap on the hydraulic tank to release the residual pressure. 3. Disconnect connector (1) of the solenoid valve from the wire harness.



Figure 1 Disconnection, wire harness connector 4. Disconnect proportional solenoid valve hose (3). 5. Remove screws (2). NOTE! Prepare a small container for some oil leakage from the pump body. 6. Transfer fitting (1) to the new proportional solenoid valve.



Figure 2 Transfer, fitting 7. Install the new proportional solenoid valve. NOTE! Replace O-ring and pay attention not to pull out seat of check valve, ball , and stopper from pump body. Also take care to assemble properly. 8. Connect the proportional solenoid valve hose (3). 9. Connect wire harness connector (1) to the solenoid valve. 10. Start the engine. Check for leaks and repair if needed.



Service Information Document Title: Servo pump, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Servo pump, description Model code Model code : G200 15.2 + 15.2R (fan + servo pump), G200 20.3 +15.2 +15.2R (X3 + fan + servo pump), G200 27.9 + 15.2 +15.2R (X3 + fan + servo pump) Code



Description



G200



Pump model



20.3



P1 pump displacement : cm3/rev (40 lpm)



X3 option



27.9



P1 pump displacement : cm3/rev (60 lpm)



X3 option (tropical)



15.2



P2 pump displacement : cm3/rev



Cooling system



15.2



P3 pump displacement : cm3/rev



Servo hydraulic system



Structure



Figure 1 Structure, servo pump A



Standard pump (P2 + P3)



Remark



B



Option pump (P1 + P2 + P3)



S1



Suction port (option)



S2



Suction port (standard)



P1



Discharge port (rotator pump - option)



P2



Discharge port (fan motor pump - standard)



P3



Discharge port (servo hydraulic pump - standard)



Sectional view



Figure 2 Structure, servo pump 1 Cover



6 Gear-shaft



11 Channel seal



16



Stud screw



2 Housing



7 Driven gear



12 Back-up seal



17



Washer



3 Housing



8 Driven gear



13 Square seal



18



Nut



4 Carrier



9 Gear connecting



14 Dowel pin



19



Name plate



15 Oil seal



20



Screw



5 Cover



10 Thrust plate



Tightening torque Tightening torque No.



Size



N m (kgf m) (lbf ft)



Remark



18



1/2 - 13UNF



147.1(15) (108.3)



Exploded view



Figure 3 Structure, servo pump 1 Cover



6 Gear-shaft



11 Channel seal



16



Stud screw



2 Housing



7 Driven gear



12 Back-up seal



17



Washer



3 Housing



8 Driven gear



13 Square seal



18



Nut



4 Carrier



9 Gear connecting



14 Dowel pin



19



Name plate



15 Oil seal



20



Screw



5 Cover



10 Thrust plate



Gear pump, principle of operation 



The fan pump is a gear pump attached to the PTO (Power Take Off) of the main pump. The fan pump consists of gear housing (E), drive gear (A), and driven gear (B).



Figure 4 Fan pump, operation A. B. C. D. E. 



Drive gear Driven gear Suction side (low pressure) Discharge side (high pressure) Gear housing



This pump has two mating gears that are turned in a closely fitted gear housing. Rotation of the drive gear causes the other gear to turn. External gear pumps are positive fixed displacement rotary pumps. When the pump is turned, the oil is trapped between the teeth of the gears and gear housing. Continued rotation of the gears forces the constant amount of oil out of the pump. On the suction side, the teeth confine and carry the oil and a vacuum is formed in the cavity between the teeth as they unmesh, causing oil to be drawn into the pump. Pressure rise in a gear pump is produced by squeezing action on the oil as it is expelled from between the meshing gear teeth and the gear housing.



Service Information Document Title: Gear pump, inspection



Function Group: parts



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Gear pump, parts inspection Inspection item Part name



Inspection item



Remedy



Gear housing 



Existence of cut out







Replacement when the cut out of the gear housing is more than 0.18 mm (0.0071 in) deep.







Existence of scoring, grooving, nicking and fretting etc on gear Existence of wear of seal contact area



 



Replacement when damaged. Replacement when the seal contact area is worn more than 0.05 mm (0.002 in).



Existence of wear of thrust plate Existence of scratch, erosion and pitting



 



Replacement when the thrust plate is worn more than 0.05 mm (0.002 in). Replacement when damaged.







Replacement when damaged.



Gear



 Thrust plate  



Seals



Service Information Document Title: Function Group: Servo hydraulic pressure, adjustment



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Servo hydraulic pressure, adjustment   



Engine speed : high idle Oil temperature when measuring: 50 ±5°C (122 ±41°F) Working mode : "P" mode



Measurement Install a pressure gauge 100 kgf/cm2 (1422 psi) to the accumulator block gauge port (6). NOTE! The material of the accumulator block is aluminium. If tightened excessively, the threads can be damaged. Adjustment  



Loosen nut (2) and turn screw (3) to adjust. Adjust the screw as follows.  



To increase pressure, turn clockwise. To decrease pressure, turn counterclockwise.



Figure 1 Adjustment, servo pump pressure 1



Service pressure relief valve



4



Servo hydraulic pump



7



Accumulator block



2



lock nut



5



Pressure gauge



8



Servo hydraulic filter



3



Adjusting screw



6



Gauge connecting port



Service Information Document Title: Function Group: Servo hydraulic pressure, adjustment



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Servo hydraulic pressure, adjustment   



Engine speed : high idle Oil temperature when measuring: 50 ±5°C (122 ±41°F) Working mode : "P" mode



Measurement Install a pressure gauge 100 kgf/cm2 (1422 psi) to the accumulator block gauge port (6). NOTE! The material of the accumulator block is aluminium. If tightened excessively, the threads can be damaged. Adjustment  



Loosen nut (2) and turn screw (3) to adjust. Adjust the screw as follows.  



To increase pressure, turn clockwise. To decrease pressure, turn counterclockwise.



Figure 1 Adjustment, servo pump pressure 1



Service pressure relief valve



4



Servo hydraulic pump



7



Accumulator block



2



lock nut



5



Pressure gauge



8



Servo hydraulic filter



3



Adjusting screw



6



Gauge connecting port



Service Information Document Title: Servo pump, disassembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Servo pump, disassembly Op nbr 00000



Precautions     



Thoroughly clean the pump assembly prior to disassembly. Select a clean area. Thoroughly clean all parts. Use a torque wrench to tighten the screws, fittings and plugs to the specified torque. If the pump was dismantled coat the gears, shafts, and sealing surfaces with clean hydraulic oil prior to assembling.



Disassembly 1. Place the pump on the work bench with the input shaft side downward. NOTE! Mark the pump housing and covers to indicate proper positioning during reassembly.



Figure 1 Disassembly, gear pump A



Position mark



4



Bearing carrier



B



Maounting screw



5



Rear cover



C



Work bench



16



Screw



1



Front cover



17



Washer



2



Housing



18



Nut



3



Housing



2. Remove nut (18), washer (17), screws (16). 



Tools: Socket wrench 19 mm



3. Remove rear cover assembly (5). NOTE! Do not draw out dowel pins (14) from housing (3) and rear cover assembly (5). 4. Remove thrust plate (10). 5. Pull out drive gear kit (8) from gear housing (3). NOTE! Take care not to damage the inside surfaces of gear housing (3). 6. Remove bearing carrier (4) and connecting shaft (9). NOTE! Do not draw out dowel pins (14) from housing (3) and bearing carrier (4). 7. Remove thrust plate (10). 8. Pull out drive gear kit (7) from gear housing (3). NOTE! Take not to damage the inside surfaces of gear housing (3). 9. Remove bearing carrier (4) and connecting shaft (9). NOTE! Do not draw out dowel pins (14) from housing (3) and bearing carrier (4). 10. Remove thrust plate (10). 11. Remove gear housing (2) and thrust plate (10). NOTE! Do not draw out dowel pins (14) from front cover assembly (1). 12. Pull out shaft gear kit (6) from gear housing (2). NOTE! Take not to damage the inside surfaces of gear housing (2). 13. Turn front cover assembly (1) and remove oil seal (15). NOTE! Be careful not to damage the inside surfaces of front cover assembly (1).



Service Information Document Title: Servo pump, disassembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Servo pump, disassembly Op nbr 00000



Precautions     



Thoroughly clean the pump assembly prior to disassembly. Select a clean area. Thoroughly clean all parts. Use a torque wrench to tighten the screws, fittings and plugs to the specified torque. If the pump was dismantled coat the gears, shafts, and sealing surfaces with clean hydraulic oil prior to assembling.



Disassembly 1. Place the pump on the work bench with the input shaft side downward. NOTE! Mark the pump housing and covers to indicate proper positioning during reassembly.



Figure 1 Disassembly, servo pump A



Position mark



B



Mounting screw



C



Work bench



1



Front cover



16



Stud screw



2



Housing



17



Washer



3



Bearing carrier



18



Nut



4



Rear cover



2. Remove nut (18), washer (17), screws (16). 



Tools: Socket wrench 19 mm



3. Remove rear cover assembly (4). NOTE! Do not draw out dowel pins (12) from housing (2) and rear cover assembly (4). 4. Remove thrust plate (8). 5. Pull out drive gear kit (6) from gear housing (2). NOTE! Take care not to damage the inside surfaces of gear housing (2). 6. Remove bearing carrier (3) and connecting shaft (7). NOTE! Do not draw out dowel pins (12) from housing (2) and bearing carrier (3). 7. Remove thrust plate (8). 8. Remove gear housing (2) and thrust plate (8). NOTE! Do not draw out dowel pins (12) from front cover assembly (1). 9. Pull out shaft gear kit (5) from gear housing (2). NOTE! Take not to damage the inside surfaces of gear housing (2). 10. Turn front cover assembly (1) and remove oil seal (13). NOTE! Be careful not to damage the inside surfaces of front cover assembly (1).



Service Information Document Title: Servo pump, assembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Servo pump, assembly Op nbr 00000



1. Install new oil seal (15) to front cover assembly (1). NOTE! Coat the lip of the oil seal with grease. Be careful not to damage the lip of the oil seal. 2. Place the cover on the work bench with the input shaft side of front cover assembly (1) downward. Assembly, P1 pump 3. Install square seals (13) in the both side of gear housing (2) and assemble gear housing (2) to front cover assembly (1) by tapping the gear housing with a plastic hammer. NOTE! Coat the square seal with grease. NOTE! Pay attention to the mounting direction of gear housing (2). Align matching mark on front cover assembly (1) and gear housing (2) made before disassembling. NOTE! Check off the dowel pins. 4. Install channel seals (11) and back-up seals (12) in thrust plate (10). NOTE! Pay attention to the mounting direction of the seals.



Figure 1 Installation, channel seals and back-up seals A.



Gear side (coated side)



5. Assemble thrust plate (10) to gear housing (2). NOTE! Pay attention to the direction of thrust plate (10). The U-shape of the thrust plate must face toward discharge side (B).



Figure 2 Installation, thrust plate A. B.



Suction side Discharge side



6. Assemble shaft gear kit (6). NOTE! Be careful not to damage the lip of oil seal (15) by the shaft splines. 7. Apply hydraulic oil to the gear, and assemble thrust plate (10) to gear housing (2). 8. Assemble bearing carrier (4) and connecting shaft (9). Assembly, P2 pump 9. Install square seals (13) in the both side of gear housing (3) and assemble gear housing (3) to front cover assembly (1) by tapping the gear housing with a plastic hammer. NOTE! Coat the square seal with grease. NOTE! Pay attention to the mounting direction of gear housing (3). Align matching mark on gear housing (2) and bearing carrier (4) and gear housing (3) made before disassembling. NOTE! Check off the dowel pins. 10. Install channel seals (11) and back-up seals (12) in thrust plate (10). NOTE! Pay attention to the mounting direction of the seals.



Figure 3 Installation, channel seals and back-up seals A.



Gear side (coated side)



11. Assemble thrust plate (10) to gear housing (3). NOTE! Pay attention to the direction of thrust plate (10). The U-shape of the thrust plate must face toward discharge side (B).



Figure 4 Installation, thrust plate A. B.



Suction side Discharge side



12. Assemble drive gear kit (7). 13. Apply hydraulic oil to the gear, and assemble thrust plate (10) to gear housing (3). 14. Assemble bearing carrier (4) and connecting shaft (9). Assembly, P3 pump 15. Install channel seals (11) and back-up seals (12) in thrust plate (10). NOTE! Pay attention to the mounting direction of the seals.



Figure 5 Installation, channel seals and back-up seals A.



Gear side (coated side)



16. Install square seals (13) in the both side of gear housing (2) and assemble gear housing (2) to front cover assembly (1) by tapping the gear housing with a plastic hammer. NOTE! Coat the square seal with grease. NOTE! Pay attention to the mounting direction of gear housing (2). Align matching mark on bearing carrier (4) and gear housing (3) and rear cover (5) made before disassembling. NOTE! Check off the dowel pins. 17. Assemble thrust plate (10) to gear housing (3). NOTE! Pay attention to the direction of thrust plate (10). The U-shape of the thrust plate must face toward discharge side (B).



Figure 6 Installation, thrust plate A. B.



Suction side Discharge side



18. Assemble drive gear kit (8). 19. Apply hydraulic oil to the gear, and assemble thrust plate (10) to gear housing (3). 20. Assemble rear cover assembly (5). 21. Tighten nuts (18) and washer (117) to the specified torque. 



Tightening torque: 147.1 N m (15 kgf m) (108.3 lbf ft)



22. Check if shaft will rotate smoothly by hand. If not accordingly, disassemble and check. Assembly is completed



Figure 7 Gear pump assembly



Service Information Document Title: Servo pump, assembly



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB] Go back to Index Page



Servo pump, assembly Op nbr 00000



1. Install new oil seal (13) to front cover assembly (1). NOTE! Coat the lip of the oil seal with grease. Be careful not to damage the lip of the oil seal. 2. Place the cover on the work bench with the input shaft side of front cover assembly (1) downward. Assembly, P1 pump 3. Install square seals (11) in the both side of gear housing (2) and assemble gear housing (2) to front cover assembly (1) by tapping the gear housing with a plastic hammer. NOTE! Coat the square seal with grease. NOTE! Pay attention to the mounting direction of gear housing (2). Align matching mark on front cover assembly (1) and gear housing (2) made before disassembling. NOTE! Check off the dowel pins. 4. Install channel seals (9) and back-up seals (10) in thrust plate (8). NOTE! Pay attention to the mounting direction of the seals.



Figure 1 Installation, channel seals and back-up seals A.



Gear side (coated side)



5. Assemble thrust plate (8) to gear housing (2). NOTE! Pay attention to the direction of thrust plate (8). The U-shape of the thrust plate must face toward discharge side (B).



Figure 2 Installation, thrust plate A. B.



Suction side Discharge side



6. Assemble shaft gear kit (5). NOTE! Be careful not to damage the lip of oil seal (13) by the shaft splines. 7. Apply hydraulic oil to the gear, and assemble thrust plate (8) to gear housing (2). 8. Assemble bearing carrier (3) and connecting shaft (7). Assembly, P2 pump 9. Install square seals (11) in the both side of gear housing (2) and assemble gear housing (2) to front cover assembly (1) by tapping the gear housing with a plastic hammer. NOTE! Coat the square seal with grease. NOTE! Pay attention to the mounting direction of gear housing (2). Align matching mark on gear housing (2), bearing carrier (3) and gear housing (2) made before disassembling. NOTE! Check off the dowel pins. 10. Install channel seals (9) and back-up seals (10) in thrust plate (8). NOTE! Pay attention to the mounting direction of the seals.



Figure 3 Installation, channel seals and back-up seals A.



Gear side (coated side)



11. Assemble thrust plate (8) to gear housing (2). NOTE! Pay attention to the direction of thrust plate (8). The U-shape of the thrust plate must face toward discharge side (B).



Figure 4 Installation, thrust plate A. B.



Suction side Discharge side



12. Assemble drive gear kit (6). 13. Apply hydraulic oil to the gear, and assemble thrust plate (8) to gear housing (2). 14. Assemble rear cover assembly (4). 15. Tighten screws (16), washer (17) and nut (18) to the specified torque. 



Tightening torque: 147.1 N m (15 kgf·m) (108.3 lbf·ft)



16. Check if shaft will rotate smoothly by hand. If not accordingly, disassemble and check. Assembly is completed



Figure 5 Servo pump assembly



Service Information Document Title: Servo pump, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Servo pump, replacing Op nbr 914-060



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container. 1. Place the machine in the service position B : .091 Service positions



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. 2. Press the air breather cap on the hydraulic tank to release the residual pressure. 3. Remove wire harness and hose clamp screws (1) and disconnect wire harness connect (2).



Figure 1



4. Remove screws and washers (2).



Figure 2



5. Disconnect hoses (1).



Figure 3



6. Remove screws (1) and disconnect hose and pipe from the pump (3).



Figure 4



7. Remove servo pump mounting screws (1) and pump (2).



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 5 General precautions 



Replace O-rings with new ones.



8. Transfer the fittings to the new servo pump.



9. Install servo pump (2) and tighten servo pump mounting screws (1). NOTE! Tightening torque: 110.8 ±108 Nm (81.6 ±7.9 lbf ft) (11.3 ±1.1 kgf m)



WARNING The parts are heavy. Take appropriate safety cautions when handling them.



Figure 6



10. Install hose and pipe (2) with O-ring and tighten screws (1). NOTE! Tightening torque: 63.7 ±6.9 Nm (46.9 ±5 lbf ft) (6.5 ±0.7 kgf m)



Figure 7



11. Connect hoses (1).



Figure 8



12. Tighten screws with washer (2). NOTE!



Tightening torque: 48 ±4.9 Nm (35.4 ±3.6 lbf ft) (4.9 ±0.5 kgf m)



Figure 9



13. Tighten wire harness and hose clamp mounting screws (1) and connect wire harness connect (2). NOTE! Tightening torque: 14.7 ±1.5 Nm (10.8 ±1.1 lbf ft) (1.5 ±0.15 kgf m)



Figure 10



14. Start the engine and check for leaks and repair if needed.



Service Information Document Title: Function Group: Pressure accumulator, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Pressure accumulator, description 



The accumulator is installed with a check valve between the gear pump and solenoid valve, to prevent the back flow of oil charged in the accumulator.



Figure 1 Structure, accumulator 1 Housing



2 Closure button



2 Diaphragm  



The nitrogen gas in the accumulator is compressed by the oil discharged from the gear pump. When the hydraulic pressure falls, the compressed gas volume will expand and displace the accumulated pressurized oil into the circuit. When the boom is left in the raised position, and the control lever is operated with the engine stopped, the pressure of the compressed nitrogen gas inside the accumulator sends servo hydraulic pressure to the control valve to actuate it and allow the digging unit to come down under its own weight. NOTE! The servo hydraulic pressure accumulated in the accumulator can be utilized only when start switch is ON and the safety locking lever is released on the left control console. NOTE! Removal of residual pressure from the circuit must be done prior to any maintenance.



Circuit



Figure 2 Circuit, accumulator 1



Servo hydraulic pump



3



Accumulator



5



Remote control valve



2



Check valve



4



Solenoid valve



6



Main control valve



Accumulator block Pressure accumulator block, specifications Pressure accumulator block Item Check valve



Relief valve



Port



Unit



Pressure



Tightening torque



Max operating pressure



MPa (kgf/cm2) (psi) (bar)



20.6 (214) (3045) (210)



-



Nominal flow



l/min (US gal/min)



60 (15.8)



-



Cracking pressure



MPa (kgf/cm2) (psi) (bar)



0.029 (0.3) (4.3) (0.3)



-



Installation torque



N m (kgf m) (lbf ft)



-



45 ~ 50 (4.5 ~ 5.0) (32.5 ~ 36.1)



Setting pressure



MPa (kgf/cm2) (psi) (bar)



3.9 (40) (569) (39.2)



-



Adjustment ranges



MPa (kgf/cm2) (psi) (bar)



1.5~5.9 (15~60) (213~853) (14.7~58.8)



Installation torque



N m (kgf m) (lbf ft)



-



S1, S2, S3, S4, S5



N m (kgf m) (lbf ft)



9/16-18UNF



AC, PS1



N m (kgf m) (lbf ft)



3/4-16UNF



T, PS



3/4-16UNF



45 ~ 50 (4.5 ~ 5.0) (32.5 ~ 36.1)



Figure 3 Accumulator block, sectional view 1



Accumulator block



3



Check valve



2



Relief valve



PS



Plug



Service Information Document Title: Accumulator, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Accumulator, replacing Op nbr 914-051 NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container. 1. Park the machine on a level surface, lower the bucket to the ground and stop the engine. Operate each control lever (for attachment and travel) to its full stroke to release the residual pressure. 2. Press the air breather cap on the hydraulic tank to release the residual pressure. 3. Remove accumulator assembly (1).



Figure 1 Removal, accumulator 4. Remove connector (1) from accumulator (2) using a vice.



Figure 2 Removal, connector 5. Transfer the connector to the new accumulator.



6. Install accumulator (1)



Figure 3 Installation, accumulator NOTE! Replace O-ring and copper gasket with a new one.



Service Information Document Title: Remote control (Lever), description



Function Group: valve



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (Lever), description The servo hydraulic valve PV48K is a control levers of the reducing valve type and has four reducing valves controlling the secondary pressure in one valve casing. Its secondary pressure is controlled by adjusting the tilting angle of the handle. The casing has vertical bores in which the reducing valves are assembled. The pressure reducing section is composed of spool (201), spring (241) for setting secondary pressure, return spring (221), washer 1 (215), spring seat (216) and washer 2 (217). The spring for setting the secondary pressure has been preset so that the secondary pressure is 5 ~ 10 kgf/cm2 (71 ~ 142 psi) (depending on the type). The spool is pushed against push rod (212) by return spring (241). Piping For good responsiveness, piping of about 8 mm (0.31 inch) in inner diameter and 3 m (9.84 ft) in length is used. To avoid a back pressure effect, the oil is returned directly to the tank. Fundamental functions The servo hydraulic valve controls the main control valve spool stroke and direction. This function is carried out by providing a spring at one end of the main control valve spool and applying the output pressure (secondary pressure) of the servo hydraulic valve to the other end. To accomplish this function, the servo hydraulic valve consists of the following:     



Inlet port (P), receives oil from the servo hydraulic system hydraulic pump. Output ports (1, 2, 3, 4) supply oil pressure to the inlet port of the control valve spool end. Tank port (T) controls the above output pressure. Spools to connect output port to main control valve inlet port, or tank port. Mechanism including springs applied to the above spools to control output pressure.



Functions of major sections Spool (201) connects the oil passages that route port (P) oil from the hydraulic pump to outlet ports 1, 2, 3, 4 or to tank port (T). Secondary pressure setting spring (241) works on this spool to determine the output pressure. To change the force of this spring, push rod (212) slides in plug (211) reacting on the spring. For the purpose of changing the displacement of the push rod, disc (302) and adjusting nut (312) are provided; the handle can be tilted in any direction around the fulcrum of universal joint (301). Spring (221) works on casing (101) and spring seat (216) and tries to return push rod (212) to the zero displacement position irrespective of the output pressure. This ensures its resetting to the center position. This also has the effect of a reaction spring to give an accurate sense of control to the operator. The output pressure in relation to the secondary pressure is directly proportional to the inclination of the control levers control handle. External view, control levers



Figure 1 Single switch, 4 switch and 3 switch + proportional 1



Proportional switch



11 Single switch



A



Neutral adjusting position mark of white paint on forwarding



2



Switch 1



12 Red color



B



Single operating angle (19°)



3



Switch 3



13 Yellow color



Bb Single operating angle (25°)



4



Switch 5



14 Black color



C



Tilting angle of handle (19°)



5



Switch 2



15 White color



Cc



Tilting angle of handle (23.3°)



6



Switch 6



16 Brown color



D



Double operating angle (19°)



7



1 push rod



17 Blue color



E



Tilted direction of handle (No. 3 push rod direction)



8



2 push rod



19 Cavity color



U



Tilted direction of handle (No. 1 push rod direction)



9



3 push rod



20 Gray color



F



1 0



4 push rod



21 Green color



6-9/16–18 UNF-2B (tightening torque: 29.4 ±2.0 Nm (22 ±2 lbf ft)



NOTE! Switch ON: When depressing, Switch OFF: When releasing



Figure 2 Control levers - sectional view 101 Casing



211 Plug



315 Lock nut



125 Screw M8: 20.6 ±1.5 Nm (152.4 ±1.1 lbf ft)



111 Plate



212 Push rod



323 Handle bar



301 Joint M14: 47.1 ±2.9 Nm (34.8 ±2.1 lbf ft)



121 Washer (seal)



213 Seal



402 Grip (handle)



302 Disc M14: 68.6 ±4.9 Nm (50.7 ±3.6 lbf ft)



122 O-ring



214 O-ring



403 Insert



126 Spring pin



216 Spring seat



404 Tube



312 Adjust nut M14: 68.6 ±4.9 Nm (36.2 ±4.9 lbf ft)



131 Bushing



217 Washer 2



454 Rubber tube



431 Screw: 0.39 ~ 0.49 Nm (0.28 ~ 0.36 lbf ft)



151 Plate



221 Spring



455 Switch



201 Spool



241 Spring



501 Bellows



432 Screw M5: 1.96 ±0.2 Nm (1.4 ±0.14 lbf ft)



When the push rod is pushed down by tilting the handle, the spring seat moves down simultaneously and changes the setting of the secondary pressure spring. The casing has the oil inlet (primary pressure), port (P), and the oil outlet (tank), port (T). In addition the secondary pressure is routed through ports 1, 2, 3 and 4 provided at the bottom face. An electric switch is fitted to each control valve and switch (455) is built into the top of the handle grip. When the center of handle grip (402) at the handle head is pushed, the switch will function. Wire lead connected to the switch, is led through the handle section and casing to the outside. Control lever patterns The patterns in the left and right columns are applied to the left and right control levers. Arm out (1) - move the lever here to move the arm out.



Slew right (2) - move the lever here to slew the superstructure to the right. Arm in (3) - move the lever here to move the arm in. Slew left (4) - move the lever here to slew the superstructure to the left. Boom lower (5) - move the lever here to lower the boom. Bucket dump (6) - move the lever here to dump the bucket. Boom raise (7) - move the lever here to raise the boom. Bucket curl (8) - move the lever here to curl the bucket.



Figure 3



Operation, control levers A SAE system (Volvo CE Korea system) B MHI system C KOB system D Standard backhoe loader system E SCM system Hold (9) - When the lever is released from any position, the lever will return to HOLD. Slew, arm, bucket or boom movement will stop. Two functions may be performed at the same time by moving the lever diagonally. (If equipped with a hydraulic hammer) Hammer Raise (6) - Move the lever here to raise the hammer. Hammer lower (8) - Move the lever here to lower the hammer. 



Servo hydraulic line ports of Volvo CE korea system (SAE system). – See the hydraulic circuit drawing.



WARNING The remote control valve lever pattern decal must conform with machine control pattern. Failure to comply could result in injury or death. NOTE! The control lever pattern can be changed at the connector block. Operation The operation of the servo hydraulic valve is described on the basis of the hydraulic circuit diagram and sectional view which is a typical application example of the servo hydraulic valve.



Figure 4 Diagram, control levers 1 Control levers



4 Main control valve



2 Servo hydraulic pump



5 Hydraulic motor



3 Main pump



6 Hydraulic cylinder



Handle is in neutral position The force of spring (241) determines that the output pressure of the servo hydraulic valve is not applied to spool (201). Therefore, the spool is pushed up by spring (221) to the position of port 3. Then since the output is connected to tank port (T) only, the output port pressure becomes equal to tank pressure.



Figure 5 Operation, handle is in neutral position Handle is in operating position When push rod (212) is stroked, spool (201) moves downward. Then port (P) is connected with port 1, and the oil supplied from the servo hydraulic pump flows through port 1 to generate the pressure. When the pressure at port 1 increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force. If the pressure at port 1 increases higher than the set pressure, port (P) is disconnected from port 1 and port (T) is connected with port 1. If it decreases lower than the set pressure, port (P) is connected with port 1 and port (T) is disconnected from port 1. In this manner the secondary pressure is kept at a constant value. In some valves, when the handle is tilted more than a certain angle, the upper end of the spool contacts the inside bottom of the push rod and the output pressure is connected with port (P).



Figure 6 Operation, handle is in operating position



Operating pressure chart (Single switch)



Figure 7



SP Secondary pressure



OA Operating angle



PD Push rod operating distance



OT Operating torque



Operating pressure chart (4 switch and 3 switch + proportional)



Figure 8



SP Secondary pressure



OA Operating angle



PD Push rod operating distance



OT Operating torque



Service Information Document Title: Remote control (lever), replacing



Function Group: valve



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (lever), replacing Op nbr 914-081 1. Park the machine in the service position A, see 091 Service positions. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to "ON" position, and move control lever to both direction slowly and smoothly 2~3 times. Turn ignition key to "OFF" position. NOTE! Plug all disconnect hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Press breather (1) on top of tank to release residual pressure from hydraulic tank. 3. Remove covers (2) from control panel, and remove mounting screws (4) of upper cover (3). Remove upper cover (3) from control panel.



Figure 1 Right control panel 4. Remove mounting screws (9) of control lever (7).



Figure 2



5. Disconnect and pull out connector (10). 6. Remove servo hoses (6) of control lever (7).



Figure 3 Control lever assembly 7. Transfer connector to new control lever. 8. Install servo hoses (6) to new control lever. 9. connect the wire harness (10). 10. Install mounting screws (9) of control lever (7). 11. Connect air conditioner and ignition switch wire harness before assembling the cover. 12. Assemble connector of control lever (7). 13. Install screws (4) and cover (2).



Figure 4 Right control panel



Service Information Document Title: Function Group: Remote control valve (Lever), troubleshooting



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (Lever), troubleshooting It isn’t always easy to trace a malfunction. Some general phenomenon to be considered are listed in following table. See cause and remedy. However, the trouble is not always caused by one faulty part only, but by its relation to other parts. So remedies other than listed in the table may be necessary. Troubleshooting Phenomenon



Cause



Secondary pressure will not rise.



Secondary unstable.



pressure



  



Remedy   







Primary pressure is low. Spring (241) breaks or yields. Clearance between spool and casing is excessive. There is play at handle section.



  



Sliding part is sticking. Tank line press fluctuates. Air in hydraulic circuit.



  



Repair/replace parts. Return oil directly to tank. Carry out operation several times to bleed air from the system.



 



Tank line pressure is too high. Sliding part is stuck.



 



Return oil directly to tank. Repair/replace defective parts.







Adjust primary pressure. Replace it with new one. Replace spool subassembly and casing. Disassemble and repair handle section or replace it.



is



Secondary pressure is too high.



Service Information Document Title: Remote control (pedal), description



Function Group: valve



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (pedal), description Remote control valve PVD8P is a reducing valve type remote control valve. The inclination of the controller is adjusted by pedal or lever, and in relation to secondary pressure, output pressure proportional to inclination will be generated. The servo hydraulic valve controls the main control valve spool stroke and direction. This function is carried out by providing a spring at one end of the main control valve spool and applying the output pressure (secondary pressure) of the servo hydraulic valve to the other end. To accomplish this function, the servo hydraulic valve consists of the following:     



Inlet Port (P), receives oil from the servo hydraulic system hydraulic pump. Outlet ports (1, 2), supply oil pressure to the inlet port, of the control valve spool end. Tank port (T), controls the above output pressure. Spools to connect the outlet port to main control valve inlet ports, or tank port. Mechanism including springs applied to the above spools to control the output pressure.



Principal function Spool (301) connects the oil passages that route (P) port oil from the hydraulic pump to outlet port (1, 2) or to tank port (T). The secondary pressure setting spring (324) works on this spool to determine the output pressure. To change the spring force, push rod (214) slides into plug (202), reacting on the spring. The displacement of the push rod is changed by the use of cam (420): a pedal or lever is attached and the cam can be rotated ±12.4° over center of camshaft (413). Return spring (335) acts on casing (101) and spring seat (311), it sets the displacement of push rod (214) to “0” regardless of output pressure, and returns the spool to neutral. Also, it acts as a reaction spring to give an accurate sense of control to the operator. The damping valve installed in the servo hydraulic valve prevents hunting symptoms that may occur due to abrupt pedal (lever) operation.



Figure 1 Structure, remote control valve (pedal) 101 Casing



217 Washer 2



337 Spring



102 Casing



218 Spring seat



412 Bushing



171 Screw



220 Screw



413 Camshaft



201 Cover



224 Piston



420 Cam



202 Plug



225 Ball



423 Set screw



203 Grease cap



271 Screw



471 Set screw



204 Cover 2



301 Spool



472 Lock nut



210 NHU packing



311 Spring seat



501 Bellows



211 O-ring



313 Washer 3



520 Pedal



212 O-ring



324 Spring



522 Cover



213 O-ring



335 Spring



214 Push rod



336 Spring



524 Screw



Tightening torque, unit: kgf·cm (lbf·in) No.



Size



Tightening torque



171



M8



300 ± 30 (260 ± 26)



220



M6



90 ± 10 (78 ± 9)



271



M 12



560 ± 100 (486 ± 86)



423



M6



70 ± 10 (61 ± 9) NOTE! Apply loctite No. 241



472



M 10



340 ± 35 (295 ± 30)



Operation The operation of the remote control valve (pedal) is explained in accordance with the hydraulic circuit diagram and sectional view which is a typical application example of the remote control valve.



Figure 2 Diagram, remote control valve (pedal) 1 Remote control



4 Control valve



2 Servo hydraulic pump



5 Hydraulic motor



3 Main pump



6 Hydraulic cylinder



Neutral position Spool (301), spring seat (311) and washer (215) are pushed upward, by return spring (335), and set at the position as shown in the sectional view. Therefore, pressure at outlet port 1, 2, will be the same as tank pressure because the outlet port is connected to tank port (T) due to the spool conversion function. Operating position According to the sectional view, pedal cam (420) rotates counterclockwise and push rod (214) at port 1 side pushes spool (301) downward through washer 1, spring nozzle and secondary pressure setting spring (314). Then port (P) and port 1 are connected, and oil supplied from (P) port flows into port 1 and pressure is generated. When the pressure of port (P) rises to equal the force of the secondary pressure setting spring, created by depressing the controller, the oil pressure and spring pressure will be balanced so the output pressure can be maintained to a constant value. Port 2 side maintains a neutral condition and the oil returned from the control valve will be drained through port (T).



Damping valve Neutral position The push rod is pushed upward through piston (224) by return spring (336, 337), and set at the position as shown in the sectional view. Operating position According to the sectional view below, the pedal cam rotates clockwise and the push rod at port 1 side is pushed downward. Oil in the damping piston is drained through the piston orifice and dampened by the pressure generated at that time. In normal operating, the push rod at port 2 moves upward through the piston by return spring. Thereby, it draws in oil from the tank through the check ports (3 places) produced by bushing (223) and check ball (225) in the damping piston. The oil outside the piston chamber flows through the passage connected to port (T) in the upper casing.



Figure 3 Damping valve 1 Push rod 2 Orifice



5 In neutral position, the oil in the right (left) side piston chamber is drained through the orifice, and damped by the pressure generated.



3 Piston 4 Piston seal Operating opposite position According to the sectional view below, when operating the pedal to the opposite direction completely the pedal cam rotates fully clockwise, and then rotates counterclockwise again, and push rod at port 2 side is pushed downward and the piston moved upward. At this point of time, as explained before, oil in the damping piston is drained through the piston orifice and damped by the



pressure generated at that time. In normal operating, the push rod at port 1 moves upward through the piston by return spring (335) and damping spring. Thereby, it draws in oil from the tank through the check ports (3 places) in the damping piston. The oil outside the piston chamber flows through the passage connected to the tank port in the upper casing. Therefore, the operation is dampened from the neutral position to the complete operating position or from the operating position to the neutral position.



Figure 4 When operating the pedal to the opposite direction When handing the lever reversely from ⇒ to ··· >, the left piston is immediately activated. Always damping happens to both directions. 1. 2. 3. 4. 5. 6.



When converting to the opposite direction from neutral, the push rod is pushed upward by the damping spring. (During operating). Neutral position Operating angle The oil outside the piston is drained through the passage connected to T port in the upper part of casing (During operating). Oil The oil in piston chamber is damped by the pressure produced when it is drained through the hole (During operating).



7.



The oil of T line flows through the ball checks (3 places) and enters the damper chamber (During operating).



Secondary pressure and operating force



Figure 5 Secondary pressure and operating force SP Secondary pressure



OA Operating angle



PD Push rod operating distance



OT Operating torque



Service Information Document Title: Remote control (pedal), replacing



Function Group: valve



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (pedal), replacing Op nbr 914-084 1. Park the machine in the service position A, see 091 Service positions. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to "ON" position, and move control lever to both direction slowly and smoothly 2~3 times. Turn ignition key to "OFF" position. NOTE! Plug all disconnect hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Press breather on top of tank to release residual pressure from hydraulic tank. 3. Remove under cover (2). 4. Remove servo hoses (4EA) (3) and connectors (4EA) (4) of travel pedal bottom. Mark on the each connectors (4) and hoses (3) for identification before disassembly. 5. Remove hoses (2EA) (5) and connectors (2EA) (6).



Figure 1



6. Open the cab door and remove travel pedal rubber covers (7). 7. Remove travel pedal plates (8). 8. Remove floor mat (9).



Figure 2



9. Remove rubber covers (11) and travel pedal mounting screws (10). 10. Mount connectors (4) to the new travel pedal. connector is an elbow fitting, conform its direction. 11. Mount travel pedals mounting screws (10).



Figure 3



12. Install rubber covers (11). 13. Install floor mat (9). 14. Install travel pedals plates (8). 15. Install travel pedals rubber covers (7).



Figure 4



16. Mount travel pedals hoses (2EA) (5) and connectors (6). 17. Mount servo hoses (4EA) (3). 18. Mount under cover. NOTE! Travel pedals test.



Figure 5



Service Information Document Title: Function Group: Remote control valve (pedal), troubleshooting



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (pedal), troubleshooting It isn’t always easy to trace a malfunction. Some general phenomenon to be considered are listed in following table. See cause and remedy. However, the trouble is not always caused by one faulty part only, but by its relation to other parts. So remedies other than listed in the table may be necessary. Troubleshooting Phenomenon



Cause



Secondary pressure will not rise.



 



  







Lack of primary pressure. Damaged secondary pressure setting spring. Clearance between spool and casing is excessive. Play in controller.



  



Related to sliding part. Tank line pressure fluctuates. Air in hydraulic circuit.



  



Repair/replace the related parts. Return oil directly to the tank. Bleed the air by repeating pedal operation several times.



 



Pressure of tank line is too high. Related to sliding part.



 



Return oil directly to tank. Repair/replace defective part.



   



Air in piston chamber. Sliding parts are sticking. Damping springs (336, 337) failure. Excessive clearance between damping piston (224) and casing. Check valve malfunction. Orifice of damping piston oversized.











Bleed the air by repeating operation several times. Repair replace sticking part. Replace spring. Replace the damping piston assembly. Disassemble/check/repair the check valve. Replace the damping piston.



 



Repair defective parts. Clean/replace the damping piston.







Secondary pressure is unstable.



Secondary pressure is too high.



Remedy







Adjust the primary pressure. Replace it with new parts. Replace spool subassembly and casing. Disassemble, and repair or replace controller parts.



Damping is not done.



 



Damping heavy.



torque



   



is  



Sliding parts malfunction. The hole of damping piston is clogged.



Service Information Document Title: Function Group: Remote control valve (Lever), maintenance standard



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (Lever), maintenance standard Maintenance standard Maintenance check item



Criteria



Remark



Leakage



The valve is to be replaced when the leakage becomes more Conditions: than 1000 cc/min at neutral handle position, or more than - Primary pressure: 2.94 MPa (426 psi) 2000 cc/min during operation. (29.4 bar) - Oil viscosity: 23 cSt



Spool



This is to be replaced when the sliding surface has worn more The leakage is estimated to be nearly than 10 µm, compared with the non–sliding surface. equal to the above leakage.



Push rod



A.



Worn more than 1 mm (0.004 inch)



This is to be replaced when the top end has worn more than 1 mm (0.004 inch). Play operating section Operation stability



at The pin, shaft, and joint of the operating section are to be When the play is due to loose parts / replaced when the play becomes more than screws, tighten to specifications. 2 mm (0.008 inch) When abnormal noises, hunting, primary pressure drop, etc. are generated during operation, and these cannot be remedied, see causes of troubles and countermeasures, replace the related parts.



NOTE! In principle, replace seals and O-rings during reassembly.



When loosening the screws (125), replace the seal washers (121) without fail.



Service Information Document Title: Remote control (Lever), disassembly



Function Group: valve



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (Lever), disassembly Op nbr 00000 Tools: Add special tool for joint Torque wrench 9.8 - 98 Nm (1 - 10 kgf m) (7.2 - 72.2 lbf ft) Rust inhibitor Cleaning solvent High temperature grease (Spray type recommended) Locitite #241 Sandpaper (# 1000, # 2000) Oilstone Vise Tightening torque, See 9148 Tightening torques



Preparation  



Thoroughly clean the exterior of the valve prior to disassembly. Dismantle in a clean environment. Prepare the tools and materials.



General precautions   



All parts are precision fitted to very close tolerances therefore utmost care must be taken not to damage them during the dismantling and assembling procedure. Do not strike or force any parts that may be partially seized. Protect the parts from rusting prior to assembling, and check all surfaces for scratches, nicks and wear. Replace any damaged part.



Disassembly 1. Clean servo hydraulic valve with cleaning solvent. NOTE! Use plugs to cover all ports. 2. Fix servo hydraulic valve in a vise with copper (or lead) sheets.



Figure 1 Fixing with the vise 3. Lift the end of bellows (501) upward from casing (101). NOTE! Pay attention not to damage the bellows.



Figure 2 V1004864



Figure 3 Lifting, bellows 4. Loosen lock nut (315) and adjusting nut (312). Use a spanner on each nut.



Figure 4 Removal, adjusting nut 5. Remove handle (402).



Figure 5 Removal, handle



6. Remove disc (302).



Figure 6 Removal, disc 7. Turn the joint counterclockwise to loosen it, utilizing jig (special tool). NOTE! [Photo] shows how to fit jig. NOTE! Take care when loosening the joint. Plate (151), plug (211) and push rod (212) may fly out due to compresdsed return spring (221).



Figure 7 Using special tool



Figure 8 Removal, joint 8. Remove plate (151).



Figure 9 Removal, plate 9. When return spring (221) is released plug (211) stays in the casing because of the sliding resistance of the o-ring. Take it out with a screwdriver. NOTE! Take it out, utilizing the external periphery groove of the plug and pay attention not to damage it by partial loading. During removal, the plug may fly out due to return spring (211) force. Pay attention to this.



Figure 10 Removal, spring 10. Remove push rod (212), plug (211), reducing valve subassembly and return springs (221) from the casing. NOTE! Record relative position of reducing valve subassembly and return springs.



Figure 11 Removal, reducing valve subassembly 11. Fix servo hydraulic valve in a vise, port plate (111) upward. Loosen screws with hexagon socket key.



Figure 12 Loosening, screws 12. Remove port plate (111) and o-ring (122) from the casing (101).



Figure 13 Removal, o-ring 13. Remove bushing (131) from the casing (101).



Figure 14 Removal, bushing 14. To disassemble the reducing valve section, push down secondary pressure spring (241) and remove the spring (241) through large hole of the spool (201). NOTE! Pay attention not to damage spool surface. Do not push down spring seat more than 6mm.



Figure 15 Removal, reducing valve 15. Separate spool (201), spring seat (216), secondary pressure spring (241) and washer 2 (217).



Figure 16 Removal, spool, spring seat and spring etc. 16. Remove push rod (212) from plug (211).



Figure 17 Removal, push rod 17. Remove o-ring (214) from plug (211).



Figure 18 Removal, o-ring 18. Remove seal (213) from plug (211) using a small screwdriver.



Figure 19 Removal, seal 19. Remove bellows (501) by pulling the top from its groove in the grip.



Figure 20 Removal, bellows 20. Remove handle (402) cover. Remove tap screw (431), and take off grip (402) cover.



Figure 21 Removal, tap screws 21. Remove the switch bracket.



Figure 22 Removal, switch bracket 22. Remove switches (455). NOTE! Record the location relationship between the color of wire and the position at the handle.



Figure 23 Removal, switches 23. Cleaning of parts: 



Initially wash the remote control valve assembly with clean solvent to remove the heavy accumulation of dirt. NOTE! Allow the parts to soak in the solvent to soften the dirt. Do not wash the internal parts with contaminated solvent. Ensure that all parts are thoroughly cleaned prior to reassembly.







In the final stage, wash all passages, chambers, grooves with clean solvent, to ensure the utmost cleanliness. Wipe off the parts with a clean cloth. NOTE! Do not dry parts with compressed air, since they may be damaged and/or rust may develop due to moisture in the air.



24. Rust prevention of parts: Apply rust inhibitor to all parts. NOTE! If left untreated after being cleaned, they will rust and will not function properly after being reassembled.



Service Information Document Title: Remote control (Lever), assembly



Function Group: valve



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (Lever), assembly Op nbr 00000



Preparation 



Prepare the workbench, tools and parts. Assemble the valve in a clean area.



General precautions       



See the general precautions during disassembling. Remove all contamination from the parts and check that parts are free from burrs, nicks scratches, etc. Replace o-rings and back-up rings with new ones. In fitting o-rings and back-up rings, pay attention not to damage them. Apply grease to the parts to hold them in place during assembly. Tighten screws to specified torques shown in the tightening torque table. After assembling, cover all ports to prevent contamination from entering the valve.



Assembly 1. Install bushing (131) into casing (101).



Figure 1 Assembly, bushing 2. Install o-ring (122) into casing (101).



Figure 2 Assembly, o-ring 3. Install port plate to casing (101) with screws (125) and seal washers (121). NOTE! Position the port plate so spring pin (126) can enter into the casing hole. Replace washers (121) with new ones.



Figure 3 Assembly, port plate



Figure 4 Replacement, washers with new ones 4. Tighten screws (125) to the specified torque. NOTE! Tighten two screws alternately and evenly.



Figure 5 Tightening, screws 5. Assemble washer (217), secondary pressure spring (241) and spring seat (216) onto spool (201) in this order. NOTE! Do not push down spring seat more than 6 mm.



Figure 6 Assembly, washer, secondary pressure spring and spring seat 6. To assemble the reducing valve section, push down secondary pressure spring (241) and install the spring (241) through large hole of the spool (201).



Figure 7



7. Install return spring (221) into the casing. Install reducing valve subassembly into the casing (101). NOTE! Install them to their original positions.



Figure 8 Assembly, spring 8. Assemble o-ring (214) onto plug (211).



Figure 9 Assembly, o-ring 9. Assemble seal (213) to plug (211). NOTE! Assemble seal lip direction as shown below.



Figure 10 Assembly, seals 10. Assemble push rod (212) to plug (211). NOTE! Apply oil on push rod surface.



Figure 11 Assembly, push rod



Figure 12 Apply oil on push rod surface 1 Seal



3 Plug



2 Push rod



4 Apply working oil



11. Assemble plug subassembly to casing (101). NOTE! When return spring is relaxed, subassembly stops due to resistance of o-ring.



Figure 13 Assembly, plug subassembly 12. When return spring is compressed, assemble 4 sets at the same time, utilizing plate (151), and tighten joint (301) temporarily. NOTE! The plug subassembly and plate (151) may fly out due to return spring (221) force. Pay attention to this.



Figure 14 Assembly, 4 sets of plug 13. Fit plate (151). 



E- tool part no.: 8940 - 00200



Figure 15 Fit, plate 14. Tighten joint (301) to the specified torque to casing, utilizing jig.



Figure 16 Tightening, joint 15. Assemble disc (302) to joint (301). NOTE! Screw it to a position that it contacts the 4 push rods evenly.



NOTE! Do not screw it past this position.



Figure 17 Assembly, disc 16. Assemble adjusting nut (312). Tighten adjusting nut to the specified torque. NOTE! During tightening, do not change position of disc. NOTE! Hold disc (302) with a spanner when tightening the lock nut.



Figure 18 Assembly, adjusting nut 17. Place the switches and bracket at the original position, and tighten screw.



Figure 19 Assembly, switch bracket 18. Place the handle cover, and tighten tap screw (431).



Figure 20 Assembly, handle cover 19. Fix top of the bellows into the groove in the lower end of handle (402).



Figure 21 Assembly, bellow 20. Assemble adjusting nut (312) to the handle, and place it to the joint (301).



Figure 22 Assembly, handle and joint 21. Determine handle direction, and tighten lock nut (315) to specified torque.



Figure 23 Assembly, lock nut 22. Apply grease to rotating section of joint and contacting faces of disc and push rod. NOTE! Molybdenum based CSE 115B paste type grease is recommended, but commonly used spray type grease is also acceptable.



Grease should be applied every six months.



Figure 24 Applying, grease 23. Install the lower end of bellows (501) onto casing (101).



Figure 25 Assembly, bellows



Service Information Document Title: Function Group: Remote control valve (pedal), maintenance standard



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (pedal), maintenance standard Maintenance standard Check item



Criteria



Remark



Leakage



Handle in neutral: more than 500 cc/minute. During operation: more than 1000 cc/minute.



Conditions:  



Spool



Primary pressure: 2.94 MPa (426 psi) (29.4 bar) Oil viscosity: 23 cSt



When the sliding part worn more than 10 mm (0.39 in) compared with the non-sliding part, replace it.



Push rod



A.



Worn more than 1 mm (0.004 in)



When the top end is worn more than 1 mm (0.004 in), replace it. Set screw



A.



Worn more than 1 mm (0.004 in)



When the end is worn more than 1 mm, replace it. Play of controller When the play is more than 2 mm (0.008 in) on cam, When the play is due to loose parts/ camshaft and bushing of controller due to wear, replace the screws, tighten to specifications. parts. Operation stability



When abnormal noise, hunting and primary pressure drop occurs and can"t be corrected in accordance with “Troubleshooting”, replace the remote control valve.



NOTE! In principle, replace the O-rings and seals during reassembly.



Service Information Document Title: Remote control (pedal), disassembly



Function Group: valve



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (pedal), disassembly Op nbr 00000 Tools: Special tool_8920-00210 Special tool_8920-00220 Torque wrench 2.9 - 4.9 Nm (0.3 - 0.5 kgf m) (0.3 - 3.63 lbf ft) Rust inhibitor Cleaning solvent Heat resisting grease (Spray type recommended) Loctite # 241 Sand paper # 1000, # 2000 Oilstone Vise Spatula for greasing Tightening torque, See 9148 Tightening torques.



Preparation  



Thoroughly clean the exterior of the valve prior to disassembly. Dismantle in a clean environment. Prepare the tools and materials.



General precautions   



All parts are precision fitted with very close tolerances therefore utmost care must be taken not to damage them during the dismantling and assembling procedure. Do not strike or force any parts that may be partially seized. Protect the parts from rusting prior to assembling, and check all surfaces for scratches, nicks, and wear. Replace any damaged part.



Disassembly 1. Clean the servo hydraulic valve with cleaning solvent. 



Block each port with blind plugs.



2. Fix servo hydraulic valve in a vise with copper (or lead) plates. 



Remove the lower part of bellows (501) from cover (201).



Figure 1 Removal, bellows 3. Loosen screw (423) using an allen wrench. 



Loctite # 242 is applied and releasing torque is high. Take care not to damage the threads.



Figure 2 Loosening, screws 4. Match the round bar (φ 8 and less) to one end of camshaft (413), and push out by tapping lightly with a hammer.



Figure 3 Matching, end of camshaft 5. Remove cam (420) as an assembly with set screw (471), lock nut (472) attached. 



Record the position relationship with casing.



Figure 4 Removal, cam 6. Remove screws (271). Loosen each screw simultaneously so the cover is kept horizontal. NOTE! Take care, push rod (214) can spring out due to return spring force.



Figure 5 Removal, screws 7. Remove cover (201).     



Record the position relationship with casing (101). When return spring (335) is relaxed, plug (202) is left inside the casing due to sliding resistance of o-ring (212). Pull it out with a screwdriver. Prevent any damage caused by a partial load on the plug outer diameter groove. Take care, the plug can spring out due to return spring force.



Figure 6 Removal, cover 8. Remove the push rod from the plug. Record the location relationship between push rod and plug. NOTE! Be careful not to damage the surface of push rod. NOTE!



Take care, the plug can spring out.



Figure 7 Removal, push rod 9. Remove grease cap (203) and NHU packing (210) from plug. Record the location relationship between plug and casing. NOTE! Take care, the plug can spring out due to return spring force.



Figure 8 Removal, grease cap 10. Record the location relationship between piston (224), separate piston and casing, and then disassemble.



Figure 9 Disassembly, piston and casing 11. Pull out the damping springs (336, 337) from casing. 



Record the location relationship between damping spring and casing.



Figure 10 Removal, damping spring 12. Remove spring seat (218) from casing. 



Record the location relationship between spring seat and casing.



Figure 11 Removal, spring seat 13. Pull out the check ball (225) using a magnet. NOTE! Take care not to lose the check ball.



Figure 12 Removal, check ball 14. Pull out O-ring (213) from casing. 15. Pull out the reducing valve assembly and return spring (335) from casing. 



Record the location relationship between reducing valve assembly and casing bore.



Figure 13 Removal, reducing valve assembly and return spring 16. Put cover (201) on a flat plate in a horizontal position, and match the special tool to the bushing. Push out the bushing by tapping lightly with a hammer.



Figure 14 Removal, bushing 17. Fix the cam assembly into the vise. Remove lock nut (472) and set screw (471) with a spanner. 



Set screw is required for neutral adjusting when assembling. If the set screw does not need to be replaced, do not remove it.



Figure 15 Removal, lock nut and set screw 18. Disassembly of reducing valve. Put the lower part of spool (301) on a flat surface vertically, lower spring seat (311), and remove the 2 semicircular washers (215) with a screwdriver. 



Take care not to damage the spool surface.







Never lower the spring seat more than 4 mm.



Figure 16 Removal, washer 19. Remove spool (301), spring seat (311), secondary pressure spring (324), washer 3 (313) and washer 2 (217).  



Handle as an assembly before assembling. Washer 2 (217) is used for adjusting the preset of secondary pressure setting spring (324), and the thickness is different for each spool assembly.



However, sometimes the washer is not factory installed.



Figure 17 Removal, spool 20. Remove grease cap (203) from plug (202). 



Take care not to damage the push rod surface.



Figure 18 Removal, grease cap 21. Remove NHU packing (210) from plug with a small blade screwdriver. 



Take care not to damage the inside of the plug.



Figure 19 Removal, NHU packing 22. Remove o-ring (212) from plug.



Figure 20 Removal, o-ring 23. Cleaning of parts: 



Initially wash the remote control valve assembly with clean solvent to remove the heavy accumulation of dirt. NOTE! Allow the parts to soak in the solvent to soften the dirt. Do not wash the internal parts with contaminated solvent. Ensure that all parts are thoroughly cleaned prior to reassembly.







In the final stage, wash all passages, chambers, grooves etc. to ensure the utmost cleanliness. Wipe off the parts with a clean cloth. NOTE! Do not dry parts with compressed air. They may be damaged and/or rust may develop due to moisture in the air.



24. Apply rust inhibitor to all parts. NOTE! If left untreated after being cleaned, they will rust and will not function properly after being reassembled.



Service Information Document Title: Remote control (pedal), assembly



Function Group: valve



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Remote control valve (pedal), assembly Op nbr 00000



Preparation 



Prepare the workbench, tools and parts. Assemble the valve in a clean area.



General precautions      



See the general precautions during disassembling. Remove all contamination from the parts and check that parts are free from burrs, nicks scratches, etc. Replace o-ring and NHU packings with new ones. In fitting o-ring and NHU packings pay attention not to damage them. Apply grease to the parts, to hold them in place during assembly. Tighten screws to specified torques shown in the tightening torque table. After assembling, cover all ports to prevent contamination from entering the valve.



Assembly 1. Assemble washer 3 (313), washer 2 (217), spring (324) and spring seat (311) onto spool (301) in this order. The washer 2 is for secondary pressure adjusting, and its thickness differs with every spool assembly. 



Washer 2 is not necessarily factory installed.



Figure 1 Assembly, spool 2. Stand spool vertically with its bottom placed on a flat workbench, and with spring seat pushed down, put the two semicircular washers 1 (215) on the spring seat without prying them on.



Figure 2 Assembly, washers 3. Assemble washer 1 (215) so that its sharp edge side will be caught by the spool head. NOTE! Do not push down spring seat more than 4 mm.



Figure 3 Assembly limit, washers A.



Sharp edge



4. Assemble return spring (335) into the casing. 



Assemble to original position.



Figure 4 Assembly, return spring 5. Assemble the No. 1 reducing valve into casing. 



Assemble to original position.



Figure 5 Assembly, No. 1 reducing valve 6. When installing the reducing valve sub assembly, take care that the lower part of the spool does not hit the casing edge.



Figure 6 Installing the reducing valve subassembly A.



Do not strike casing edge.



7. Assemble O-ring (213). 8. Assemble check ball (225) into the bushing.



Figure 7 Assembly, check ball 9. Assemble spring seat (218) into the bushing. 



Assemble to the original position.



Figure 8 Assembly, spring seat 10. Assemble damping spring (336) into casing. 



Assemble to the original position.



Figure 9 Assembly, damping spring 11. Assemble damping spring (337) into casing.  



Assemble to the original position. Take care that damping springs (336, 337) are not entangled.



Figure 10 Assembly, damping spring 12. Assemble piston (224). 



Assemble to the original position.



Figure 11 Assembly, piston 13. Assemble o-ring (212) onto plug (202).



Figure 12 Assembly, o-ring 14. Assemble NHU packing seal (210), scraper (211) and o-ring (212) into plug (202).  



Note the direction of seal and scraper when assembling. Apply grease thinly onto seal and scraper before assembling.



Figure 13 NHU packing seal A.



NHU packing



Figure 14 Assembly, NHU packing seal



15. Assemble grease cap (203) onto plug.



Figure 15 Assembly, grease cap 16. Insert push rod (214) into plug (202).  



Apply hydraulic oil onto the surface of the push rod before assembling. Take care not to damage the lip of the seal and scraper when assembling.



Figure 16 Assembly, push rod 17. Install the push rod subassembly of step no. 13, 14, 15, 16 into the casing.



Figure 17 Assembly, push rod subassembly 18. Attach bushing (412) to cover (201) by use of special tool, and press-fit by tapping lightly. 



Take care that the bushing edge does not protrude inside.



Figure 18 Assembly, bushing 19. Assemble the cover onto housing (101).  



Assemble to the original position. Keep damping springs (336, 337) and the cover properly aligned.



Figure 19 Assembly, cover 20. Assemble the cover and tighten screws (271) to specified torque. 



Keep the cover horizontal during installation, ensure that there is no gap between the cover and casing.



Figure 20 Tightening screws to specified torque 21. Assemble set screw (471) and lock nut (472) to cam (420) temporarily.



Figure 21 Assembly, set screw and lock nut 22. Assemble cam (420) to the cover. 



Assemble to the original position.



Figure 22 Assembly, cam 23. Insert camshaft (413) through cover (201) and cam (420).



Figure 23 Assembly, cam and cover 24. Apply loctite # 241 or equivalent onto the screw thread and tighten to the specified torque.



Figure 24



Applying, loctite 25. Tighten screw (423) to the specified torque.



Figure 25 Screw in, set screws 26. Make the upper surface of cam and lower surface of cover parallel by adjusting the height of set screw (471). Tighten lock nut (472) to specified torque after making the clearance against push rod “0”. 



If the set screw is excessively tightened, play will occur in neutral.



Figure 26 Adjusting, the height of set screw 27. Apply grease onto top of push rod and top of plug by inclining the cam. 



When greasing, use a spatula of softer material to prevent scratching the surface of push rod and plug.



Figure 27 Applying, grease 28. Insert the upper part of bellows (501) into cam groove and then the lower part into cover groove. 



Before inserting the lower part of bellows into cover groove, spray anti-rust oil on the inner parts.



Figure 28 Spraying, anti-rust oil 29. If the bellows is inserted improperly or twisted, the anti-rust protection is significantly lowered.



Figure 29 Assembly, bellows



Service Information Document Title: Function Group: Solenoid valve, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Solenoid valve, description   



Solenoid coil: An electronic coil to apply a force on the spool. Body: A main body with the flow passage and the port. Spool: Moved by solenoid coil and spring, and limits the flow passage of each port.



When power is supplied to a solenoid coil, an electro-magnetic force is formed and the spool in the guide is activated, which pushes the spool and converts the oil flow passage while compressing the spring. By the spool movements, the flow passage to each port is connected or disconnected, and if power is turned off, the spool is returned by the spring force and each port also returns to the original condition. These solenoid valves perform the following functions when activated. Solenoid valve function 1



Servo hydraulic system control lockout (A1)



2



Boom raise conflux shutoff signal (A2)



3



Arm in conflux shutoff signal (A3)



4



Main relief pressure boost (A4)



5



Travel speed selection (A5)



Solenoid valve, structure



Figure 1 Structure, 5 serial solenoid valve Coil case (14) : Tightening torque : 39 ~ 49 N m (4 ~ 5 kgf m) (30 ~ 36 lbf ft) Control lockout lever (A1) Servo hydraulic control lockout lever lock function: when the left control console control lockout lever is moved to the operate position, the switch is turned ON, directing the primary servo hydraulic pressure at port P1 to A1, and then to the remote control valve control valves. When the lever is moved to the lever lock position the switch is turned OFF, and the spring force moves the solenoid valve spool, making it impossible to operate all the implement levers and travel system levers. Boom conflux shut-off valve (A2) (Fine mode) Activating the switch shuts off the oil flow connected to the boom secondary servo hydraulic pressure 5pb2 the A2 solenoid and only the oil of P1 pump is supplied to the boom. 



The boom 2 spool opens to the negative line of P1 pump, and reduces the output of P1 pump oil.



Arm in conflux shut-off valve (A3) (Fine mode) Activating the switch shuts off the oil flow connected to the arm secondary servo hydraulic pressure main control valve the A3 solenoid and only the oil of P2 pump is supplied to the arm. Main relief valve pressure boost (A4) When the digging unit boost pressure switch is pressed, solenoid valve A4 is activated and port P4 is opened to port A4. The servo hydraulic pressure from port A4 raises the relief pressure of the main relief valve. Travel speed selection (A5) When the 2-speed travel switch is pressed, solenoid valve A5 is activated routing primary servo hydraulic pressure at port P4 to A5, shifting to the travel valve to 1st/2nd automatic speed change position.



Service Information Document Title: Solenoid valve, inspection



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Solenoid valve, inspection  



Use a sensory organ: By the sense of hearing or touch, check the solenoid valves for operating at switch ON. Coil continuity test: Check for coil damage by tester.



Figure 1 Inspection method 



Spool malfunction: In the event that the solenoid valve malfunctions and there is no electrical abnormality, the spool may be stuck in the valve. Press the spool on the solenoid to check for spool sticking. Disassemble and clean thoroughly, if damaged it must be replaced.



NOTE! For hydraulic operation related information, refer to the hydraulic system.



Service Information Document Title: Function Group: Solenoid valve, disassembly and assembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Solenoid valve, disassembly and assembly Op nbr 00000



Tightening torque, unit: kgf·cm (lbf·ft) Part name



Tools



Tightening torque



Spring guide (4) (5)



26 mm



1900 ± 50 (1646 ± 43)



Guide kit (7) (8)



5 mm



70 ± 5 (61 ± 35)



Nut (9) (10)



27 mm



55 ± 5 (61 ± 35)



Disassembly Precautions    



Thoroughly clean the exterior of the valve prior to disassembly. Dismantle in a clean environment. All parts are precision fitted to very close tolerances therefore utmost care must be taken not to damage them during the dismantling and assembling procedure. Do not strike or force any parts that may be partially seized. Protect the parts from rusting prior to assembling, and check all surfaces for scratches, nicks and wear. Replace any damaged part.



Disassembly procedure 1. Remove the spring guide and spring from the valve casing. 2. Unscrew the coil case nut and extract the solenoid coil. 3. Remove the guide kit, retainer and the spool. 4. Extract the spool slowly to avoid binding the spool lands in the valve casing. Precautions      



Follow the same precautions as disassembly. Minor scratches, nicks, and sharp edges may be polished with very fine emery or crocus cloth. Replace all o-rings. Lightly coat the o-rings with grease to hold them in place during assembly. Lubricate the spool prior to assembly. Upon completion of assembly, plug all ports to prevent contamination intruding into the valve.



Assembly procedure



Assembly 5. Insert the spool and retainer. 6. Install the o-ring and guide kit.



7. Assemble the solenoid coil, o-ring and coil case. 8. Tighten the coil case nut to specified torque. 9. Install the spring and spring guide with a new o-ring. 10. Tighten the spring guide to specified torque. Troubleshooting For minor problems, refer to the following causes and corrective actions. Troubleshooting No.



Problem



Cause



Remedy



1



Spool does not move.



Solenoid voltage is low.



Check the electric wiring. Test the solenoid coil.



Solenoid coil is burnt.



Replace the coil.



Spool spring is broken.



Replace the spring.



Contamination in the casing.



Check the circuit and hydraulic oil for contamination, clean as required.



2



Leakage from coil case O-rings are damaged. or spring guide. Coil case nut, spring guide are loose.



Replace the o-rings. Tighten to specified torque.



Service Information Document Title: Solenoid valve, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Solenoid valve, replacing Op nbr 914-091 NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container.



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries 1. Place the machine in the service position B. See : 091 Service positions Park the machine on a level surface, lower the bucket to the ground and stop the engine. Operate each control lever (for attachment and travel) to its full stroke to release the residual pressure. Press the air breather cap on the hydraulic tank to release the residual pressure. 2. Connect vacuum pump. See 9111 Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump NOTE! Mark the solenoid valve block, wire harness connectors and hoses to indicate proper positioning during reassembly



WARNING When the last bolt has been removed, the cover plate falls down. 3. Remove screws (1) and hydraulic oil tank under cover (2).



Figure 1 Removal, cover 4. Disconnect wire harnesses (1) from solenoid valve. Remove hoses (2) from solenoid valve block. Remove screws (3) and the solenoid valve block.



Figure 2 Removal, solenoid valve 5. Transfer fittings to a new solenoid valve block from the old solenoid valve block. NOTE! Replace O-rings with new ones. 6. Install the solenoid valve block and tighten screws. Connect the hoses to the solenoid valve block. Connect the wire harnesses. 7. Install the under cover (2) and tighten screws (1).



Figure 3 Removal, cover 8. Start the engine. Check for leaks and repair if needed.



Service Information Document Title: X1 Line, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



X1 Line, description X1 control system consists of pump, main control valve, solenoid valves, hydraulic tank, filters, proportional valve and stop valve. The information given in this manual shows the construction and explanation of the X1 control system. In regard to purchase parts and installation, contact your authorize d Volvo Construction Equipment Dealer workshop. Diagram for X1 single acting and double acting See 990 Hydraulic diagram, with option components.



Service Information Document Title: Function Group: Hammer and shear pedal valve (RCV), replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hammer and shear pedal valve (RCV), replacing Op nbr 916-096 1. Place the machine in the service position D, see 091 Service positions.



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping.



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container. 2. Press the air breather cap on the hydraulic tank to release the residual pressure. 3. Remove under cover.



Figure 1



4. Remove hoses (1). Remove connectors and elbows (2) of hammer and shear pedal valve. 5. Remove rubber cover (1) of hammer and shear pedal.



Figure 2



6. Remove screws and pedal (2). 7. Remove rubber boot (1) and screws (2) of hammer and shear valve.



Figure 3



8. Remove the hammer and shear valve. 9. Install a new hammer and shear valve.



Figure 4



10. Install rubber boot (1) and screws (2). 11. Install pedal screws (2).



Figure 5



12. Install rubber cover (1) on hammer and shear pedal. 13. Transfer connector and elbow (1) with new O-rings to the new hammer and shear valve.



Figure 6



14. Connect hoses (1, 2).



Figure 7



15. Install the under cover.



Service Information Document Title: Hammer return description



Function Group: filter,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hammer return filter, description The hammer/shears equipment consists of single pedal, hammer/shears selector valve, flow control valve, solenoid valve, shuttle and the hoses etc. The information given in this manual shows a construction and explanation on the hammer/shears. In regard to purchase parts and installation, contact your authorized Volvo Construction Equipment dealer. NOTE! When assembling filter be careful to assembly direction.



Service Information Document Title: Function Group: Solenoid valve, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Solenoid valve, description   



Solenoid coil: An electronic coil to apply a force on the spool. Body: A main body with the flow passage and the port. Spool: Moved by solenoid coil and spring, and limits the flow passage of port.



When power is supplied to a solenoid coil, an electro-magnetic force is formed and the spool in the guide is activated, which pushes the spool and converts the oil flow passage while compressing the spring. By the spool movements, the flow passage to port is connected or disconnected, and if power is turned off, the spool is returned by the spring force and each port also returns to the original condition. Solenoid valve (1) for hammer and shear selection



Figure 1 Solenoid valve (1) 1



Valve body



9



DC solenoid guide



2



Spool



10



Solenoid coil



3



Retainer - A



11



O-ring



4



Retainer - B



12



O-ring



5



Spacer



13



O-ring



6



Spring



14



O-ring



7



Nut



15



Name plate



8



Rod



16



Screw



Solenoid valve (2) for X1_1 switch and 2 pump flow



Figure 2 Solenoid valve (2) Solenoid valve (3) for X1_2 switch



Figure 3 Solenoid valve (3) 1



Valve body



8



Solenoid coil



2



Spool



9



Nut



3



Spring



10



O-ring



4



Plug



11



O-ring



5



Retainer



12



O-ring



6



Rod



13



Name plate



7



DC solenoid guide



Service Information Document Title: 3 way selector description



Function Group:



Information Type: Service Information



valve,



Profile: EXC, EC480D L [GB]



3 way selector valve, description



Figure 1



1



Valve body



10



Plug



2



Poppet



11



Spool



3



Poppet



12



Spring



4



Spring



13



O-ring



5



O-ring



14



Cover



6



O-ring



15



Screw



7



Back-up ring



16



Plug



8



Plug



17



Plug



Date: 2014/7/15



9



O-ring



Specifications Description



Unit



Specifications



Maximum flow rate



Liter/min (gal/min)



870 (211)



Maximum pressure



kgf/cm2 (psi)



380 (5405)



Maximum pilot pressure



kgf/cm2 (psi)



40 (569)



Operating pilot pressure range



kgf/cm2 (psi)



2.8 ~ 12.3 (40 ~ 175)



Tightening torque Item



Unit



Specifications



M14



kgf·m (lbf·ft)



16 ± 2 (116 ± 14)



M12



10 ± 1 (72 ± 7)



M10



6.7 ± 0.7 (48 ± 5)



Service Information Document Title: Function Group: Proportional solenoid valve, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Proportional solenoid valve, description Proportional solenoid control valve (X1/ X3) When the switch moves to the left or right, the proportional valve PWM9124 or PWM9123 current is set according to the position of the switch SW9162. The valve PWM9124 or PWM9123 is activated as long the switch moves out of the neutral position. There is also possibility to choose among three different response modes in the I-ECU for the X3 when the proportional function is selected. The three X3 response modes are:   



Active Normal Soft



Figure 1 Proportional solenoid control valve (X1/ X3) 1. 2. 3.



DT04-2P Tightening torque: 7 ±1 Nm (5.2 ±0.74lbf ft) Tightening torque (2-M8): 29 ±3 Nm (21.5 ±2.2 lbf ft)



Service Information Document Title: Straight travel description



Function Group: pedal,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Straight travel pedal, description The straight travel pedal reduces operator fatigue while traveling long distances. Instead of operating both right and left pedals, operators can travel by holding down the straight travel pedal.



Figure 1 Straight travel pedal schematic and hydraulic diagram 1



Straight travel pedal (option)



A



Left travel (forward)



2



Remote control valve (pedal)



B



Right travel (forward)



3



Shuttle valve



C



Right travel (reverse)



4



Hydraulic oil tank



D



Left travel (reverse)



5



Servo hydraulic oil pump



Service Information Document Title: Control pattern valve, description



Function Group: selector



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Control pattern selector valve, description Control pattern selector valve is mounted at the front left of the air cleaner compartment. This valve makes it possible to change oil flow direction by moving the lever of valve. Sectional view



Figure 1 Structure, control pattern selector valve 1



Name plate



6



Bracket



11



Plate



16



Pin



2



Nut



7



Pin



12



Plate



17



O-ring



3



Handle



8



Sleeve



13



Screw



18



O-ring



4



Plate



9



Spring



14



Washer



19



Lever



5



Stopper



10



Pin



15



Rivet



No.



Screw size



Tightening torque



2



M8



19.6 ±2.0 Nm (2.0 ±0.2 kgf m)



14



M16



78.0 ±7.8 Nm (8.0 ±0.8 kgf m)



8



G1/4



19.6 ±2.0 Nm (2.0 ±0.2 kgf m)



10



M6



4.9 ±1.0 Nm (0.5 ±0.1 kgf m)



9/16–18 UNF



32.0 ±3.2 Nm (3.3 ±0.3 kgf m)



Pattern change mode When lever of valve moves from position S to B, remote control valve (lever) operates as follows: Lever position



Remote control valve (lever)



Remarks



Position S



ISO pattern



Position B



Standard backhoe loader pattern



Service Information Document Title: Rotator pump, description



Function Group:



Profile: EXC, EC480D L [GB]



Rotator pump, description See 9143 Servo pump, description.



Information Type: Service Information



Date: 2014/7/15



Service Information Document Title: Function Group: Rotator (X3 Line option), description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Rotator (X3 Line option), description The rotator equipment consists of the rotator valve, pump and the hoses. To obtain tank and servo pressure, the hydraulic hoses are connected between pump and tank/rotator valve. The two feed/return hoses continue from the rotator valve out to the hydraulic device, the rotator.



Figure 1 Rotator (X3 Line option) 1. 2. 3. 4. 5. 6.



PWM9145 PWM9146 Relief valve Rear cap Relief valve Front cap



The function for X3 equipment has two applications, on/off or proportional operated. The X3 valve is a control valve, and the function is to supply the X3 equipment (tool) with flow. The valves PWM9145 and PWM9146 are to decide the flow direction through the spool. The valve is controlled by the V-ECU and the inputs to the V-ECU are from the left hand control lever's on/off switches or the roller switch. In the I-ECU is it possible to save settings for X3 tool and the setting is: 



X3 control (push, toggle and proportional)



When a X3 tool is selected in the I-ECU menu, the setting of this tool are sent to V-ECU.



Service Information Document Title: Boom float description



Function Group: position,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom float position, description Floating position means that both the piston and piston rod sides of the boom cylinders are connected to the hydraulic tank. The boom can float freely and it is only the weight of the digging equipment and the load that lowers the boom when the control lever is moved forward. The raising of the boom is not affected by the floating position. Floating position results in fuel saving, faster excavating cycle and less wear and vibrations. When the floating position is engaged, the pump flow can be used for purposes other than lowering the boom, e.g. dipper arm and bucket movements. These functions will therefore be faster. The floating position is only active when button has been actuated and the right hand control lever is being held in the forward position. If the attachment is to follow the ground, the right hand control lever must be constantly held in the forward position, while the dipper arm and the attachment are being operated. The boom can then move freely upward or downward depending on the ground conditions. When button switch is actuated and the control lamp for floating position lights up on the instrument control unit I-ECU, a signal is sent to machine control unit V-ECU, which energizes solenoid valve. During the "boom down" movement, the control pressure passes from control valve via solenoid valve and actuates floating valve. The control pressure also passes from control valve and actuates the spools in line-rupture valves. The return oil from the piston sides passes via the line rupture valves in through port B in the floating position valve and out through port A to the piston rod sides of the cylinders. The surplus oil from the piston sides passes via port T in the floating position valve and then through the pressure back-up valves of the main valve block to the hydraulic tank.



Service Information Document Title: Function Group: Rotator pump, disassembly Profile: EXC, EC480D L [GB]



Rotator pump, disassembly See 9143 Servo pump, disassembly.



Information Type: Service Information



Date: 2014/7/15



Service Information Document Title: Rotator pump, assembly



Function Group:



Profile: EXC, EC480D L [GB]



Rotator pump, assembly See 9143 Servo pump, assembly.



Information Type: Service Information



Date: 2014/7/15



Service Information Document Title: Rotator pump, inspection



Function Group: parts



Profile: EXC, EC480D L [GB]



Rotator pump, parts inspection See 9143 Servo pump, parts inspection.



Information Type: Service Information



Date: 2014/7/15



Service Information Document Title: Rotator valve, adjustment



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Rotator valve, adjustment Measuring condition  



Engine speed: high idle Oil temperature when measuring: 50 ~ 60 °C (122 ~ 140 °F)



Hydraulic pressure specifications, See 030 Rotator valve, specifications



WARNING Lower the digging units to the ground and stop the engine (start switch ON position). Operate the control levers several times to release the remaining pressure in the hydraulic piping. Main relief valve, adjustment 



Stop the machine on even ground and block the rotator securely to prevent left and right rotation.



Figure 1 Port relief valve, adjustment 1. 2. 3. 4. 5.      



Lock nut Screw Pressure gauge Lock nut Screw



Remove the plug from port (G) and connect an oil pressure gauge 60 MPa (600 kgf/cm2), (8530 psi) to gauge port (G). Start the engine, and operate the hydraulic rotator (left or right rotation). Increase the gauge port (G) pressure to exceed 20 MPa (200 kgf/cm2), (2845 psi). Loosen lock nut (1), and turn adjusting screw (2) as follows: To increase pressure, turn clockwise. To decrease pressure, turn counterclockwise. Set the main relief valve pressure with 18.6 MPa (190 kgf/cm2), (2698 psi). Hold adjusting screw (2) securely and tighten lock nut (1).



Port relief valve, adjustment        



Stop the machine on even ground and block the rotator securely to prevent left and right rotation. Remove the plug from port (G) and connect an oil pressure gauge (600 kgf/cm2, 8530 psi) to gauge port (G). Start the engine, and operate the hydraulic rotator (left or right rotation). Adjust the main relief pressure higher than port relief valve pressure. Loosen lock nut (4), and turn adjusting screw (5) as follows: To increase pressure, turn clockwise. To decrease pressure, turn counterclockwise. Set the port relief valve pressure with 21.6 MPa (220 kgf/cm2), (216 psi). Hold adjusting screw (5) securely and tighten lock nut (4). After completion of adjustment, reset the main relief valve pressure.



Service Information Document Title: Hydraulic description



Function Group: quickfit, 924



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic quickfit, description The quickfit attachment consists of a flat assembly plate, which is fitted to the arm end and bucket link. There are two hooks (6) on the plate, for the front shafts (2) on the bucket. There is a lifting hook (3) on the quickfit attachment. With the bucket removed, the permitted load increases and the operator’s field of vision is improved. The quickfit attachment is equipped with a double acting hydraulic cylinder. The quickfit lock wedge (4) is fitted to the piston rod. Servo pressure acts on the piston side of the lock cylinder, locking the bucket in place against the rear hook (5). This means that the lock wedge adjusts itself and provides gap-free locking. When lock wedge (4) is released, the servo pressure is transferred to the piston rod side. If necessary, the release pressure can be increased by loading the bucket cylinder in its end position. There is a quickfit indicator (1) on the left side of the quickfit attachment, which is folded in when the lock wedge is in the locked position and folded out when the lock wedge is released.



Figure 1 Hydraulic quickfit, install 1. 2. 3. 4. 5. 6.



Quickfit indicator Bucket shaft Lifting hook Locking wedge Bucket rear hook Tool attachment hook



Quickfit, structure



Figure 2 Quickfit, structure (1) 1



Spacer



7



Shim



2



Spacer



8



Shim



3



Screw



a



Maximum 0.4 mm gap



4



Screw



b



Maximum 0.4 mm gap



5



Shim



c



Minimum 5 mm gap



6



Shim



d



16 mm



NOTE!



Tightening torque (8): 11.3 ± 1.1 kgf·m (81.6 ± 7.9 lbf·ft)



Figure 3 Quickfit, structure (2) 1. 2. 3. 4. 5. 6. 7. 8. 9.



Lock wedge Hydraulic cylinder Screw Nut Quick indicator Washer Split pin Pin Quickfit assembly



Service Information Document Title: Quickfit system, operation



Function Group: 924



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Quickfit system, operation S quickfit valve In the case of solenoid valve (6) is turned OFF, 







The hydraulic oil from servo pump (7) flows Pi of safety solenoid valve (9) → PS of quickfit valve (5) → check valve (8) → shuttle valve (3) → solenoid valve (6) → port A of quickfit valve (5) → check valve (2) → piston side of quickfit cylinder (1) The hydraulic oil from the piston rod side flows Port B of solenoid valve → solenoid valve (6) → hydraulic oil tank (T)



Figure 1 Quickfit system, solenoid valve : OFF X



ON



Y



OFF



In the case of solenoid valve (6) is turned ON, 



The hydraulic oil from servo pump (7) flows 1. 2.



 



Pi of safety solenoid valve (9) → PS of quickfit valve (5) → check valve (8) → shuttle valve (3) → solenoid valve (6) → press up servo valve (4) Quickfit valve (B) → open the check valve (2) → rod side of the quickfit cylinder (1)



The oil of the piston side of the quickfit cylinder flows Check valve (2) → port A of quickfit valve (5) → solenoid valve (6) → hydraulic oil tank (T) The oil from the main pump flows (as the servo valve (4) was moved upward): Port P3 of quickfit valve (5) → servo valve (4) → shuttle valve (3) → solenoid valve (6) → port B of quickfit valve (5) → rod side of quickfit cylinder (1)



Figure 2 Quickfit system, solenoid valve: ON X



ON



Y



ON



U quickfit valve Operation with solenoid valve (4) turned OFF, 







The hydraulic oil from the servo hydraulic pump (9) flows via A1 of safety solenoid valve (8) → PS port of quickfit valve (3) → check valve (7) → shuttle valve (6) → solenoid valve (4) → port A of quickfit valve (3) → relief valve (2) → piston side of quickfit cylinder (1). The hydraulic oil from the rod side flows via port B of quickfit valve (3) → solenoid valve (4) → hydraulic oil tank (T2).



Figure 3 Quickfit system, solenoid valve OFF Operation with solenoid valve (4) turned ON, 



The hydraulic oil from the servo pump (9) flows via A1 of safety solenoid valve (8) → PS port of quickfit valve (3) → check valve (7) → shuttle valve (6) → solenoid valve (4) → shift servo hydraulic valve (5) of quickfit valve (3) → rod



 



side of the quickfit cylinder (1). The oil from the piston side of quickfit cylinder (1) flows to relief valve (2), (closing it) → relief valve (2) → port A of quickfit valve (3) → solenoid valve (4) → hydraulic oil tank (T2). The oil from P1 main pump flows via P3 port of quickfit valve (3) → servo hydraulic valve (5) → shuttle valve (6) → solenoid valve (4) → port B of quickfit valve (3) → rod side of quickfit cylinder (1) to overcome the spring force.



Figure 4 Quickfit system, solenoid valve ON



Service Information Document Title: Hydraulic adjustment



Function Group: quickfit, 924



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic quickfit, adjustment Op nbr 00000



1. Remove any shims between the screw holder and mating plates. Hook the bucket on and lock it in accordance with the instructions for installing a bucket or tool.



Figure 1 Tool attachment, adjustment 1. 2. 3. 4.



Bucket/tool Screw holder Shim Spacer



2. Check the lock wedge position and the way the attachment butts up against the mating plates. Then calculate any adjustment to the plate shims as follows:  



Put in thicker shims if the locking wedge goes too far into the hook. Put in thinner shims if the locking wedge does not go far enough into the hook.



Figure 2 Adjustment using shims 1.



Shims



2. 3.



Bucket hook Lock wedge



3. Remove the bucket or tool in accordance with the instructions for removing a bucket or tool. 4. Fit the requisite number of shims beneath the mating plates, then re-install the bucket or tool. 5. Check that the locking wedge position is in accordance with the specified tolerances. 6. Measure and install the requisite number of shims between the screw holder and the mating plates. Tension the mating plates with the requisite number of fastening screws. NOTE! All mating plates and adjustment screws must be adjusted to give a good fit.



Service Information Document Title: Quickfit, removal



Function Group: 924



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Quickfit, removal Op nbr 924-005 1. Park the machine in the service position B. See 091 Service positions. 2. Press the quick fit switch to unlock position and remove the bucket assembly.



Figure 1 Quick fit switch 1. 2. 3.



Unlock position Lock position Locker



3. Remove the hydraulic hoses. NOTE! When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual pressure inside the hydraulic line by operating the control lever smoothly for 3~4 times with the ignition switch at “ON” position. NOTE! Plug all disconnect hoses to prevent oil leakage and contamination from entering the hydraulic system. NOTE! Prepare container for collecting oil.



WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries



Figure 2 Quick fit, position 1. 2. 3. 4. 5.



Hoses Bucket pin Lock screw Bucket link pin Lock screw



4. Remove lock screws, bucket link pin, bucket pin and code rings. 5. Remove quick fit.



Service Information Document Title: Quickfit, installation



Function Group: 924



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Quickfit, installation Op nbr 924-006



WARNING Never use your fingers to check alignment of the bearings' different parts. NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 1. Install code ring, bucket pin and lock screw. NOTE! Apply grease on the code rings and place the code rings on the edge of the hub.



Figure 1 Bucket pin, installation 1. 2. 3.



Code rings Lock screw Bucket pin



2. Install code ring, bucket link pin and lock screw.



Date: 2014/7/15



Figure 2 Quick fit, installation 1. 2. 3. 4.



Hoses Bucket link pin Lock screw Code rings



3. Install hydraulic hoses. NOTE! When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual pressure inside the hydraulic line by operating the control lever smoothly for 3~4 times with the ignition switch at “ON” position. 4. Hook the front pin of the bucket and curl the bucket to match up lock position.



Figure 3 Bucket, installation 1. 2.



Quick fit Bucket



5. Press the quick fit switch to lock position.



Figure 4 Bucket, installation 1. 2. 3.



Unlock position Lock position Locker



Service Information Document Title: Function description



Function Group: 970



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Function description Attachments



Figure 1 Digging equipment NOTE! The above illustration is a typical graphic of excavator. Digging unit consists of Boom (1), Boom cylinder (2), Arm (4), Arm cylinder (3), Bucket (6) and Bucket cylinder (5) and options are Line Rupture Valve (8), Two-Piece Boom (9) and Two-Piece Boom cylinder (10). Available booms are Mass excavation Boom, General Purpose (GP) Mono Boom, Heavy-Duty (HD) Mono Boom, Two-Piece Boom, offset Boom and Long Reach Boom. Available arms are Short Arm, Mass excavation Arm, General Purpose (GP) Arm, Heavy-Duty (HD) Arm, Long Arm and Long Reach Arm. Line Rupture Valves (8) are installed on boom cylinder (2) and arm cylinder (3). The line rupture valve function is to prevent an accident caused by a sudden dropping of the boom when a pipe or hose ruptures. It also prevents boom cylinder creep caused by internal leakage of the main control valve. The equipment makes quick attachment changes simple and smooth. There is a lifting hook on the quickfit (7) attachment. With the bucket removed, the permitted load increases and the operator’s field of vision is improved. The hydraulic attachment bracket (quickfit) consists of a flat mounting plate mounted on the dipper arm end and bucket link.



Service Information Document Title: Cylinder, description



Function Group: 970



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Cylinder, description By construction the hydraulic cylinder consists largely of cylinder tube (1), piston (10) that reciprocates in it, piston rod (3) that takes the movement of the piston, and head-cover (5) that serves as a head/guide. The cylinder tube (1) and the piston rod (3) has a eye to mount the cylinder assembly. Packings, seals and bushing are used in the moving part or on the mounting part between piston (10) and cylinder tube (1), between piston rod (3) and head-cover (5) and between cylinder tube (1) and head-cover (5).



Figure 1 Structure, cylinder 1



Tube



3



Piston rod



5



Head-cover



10 Piston Operation of cylinder with cushion If pressurized oil is fed alternately to the oil inlet and outlet provided in the cylinder, force acts on the piston which in turn causes piston rod (3) to extend and retract. Cushion on head-cover side If moving piston (10) strikes head-cover (5) without deceleration, impact results. A cushioning mechanism is provided to prevent it, as shown in following figure. When the piston is in its intermediate stroke with the head side under pressure, the oil in chamber “A” passes through path “B” at a constant velocity and returns to the tank. Then as cushion ring (7) plunges into path “B” before the stroke end, the oil in chamber “A” goes through clearance “D”. As a result the oil flow returning to the tank decreases sharply which in turn reduces the moving speed of the piston.



Figure 2 Cushion action on rod side A



Chamber



T



Tank



C



Cushion ring



5



Head-cover



D



Clearance



7



Cushion ring



S



Stroke



Cushion on piston side In the same way as the construction of the rod side cushion, the oil passes through path “B” at a constant velocity and goes back to the tank when the piston is at its intermediate stroke with the rod side under pressure. Next, if cushion plunger (9) plunges into path “B” before the stroke end, the oil goes only through clearance (A) between pass “B” and cushion plunger (9). As a result the oil flow returning to the tank decreases sharply which in turn reduces the speed of the piston.



Figure 3 Cushion action on piston side A



Clearance



T



Tank



9



Cushion plunger



Service Information Document Title: Cylinder, troubleshooting



Function Group: 970



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Cylinder, troubleshooting Troubleshooting of hydraulic cylinder and remedy It is not easy to detect the all the causes of a problem. A cylinder malfunction may not result from the failure of only one part, but from a combination of different causes in the total system. The following table describes general phenomenon, assumptive cause and remedy. See assumptive cause and remedy of table for repairs. Other remedies may be needed beyond this table. If so, contact your dealer or Volvo for further detailed investigation. Trouble



Faulty part



Oil leaks past piston rod the sliding surface of piston rod (oil forms on piston rod and drips) Rod packing (Buffer ring, Uring)



Cause



Remedy



Scoring and rust on sliding surface of piston rod Hard chromium plating has peeled off



Remove scoring and smooth surface with an oilstone. If it still leaks replace all seals and rod bushing Inspect rod and replace if required Replace the rod



Contamination is caught in the cylinder bore Packing worn or chaffed. Packing is burnt due to compression of air in cylinder Elasticity of packing is deteriorated and ragged Packing is protruding thru wiper ring



Remove contamination Replace packing Replace packing and bleed cylinder Replace packing and inspect quality of hydraulic oil. Check for cause of abnormal temperature and change oil if required Replace packing and check for abnormal high pressure setting



Buffer ring



Deformed irregularity



Wiper ring



Contamination is caught Remove contamination in the bore of wiper ring Replace wiper ring Ring lip is damaged



Cylinder bushing



head Worn beyond limit or scored



Oil leak at joint O-ring between cylinder head and cylinder Buffer ring tube



other Replace rod packing and check for abnormal high pressure setting



service Replace bushing



Contamination or Remove contamination, replace O-ring and check mating damage to O-ring during surfaces assembly Deformed damage



Piston



Cylinder bolts



or



or



other Replace buffer ring



Piston loosening on rod



head Bolts loosening



Cylinder tube



Disassemble and retorque nut, retorque locking set screw, also check rod threads for damage and replace rod if required Retorque bolts, if bolts are stretched replace all bolts



Deformed or rod travel If deformed replace tube jamming It rod jams check for internal scoring, If tube is beyond polishing replace it



Oil leak at tube Cylinder tube welds



Cracks in weld joints



Grind out weld and reweld using proper method. If severe replace tube



Oil leak at pipe Pipe assembly



Loose bolts



Retorque bolts



joint or welds



Cylinder does Piston rod not operate smoothly



Cracked pipe



Replace pipe assembly



Cracks in weld joints



Grind out weld and reweld using proper method



Rod bend allowable limit



exceeds Replace rod



Binding in cylinder head



Check for contamination or damaged head seals, inspect bushing



Cylinder tube



Deformed, dented Piston and tube scoring



Replace tube Replace piston and tube



Piston rod extends and retracts by itself, also does not have power at specified speed, (internal leakage)



Piston seal



Damaged or worn



Replace seals, check for faulty piston and tube



Cylinder tube



Deformed or scored



Replace tube, if minor score repair



Piston nut



Loose



Retorque nut and lock set screw, check rod threads for damage and repair or replace rod



Control valve



Leakage in valve



Check for contamination or faulty valve. Replace if damaged



Abnormal operation



Cylinder circuit



or Air in system, properly purged



Heavy impact Mounting pins Excessive wear when cylinder is and bushings damaged parts extended or retracted



not Perform bleeding operation and recheck performance. (A long stroke cylinder may retract upon a sudden stop) or



Abnormal noise Mounting pins Insufficient or wrong Replace pins and bushings as required of cylinder and bushings type of lubrication Apply lubrication and ensure it is worked completely when moving through pin/bushing Damaged or worn Replace as required NOTE! Hydraulic fluid viscosity changes according to temperature and pressure.



This may cause a cylinder to extend or retract to some extent. This action is sometimes mistaken as internal leakage.



Always check internal leakage at normal operating temperature and pressure.



Service Information Document Title: Digging unit, maintenance



Function Group: 970



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Digging unit, maintenance Clearance between pins and bushing



Figure 1 Position, pin and bushing Wear limits, series: mm (in) Check item



Standard size



Pin diameter



Bushing bore



Repair limit



Repair limit



Clearance limit



Clearance limit



A



Boom mounting pins



110 (4.33)



109 (4.29)



B



Boom cylinder mounting pins



100 (3.93)



99 (3.83)



98.5 (3.87) 101 (3.97) 101.5 (3.99)



C



Boom cylinder rod end pin



110 (4.33)



109 (4.29)



108.5 (4.27) 111 (4.37) 111.5 (4.38)



D



Arm cylinder mounting pin



110 (4.33)



109 (4.29)



108.5 (4.27) 111 (4.37) 111.5 (4.38)



E



Boom – Arm coupling pin



120 (4.72)



119 (4.68)



118.5 (4.66) 121 (4.76) 121.5 (4.78)



F



Arm cylinder rod end pin



110 (4.33)



109 (4.29)



108.5 (4.27) 111 (4.37) 111.5 (4.38)



G



Bucket cylinder mounting pin



100 (3.93)



99 (3.89)



98.5 (3.87) 101 (3.97) 101.5 (3.99)



H



Arm – Link coupling pin



100 (3.93)



99 (3.89)



98.5 (3.87) 101 (3.97) 101.5 (3.99)



I



Bucket – Arm coupling pin



110 (4.33)



109 (4.29)



108.5 (4.27) 111 (4.37) 111.5 (4.38)



J



Bucket cylinder rod end pin



110 (4.33)



109 (4.29)



108.5 (4.27) 111 (4.37) 111.5 (4.38)



K



Bucket – Link coupling pin



100 (3.93)



99 (3.89)



98.5 (3.87) 101 (3.97) 101.5 (4.38)



Greasing Lubricating position



Remedy



108.5 (4.27) 111 (4.37) 111.5 (4.38) Replace



Figure 2



See the lubrication charts in Operator's Manual.



Service Information Document Title: Function Group: Cylinder, disassembly and 970 assembly



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Cylinder, disassembly and assembly Precautions 



When reinstalling a hydraulic cylinder it is essential to bleed the air from the cylinder. 



Observe the following procedure : 1. 2.



3.



       



Run engine at low idle speed. Operate cylinder retraction and extension 4 ~ 5 times. Do not operate to the end of the stroke, but stop about 100 mm (4 in) from the end of the stroke. (Do not relieve at the end of stroke.) Operate cylinder 4 ~ 5 times to the end of stroke. After completing above procedure, run the engine for normal working conditions and start actual work operation.



When storing the hydraulic cylinder for more than 1 month, coat the cylinder rod with grease to protect the chrome plated area from rust (Oxidization). Clean the packing with hydraulic oil. Other oils shorten packing life. Coat grease on pins and bushings. Excessive temperatures of a paint drying booth can affect cylinder packing and seals, resulting in cylinder failure or oil leaks. Paint overspray on a cylinder rod can damage the wiper seal, allowing contamination into the cylinder assembly. Prior to painting wrap the exposed chrome plating and after completion of painting clean the rod thoroughly. Salt water and materials containing chlorides or acids can cause the chrome plating to peel, pit or rust. Daily, upon completion of work, clean the cylinder rod and apply an anti–corrosive. Traverse loading of a cylinder rod (bending) or excessive vibration can damage the cylinder head dry bushing, wiper seal and the rod chrome plating, resulting in an oil leak and the ingression of contamination. High pressure washers can force dirt and water under the wiper seal lip, contaminating the cylinder. Always keep the spray nozzle at an angle of 45° or greater to the rod.



Preparation before disassembly Before disassembly, clean working area and facilities. Work area The following working area is required for disassembly : Sufficient space For disassembly of the hydraulic cylinder, the cylinder head and the piston rod must be extracted. Therefore, the first prerequisite is that the working area must have sufficient space for such work. It is also necessary that the area have ample space widthwise to accommodate disassembly, cleaning and measuring facilities. Suitable working environment The hydraulic cylinder is a precision machined product incorporating seals and packing made of rubber and plastic materials. For this reason, care should be used so that the hydraulic cylinder is free from dust, dirt, sand, metal chips, weld slag and other contaminants. If the hydraulic cylinder is assembled with hard particles stuck on the cylinder tube and piston rod, the tube inner surface and the rod surface will be scratched as the cylinder operates, thereby disabling it. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding should be avoided near the working area to keep it clean. Apparatus The following equipment is required for disassembly :



Hoist or crane The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable of making level and linear movement under load for inserting and extracting the piston rod. Work bench The work bench must have strength and rigidity capable of accommodating the total length of the cylinder in its most retracted condition and of withstanding the rotary force of the tightening torques of the cylinder head and the piston nut. Support stand If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent such damage. Hydraulic source A hydraulic source is required for disassembly and assembly of the rod, piston nut and for oil leak tests after completion of assembly. Compressed air source It is used for drying after oil draining and cleaning of the cylinder. Cleaning tank, cleaning solvent Oil pan and oil reservoir An oil pan is necessary to contain oil drained from the cylinder and spilt during work. An oil reservoir is required to collect oil spilt on the floor and waste oil. Others Oil extracting hoses, wooden skids, rags and absorbent for absorbing oil are also necessary. External cleaning Prior to bringing a hydraulic cylinder into the workshop thoroughly steam clean it to remove all mud, grease etc. NOTE! The cylinder described below is the cushion type, however, check the construction of the cylinder with the parts catalogue when disassembling and servicing the cylinder. Discharging oil Place wooden blocks on the workbench to support the cylinder, and clamp it in a vise to prevent it from rotating. Push/pull the piston rod till all hydraulic oil in the cylinder is drained out. At this time, connect a suitable hose to each port to drain the hydraulic oil into a container.



Figure 1 Discharging, oil 1



V - Block



4



Oil pan



2



Port B



5



Port A



3



Wood



Cylinder, disassembly



Op nbr 00000 Tool (Boom cylinder) : 14560123 Socket wrench Tool (Arm cylinder) : 14632430 Socket wrench Tool (Bucket cylinder) : 14560123 Socket wrench Disassembly of piston rod and cylinder head assembly 1. Disassemble the cylinder head assembly from the cylinder tube. 1. 2.



Remove mounting screws of cylinder head assembly. Disassemble piston rod and cylinder head assembly from cylinder.  



When piston rod and cylinder head unit are removed, hydraulic oil in the cylinder will drain out. Place a proper container under the cylinder head. If it is difficult to remove, pull the piston rod from the cylinder by rotating it slightly.



Figure 2 Cylinder head, disassembly 1. 2.



Cylinder head assembly Mounting screw



2. Place the piston rod and cylinder head assembly on the supporting block.



Figure 3 Piston rod from cylinder, disassembly 1. 2. 3.



Cylinder Hoist Piston rod



For boom and bucket cylinder 3. Remove lock nut with special tool and then remove washer.



Figure 4 Lock nut, disassembly 1. 2.



Lock washer Lock nut



For arm cylinder 4. Remove set screw, pin and cushion plunger. Remove lock nut with socket wrench and then remove washer.



Figure 5 Lock nut, disassembly 1. 2. 3. 4.



Lock washer Set screw Cushion plunger Lock nut



5. After removing the lock nut, remove the piston assembly, back up ring, cushion ring and cylinder head assembly. NOTE! Be careful not to damage the rod seal, or the piston rod thread when removing the cylinder head assembly. Rotate the piston assembly counterclockwise to disassemble.



Figure 6 Piston assembly, disassembly 1. 2. 3.



Cylinder head assembly Cushion ring Piston assembly



Disassembly of piston assembly NOTE! Do not remove contamination seal, wear ring and seal, if not damaged. 6. Remove contamination seal, wear ring, seal, O-ring from the piston. NOTE!



Do not reuse contamination seal, wear ring, seal and O-ring after removal.



Figure 7 Piston, disassembly 1



O-ring & back up rings



4



Wear ring



2



Piston



5



Seal



3



Contamination seal



Disassembly of cylinder head assembly



7. Figure 8 Cylinder head, disassembly 1



Retaining ring



6



Bushing



2



Wiper seal



7



Head cover



3



Rod seal



8



O-ring



4



Back up ring



9



Back up ring



5



Buffer ring



NOTE! Do not remove seal, back-up ring and wiper seal, if not damaged. NOTE! Do not reuse removed seals. When reassembling, replace the bushing with a new one if worn. NOTE! Do not remove bushing if not damaged. If removed, replace the bushing with a new one when reassembling. Inspection after disassembly Visually inspect all parts after cleaning for excessive wear, cracks and other faults. Inspection item Part



Section



Fault



Remedy



Piston rod



Neck of rod eye.



Presence of crack.



Replace.



Weld on rod eye.



Presence of crack.



Replace.



Stepped part to which piston Presence of crack. is attached.



Replace.



Threads.



Presence of seizure.



Recondition or replace.



Bend.



Measure degree of bend Check that :



Plated surface.



Cylinder tube



Cylinder head



Plating is not worn off to base Replace or replate. metal. Rust is not present on plating.



Replace or replate.



Scratches are not present.



Recondition, replate or replace.



Rod.



Wear of outer diameter.



Recondition, replate or replace.



Bushing at mounting part



Wear of outer diameter.



Replace.



Weld on bottom.



Presence of crack.



Replace.



Weld on head.



Presence of crack.



Replace.



Weld on hub.



Presence of faults.



Replace if oil leakage or bypassing is evident.



Tube interior.



Wear on inner surface.



Replace.



Bushing.



Wear on inner surface.



Replace.



Flaw on inner surface.



Replace if flaw is deeper than coating.



Repair method Check all seals and parts to see that they do not show excessive damage and wear. For correction of faults on the piston rod, observe the following procedure:  



Correct fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep that it may be caught by your nail. In case of a smooth indentation, recondition by removing the sharp area around the indentation with an oilstone : if the flaw or the indentation is excessive, replace or replate the piston rod.



NOTE! Always regrind after replating. The thickness of the plating must be minimum 0.25 mm (0.010 in). NOTE! If the plating is removed to the base metal during reconditioning with an oilstone, the rod must be replated. Limit of serviceability Clearance between piston rod and rod bushing Replace the bushing if the clearance between the piston rod and rod bushing exceeds 0.25 mm (0.010 in). Bend of piston rod The allowable bend of the rod is maximum 1mm/m (0.040″). For measurement, support both ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the center between the two V-blocks, turn the piston rod, and read the difference between the maximum and minimum oscillations on the dial indicator



Figure 9 Measurement, bend Bend limit Spacing between V–blocks



Intermediate value in dial indicator readings × 1/2



Remedy



1 m (3′3″)



1 mm (0.040″)



Replace



NOTE! If the bend is within the above limit, the cylinder may not operate smoothly because of localized bend. Beware of it during function test after assembly. Replace the rod if the cylinder makes an abnormal sound or does not operate smoothly. Cylinder, assembly Op nbr 00000 Tool (Boom cylinder) : 14560123 Socket wrench 8920-01450 Drift 8920-01500 Drift 8920-01680 Installation sleeve Tool (Arm cylinder) : 14632430 Socket wrench 8920-01460 Drift 8920-01510 Drift 8920-01690 Installation sleeve Tool (Bucket cylinder) : 14560123 Socket wrench 8920-01430 Drift 8920-01450 Drift 8920-01490 Drift 8920-01500 Drift 14514405 Installation sleeve 8920-01680 Installation sleeve Installation of cylinder head seals. NOTE! To prevent damage of the seal when inserting it, check for sharp edges on the mounting grooves for the seal and wiper seal. If any, remove sharp edges with an oilstone.



Figure 10 Sharp edge, removal 1. 2.



Splinter Oilstone 1. Press the dry bushing into the head and install the retaining ring.



Figure 11 Dry bushing, assembly 1. 2. 3. 4.



Retaining ring Dry bushing Press Jig



2. Apply hydraulic oil on the inner diameter of cylinder head and mounting grooves.



Figure 12 Applying, grease 1.



Apply grease



3. Install buffer ring and the rod seal with care to the direction.



Figure 13 Ring and seal, assembly 1. 2.



Buffer ring Rod seal



4. Install back-up ring to groove B by pressing against inner diameter D. Make sure that the bias edge of installed back-up ring is not overlapped.



Figure 14 Back-up ring, assembly 1.



Back-up ring



5. Assemble the wiper seal into head using the jig.



Figure 15 Dust wiper seal, assembly 1. 2.



Jig Wiper seal



6. Install retaining ring into the head. NOTE! Use jig made of copper, aluminium or plastic, and be careful of sharp edges on the jig. Insert the packing by hand not with the jig, if possible.



Figure 16 Retaining ring, assembly 1.



Retaining ring



7. Install O-rings and back-up rings.



NOTE! Take care to the position of back-up ring.



Figure 17 O-ring and back-up ring, assembly 1. 2.



O-ring Back-up ring



Assembly of piston unit NOTE! Check for sharp edges at piston ring groove.



If any, remove sharp edge with an oilstone.



Figure 18 Piston unit, assembly 1



O-ring



4



Wear ring



2



Piston



5



Seal



3



Contamination seal



Figure 19 Sharp edges, removal 1. 2.



Splinter Oilstone



8. Apply hydraulic oil to locations A.



Figure 20 Applying, hydraulic oil 9. Assemble the piston ring into the center groove of piston.



Figure 21 Piston ring, assembly 10. Assemble wear ring to piston.



Figure 22 Wear ring, assembly 1



O-ring & back up rings



2



Piston



3



Piston seal



4



Wear ring



5



Contamination seal



11. Assemble contamination seal to piston. 12. Assemble O-ring and back up rings into the inner side of piston. Replacement of piston rod and cylinder tube bushing NOTE! If necessary to replace bushing, remove the bushing in the same method as figure, and replace with new one.   



Replace the lower boom cylinder bushing, see: 9743 Lower boom cylinder bushing, replacing. Replace the upper boom cylinder bushing, see: 9743 Upper boom cylinder bushing, replacing. Replace the dipper arm cylinder 9753 Dipper arm cylinder bushing on boom, replacing.



bushing







Replace the dipper arm cylinder bushing 9753 Dipper arm cylinder bushing on dipper arm, replacing.







Replace the bucket cylinder bushing 9755 Bucket cylinder bushing on dipper arm, replacing.



on on



on dipper dipper



boom, arm, arm,



see: see: see:







Replace the bucket cylinder bushing lever-link, see: 9755 Bucket cylinder bushing lever-link, replacing.



Assembly of piston rod and head assembly 13. Mount the piston rod on the work table and be careful not to damage chrome plated sliding surface of rod.



Figure 23 Head, assembly 1.



Head



14. Install head assembly to piston rod. NOTE! Be careful not to damage the rod seal on the piston rod thread. 15. Assemble cushion ring to piston rod.



Figure 24 Cushion ring, assembly 1. 2.



Head Cushion ring



For boom and bucket cylinder 16. Assemble the piston assembly and tighten it to piston rod. NOTE! Take care not to damage the O-ring inside the piston.



Figure 25 Piston and lock nut, assembly 1



Head



2



Cushion ring



3



Piston assembly



5



Lock nut



4



Lock washer



NOTE! Be careful of the tightening direction of piston. 17. Assemble the lock washer and tighten the lock nut. NOTE! Be careful of the tightening direction of lock nut. For arm cylinder 18. Assemble the piston assembly and tighten it to piston rod. NOTE! Take care not to damage the O-ring inside the piston.



Figure 26 Piston and cushion plunger, assembly 1



Head



2



Cushion ring



3



Piston assembly



4



Lock washer



5



Lock nut



6



Set screw



7



Pin



4



cushion plunger



2



Head



NOTE! Be careful of the tightening direction of piston. 19. Assemble the lock washer and tighten the lock nut. NOTE! Be careful of the tightening direction of lock nut. 20. Assemble the cushion plunger and tighten the set screw. Assembly of piston rod and cylinder tube 21. Insert the piston rod assembly into the cylinder tube.



Figure 27 Insertion, head 1



Tube



3



Piston rod



NOTE! Take care not to damage the piston seal when assembling. NOTE! The piston rod and cylinder tube must be kept parallel. NOTE! Carefully insert the head so as not to damage the O-rings. 22. Align the screw holes of cylinder tube with head and tighten it to the specified torque. Inspection after assembly No load functional test Place the cylinder level under no load. NOTE! Do not raise the hydraulic pressure above the maximum pressure of the machine circuit. NOTE! Grease coated on the O-rings and seals of the head may ooze out. Wipe it off and retest the cylinder. Leak test 1.



Apply a test pressure to the retracting and extending sides of the cylinder for three minutes independently, and check that the rod section and the welds have no external leaks. For an internal leak test, connect the cylinder as shown in Figure.



Figure 28 External leak test A. B. C. 2.



Hydraulic cylinder Control valve Pump



After completing the test, install a plug to each port.



Figure 29 Internal leak test A. B. NOTE!



Measure the internal leak From main control valve



For storage, place the cylinder on wooden V-blocks and bring the cylinder to the most retracted position.



Figure 30 Storage method A. B. C.



Plug Cylinder assembly Plug



Service Information Document Title: Boom, description



Function Group:



Profile: EXC, EC480D L [GB]



Boom, description



Figure 1 Boom, structure Gap and shims: mm (in)



Information Type: Service Information



Date: 2014/7/15



Items



Gap



Necessary shims for maximum gap



Position



Minimum



Maximum



Shim (1t) quantity



Shim (0.5t) quantity



GAP1



+0.2 (0.007)



+1.0 (0.039)



-



1



GAP2



+0.5 (0.019)



+2.5 (0.098)



2



2



GAP3



0.0 (0.0)



+3.0 (0.118)



2



2



GAP4



+0.5 (0.019)



+2.5 (0.098)



1



1



GAP5



+0.6 (0.024)



+1.2 (0.047)



-



-



NOTE! GAP1 should be smaller than 0.5 mm (0.019 in).



The other parts should be smaller than 1.0 mm (0.039 in). Initial lubricating table (unit : cc) Nipple



Initial grease amount



Location



GR1



40 x 2 = 80



Boom rear bearing



GR2



150 x 2 = 300



Boom cylinder rod



GR3



180



Arm cylinder tube



GR4



30 x 2 = 60



Boom cylinder tube



NOTE! Grease hose/bearing inner space included.



Service Information Document Title: Boom, removal



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom, removal Op nbr 974-013 1. Park the machine on level, firm ground. Secure enough space around the machine to work safety. Park the machine in the service position D, see 091 Service positions.



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Plug all disconnect hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Lower the attachment so that the bottom of the bucket is in full contact with the ground.



Figure 1



3. Curl arm (1) completely, lower attachment assembly to the ground and lay wooden block (2) position as shown. 4. Remove grease hose (4) at arm cylinder rod. 5. Remove lock screws (5) and pin (6) of arm cylinder rod. 6. Restrict arm cylinder rod fully, and fix cylinder rod (7). 7. Remove hydraulic hoses (3) of boom. 8. Remove split pin, castle nut, spacer, lock screw (9) and pin (8) of joining boom (10) and arm (1). 9. Remove boom (10) and arm (1). 10. Park the machine in the service position E, see 091 Service positions. 11. Remove grease hose (15) at boom cylinder rod. 12. Hold one boom cylinder (17) with hoist (11). 13. Remove lock screw (13), lock collar (14) then push pin (16) to opposite side. Remove boom cylinder rod. 14. Restrict boom cylinder rod fully and hold securely. Lower boom cylinder (17) and place on wooden block (20). 15. Carry out same work with opposite boom cylinder.



Figure 2



16. Remove work lamp connector wire for boom. Remove arm and bucket cylinder hoses.



Figure 3



17. Hold boom and hydraulic line with hoist (11), and prepare for lifting. 18. Remove lock plate (22) at boom mounting lift pin (21). 19. Remove boom mounting lift pin (21). 20. Remove lock plate (24) at boom mounting right pin (23). 21. Remove boom mounting right pin (23). 22. Lift boom (10) and lower to work bench safely.



Service Information Document Title: Boom, installation



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom, installation Op nbr 974-014 1. Park the machine on level, firm ground. Secure enough space around the machine to work safety. Park the machine in the service position E, see 091 Service positions.



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Plug all disconnected hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Hold boom (17) with hoist (11).



Figure 1



3. Install boom (10) to machine with boom mounting right pin (23). 4. Install lock plate (24) of boom mounting right pin (23). 5. Install boom (10) to machine with boom mounting left pin (21). 6. Install lock plate (22) of boom mounting lift pin (21).



7. Connect hoses of arm and bucket cylinders. 8. Install work lamp connector wire for boom (10). 9. Hold one boom cylinder (17) with hoist (11). 10. Install pin (16) from opposite side, install lock collar (14) and lock screw (13). 11. Carry out the same work with the opposite boom cylinder. 12. Connect grease hose (15) at boom cylinder rod.



Figure 2



13. Install pin (8), lock screw (9), spacer, castle nut, and split pin of joining boom (10) and arm (1). 14. Install pin (6), lock plate (5) and screw for arm cylinder rod. 15. Connect grease hose (4) of arm cylinder. 16. Connect hoses (3) at bucket cylinder.



Figure 3



Service Information Document Title: Boom, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom, replacing Op nbr 974-010 1. Park the machine on level, firm ground. Secure enough space around the machine to work safety. Park the machine in the service position E, see 091 Service positions.



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Plug all disconnected hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Refer to the boom (1) removal for detailed information, see 9741 Boom, removal.



Figure 1



3. Remove work light wire harness, and assemble to new boom. 4. Remove work light bracket, and assemble to new boom. 5. Remove arm cylinder, and assemble to new boom. Refer to the dipper arm cylinder replacing for detailed information, see 9753 Dipper arm cylinder, replacing. 6. Remove bucket cylinder pipe, and assemble to new boom. 7. Remove arm cylinder pipe and hose, and install to new boom. 8. Remove grease hose and connector fitting, and install to new boom. 9. Refer to the boom installation for detailed information, see 9741 Boom, installation. 10. Check the machine operation.



Service Information Document Title: Boom cylinder, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom cylinder, description



Figure 1 Boom cylinder, exploded view 1 Tube



9 Cushion ring



17 Rod packing



25 Contami seal



2 Bushing



10 Piston



18 Buffer ring



26 Dust seal



3 Rod



11 Lock washer



19 Back-up ring



27 Set screw



4 Bushing



12 Lock nut



20 O-ring



5 Head cover



13 Screw



21 O-ring



6 Bearing



14 Grease nipple



22 Back-up ring



7 Retaining ring



15 Wiper-seal



23 Piston packing



8 Retaining ring



16 Back-up ring



24 Wear ring



Tightening torque



Figure 2



Tightening torque, unit: Nm (lbf ft) A



B



Piston nut, to tighten turn Lock nut, to tighten clockwise counterclockwise 950 ±95 (703 ±70) NOTE!



600 ±60 (444 ±44)



C turn Set-screw 17 ±1.7 (12.5 ±1.25)



D Screw 512 ±51 (379 ±37.7)



Apply Loctite #277 on the piston, lock nut and thread of the rod. Volume of oil leakage Oil leakage Cylinder



Volume of internal oil leakage



Boom



11.6 cc (0.70 cu·in) 10 minutes (0.39 inch) or below



Wear limits



Figure 3 Maintenance standards Wear limits, unit: mm (inch) Item



Standar Tolerance d value Shaft



Standard clearance Hole



Clearance limit



Clearance between 110 (4.3) –0.036 ~ –0.090 piston rod and bushing (-0.0014 ~ 0.0035) (A)



+0.195 ~ +0.060 (+0.0076 ~ +0.0023)



0.096 ~ 0.285 (0.0037 ~ 0.011)



0.585 (0.023)



Clearance piston rod bushing (B)



between 110 (4.3) pin and



+0.036 ~ +0.226 (+0.0089 ~ +0.0014)



+0.036 ~ +0.226 (+0.0089 ~ +0.0014)



1.0 (0.039)



Clearance between rear 100 (3.9) end pin and bushing (C)



+0.036 ~ +0.226 (+0.0089 ~ +0.0014)



+0.036 ~ +0.226 (+0.0089 ~ +0.0014)



Service Information Document Title: Boom cylinder, removal



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom cylinder, removal Op nbr 974-031 1. Park the machine on level, firm ground. Secure enough space around the machine to work safely. Park the machine in the service position E, see 091 Service positions.



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Plug all disconnected hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Hold one boom cylinder with hoist.



Figure 1 Boom cylinder, removal 1. 2. 3. 4. 5. 6.



Hoist Lock collar Grease hose Pin Lock screw Wooden block



3. Remove the grease hose on the boom cylinder rod. 4. Remove the lock screw and the lock collar, then push the pin to opposite side to remove it from the cylinder rod. 5. Retract the boom cylinder rod fully and fix securely. 6. Remove the boom cylinder hose.



Figure 2 Boom cylinder, removal 1.



Hoses



7. Lower the boom cylinder onto wooden block with hoist. 8. Hold boom cylinder with hoist again.



Figure 3 Boom cylinder, removal 1. 2. 3.



Hoist Pin Lock plate



9. Remove lock plate and the cylinder mounting pin. 10. Lift boom cylinder and lower to work area safely.



Service Information Document Title: Boom cylinder, installation



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom cylinder, installation Op nbr 974-032 1. Park the machine on level, firm ground. Secure enough space around the machine to work safely. Park the machine in the service position E, see 091 Service positions.



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Plug all disconnected hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Hold the boom cylinder with hoist.



Figure 1 Boom cylinder, installation 1. 2. 3.



Hoist Pin Lock plate



3. Install the boom cylinder mounting pin and lock plate. 4. Install the boom cylinder hoses.



Figure 2 Boom cylinder, installation 1.



Hoses



5. Lift the boom cylinder to install the cylinder rod with hoist. 6. Insert pin into boom cylinder rod. Install lock collar and lock screw.



Figure 3 Boom cylinder, installation 1. 2. 3. 4. 5. 6.



Hoist Lock collar Grease hose Pin Lock screw Wooden block



7. Install boom cylinder grease hose.



Service Information Document Title: Boom cylinder, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Boom cylinder, replacing Op nbr 974-021 1. Park the machine on level, firm ground. Secure enough space around the machine to work safely. Park the machine in the service position E, see 091 Service positions.



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Plug all disconnected hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Hold the boom cylinder with hoist.



Figure 1 Boom cylinder, removal 1. 2. 3. 4. 5. 6.



Hoist Lock collar Grease hose Pin Lock screw Wooden block



3. Remove the grease hose on the boom cylinder rod. 4. Remove the lock screw and lock collar, then push the pin to opposite side to remove it from the cylinder rod. 5. Retract boom cylinder rod fully and fix securely. 6. Remove the boom cylinder hoses.



Figure 2 Boom cylinder, removal 1.



Hoses



7. Lower the boom cylinder onto wooden block with hoist. 8. Hold boom cylinder with hoist again.



Figure 3 Boom cylinder, removal 1. 2. 3.



Hoist Pin Lock plate



9. Remove lock plate and the boom cylinder mounting pin. 10. Lift boom cylinder and lower to work area safely. 11. Transfer pipe, clamp and cover to new boom cylinder. 12. Hold the boom cylinder with hoist.



Figure 4 Boom cylinder, installation 1. 2. 3.



Hoist Pin Lock plate



13. Install the boom cylinder mounting pin and lock plate. 14. Install the boom cylinder hoses.



Figure 5 Boom cylinder, installation 1.



Hoses



15. Lift the boom cylinder to install the cylinder rod with hoist. 16. Insert pin into boom cylinder rod. Install lock collar and lock screw.



Figure 6 Boom cylinder, installation 1. 2. 3. 4. 5. 6.



Hoist Lock collar Grease hose Pin Lock screw Wooden block



17. Install boom cylinder grease hose.



Service Information Document Title: Dipper arm, description



Function Group:



Profile: EXC, EC480D L [GB]



Dipper arm, description



Figure 1 Dipper arm, structure 1 Dust seal 2 Bushing 3 Shim 4 Shim



Information Type: Service Information



Date: 2014/7/15



Gap and shims: mm (in) Items



Gap



Necessary shims for maximum gap



Position



Minimum



Maximum



Shim (1t) quantity



Shim (0.5t) quantity



GAP1



+0.5 (0.019)



+2.5 (0.098)



1



1



GAP2



+0.5 (0.019)



+2.5 (0.098)



1



1



GAP3



+2.0 (0.078)



+3.0 (0.118)



2



-



NOTE! GAP should be smaller than 1.0 mm (0.039 in). Initial lubricating table (unit : cc) Nipple



Initial grease amount



Location



GR1



5 x 2 = 10



Boom bearing



GR2



5 x 2 = 10



Arm cylinder rod



GR3



5 x 2 = 10



Bucket cylinder tube



GR4



2383



Yoke bearing



GR5



4x2=8



Bucket bearing



NOTE! Grease hose/bearing inner space included.



Service Information Document Title: Dipper arm, removal



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Dipper arm, removal Op nbr 975-011 1. Park the machine on level, firm ground. Secure enough space around the machine to work safely. Park the machine on level, firm ground. Secure enough space around the machine.



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Plug all disconnect hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Lower the attachment so that the bucket is in full contact with the ground. Park the machine in the service position D, see 091 Service positions.



Figure 1 Dipper arm, removal 1. 2. 3.



Bucket link pin Lock screw Code rings



3. Remove lock screw, bucket link pin and code rings. 4. Retract the bucket cylinder rod fully.



Figure 2 Dipper arm, removal 1. 2. 3.



Bucket pin Lock screw Arm connecting rod



5. Remove lock screw and bucket pin. 6. Remove hydraulic hoses.



Figure 3 Dipper arm, removal 1.



Hoses



7. Hold arm cylinder with hoist.



Figure 4 Dipper arm, removal 1. 2.



Hoist Arm cylinder



8. Remove the grease hose at arm cylinder rod. Remove lock plate and arm cylinder rod pin. Place wooden block on boom and lower arm cylinder on wooden block.



Figure 5 Dipper arm, removal 1. 2. 3. 4.



Grease hose Arm cylinder rod Arm cylinder rod pin Lock plate



9. Retract arm cylinder rod fully. Install arm cylinder rod pin and lock plate. Hold arm with hoist.



Figure 6 Dipper arm, removal 1. 2. 3. 4. 5.



Arm cylinder rod pin Lock plate Hoist Lock screw Pin



10. Remove lock screw and pin. Remove dipper arm.



Service Information Document Title: Dipper arm, installation



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Dipper arm, installation Op nbr 975-012 1. Park the machine on level, firm ground. Secure enough space around the machine to work safely. Park the machine in the service position A, see 091 Service positions



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Plug all disconnect hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Hold arm with hoist. Install pin and lock screw.



Figure 1 Dipper arm, installation 1. 2. 3. 4. 5.



Arm cylinder rod pin Lock plate Hoist Lock screw Pin



3. Remove hoist, arm cylinder rod pin and lock plate. 4. Hold arm cylinder with hoist.



Figure 2 Dipper arm, installation 1. 2.



Hoist Arm cylinder



5. Install arm cylinder rod pin and lock plate.



Figure 3 Dipper arm, installation 1. 2. 3. 4.



Grease hose Arm cylinder rod Arm cylinder rod pin Lock plate



6. Install grease hose at arm cylinder rod. 7. Install hydraulic hoses.



Figure 4 Dipper arm, installation 1.



Hoses



8. Install bucket pin and lock screw.



Figure 5 Dipper arm, installation 1. 2. 3.



Bucket pin Lock screw Arm connecting rod



9. Install bucket link pin, code rings and lock screw.



Figure 6 Dipper arm, installation



1. 2. 3.



Bucket link pin Lock screw Code rings



10. Check the machine operation.



Service Information Document Title: Dipper arm, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Dipper arm, replacing Op nbr 975-039



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Plug all disconnected hoses to prevent oil leakage and contamination from entering the hydraulic system. 1. Refer to the dipper arm (1) removal for detailed information. see 9751 Dipper arm, removal.



Figure 1



2. Transfer work light harness and bracket to new arm. 3. Remove bucket cylinder and assemble to new arm. see 9755 Bucket cylinder, replacing. 4. Transfer bucket cylinder pipe and hose to new arm. 5. Transfer grease hose and connector fitting to new arm. 6. Refer to the dipper arm (1) installation for detailed information. see 9751 Dipper arm, installation.



Service Information Document Title: Link, description



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Link, description



Figure 1 Link, structure 1. 2. 3. 4. 5.



Screw Nut Shim Shim Pin with lock



Gap and shims: mm (in) Items



Gap



Necessary shims for maximum gap



Position



Minimum



Maximum



Shim quantity (1.0t)



Shim quantity (0.5t)



GAP1



+0.5 (0.020)



+2.5 (0.098)



2



-



GAP2



+2.0 (0.078)



+3.0 (0.118)



2



-



GAP3



+2.0 (0.078)



+1.5 (0.059)



-



-



GAP4



-



+2.0 (0.078)



-



-



NOTE! GAP should be smaller than 1.0 mm (0.039 in) Initial lubricating table (unit: cc) Nipple



Initial grease amount



Location



GR1



25



Bucket cylinder rod



GR2



25 × 2 = 50



Connecting rod + cylinder



GR3



25 × 2 = 50



Connecting rod + bucket



NOTE!



Grease hose/bearing inner space included.



Service Information Document Title: Function Group: Dipper arm connecting rod, removal



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Dipper arm connecting rod, removal Op nbr 975-006



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine in the service position A, see 091 Service positions. Park the machine on level, firm ground. Secure enough space around the machine to work safely. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. NOTE! Plug all disconnected hoses, to prevent oil leakage and contamination from entering the hydraulic system. 2. Place wooden block between arm and bucket cylinder. Place wooden block between arm and connecting rod.



Figure 1 Arm connecting rod, removal 1. 2. 3. 4. 5. 6.



Connecting rod Hoist Bucket cylinder rod pin Lock screw Bucket cylinder Wooden block



3. Hold yoke with hoist. 4. Remove the lock screw and bucket cylinder rod pin carefully. Lower both sides of yoke carefully. 5. Hold connecting rod with hoist.



Figure 2 Arm connecting rod, removal 1. 2. 3. 4.



Hoist Connecting rod Lock screw Bucket link pin



6. Remove lock screw and bucket link pin. Remove the connecting rod.



Service Information Document Title: Function Group: Dipper arm connecting rod, installation



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Dipper arm connecting rod, installation Op nbr 975-007



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine in the service position A, see 091 Service positions. Park the machine on level, firm ground. Secure enough space around the machine to work safely. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. 2. Hold connecting rod with hoist.



Figure 1 Arm connecting rod, installation 1. 2. 3. 4.



Hoist Connecting rod Lock screw Bucket link pin



3. Install bucket link pin and lock screw. 4. Place wooden block between arm and connecting rod.



Figure 2 Arm connecting rod, installation 1. 2. 3. 4. 5. 6.



Hoist Wooden block Connecting rod Bucket cylinder Yoke Bucket cylinder pin



5. Install the yoke, shim, connecting rod and bucket cylinder pin with hoist as shown in figure. NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 6. Remove wooden block between arm and connecting rod. 7. Check the bucket cylinder operation.



Service Information Document Title: Function Group: Dipper arm connecting rod, replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Dipper arm connecting rod, replacing Op nbr 975-024



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine in the service position A, see 091 Service positions. Park the machine on level, firm ground. Secure enough space around the machine to work safely. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. NOTE! Plug all disconnected hoses, to prevent oil leakage and contamination from entering the hydraulic system. 2. Place wooden block between arm and bucket cylinder. Place wooden block between arm and connecting rod.



Figure 1 Arm connecting rod, removal 1. 2. 3. 4. 5. 6.



Connecting rod Hoist Bucket cylinder rod pin Lock screw Bucket cylinder Wooden block



3. Hold yoke with hoist. 4. Remove the lock screw and bucket cylinder rod pin carefully. Lower both sides of yoke carefully. 5. Hold the connecting rod with hoist.



Figure 2 Arm connecting rod, removal 1. 2. 3. 4.



Hoist Connecting rod Lock screw Bucket link pin



6. Remove lock screw and bucket link pin. Remove the connecting rod. 7. Hold a new connecting rod with hoist. Install bucket link pin and lock screw. 8. Place wooden block between arm and connecting rod.



Figure 3 Arm connecting rod, installation 1. 2. 3. 4. 5. 6.



Hoist Wooden block Connecting rod Bucket cylinder Yoke Bucket cylinder pin



9. Install the yoke, shim, connecting rod and bucket cylinder pin with hoist as shown in figure. NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 10. Remove wooden block between arm and connecting rod. 11. Check the bucket cylinder operation.



Service Information Document Title: Connecting rod removal



Function Group: yoke,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Connecting rod yoke, removal Op nbr 975-032



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine in the service position A, see 091 Service positions. Park the machine on level, firm ground. Secure enough space around the machine to work safely. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. NOTE! Plug all disconnected hoses, to prevent oil leakage and contamination from entering the hydraulic system. 2. Place wooden block between arm and bucket cylinder. Place wooden block between arm and connecting rod.



Figure 1 Connecting rod yoke, removal 1. 2. 3. 4. 5. 6.



Connecting rod Hoist Bucket cylinder rod pin Lock screw Bucket cylinder Wooden block



3. Hold yoke with hoist. 4. Remove the lock screw and bucket cylinder rod pin. Lower both sides of yoke carefully. 5. Hold yoke with hoist.



Figure 2 Connecting rod yoke, removal 1. 2. 3. 4.



Yoke Hoist Yoke pin Lock screw



6. Remove the lock screw and the yoke. 7. Hold the other yoke with hoist.



Figure 3 Connecting rod yoke, removal 1. 2. 3.



Hoist Yoke Yoke pin



8. Remove the other yoke and yoke pin.



Service Information Document Title: Connecting rod installation



Function Group: yoke,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Connecting rod yoke, installation Op nbr 975-035



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine in the service position A, see 091 Service positions. Park the machine on level, firm ground. Secure enough space around the machine to work safely. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. 2. Place wooden block between arm and connecting rod.



Figure 1 Connecting rod yoke, installation 1. 2. 3. 4.



Wooden block Hoist Yoke Yoke pin



3. Install the yoke and yoke pin into arm with hoist. 4. Hold the yoke with hoist. Install yoke pin and lock screw.



Figure 2 Connecting rod yoke, installation 1. 2. 3. 4.



Yoke Hoist Yoke pin Lock screw



NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 5. Install the yoke, shim, connecting rod and bucket cylinder pin with hoist as shown in figure.



Figure 3 Connecting rod yoke, installation 1. 2. 3. 4. 5. 6.



Hoist Wooden block Connecting rod Bucket cylinder Yoke Bucket cylinder pin



NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 6. Remove wooden block between arm and connecting rod. 7. Check the connecting rod yoke operation.



Service Information Document Title: Connecting rod replacing



Function Group: yoke,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Connecting rod yoke, replacing Op nbr 975-028



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine in the service position A, see 091 Service positions. Park the machine on level, firm ground. Secure enough space around the machine to work safely. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. NOTE! Plug all disconnected hoses, to prevent oil leakage and contamination from entering the hydraulic system. 2. Place wooden block between arm and bucket cylinder. Place wooden block between arm and connecting rod.



Figure 1 Connecting rod yoke, removal 1. 2. 3. 4. 5. 6.



Connecting rod Hoist Bucket cylinder rod pin Lock screw Bucket cylinder Wooden block



3. Hold yoke with hoist. 4. Remove the lock screw and bucket cylinder rod pin. Lower both sides of yoke carefully. 5. Hold yoke with hoist.



Figure 2 Connecting rod yoke, removal 1. 2. 3. 4.



Yoke Hoist Yoke pin Lock screw



6. Remove the lock screw and the yoke. 7. Hold the other yoke with hoist.



Figure 3 Connecting rod yoke, removal 1. 2. 3. 4.



Wooden block Hoist Yoke Yoke pin



8. Remove the other yoke and yoke pin. 9. Install a new yoke and yoke pin into arm with hoist. 10. Hold yoke with hoist. Install yoke pin and lock screw.



Figure 4 Connecting rod yoke, installation 1. 2. 3. 4.



Yoke Hoist Yoke pin Lock screw



NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 11. Install the yoke, shim, connecting rod and bucket cylinder pin with hoist as shown in figure.



Figure 5 Connecting rod yoke, installation 1. 2. 3. 4. 5. 6.



Hoist Wooden block Connecting rod Bucket cylinder Yoke Bucket cylinder pin



NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 12. Remove wooden block between arm and connecting rod. 13. Check the connecting rod yoke operation.



Service Information Document Title: Dipper arm description



Function Group: cylinder,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Dipper arm cylinder, description



Figure 1 Dipper arm cylinder view 1



Tube



8



Piston



15 Rod seal



22 Contamination seal



2



Rod



9



Cushion plunger



16 Buffer ring



23 Wear ring



3



Head cover



10 Pin



17 Back-up ring



4



Bushing



11 Set screw



18 O-ring



5



Retaining ring



12 Screw



19 Back-up ring



6



Retaining ring



13 Seal



20 O-ring



7



Cushion ring



14 Back-up ring



21 Piston seal



Tightening torque



Figure 2



Tightening torque, unit: Nm (lbf ft) A



B



C



Piston nut, to tighten turn clockwise



Set-screw



Screw



950 ±95 (703 ±70)



30 ±3 (22.2 ±2.2)



690 ±70 (510.6 ±51.8)



NOTE! Apply Loctite #277 to the piston and set-screw before tightening. Volume of oil leakage



Oil leakage Cylinder



Volume of internal oil leakage



Arm



15.2 cc (0.92 cu·in) 10 minutes or below



Maintenance standard (wear limits)



Figure 3



Wear limits, unit : mm (in) Item



Standar d value



Tolerance



Standard clearance



Clearance limit 0.606 (0.023)



Shaft



Hole



Clearance between 130 piston rod and bushing (5.11) (A)



–0.043 ~ –0.106 (–0.0016 ~ –0.0041)



+0.200 ~ +0.060 (+0.0078 ~ +0.0023)



0.103 ~ 0.306 (0.004 ~ 0.012)



Clearance piston rod bushing (B)



between 110 pin and (4.33)



–0.036 ~ –0.090 (–0.0014 ~ –0.0035)



+0.036 ~ +0.226 (+0.0014 ~ +0.0089)



+0.036 ~ +0.226 1.0 (0.039) (+0.0014 ~ +0.0089)



Clearance between rear 110 end pin and bushing (C) (3.93)



–0.036 ~ –0.090 (–0.0014 ~ –0.0035)



+0.036 ~ +0.226 (+0.0014 ~ +0.0089)



+0.036 ~ +0.226 1.0 (0.039) (+0.0014 ~ +0.0089)



Service Information Document Title: Dipper arm removal



Function Group: cylinder,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Dipper arm cylinder, removal Op nbr 975-014



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine in the service position D, see 091 Service positions.



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Plug all disconnected hoses to prevent oil leakage and contamination from entering the hydraulic system. 2. Hold arm cylinder with hoist.



Figure 1 Arm cylinder rod pin, removal 1. 2. 3. 4.



Hoist Grease hose Arm cylinder rod pin Lock plate



3. Remove grease hose. 4. Remove lock plate and arm cylinder rod pin. 5. Retract arm cylinder rod fully and tie the arm cylinder rod to prevent oil leakage from the main circuit.



Figure 2 Arm cylinder rod, retraction 1. 2.



Arm cylinder rod Hoist



6. Remove arm cylinder hydraulic hoses and grease hose.



Figure 3 Arm cylinder hoses, removal 1.



Hoses



7. Remove arm cylinder lock plate and mounting pin.



Figure 4 Arm cylinder mounting pin, removal 1. 2. 3.



Hoist Arm cylinder mounting pin Lock plate



8. Lift arm cylinder and lower it to work bench safely.



Service Information Document Title: Dipper arm installation



Function Group: cylinder,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Dipper arm cylinder, installation Op nbr 975-015 1. Park the machine in the service position D, see 091 Service positions.



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. 2. Hold arm cylinder with hoist as shown in figure.



Figure 1 Arm cylinder mounting pin, installation 1. 2. 3.



Hoist Arm cylinder mounting pin Lock plate



3. Install arm cylinder mounting pin and lock plate. 4. Lower arm cylinder and install arm cylinder hydraulic hoses.



Figure 2 Arm cylinder hydraulic hoses, installation 1.



Hoses



5. Install arm cylinder grease hose. 6. Extract arm cylinder rod as shown in figure.



Figure 3 Arm cylinder rod pin, installation 1. 2. 3. 4.



Hoist Grease hose Arm cylinder rod pin Lock plate



7. Install arm cylinder rod pin and lock plate. 8. Install arm cylinder rod grease hose. 9. Check the arm cylinder operation.



Service Information Document Title: Dipper arm replacing



Function Group: cylinder,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Dipper arm cylinder, replacing Op nbr 975-025 1. Park the machine in the service position D, see 091 Service positions.



WARNING When the engine is running, the hydraulic line is under high pressure. Stop the engine, and release the residual pressure by operating the control lever. NOTE! Disconnect hose, and stop with plug for preventing oil leakage and contamination. 2. Hold arm cylinder with hoist.



Figure 1 Arm cylinder rod pin, removal 1. 2. 3. 4.



Hoist Grease hose Arm cylinder rod pin Lock plate



3. Remove grease hose. 4. Remove lock plate and arm cylinder rod pin. 5. Retract arm cylinder rod fully and tie the arm cylinder rod to prevent oil leakage from the main circuit.



Figure 2 Arm cylinder rod, retraction 1. 2.



Arm cylinder rod Hoist



6. Remove arm cylinder hydraulic hoses and grease hose.



Figure 3 Arm cylinder hydraulic hoses, removal 1.



Hoses



7. Remove arm cylinder lock plate and mounting pin.



Figure 4 Arm cylinder, removal 1. 2. 3.



Hoist Arm cylinder mounting pin Lock plate



8. Lift arm cylinder and lower it to work bench safely. 9. Transfer the arm cylinder pipe and clamp to a new arm cylinder. 10. Hold arm cylinder with hoist as shown in figure. 11. Install arm cylinder mounting pin and lock plate. 12. Lower arm cylinder and install arm cylinder hydraulic hoses.



Figure 5 Arm cylinder hydraulic hoses, installation 1.



Hoses



13. Install arm cylinder grease hose. 14. Extract arm cylinder rod as shown in figure.



Figure 6 Arm cylinder rod pin, installation 1. 2. 3. 4.



Hoist Grease hose Arm cylinder rod pin Lock plate



15. Install arm cylinder rod pin and lock plate. 16. Install arm cylinder rod grease hose. 17. Check the arm cylinder operation.



Service Information Document Title: Function Group: Bucket cylinder, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Bucket cylinder, description



Figure 1 Standard: Bucket cylinder view



Figure 2 Mass excavator: Bucket cylinder view 1 Tube



8 Retaining ring



16 Back-up ring



23 Piston packing



2 Bushing



10 Piston



17 Rod packing



24 Wear ring



3 Rod



11 Lock washer



18 Buffer ring



25 Contami seal



4 Bushing



12 Lock nut



19 Back-up ring



26 Dust seal



5 Head-cover



13 Screw



20 O-ring



27 Set screw



6 Bearing



14 Grease nipple



21 O-ring



7 Retaining ring



15 Wiper-seal



22 Back-up ring



Tightening torque



Figure 3



Standard: Bucket cylinder view



Figure 4 Mass excavator: Bucket cylinder view Tightening torque, unit: Nm (lbf ft) A



B



C



Piston nut, to tighten turn clockwise



Lock nut, to counterclockwise



tighten



turn Set-screw



Standard: 950 ±95 (703 ±70) Mass excavation: 950 ±95 (703 ±70)



Standard: 600 ±60 (444 ±44) 17 ±1.7 (12.5 ±1.2) Mass excavation: 600 ±60 (444 ±44)



NOTE! Apply Loctite #277 to the piston and set-screw before tightening. Volume of oil leakage Oil leakage Cylinder



Volume of internal oil leakage



Bucket



11.6 cc (0.70 cu·in) 10 minutes or below



Mass Bucket



13 cc (0.79 cu·in) 10 minutes or below



Wear limits



Figure 5 Standard: Bucket cylinder view



Figure 6 Mass excavator: Bucket cylinder view Wear limits, unit : mm (in)



D Screw 520 ±52 (384 ±38)



Item



Standar d value



Tolerance Shaft



Hole



Standard clearance



Clearance limit



Standard:Clearance between piston rod and bushing (A)



110 (3.93)



–0.036 ~ –0.090 (–0.0014 ~ –0.0035)



+0.195 ~ +0.060 (+0.0076 ~ 0.0023)



0.096 ~ 0.285 (0.0037 ~ 0.0112)



0.585 (0.023)



Mass excavation:Clearance between piston rod and bushing (A)



115 (4.52)



–0.036 ~ –0.090 (–0.0014 ~ –0.0035)



+0.195 ~ +0.060 (+0.0076 ~ 0.0023)



0.096 ~ 0.285 (0.0037 ~ 0.0112)



0.585 (0.023)



Clearance between piston rod pin and bushing (B)



110 (4.33)



–0.036 ~ –0.090 (–0.0014 ~ –0.0035)



+0.036 ~ +0.226 (+0.0014 ~ 0.0089)



+0.036 ~ +0.226 (+0.0014 ~ 0.0089)



1.0 (0.039)



Clearance between rear end pin and bushing (C)



100 (3.93)



–0.036 ~ –0.090 (–0.0014 ~ –0.0035)



+0.036 ~ +0.226 (+0.0014 ~ 0.0089)



+0.036 ~ +0.226 (+0.0014 ~ 0.0089)



1.0 (0.039)



Service Information Document Title: Bucket assembly, removal



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Bucket assembly, removal WARNING The parts are heavy. Take appropriate safety cautions when handling them. Op nbr 925-012 1. Park the machine on level, firm ground. Secure enough space around the machine to work safely. Park the machine in the service position B, see 091 Service positions. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. 2. Remove lock screw, bucket link pin and code rings.



Figure 1 Bucket link pin, removal 1. 2. 3.



Code rings Bucket link pin Lock pin



3. Retract the bucket cylinder rod.



Figure 2



Bucket assembly, removal 1. 2. 3. 4.



Bucket cylinder rod Bucket pin Lock pin Code rings



4. Remove lock screw, bucket pin and code rings. 5. Remove dipper arm.



Service Information Document Title: Bucket installation



Function Group: assembly,



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Bucket assembly, installation Op nbr 925-013



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine on level, firm ground. Secure enough space around the machine to work safely. Park the machine in the service position B, see 091 Service positions. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. 2. Install code rings, bucket pin and lock screw.



Figure 1 Bucket pin, installation 1. 2. 3. 4.



Bucket cylinder rod Bucket pin Lock pin Code rings



NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 3. Extend the bucket cylinder rod. 4. Install code rings, bucket link pin and lock screw. NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch).



Figure 2 Bucket link pin, installation 1. 2. 3.



Code rings Bucket link pin Lock pin



5. Check the bucket operation.



Service Information Document Title: Function Group: Bucket assembly, replacing



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Bucket assembly, replacing WARNING The parts are heavy. Take appropriate safety cautions when handling them. Op nbr 925-011 1. Park the machine on level, firm ground. Secure enough space around the machine to work safely. Park the machine in the service position B, see 091 Service positions. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. 2. Remove lock screw, bucket link pin and code rings.



Figure 1 Bucket link pin, removal 1. 2. 3.



Code rings Bucket link pin Lock pin



3. Retract the bucket cylinder rod.



Figure 2



Bucket assembly, removal 1. 2. 3. 4.



Bucket cylinder rod Bucket pin Lock pin Code rings



4. Remove lock screw, bucket pin and code rings. 5. Remove dipper arm. 6. Install code rings, bucket pin and lock screw.



Figure 3 Bucket pin, installation 1. 2. 3. 4.



Bucket cylinder rod Bucket pin Lock pin Code rings



NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 7. Extend the bucket cylinder rod. 8. Install code rings, bucket link pin and lock screw.



Figure 4 Bucket link pin, installation 1. 2. 3.



Code rings Bucket link pin Lock pin



NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 9. Check the bucket operation.



Service Information Document Title: Bucket cylinder, removal



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Bucket cylinder, removal Op nbr 975-062



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine in the service position A, see 091 Service positions. Park the machine on level, firm ground. Secure enough space around the machine to work safely. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. NOTE! Plug all disconnected hoses, to prevent oil leakage and contamination from entering the hydraulic system. 2. Place wooden block between arm and bucket cylinder. Place wooden block between arm and connecting rod.



Figure 1 Bucket cylinder pin, removal 1. 2. 3. 4. 5. 6.



Connecting rod Hoist Bucket cylinder pin Lock screw Bucket cylinder Wooden block



3. Hold the yoke with hoist. 4. Remove the lock screw and bucket cylinder pin carefully. Lower both sides of yoke carefully. 5. Tie the bucket cylinder rod to prevent oil leakage from the main circuit.



Figure 2 Hoses, removal 1.



Hoses



6. Remove the bucket cylinder hydraulic hoses and grease hose. 7. Hold the bucket cylinder with hoist.



Figure 3 Bucket cylinder, removal 1. 2. 3.



Hoist Bucket cylinder mounting pin Lock plate



8. Remove lock plate and bucket cylinder mounting pin. 9. Lift the bucket cylinder and lower to work area safely.



Service Information Document Title: Function Group: Bucket cylinder, installation



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Bucket cylinder, installation Op nbr 975-065



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine in the service position A, see 091 Service positions. Park the machine on level, firm ground. Secure enough space around the machine to work safely. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. 2. Hold the bucket cylinder with hoist.



Figure 1 Bucket cylinder, installation 1. 2. 3.



Hoist Bucket cylinder mounting pin Lock plate



3. Install the bucket cylinder mounting pin and lock plate. 4. Lower the bucket cylinder to install hydraulic hoses and grease hose.



Figure 2 Hoses, installation 1.



Hoses



5. Connect the bucket cylinder hydraulic hoses and grease hose. 6. Place wooden block between arm and connecting rod.



Figure 3 Bucket cylinder rod, installation 1. 2. 3. 4. 5. 6.



Hoist Wooden block Connecting rod Bucket cylinder Yoke Bucket cylinder pin



7. Install the yoke, shim, connecting rod and bucket cylinder pin with hoist as shown in figure. NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch). 8. Remove wooden block between arm and connecting rod. 9. Check the bucket cylinder operation.



Service Information Document Title: Bucket cylinder, replacing



Function Group:



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Bucket cylinder, replacing Op nbr 975-061



WARNING The parts are heavy. Take appropriate safety cautions when handling them. 1. Park the machine in the service position A, see 091 Service positions. Park the machine on level, firm ground. Secure enough space around the machine to work safely. In order to remove residual pressure in hydraulic system, stop engine, turn ignition key to “ON” position, and move pressure in line, move control lever 3~4 times. Turn ignition key to “OFF” position. NOTE! Plug all disconnected hoses, to prevent oil leakage and contamination from entering the hydraulic system. 2. Place wooden block between arm and bucket cylinder. Place wooden block between arm and connecting rod.



Figure 1 Bucket cylinder pin, removal 1. 2. 3. 4. 5. 6.



Connecting rod Hoist Bucket cylinder pin Lock screw Bucket cylinder Wooden block



3. Hold the yoke with hoist. 4. Remove lock screw and bucket cylinder pin carefully. Lower both sides of yoke carefully. 5. Tie the bucket cylinder rod to prevent oil leakage from the main circuit.



Figure 2 Hoses, removal 1.



Hoses



6. Remove the bucket cylinder hydraulic hoses and grease hose. 7. Hold the bucket cylinder with hoist.



Figure 3 Bucket cylinder, removal 1. 2. 3.



Hoist Bucket cylinder mounting pin Lock plate



8. Remove lock plate and bucket cylinder mounting pin. 9. Lift the bucket cylinder and lower to work area safely. 10. Transfer the bucket cylinder pipe and clamp to a new bucket cylinder. 11. Hold the bucket cylinder with hoist.



Figure 4 Bucket cylinder, installation 1. 2. 3.



Hoist Bucket cylinder mounting pin Lock plate



12. Install the bucket cylinder mounting pin and lock plate. 13. Lower the bucket cylinder to install hydraulic hoses and grease hose.



Figure 5 Hoses, installation 1.



Hoses



14. Connect the bucket cylinder hydraulic hoses and grease hose. 15. Install the yoke, shims, connecting rod and bucket cylinder pin with hoist as shown in figure. NOTE! Clearance between lock screw nut is approximately 2 mm (0.079 inch).



Figure 6 Bucket cylinder, installation 1. 2. 3. 4. 5. 6.



Hoist Wooden block Connecting rod Bucket cylinder Yoke Bucket cylinder pin



16. Remove wooden block between arm and connecting rod. 17. Check the bucket cylinder operation.



Service Information Document Title: Function Group: Explanations to hydraulic 990 diagram



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Explanations to hydraulic diagram Symbols Symbol



Explanation Line Servo line / Pilot line Line junction



Crossing lines not connecting



Outlet, plugged Quick-action coupling (e.g. checking point) Restriction Restriction, insignificantly viscosity-dependent Adjustable restriction



Reservoirs and accumulators Atmospheric (open) reservoir



Accumulator Filter Filter, strainer



Filter with magnetic element



Heat exchanger



Cooler without representation of lines for the coolant



Control devices Manual control by push button



Manual control by lever



Manual control by pedal



Mechanical control by spring, neutral position spring, return spring



Electromagnetic control (one winding)



Hydraulic pressure control



Hydraulic pressure control, two pressure levels



Control via hydraulic pressure drop



Pneumatic control



Control via pneumatic pressure drop



Sources of energy Combustion engine



Electric motor



Pumps



Hydraulic pump with fixed displacement and one direction of flow



Hydraulic pump with variable displacement and one direction of flow



Hydraulic pump with variable displacement and two directions of flow



Hydraulic pump with variable displacement, pressure controlled



Hydraulic pump with variable displacement, pressure controlled with pressure-compensated control



Motors Hydraulic motor with fixed displacement and one direction of flow



Hydraulic motor with fixed displacement and two directions of flow



Cylinders Single-acting cylinder with return stroke by spring



Double-acting cylinder with single piston rod (The piston end is called plus side and the piston rod end is called minus side)



Valves Non-return valve which requires very low opening pressure



Non-return valve which requires a certain opening pressure Shuttle valve



Pressure-limiting valve



Pressure-limiting valve with adjustable opening pressure



Pressure-reducing valve



Pressure-reducing valve with adjustable closing pressure



Pressure-reducing valve, pressure controlled



Three-position valve, lever-controlled and spring-centred



Lines parallel with the long sides of the valve symbol show that the valve can take up any position between its end positions (stepless movement) Shut-off valve / Breather valve



Application The symbols in a diagram show connections, flow paths and function of the components in the system, but does not show



the design of the components. NOTE! In a hydraulic diagram the valve symbols are always drawn in neutral position. Valve symbols The basic element of a valve symbol is a square box. One box is shown for each position that the moving part of a valve (spool or similar) can take up.



Figure 1 Valve symbol If the valve does not have fixed positions, but can be operated steplessly, this is shown with parallel lines along the valve symbol.



Figure 2 Valve symbol, steplessly controlled valve Internal flow paths and flow directions are drawn in the boxes. Line connections to the valve are drawn to the box that shows the valve position when other components are actuated according to the diagram.



Figure 3 Closed valve



Figure 4 Open valve Interpretation of valve symbols In a three-position valve the spool can be placed in three positions, which in the symbol are represented by one box for each position. The box that represents the intended position is drawn between the line connections, which means that the appropriate connecting paths in the valve are shown in the diagram. The position in the diagram



Figure 5 Neutral position 1. 2.



Inlet Outlet



The spool is centred in neutral position by the springs. The inlet is connected to the outlet through the spool. Imagined position for piston movement outwards



Figure 6 The piston rod is pressed out 1. 2.



Inlet Outlet



The spool is actuated with the lever so that the plus side of the cylinder is connected to the inlet at the same time as the minus side is connected to the tank. Imagined position for piston movement inwards



Figure 7 The piston rod is pressed in 1. 2.



Inlet Outlet



The spool is actuated with the lever so that the minus side of the cylinder is connected to the inlet at the same time as the plus side is connected to the tank.



Service Information Document Title: Hydraulic standard



Function Group: diagram, 990



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic diagram, standard 1 Main pump



22 Solenoid valve (5 serial)



2 Gear pump (servo and cooling)



23 Remote control valve (lever) - left



3 Main control valve



24 Remote control valve (lever) - right



4 Boom cylinder



25 Remote control valve (pedal)



5 Arm cylinder



26 Shuttle valve block



6 Bucket cylinder



27 Flow control valve



7 Slew motor



28 Check valve (1.5 kgf/cm2)



8 Slew drive unit



29 Check valve (3.0kgf/cm2)



9 Slew gearbox



30 Hydraulic oil cooler



10 Pinion



31 Return oil filter



11 Slew ring gear



32 Bypass valve



13 Track motor



33 Bypass strainer



14 Track gearbox



34 Air breather



15 Center passage



35 Strainer assembly



16 Fan motor



36 Drain oil filter



17 Proportional relief valve



37 Hydraulic oil tank



18 Servo hydraulic oil filter



38 Pressure switch



19 Accumulator block



39 Drain block



20 Accumulator



40 Servo hydraulic block



21 Measuring nipple



98 Orifice connector



Figure 1 Hydraulic diagram, standard



Service Information Document Title: Hydraulic diagram, option components



Function Group: with 990



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Hydraulic diagram, with option components 1



Main pump



51



Solenoid valve (hammer and scissors)



2



Gear pump (servo and cooling)



52



Shuttle valve



3



Main control valve



53



Hammer and scissors shuttle valve



4



Boom cylinder



54



Remote control valve (X1)



5



Arm cylinder



55



Solenoid valve 1 switch)



6



Bucket cylinder



56



Solenoid valve (2 switch)



7



Slew motor



57



Proportional valve (X1, X3)



8



Slew drive unit



58



X1 pump control proportional valve



9



Slew gearbox



59



3 way selector valve



10



Pinion



60



X1 return filter



11



Slew ring gear



61



Stop valve



13



Track motor



62



3 way non leak valve



14



Track gearbox



63



2 pump solenoid valve



15



Center passage



64



Pressure switch



16



Hydraulic oil cooling Fan motor



65



X1 preset proportional relief valve (right)



17



Proportional relief valve



66



X1 preset proportional relief valve (left)



18



Servo hydraulic oil filter



70



Remote control valve (straight travel)



19



Accumulator block



71



Gear pump (servo, cooling and X3) 60 LPM



20



Accumulator



72



Gear pump (servo, cooling and X3) 40 LPM



21



Measuring nipple



73



X3 (rotator valve)



22



Solenoid valve (5 serial)



74



X3 solenoid valve



23



Remote control valve (lever) - left



75



X3 valve



24



Remote control valve (lever) - right



81



Line rupture valve (right boom cylinder)



25



Remote control valve (pedal)



82



Line rupture valve (left boom cylinder)



26



Shuttle valve block



83



Line rupture valve (arm cylinder)



27



Flow control valve



84



Over load warning pressure switch



28



Check valve (1.5 kgf/cm2)



86



Block assembly



29



Check valve (3.0 kgf/cm2)



87



Quickfit valve (S-type)



30



Hydraulic oil cooler



88



Control pattern change valve



31



Return oil filter



89



Boom float position valve (with line rupture valve)



32



Bypass valve



90



Boom float position solenoid valve



33



Bypass strainer



91



Shuttle valve



34



Air breather



94



Removal counterweight valve



35



Strainer assembly



95



Slow return valve



36



Drain oil filter



96



Solenoid valve



37



Hydraulic oil tank



97



Stop valve



38



Pressure switch



98



Orifice connector



39



Drain block



99



Boom float position valve (with out line rupture valve)



40



Servo hydraulic block



Figure 1 Hydraulic diagram with option parts



Service Information Document Title: Overview



Function Group: 993



Information Type: Service Information



Profile: EXC, EC480D L [GB]



Overview Automatic lubrication pump



Figure 1 Automatic lubrication pump, KFG and KFGS 1



KFG: Not programmable



6



Excess pressure valve



2



KFGS: Programmable



7



Pump element



3



Pump cover (hinged lid)



8



Filling port



4



Lubricant reservoir



9



Programming



5



Installation bracket



10 Control, in general



11 Electrical connection (DC 12V, Fuse 5A) (DC24V, Fuse 3A)



Date: 2014/7/15



Figure 2 Automatic lubrication pump, description (KFGS3) 1



Piston pump with reservoir



8



Adapter



14 Elbow connector



2



Basic setting factory made: Timer, Run time, Pause, Monitoring



9



Conical head nipple



15 Hose set



3



Washer



10 Safety cap



18 Adapter



5



Washer



11 Pump element



19 Banjo fitting



6



Blind rivet 2.4 x 6



12 Pressure relief valve



20 Label



7



Rating plate



13 Filler nozzle



21 Label Volvo Part No.



Service Information Document Title: Function Group: Automatic lubrication 993 system, description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Automatic lubrication system, description Systems overview Lubricant Selection criteria



Type designation



Grease up to NLGI grade 2 Delivery rate



Delivery rate depends on the running time and pump elements used.



Pump suitable for



Farm machinery Construction machinery Special vehicles Tractive units with superstructure Trailers and semi trailers (hazardous-goods types on request)



Type of drive



Electric



Pump



Piston pump, group



Figure 1 KFG Technical data Auxiliary equipment



Figure 2 KFGS



Operating pressure



300 bars maximum



Reservoir capacity



2, 6 or 10 litres



Lubricant distribution



Progressive feeders VPM, VPKM, VPBM



Control system



IG502–E control unit with and IG502–I integrated control unit with without monitoring and without monitoring (integrated in the pump unit)



Single-line systems for commercial vehicles for grease up to NLGI grade 000, 00, or 0, see brochure 1–9420–US. Piston pump, Group KFG / KFGS The pumps are driven by a DC motor. The reservoir capacity and type of filling varies. The pumps have a maximum of 3 lubricant outlets. One pump element is required for each outlet. The elements are available for different delivery rates and can be exchanged. The grease level is checked by a visual inspection of the reservoir. Group KFG pumps are controlled by an IG502–E control unit. Group KFGS pumps are controlled by a control system integrated in the unit (IG502–I). Progressive feeders, groups VPM, VPKM, VPBM Progressive feeders are used for grease up to NLGI grade 2. Their design makes it possible to adjust the feeders to the amount of lubricant required by the lubrication points to be connected. When planning a system care must be taken to see to it that the progressive feeders apportion the entire amount of grease delivered by the pump each running cycle. Thus, the metered quantities only define the proportions and not the absolute quantities.



Lines and fittings In systems for grease up to NLGI grade 2 it is necessary to lay main lines in a high-pressure hose with a 6, 8 or 10 mm diameter. connector; in special circumstances it is also possible to use steel tubing with a diameter of 6, 8 or 10 mm. 6 x 1.25 polyamide tubing is used for secondary lines, or also a 6 mm high-pressure hose or 6 mm steel tubing in the off-road sector. Main and secondary lines are supplied prefilled with grease. Control Units Electronic control and monitoring unit IG502–E for systems with KFG/KFA piston pumps in conjunction with a cycle switch. With this control unit the pump’s running time is determined by the progressive feeder lubrication cycle. The lubrication cycle is monitored by a cycle switch. The interval time can be set on the control unit.



Service Information Document Title: Function Group: Central lubrication system, 993 description



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Central lubrication system, description Automatic central concentrated lubrication system is constructed with the following main assembling components.



Figure 1 Automatic central concentrated lubrication system 1. 2. 3. 4.



Lubrication pump Main line Master feeder Secondary line



5. 6. 7.



Secondary feeders Lines leading to lube points Cycle switch



Lubrication system supplies to all connecting points at a constant interval. If necessary, each lubrication point can be supplied separately with a specified lubricating amount from the supply unit. And there is no remaining or forgotten position. KFGS pump drives electrically with integrated electric control unit and instrument panel. The KFGS pump is available with a 2 kg, 6 kg or 10 kg lubricant reservoir. The electric unit records machine operating hours and operates the pump at specified intervals. Generally, the interval is 1 hour for construction equipment. The pump operates at pre-specified contact times, and supplies grease to all bearing points. System stops and returns to the pre-specified stop timing, and then the instrument panel displays a PAUSE sign. When the pump starts, the instrument panel displays a CONTACT light. Similarly, the push button light is displayed



during pump operation.



Figure 2



This orange light push button can be used for operating pump additionally without any change at pre-selecting electric unit. Detecting function Central concentrated lubrication system has two detecting functions (pressure limit valve (PLV) and mechanical monitoring). This valve is installed to pump (pump element), and prevents excessive high system pressure. When system pressure is more than 300 bar or system is clogged, the valve opens and the grease is released (remedy the defect)



Figure 3



Electrical controls The cycle switch is installed to the master supply unit. This sensor checks system functions during pump operation. If grease does not flow, the orange indicating light in the cab flashes continuously and a red “FAULT” marker is displayed in the pump instrument panel



Figure 4 Master supplying unit The level of grease is detected in the lubricant grease reservoir. If grease quantity decrease below specified level, the yellow indicator light in the cab flashes continuously, and a red “FAULT” marker is displayed in the pump instrument panel. In this case, the KFGS pump cannot be operated. Refill grease reservoir (remedy the defect).



Figure 5



Service Information Document Title: Control units, functions



Function Group: software 993



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Control units, software functions Block mode If there is no signal from the cycle switch during the pump run time (contact time), then normal operation stops, and the block pause starts with cycle switch request. Possible causes are:    



Defective lubrication lines Immobilized progressive feeder Defective cycle switch or defective cable Critically low lubricant level



If there is no signal from the cycle switch during C1 (cycle 1), then the second lubrication cycle C2 in the block mode starts. As soon as a signal from the cycle switch is received, the block mode is interrupted and the normal lubrication cycle begins with the pause. There are a total of three lubrication cycles carried out with cycle switch request. Three lubrication cycle (C1–C3) will be performed with the cycle switch request. After three pump operation (tCO) and two block pauses (bLo) without the signal from the cycle switch, fault message 'FCS' will be displayed in the control unit.



Figure 1 Block mode tCO



Contact time (pump operation time), time controlled



bLo



Block mode



CS



Cycle switch signal



C1–3



Cycle 1–3



F



System fault



Display and operating unit



Figure 2



Display and operating unit A transparent plastic screen protects the display and operating unit against splash water and mechanical damage. For the purpose of programming, remove the screen with a screwdriver and fix it again afterward. NOTE! KFGS series only LED display Display



Description Seven-segment display: values and operating conditions Progression of pause Pump operation Monitoring of system functions by means of an external cycle switch CS = cycle switch Without function in progressively-acting systems



Fault message Push-button switches Switching the display on Displaying valves and parameters Setting valves and parameters Changing between programming and display modes Confirming values Releasing intermediate lubrication Deleting a fault message The three-digit LED display



In normal operation the display is switched off. It can be activated by shortly pressing one of the two push-buttons. . The display shows current values and preset parameters. Furthermore, the display serves for user prompting when operating parameters are programmed. LED displays Display tPA



Function t: timer PA: Pause



Meaning The control device is working as timing pulse generator (TIMER) and is in the PAUSE mode.  



cPA



c: Counter PA: Pause



Part of lubrication cycle Input and display values in hours



The control device is working as pulse counter (COUNTER) and is in the PAUSE mode.  



Part of lubrication cycle The device is counting the pulses of the external pulse generator and is comparing them with the preset values



tCO



t: timer CO: Contact



The control device is working as timing pulse generator (TIMER) and is in the pump operating period (CONTACT)  



cCO



c: Counter CO: Contact



CONTACT = time while the pump delivers Input and display values in minutes



The control device is working as pulse counter and is in the pump operating period (CONTACT)  



CONTACT = time while the pump delivers Input and display values in pulse



COP



c: Cycle O: Off P: Pressure



Display of menu start “monitoring settings”



OFF



Monitoring OFF



PS and CS monitoring function is switched off. 



CS



Cycle Switch



Monitoring of cycle switch is activated. 



FLL



Fault Low Level



During the CONTACT pump operating period, the cycle switch is monitored for pulse generation.



Minimum filling level in storage vessel is reached  



FCS



No system monitoring



Fault Cycle Switch



The control device is in the FAULT mode The process of functions has been stopped



No signal of cycle switch during pump operating period  



The control device is in the FAULT mode The process of functions has been stopped



0h



Operation Hour meter



The values displayed in the following are the operating hour of the control device



Fh



Fault Hour meter



The values displayed in the following are the fault hours which is the time while the vehicle or machine has been operated in the FAULT mode.



bLo



Block Mode



Signal from cycle switch not available. As opposed to normal operation, the control device is still in the monitoring process. If the fault continues over 3 pump periods, a fault message will be displayed.



Display mode The display mode can be recognized by the lighted LED displays. The LEDs are not flashing. This mode serves for the check back of current setting and operating parameters. Always start the display mode by briefly pressing one of the two keys



.



Display mode Step



Buttons



LED status



Display example



Description



1



PAUSE lights tPA



Current operating state is displayed. Example: Timer operation pause



2



PAUSE lights 02.6



Remaining time for pause of current lubrication cycle is displayed. Example: 2.6 hour



3



PAUSE lights 01.0



Preset total time of pause is displayed. Example: 1 hour (factory set)



4



PAUSE lights tCO



Pump operation time is displayed. Example: Timer operation



5



PAUSE lights – – –



Example: System is in the pause mode, current tCO display not possible



6



PAUSE lights 04.0



Preset value is displayed. Example: 4 minute (setting by factory)



7



PAUSE lights COP



System monitoring is displayed.



8



PAUSE lights OFF or PS or OFF: Monitoring switched off CS PS: Monitoring by pressure switch (not valid) CS: Monitoring by cycle switch (factory set)



9



PAUSE lights Oh



Display of system operation hours



10



PAUSE lights 005



The first part of the total value.



11



PAUSE lights 33.8



The second part of the total value. Example: 00533.8 hour (maximum value: 99999.9 hour)



12



PAUSE lights Fh



Display of fault hours



13



PAUSE lights 000



The first part of the total value.



14



PAUSE lights 33.8



The second part of the total value. e.g. 00033.8 hour (maximum value: 99999.9 hour)



15



Display goes off. Oh and Fh values will unerasably be stored in the EEPROM.



Programming NOTE! The program mode is recognized by the flashing of the displays. If the factory code 000 has already been changed, then the changed code must be selected and confirmed. Programming Step



Buttons



1



LED status



Display example



Description



PAUSE lights 000



Display flashing 000 000: factory set code



PAUSE flashes



Automatic display of the first parameter, i.e. “Pause in timer operation"



Press SET longer than 2 seconds 2



tPA



Press SET shortly 3



PAUSE lights 01.0



Pause time 1 hour (setting by factory)



PAUSE lights 06.8



Set new value Example: 6.8 h = 6 h 48 min



Press SET shortly 4



5



CONTACT flashes



tCO



Press SET shortly 6



Display of the next parameter "Pump operation time in timer operation" The contact LED is flashing.



PAUSE lights 04.0



Pump operation time Example: 4 minute (factory set)



CONTACT lights



Set new value Example: 3 minute



Press SET shortly 7



03.0



8



Confirm new value. Press SET shortly



9



Alterations will be written in the memory, and the display goes off. Press SET longer than 2 seconds



Alteration of system monitoring NOTE! The program mode is recognized by the flashing of the displays. If the factory code 000 has already been changed, then the changed code must be selected and confirmed. Alteration of system monitoring Step



Buttons



LED status



1



Display example



Description



000



Display flashing 000 000: factory set code



tPA



Automatic display of the first parameter, i.e. “Pause in timer operation"



Press SET longer than 2 seconds 2



PAUSE flashes



3



LED1 and COP LED2 light



Start of monitoring settings is displayed.



Press until “COP” is displayed. 4



OFF



System monitoring switched off.



Press SET shortly 5



LED1 or CS or PS LED2 flashes



6



CS: Monitoring using a cycle switch (factory set) PS: Monitoring using a pressure switch (not valid for Volvo excavators) Confirm new value.



Press SET shortly 7



Changes are written in the memory, and the display goes off. Press SET longer than 2 seconds



Alteration of operating modes NOTE! The program mode is recognized by the flashing of the displays. If the factory code 000 has already been changed, then the changed code must be selected and confirmed. Alteration of operating modes



Step



Buttons



LED status



1



Display example



Description



000



Display flashing 000 000: factory set code



Press SET longer than 2 seconds 2



PAUSE flashes



tPA



Automatic display of the first parameter, i.e. “Pause in timer operation"



3



PAUSE lights cPA



Changing of pause period to counter operation (only possible with an external electric sensor values in impulses).



4



CONTACT lights



tCO



Display pump run time in the timer operation



cCO



Changing pump run time to counter operation (Not applied for Volvo excavator)



Press SET shortly to confirm counter operation 5 6



Confirm new value.



7



Changes are written in the memory, and the display goes off. Press SET longer than 2 seconds



Alteration of code NOTE! Changing code is possible only one time. Keep the code in a safe place. If another changing is needed, consult Volvo.



The program mode is recognized by the flashing of the display. Operating mode changing steps Step



Buttons



Display example



Description



000



Display flashing 000. 000: factory set code



2



321



Select key number for changing code. 321: factory set



3



000



Display flashing 000. 000: factory set



4



000



Display is flashing.



5



666



Enter new code. Example: 666



1



LED status



Press SET longer than 2 seconds



Press SET shortly



6



Confirm new value. Press SET shortly



7



Changes are written in the memory, and the display goes off. Press SET longer



than 2 seconds



Service Information Document Title: Troubleshooting



Function Group: 993



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Troubleshooting Pump trouble Error



Cause



Pump ● Mechanical damage, e.g. faulty motor. Stirring arm in the grease storage vessel does not rotate during the activated pump operation period.



● Electrical connection interrupted.



Pump without ● Electrical control has failed. function ● Pump drive / motor is faulty. When pressing the DK key, although all the electrical connections are in order. Pump without function Pump is not delivering lubricant, although the stirring arm is rotating.



Action ● Replace pump Take off the lubricant main line at the outlet of the excess pressure valve. Loosen the electrical connection. Loosen the three fixing screws. Demount the faulty pump. Mount the new pump and connect the lubricant line as well as the electrical cable. Start the system and carry out a function test. Set the correct values for pause and contact times. ● Check or replace fuse. ● Check electrical connections. Check cable set for damage! Replace the pump.



● Lubricant level in the vessel is below minimum. Fill lubricant reservoir up to maximum. The non-return valve in the pump element does Replace the pump element. not close. NOTE! (Indication: The outlet can be kept closed with Dosing marks with grooves. your fingers when the main line is taken off.) ● Suction problems due to air inclusions in the Dismantle the pump element and operate the grease. pump by pressing the DK key until grease emerges at the outlet of the casing. ● The pump element does not build up pressure. Replace the pump element. The pump element is worn out. (Indication: The NOTE! outlet can be kept closed with your fingers when Dosing marks with grooves. the main line is taken off.)



Pump without function Excess pressure valve on the pump opens and lubricant is emerging



● System pressure is over 300 bar, e.g. due to Check the system and repair or convert the distributor blocking or blocked lubrication point. system so that the maximum system pressure is 200 bar at 20 °C. ● Valve damaged or soiled, therefore no proper Replace the excess pressure valve. closing.



Service Information Document Title: Bleeding air



Function Group: 993



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Bleeding air NOTE! Fill only with clean lubricant using a suitable tool. Contaminated lubricant leads to serious system trouble! Venting of the system. Venting of the system    



Take off the main lines at the pump set. Keep pumping until bubble-free lubricant emerges at the screw fitting. Reinstall the main lines. Take off the main line at the main distributor. Keep pumping until there is no air in the line. Reinstall the mainline. Take off the branch lines at the main distributor. Keep pumping until bubble-free lubricant emerges from all connectors of the main distributor. Reinstall the branch lines. Then bleed the branch lines, branch distributors, lubricant lines and lubrication points and check for proper functioning.



Service Information Document Title: Maintenance general



Function Group: service, 993



Information Type: Service Information



Date: 2014/7/15



Profile: EXC, EC480D L [GB]



Maintenance service, general NOTE! All further service work other than the measures described below should be conducted by the authorized Volvo workshop only. NOTE! The service life of the pump elements is dependent on the purity of the grease used. Checking the filling level Visual checking The transparent lubricant vessel allows visual checking of the filling level. Inspect regularly for safety reasons. If the lubricant level is below the „minimum“ mark, the entire system has to be bled. Automatic checking Automatic lubricating system is provided with automatic checking of the filling level. If the level falls below the „minimum“ mark, the lubrication process is stopped with the error message „FLL“ shown on the control unit's display. Simultaneously, IECU displays 'Check' message. NOTE! Fill only with clean lubricant through the filling port using a suitable tool.



Never open the pump lid to fill in the grease to the reservoir.



Contaminated lubricant leads to serious system trouble!



Figure 1 Low filling level message Checking the system faults The cycle switch LED at the main feeder and the message 'CS' on the pump control unit display are flashed during the pump operation. Check whether there is a fault signal in I-ECU and the pump control unit after the lubrication system has stopped working. When the cycle switch does not get a signal during the pump running time, the system goes to 'Block mode'. If the message 'bLo' persists during three pump running cycle, a fault signal is created in the pump control unit and the I-ECU. Find out the fault, and repair the system. When the system is blocked, the pressure limiting valve will open, and the grease emerges from the upper side of the pressure limiting valve. NOTE!



Never close the feeder outlet port if the line is damaged. NOTE! The final system check should be done by activating the additional lubricating switch 1 in the cab.



Figure 2 Additional lubrication switch Scheduled maintenance, overview Checking items



Interval



Actions



Grease filling level visual inspection



Daily



If needed, refill the grease reservoir up to the maximum level.



Is there a grease coming out from the pressure limiting Daily valve?



Check the system. In case of the blocked feeder or lubrication points, repair the defect components.



Is there any error message related to the lubrication system ongoing on I-ECU?



Check the error codes from the pump control unit.



Are there any leakages at lines and connections?



40 hours



Retighten the connections, or replacing sealing, if needed. In case of damages, replace the lines and the connections.



Are lines and connections damaged?



40 hours



In case of damages, replace the lines and the connections.



Do the grease collars at the lubrication points show 40 hours sufficient grease?



If there is not enough grease, check for the system damage. Check the pump control unit's setting values.



Thank you for your purchase. Have a nice day.



file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/7/15 10:11:56]