EW145B Service Information

Service Information
Document Title: Function Group: Information Type: Date:

Engine, description (Deutz 200 Service Information 27/11/2019
D6D EOE2)
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EW145B Volvo
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Engine, description (Deutz D6D EOE2)

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EW145B Volvo Changwon 10001 15000
The engine is a 6–cylinder, 4–stroke, direct injected, turbocharged, aftercooled with a cast iron block and cylinder head.
Gears in the engine gear case are hardened helical type for strength and reduced noise, arranged to provide quiet, smooth
transmission of power.
The cylinder block and head are designed with internal passages forming galleries for both lubricating oil and coolant.
The fan belt is a poly type V-belt for improved performance and an auto tension adjuster maintains belt tension.
Starter side view
Figure 1
Engine, starter side view
1. Coolant inlet (from radiator)

2. Coolant outlet (to radiator)
3. Coolant make up port
4. Air inlet (from air cleaner)
5. Turbocharger
6. Intake manifold
7. Exhaust manifold
8. Starter
9. Poly-V belt
10. Lube oil pipe (supply)
11. Lube oil pipe (return)
12. Engine oil pan
Engine, front side view
Figure 2
Engine, front side view
1. Air inlet (from charge air cooler)

2. Lifting eye (front)
3. Alternator
4. Fuel feed pump
5. Coolant pump
6. Belt tension
7. Air outlet (to charge air cooler)
8. Fan drive pulley
9. Air conditioner compressor pulley
10. Pulley with vibration damper
Engine, top side view

Figure 3
Engine, top side view
1 Fuel suction port 9 Coolant make up port

2 Engine oil filter 10 Coolant outlet (to radiator)
3 Fuel filter 11 Blowby gas pipe
4 Unit injection pump 12 Air inlet (from air cleaner)
5 Emission label 13 Turbocharger
6 Engine name plate 14 Exhaust gas outlet
7 Power take off device 15 Exhaust manifold
8 Fan drive 16 Intake manifold
Engine, rear side view
Figure 4
Engine, rear side view
1. Flywheel
2. Lifting eye (rear)
3. Crankcase breather
4. Coolant temperature sensor port
Service Information

Engine, tightening torques 200 Service Information 27/11/2019
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EW145B Volvo
Engine, tightening torques


NOTICE
Regarding bolted joints which are not listed here, see “Volvo standard tightening torques”
Engine, tightening torque

Rocker arm bracket on cylinder head 30 Nm (22.2 lbf ft)
Cylinder head cover (M6) on cylinder head 13 Nm (9.6 lbf ft)
Exhaust return module on cylinder head Step 1: 10 Nm (7.4 lbf ft)
Step 2: 30 Nm (22.2 lbf ft)
Lock nut, valve adjusting screw 20 ±2 Nm (14.8 ±1.5 lbf ft)
Locking screw on cylinder head 34 Nm (25.2 lbf ft)
Solenoid valve on cylinder head 24 Nm (17.8 lbf ft)
Front cover on crankcase Step 1: 3 Nm (2.2 lbf ft)
Drain plug on oil pan, M18 55 Nm (40.7 lbf ft)
Crankcase ventilation on cylinder head 21 Nm (15.5 lbf ft)
Return line to return stop valve 30 Nm (22.2 lbf ft)
Return stop valve to crankcase 80 Nm (59.2 lbf ft)
Impulse transmitter (crankshaft) on holder on front cover 9 Nm (6.7 lbf ft)
Impulse transmitter (camshaft) on gearcase 9 Nm (6.7 lbf ft)
Turbocharger on exhaust manifold 42 Nm (31.1 lbf ft)
Clamping shoe injector on cylinder head 16 Nm (11.8 lbf ft)
Injection lines on rail and injector, high pressure line on high- 25 Nm (18.5 lbf ft)
pressure pump
Fuel supply pump on holder 22 Nm (16.3 lbf ft)
Holder fuel supply pump on holder 30 Nm (22.2 lbf ft)
V-belt pulley on fuel supply pump 27 Nm (20.0 lbf ft)
High pressure pump on crankcase, M10 Step 1: 10 Nm (7.4 lbf ft)
Fuel control valve 30 Nm (22.2 lbf ft)
Fuel pipe on high pressure pump 29 Nm (21.5 lbf ft)
Fuel pipe on control block 39 Nm (28.9 lbf ft)
Rail on cylinder head 30 Nm (22.2 lbf ft)
Pressure relief valve on rail 100 Nm (74.0 lbf ft)
Rail pressure sensor on rail 70 Nm (51.8 lbf ft)
Pipe clips, fuel line fastening 30 Nm (22.2 lbf ft)
Fuel line on control block, fuel filter console and rail 39 Nm (28.9 lbf ft)
Fuel pipe (return) on control block 49 Nm (36.3 lbf ft)
Fuel pipe (return) on cylinder head 29 Nm (21.5 lbf ft)
Fuel line on fuel filter8 39 Nm (28.9 lbf ft)
Fuel filter console/radiator tank on crankcase 30 Nm (22.2 lbf ft)
Fuel pressure sensor on fuel filter console 30 Nm (22.2 lbf ft)
Cover plate on cylinder cover, M6 30 Nm (22.2 lbf ft)
Service Information

Component locations 200 Service Information 27/11/2019
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EW145B Volvo
Component locations

Component position, engine D6E. The following figures show the position of a number of components on engine D6E.
Figure 1
Component locations, front side
1 Engine oil filler 10 Oil dipstick

2 Transport eye 11 Power take off
3 Alternator 12 Engine oil filter
4 Fuel feed pump 13 Connection to E-ECU
5 V-rib belt drive on crankshaft 14 Fuel filter
6 V-rib belt 15 Crankcase bleeding valve
7 Automatic belt tensioner 16 High pressure fuel pump
8 Coolant pump 17 Common rail
9 Engine oil cooler 18 Injector
Figure 2
Component locations, flywheel side
19 Crankcase bleeding valve 26 Turbocharger

20 Charge air manifold 27 Air outlet (to charge air cooler)Coolant inlet
21 Flywheel housing 28 Coolant inlet
22 Drain plug 29 Coolant outlet
23 Oil pan 30 Air inlet (from charge air cooler)
24 Starter motor 31 Exhaust manifold
25 Oil return line from turbocharger 32 Cylinder rocker arm cover
Service Information

Determining cylinder head 211 Service Information 27/11/2019
gasket
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EW145B Volvo
Determining cylinder head gasket


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The thickness of the cylinder head gasket is responsible for the correct piston crown clearance of the engine. The
piston crown clearance (0.65 mm) essentially influences the combustion and thus:
¡ Power
¡ Fuel consumption
¡ Exhaust emission
The piston crown clearance is adjusted by determining the piston projection and the thickness of the cylinder head
gasket.
Measuring piston projection
A dial gauge with a fixture is needed to measure the piston projection.

The piston is in its TDC position above the cylinder blackface.
Figure 1
Piston projection, measurement
1. Dial gauge
2. Bridge
3. Two spacer plates
A. Set the dial gauge on the level of the cylinder block face to “zero”.
B. Position the dial gauge at measuring points (C), at the piston pin axis on the piston and determine the
maximum projection.
C. Measuring points on the piston.
Distance X = 90 mm
This measurement is performed on each piston. The maximum measured piston projection determines the thickness of the
cylinder head gasket (see table). There are 3 different gasket thicknesses identified by bores (4):
1 bore = 1.2 mm
2 bores = 1.3 mm
3 bores = 1.4 mm
Piston projection
Piston projection Identification of cylinder head gasket

0.33 ~ 0.55 mm 1 bore
0.56 ~ 0.65 mm 2 bores
0.66 ~ 0.76 mm 3 bores
Service Information

Fitting cylinder head 211 Service Information 27/11/2019
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EW145B Volvo
Fitting cylinder head


EW145B Volvo
Op nbr 21182
1. Prior to fitting the cylinder head onto the crankcase, the sealing surfaces for the cylinder head gasket must be clean
and free from oil. Pay attention to dowel sleeves.
2. Lightly oil the cylinder head bolts.
3. It is absolutely necessary to observe the bolt tightening order in the adjacent schematic.
Figure 1
Tightening order (exhaust manifold side)
Tightening torque specification:
¡ 1st step: 30 N·m (22.2 lbf·ft, 3.1 kgf·m)

¡ 2nd step: 80 N·m (59 lbf·ft, 8.2 kgf·m)
¡ 3rd step: 90° turn
Tightening order
Service Information

Cylinder, description 213 Service Information 27/11/2019
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EW145B Volvo
Cylinder, description

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Figure 1
Cylinder liner
1 Cylinder liner
2 Crankcase
3 Liner projection: 0.07 - 0.12 mm
D6D/D6E engine with a bore about 98 mm (3.86 in) is provided with dry, plateau-honed slip-fit cylinder liners. In case of
damage, the cylinders of the D6D/D6E series are repaired by replacing the slip-fit liners.
Service Information

Piston rings, description 213 Service Information 27/11/2019
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EW145B Volvo
Piston rings, description


EW145B Volvo
Each piston is equipped with two compression rings and one oil ring. The uppermost compression ring is of the "Keystone"
type (dual trapezoid-formed cross section). Compressions rings should be placed with the text facing upwards.
The oil ring is equipped with two scraping edges, which are pressed against the cylinder wall using the spring tension in the
ring and an expander spring placed on the inside of the ring. The oil ring can be placed on either side but should be placed
with expander spring and oil ring openings 180° from one another.
Figure 1
Service Information

Piston cooling 213 Service Information 27/11/2019
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EW145B Volvo
Piston cooling

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Figure 1
Piston cooling
The piston is cooled by spraying lube oil against the inside of the piston top.
The 2-hole piston cooling nozzles made of plastic are fitted in the main bearing pedestals.
Service Information

Valve system specifications 214 Service Information 27/11/2019
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EW145B Volvo
Valve system specifications


Valves
Valve head diameter:
inlet 44.4 ±0.1 mm (1.75 ±0.004 in)
exhaust 38.7 ±0.1 mm (1.52 ±0.004 in)
Valve stem, diameter:
inlet 7.94 – 0.04 mm (0.31 –0.0015 in)
exhaust 7.94 – 0.04 mm (0.31 –0.0015 in)
Valve clearance, cold engine, value when adjusting:
inlet To zero clearance, then 75° counter-clockwise
exhaust To zero clearance, then 120° counter-clockwise
Clearance between control valve piston and rocker arm To zero clearance, then 144° counter-clockwise
Measurement between valve disc and cylinder head's face:
inlet 0.9 +0.15 –0.1 mm (0.035 +0.006 –0.0039 in)
exhaust 0.9 +0.15 –0.1 mm (0.035 +0.006 –0.0039 in))
Valve head edge, thickness:
inlet 2.36 mm (0.09 in)
exhaust 1.8 mm (0.07 in)
Valve guides
Max. clearance valve stem - guide, wear tolerance:
Inlet 0.07 — 0.13 mm (0.0027 — 0.0052 in)
Outlet 0.07 — 0.13 mm (0.0027 — 0.0052 in)
Valve springs
Inlet/exhaust
Length, unloaded 59 ±1.9 mm (2.32 ±0,039 in)
Diameter, thread 4 ±0.03 mm (0.157 ±0,012 in)
Rocker arm
Hole diameter inlet, exhaust 21.02 +0.033 (0.828 +0.0013 in)
Tapp 21 –0.021 (0.827 –0.0008 in)
Valve seat
Valve seat diameter:
Inlet 46.09 –0.02 mm
Outlet 39.99 –002 mm
Valve seat angle:
Inlet 30°
Outlet 45°
Service Information

Internal Exhaust Gas 214 Service Information 27/11/2019
Recirculation (IEGR),
description
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EW145B Volvo
Internal Exhaust Gas Recirculation (IEGR), description


A system for IEGR (Internal Exhaust Gas Recirculation) is used as part of V-ACT (Volvo Advanced Combustion Technology).
On D6E and D7E this takes place by an IEGR-opening piston, controlled by the lubrication oil's system pressure, acting on
the exhaust rocker arm which enables a second opening of the exhaust valves. When activated, the secondary piston will
give a limited valve opening of the exhaust valves during the induction phase, which leads exhausts back into the cylinder.
Included components
IEGR-unit
The hydraulic mechanism is housed in two interconnected IEGR-units, located on the rocker arm holders. Lubrication oil is
routed from the cylinder head via the solenoid valve to the high-pressure channel in the IEGR-unit through a channel in one
of the rocker arm holders.
Figure 1
1. IEGR-unit
Solenoid valve
The solenoid valve is located in the cylinder head on the flywheel side and is activated by the EECU via the control system
EMS 2. When IEGR is not activated, the solenoid valve is closed and no oil flow is allowed into the IEGR-unit. At activation of
IEGR, the solenoid valve opens the channel from the engine's lubrication system to the IEGR-unit.
Figure 2
1. Solenoid valve
Control valve
The control valve is located in the IEGR-unit between the high-pressure circuit and low-pressure circuit. When the low-
pressure circuit is supplied from the lubrication oil system, the control valve is lifted and closes the high-pressure circuit. The
ball in the control valve enables filling of the high-pressure circuit when IEGR is activated.
The lubrication oil is drained through the control valve.
Figure 3
1. Control valve
Main piston
The main piston is acted on by the adjusting screw on the inlet valve's rocker arm, and affects the oil pressure in the IEGR-
unit's high-pressure channel. At the end of the IEGR-phase, a pressure of 100 bar is generated in the high-pressure circuit.
Figure 4
1. Main piston
Servo piston
The servo piston is activated by the hydraulic pressure from the main piston via a channel in the IEGR-unit when the IEGR-
function is active/on (solenoid valve in open position). Then the servo piston opens the exhaust valves via the rocker arm an
extra time during the induction stroke.
Figure 5
1. Servo piston
Function
IEGR is activated by the system being supplied with full lubrication oil system pressure via the solenoid valve. The solenoid
valve is activated by the E-ECU.
The control valve closes the high-pressure circuit and the ball inside the valve enables filling of the system.
With the same movement as the inlet valve's rocker arm opens the valve, the main piston is forced upward. The pressure in
the IEGR-unit's high-pressure channel (up to 100 bar) overcomes the spring force in the servo piston. the servo piston forces
down the rocker arm, which results in the exhaust valve being open for a short time at the end of the induction stroke.
Exhausts from the exhaust manifold are sucked into the cylinder by vacuum from the other cylinders.
The breather hole between the low-pressure channel and the high-pressure channel in the IEGR-unit enables longer exhaust
recirculation at high engine speed.
Figure 6
IEGR-system (inactive)
1. Servo piston
2. Control valve
3. Solenoid valve
4. 2–5 Bar lubrication oil pressure
5. Breather hole
6. Oil channel, low-pressure
7. Oil channel, high-pressure
8. Main piston
9. Induction rocker arm
10. Exhaust rocker arm
Figure 7
IEGR-system activated
1. Servo piston
2. Control valve
3. Solenoid valve
4. 2–5 Bar lubrication oil pressure
5. Breather hole
6. Oil channel, low-pressure
7. Oil channel, high-pressure
8. Main piston
9. Induction rocker arm
10. Exhaust rocker arm
Checking and adjusting

Checking and adjusting of the IEGR-opening piston's clearance against the exhaust rocker arm should be done in
connection with checking and adjusting valves according to Valves, adjusting.
Software
The function monitors the EGR valve for return of combustion gases and informs the operator if the function is not ensured
or if there is a system malfunction.
The function is also used as input signal for Engine protection.
Service Information

Valves, adjusting 214 Service Information 27/11/2019
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EW145B Volvo
Valves, adjusting

The valve clearance must be checked and adjusted at specified intervals. To do this, the engine oil temperature must be
between 20 °C (68 °F) and 80 °C (176 °F).
Valve clearance adjustment
Item mm inch
Inlet valve 0.3 0.012
Exhaust valve 0.5 0.020
Adjustment
Figure 1
Valve clearance, adjustment
1. Remove rocker cover.

2. Turn crankshaft until both valves in cylinder 1 overlap (Exhaust valve about to close, inlet valve about to open).
3. Adjust clearance of valves marked in black in figure. Mark respective rocker arm with chalk to show that adjustment
has been done.
Figure 2
Lock nut, tightening
4. Tighten down the lock nut to 20 N·m (15 lbf·ft) check the adjustment again with a feeler gauge.
Figure 3
Valve clearance, adjustment
5. Turn crankshaft one full revolution (360°). Now adjust clearance of valves marked black in figure.
6. Install the valve cover together with a new gasket and tighten down the screws.
¡ Tightening torque: 9 N·m (6.6 lbf·ft)

Service Information

Crankshaft, description 216 Service Information 27/11/2019
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Crankshaft, description

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Figure 1
Crank shaft
The forged crankshaft of the D6D engine is provided with integrated balance weights. The drive gear for the timing
gears and the flywheel flange are shrunk on.
Figure 2
Fillet radii on the bearing journal
The material microstructure of the fillet radii on the bearing journals is strengthened by rolling.
Remachining of the fillet radii is therefore not permissible.
Figure 3
Allowable repair limit
In case of repair, there is available one under size of 0.25 mm (referred to the diameter) for the crank pins and main
bearing journals.
Figure 4
Allowable thrust bearing face repair limit
The thrust bearing face can only be remachined once (oversize: 0.4 mm, 0.2 mm each side).
Thrust bearing clearance of the crankshaft in installed condition: 0.1 to 0.28 mm (0.004 to 0.011 in).
Service Information

Connecting rod, 216 Service Information 27/11/2019
description
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Connecting rod, description


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Figure 1
Connecting rod
The connecting rod of forged steel is fitted at the big end bearing bore with a balance weight (1) in order to
compensate the manufacturing tolerances with regard to weight and position of the center of gravity.
The number markings (A) on the big end eye and the bearing cap must be on one side and identical.
Locating lugs (2) are provided in the lower and upper bearing shells to prevent the bearing shells from rotating in
their seat; these lugs engage in oblong shaped grooves in the big end eye and big end bearing cap.
The piston must be so installed that the flywheel symbol (B) on the piston top faces the flywheel.
When assembling connecting rod and piston, the centering pins (3) for locating the connecting rod bearing cap
must be fitted on the upper face of the piston on the side of the flywheel symbol (B).
Service Information

Engine mounting 218 Service Information 27/11/2019
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EW145B Volvo
Engine mounting

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Figure 1
Engine mounting
1 Screw 7 Frame
2 Cushion 8 Screw
3 Washer 9 Screw
4 Nut 10 Engine mounting bracket (rear)
5 Plate 11 Frame
6 Engine mounting bracket (front) 12 Screw
NOTE!
Check the color markings for cushion installation.
¡ Front (fan end): yellow and white

¡ Rear (flywheel end): Green and white
Tightening torque, unit: kgf·m (lbf·ft)
No. Part name Thread size Tightening torque

1 Screw M 22 × 2.5 × 120 L 70 ± 7 (505 ± 51)
8 Screw M 16 × 2.0 × 40 L 27 ± 2.5 (195 ± 18)
9 Screw M 12 × 1.75 × 35 L 11.5 ± 0.5 (83 ± 4)
12 Screw
Service Information

Lubrication system, 220 Service Information 27/11/2019
description
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EW145B Volvo
Lubrication system, description


Engine lubricating oil is supplied to the contact faces of rotating components such as turbocharger, crankshaft,
camshaft, piston, inlet/exhaust valve, rocker arm and timing gear by means of forced lubrication from the oil pump.
Lubrication oil flow diagram
Figure 1
Lubrication oil flow
1 Oil pan 9 Bore for piston cooling spray nozzle

2 Intake pipe 10 Spray nozzle for piston cooling
3 Lube oil pump 11 Tappet control bore for lubrication of rocker arms
4 Lube oil cooler housing 12 Push rod, oil supply for rocker arm
4-1 Pressure regulator valve: 4.1 0.4 kgf/cm2 (58 6 psi) 13 Rocker arm
4-2 Cooler bypass valve: 2.1 0.35 kgf/cm2 (30 5 psi) 14 Return line to oil pan
4-3 Lube oil filter with bypass valve: 2.5 0.5 kgf/cm2 (36 7 psi) 15 Oil line to exhaust turbocharger
4-4 Oil pressure sensor 16 Exhaust turbocharger
5 Main oil gallery 17 Oil line to compressor or to hydraulic pump
6 Crankshaft bearing 19 Hydraulic pump
7 Big end bearing 21 Return to oil pan
8 Camshaft bearing 22 Return line from turbocharger
Schematic, lube oil circuit

Specifications
Item Description Remark

1 Lube oil pump Rotary pump: Volume flow at n = 2500 min-1: 65 l/min
2 Oil cooler -
3 Bypass valve oil cooler Opening pressure: p = 2.1 0.35 kgf/cm2 (30 5 psi)
4 Oil filter With bypass valve (5)
5 Bypass valve oil filter Opening pressure: p = 2.5 0.5 kgf/cm2 (36 7 psi)
6 Pressure regulating valve Opening pressure: p = 4.0 0.4 kgf/cm2 (57 6 psi)
7 Exhaust turbocharger -
Figure 2
Schematic, lube oil circuit
Service Information

Lubrication system, 220 Service Information 27/11/2019
principle of operation
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Lubrication system, principle of operation


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Lube oil ducts

The D6D EOE2 engine is provided with forced-fed circulation lubrication with lube oil cooler and lube oil filter arranged in
full flow. The lube oil is supplied by the lube oil pump through the oil cooler to the oil filter. Both components are mounted
to the lube oil cooler housing which is flanged to the crankcase. Downstream of the filter the lube oil flows into the main oil
gallery and secondary oil gallery. From here the oil is ducked to the lubricating points.
The main oil gallery supplies:
– Crankshaft
– Camshaft
– Valve tappets
– Roller tappets
The secondary oil gallery supplies:
– Exhaust turbocharger
Lubrication of the rockers is effected via the tappets and the push rods.
Lube oil pump
Figure 1
Lube oil pump, sectional view
1. Inner rotor
2. Delivery chamber towards crankcase
3. Suction chamber
4. Driver contour
The lube oil rotary pump is installed in the front cover. The inner rotor (1) is seated on the crankshaft and is driven by same.
Its driver contour (4) has no 120° partition, i.e. the rotor can only be slid onto the crankshaft in a specific position.
This is attributable to deviating rotor widths.
Unit Specification
Rotor width mm (in) 12.3 (0.48)
Volume flow l/min 65 at 2500 rpm
Minimum oil pressure at 120 °C (248 °Φ) oil temperature, measured at oil filter bracket.
Lube oil cooler housing
Figure 2
The oil cooler housing incorporates the oil cooler, the oil filter and the pressure relief valve of the lube oil circuit.
Item Description Remark

1 Oil filter Consisting of: filter housing, filter cover, filter element.
Tightening torque of cover = 25 N·m
2 Bypass valve filter Opening pressure: p = 2.5 0.5 bar
3 Drain valve Opens when filter cover is loosened by 1 to 2 turns. The oil in the
filter housing drains into the oil pan.
4 Bypass valve cooler Protects cooler from pressure peaks.
Opening pressure: p = 2.1 0.35 bar
5 Pressure regulating valve Opening pressure: p = 4.0 0.4 bar
6 Non-return valve Prevents draining of the oil circuit when engine is not running.
Opening pressure maximum 0.12 bar
7 Oil cooler Aluminium shell-type cooler
8 Passage water Between oil cooler housing and oil cooler
9 Passage oil Between oil cooler housing and oil cooler
Service Information

Fuel system, description 230 Service Information 27/11/2019
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Fuel system, description


The engines use a pressure accumulator system known as common-rail fuel injection.
The main advantage of the common-rail system is its ability to vary injection pressure and timing over a broad scale. This is
made possible by separating the functions of pressure generation and fuel injection.
The fuel delivery system is made up of a low pressure and high pressure circuit.
The low pressure supply circuit consists of a fuel tank, water separator filter, belt driven fuel transfer pump, secondary fuel
filter and FCU (Fuel Control Unit).
The high pressure circuit consists of two high pressure pumps driven by the engine camshaft, a pressure-accumulator (fuel
rail), high pressure lines, high fuel pressure (fuel rail pressure) sensor and electronically controlled fuel injectors.
The transfer pump in the low pressure circuit draws fuel from the tank, through a water separator filter and into the pump
inlet. Fuel is then forced from the pump through the secondary filter to the FCU (Fuel Control Unit) at the inlet of the high
pressure pumps.
The FCU controls filling of the high pressure pumps so as to maintain the rail pressure set point.
The continuously operating high pressure fuel pumps produce the desired injection pressure that is stored in the pressure
accumulator (fuel rail).
High pressure fuel from the pressure accumulator is available to the injectors at all times. The electronic fuel injectors control
injection timing and quantity.
Figure 1
Fuel system
Service Information

Fuel system, specifications 230 Service Information 27/11/2019
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Fuel system, specifications


Specifications
Item Unit Specifications

Fuel injection pump – Bosch
Fuel consumption g/kW·h 224 at 2000 rpm
Fuel tank Capacity Liter 260
gal 68.7
Filter – # 60
Fuel filling pump Rated voltage DC (V) 24
Rated current A 7 (at 3m head)
Output flow lpm/gpm 35 / 9.2 (at 3m head)
Continuous working time in minutes 30 at 20 °C, 25 at 30 °C, 20 at 40 °C
ambient temperature
Working temperature °C (°F) –30 ~ 40 (–22 ~ 104)
Service Information

Fuel pressure, 230 Service Information 27/11/2019
specifications
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EW145B Volvo
Fuel pressure, specifications


Fuel feed pressure

Minimum pressure in engine starting condition 0.35 ±0.05 MPa, 51 ±7 psi, 3.5 ±0.5 bar
Minimum pressure in engine running condition 0.6 ±0.05 MPa, 87 ±7 psi, 6.0 ±0.5 bar
Maximum pressure in the pump pressure relive valve 1.15 ±0.15 MPa, 167 ±22 psi, 11.5 ±1.5 bar
Fuel return pressure

Maximum pressure in engine starting condition 0.03 MPa, 4.4 psi, 0.3 bar
Maximum pressure in engine running condition 0.05 MPa, 7.3 psi, 0.5 bar
Fuel control unit (FCU) pressure

Pressure in engine starting condition 0.07 ±0.04 MPa, 10 ±6 psi, 0.7±0.4 bar
Pressure without load in engine running condition 0.1 ±0.01 MPa, 15 ±2 psi, 1 ±0.1 bar
Pressure with load in engine running condition 0.09–0.21 MPa, 13–31 psi, 0.9–2.1 bar
Pressure without regulation in engine running condition 0.45 ±0.02 MPa, 65 ±3 psi, 4.5 ±0.2 bar
High pressure fuel pump output pressure at testing condition

Output pressure 55 ±5 MPa, 7979 ±725 psi, 550 ±50 bar
Fuel rail pressure

Pressure in engine starting condition 30 ±5 MPa, 4352 ±725 psi, 300 ±50 bar (at charge air
pressure 0 MPa, 0 psi, 0 bar)
Pressure with rail PRV open in running conditions 70 ±5 MPa, 10153 ±725 psi, 700 ±50 bar
Pressure with load above 60% in engine running condition 80–150 MPa, 11606–21762 psi, 800–1500 bar (at charge air
pressure 0.05–0.25 MPa, 7.3–36.3 psi, 0.5–2.5 bar)
Service Information

Fuel injection system, 230 Service Information 27/11/2019
description
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EW145B Volvo
Fuel injection system, description


The D6D EOE2 engine operates according to the direct injection principle.
The piston bowl has a small amount of eccentricity to the piston axis. The fuel is injected via six single cylinder
injection pumps. The maximum injection pressure reaches up to 1350 bar. This results in good exhaust emission
values which meet the requirements of EURO I to III.
Figure 1
Fuel injection system, diagram
Fuel flow system diagram
The fuel is delivered by fuel feed pump (9) from tank (2) via filter (7) to the supply duct of the single cylinder injection pumps
integrated in the crankcase. From the six single injection pumps the fuel is supplied through the injection lines to the
injectors (5). The end of the supply duct is fitted with a pressure holding valve (4).
Figure 2
Fuel line
7 Fuel filter
2 Fuel tank 8 Supply hose (to injector)
3 Water separator 9 Fuel feed pump
4 Holding valve 10 Supply line (to fuel filter)
5 Injector 11 Suction hose (from fuel tank)
6 Injector return hose 12 Return hose
NOTE!
Hose clamp tightening torque: 0.12 ~ 0.17 kgf·m (0.87 ~ 1.23 lbf·ft)
NOTE!
Never tighten hose clamp exceeding specified torque. It may cause leakage.
The fuel level sensor is installed in the fuel tank.

When the fuel level gauge indicates EMPTY, there is still approximately 45 Liters remaining.
Fuel feed pump
The fuel feed pump is a rotary pump which is driven via the Poly-V-belt.
The pump is provided with a two-way valve (item 1 Pop. 6 0.5 bar, item 2 Pop.: 0.5 bar).
The overpressure relief valve (1) is a plunger valve and opens at 5.5 bar. This valve simultaneously limits the system
pressure to 9.5 bar.
The bypass valve (2) is a ball valve. When the fuel lines have run empty, the fuel system can be primed with a hand
pump. This prevents an excessive engine starting procedure. (Starter protection).
NOTE!
Do not reduce the line cross section and connection to the fuel feed pump (see installation directions), as this may result in
engine power loss.
Figure 3
Fuel feed pump
1. Relief valve
2. Bypass valve
Service Information

Fuel tank, description 234 Service Information 27/11/2019
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EW145B Volvo
Fuel tank, description


Figure 1
Fuel tank
1. Fuel tank air ventilation filter

2. Strainer
3. Fuel tank
4. Fuel level gauge
Service Information

Inlet system, description 250 Service Information 27/11/2019
Profile:
EW145B Volvo
Inlet system, description


The air required for combustion is filtered by the air cleaner filter, and then supplied to the engine combustion
chamber through the turbocharger.
For operator convenience the clogging of the inlet system is sensed and activates a warning lamp on the dash
board.
Figure 1
Inlet system
1 Air cleaner assembly 6 Turbocharger assembly

2 Screen 7 Charge air cooler
3 Vacuum valve 8 Radiator assembly
4 Air sensor 9 Hydraulic oil cooler
5 Intake manifold
Clamp tightening torque
A 0.8 kgf·m (5.8 lbf·ft)
B 0.5 ~ 0.6 kgf·m (3.6 ~ 4.3 lbf·ft)
C 0.5 ~ 0.6 kgf·m (3.6 ~ 4.3 lbf·ft)
D 1.0 kgf·m (7.2 lbf·ft)
E 0.5 ~ 0.6 kgf·m (3.6 ~ 4.3 lbf·ft)
Service Information

Exhaust system, description 250 Service Information 27/11/2019
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EW145B Volvo
Exhaust system, description


The exhaust system is designed so that exhaust noise is remarkably reduced when the exhaust gas is passed
through the manifold and muffler.
Figure 1
Exhaust system
1. Turbocharger
2. Pipe
3. Muffler
4. Exhaust manifold
5. Turbocharger side
6. Muffler side
7. Clamp
8. Screw
Sealing clamp installation
1. Assemble the turbocharger side tube into the muffler side tube about 25 mm (1 inch) as the figure.
2. Insert the gasket supplied with the clamp into the clamp.
3. Tightening two screws by turns.
NOTE!
Tightening torque: 6.9 ~ 10.4 kgf·m (49.8 ~ 75.1 lbf·ft)
Service Information

Turbocharger, description 255 Service Information 27/11/2019
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Turbocharger, description

The turbocharger is driven by the exhaust gasses as they pass through the turbine housing.
The exhaust gas flow causes the turbine rotor in the turbine housing to rotate. The compressor rotor is positioned on the
same shaft as the turbine rotor. The compressor rotor is positioned in a housing which is connected between the air cleaner
and the engine induction manifold.
When the compressor rotor rotates, air is drawn from the air cleaner. The air is compressed and forced into the engine
cylinders, after it first has been cooled down while passing through the intercooler.
The turbochargers on some engines are equipped with a wastegate valve. The waste-gate valve, which is controlled by the
charge-air pressure, allows a small amount of the exhaust gasses to by-pass the turbine rotor at high engine speeds (high
charge-air pressure). This design makes the turbocharger efficient at low engine speeds.
Figure 1
Turbocharger, principle diagram
A. Supply of lubricating oil

B. Exhaust gases from engine into turbocharger
C. Exhaust gases out from turbocharger
D. Air via air filter
E. Air to inlet manifold
Service Information

Cooling system, description 260 Service Information 27/11/2019
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Cooling system, description


EW145B Volvo
Air is drawn into the engine compartment passing through the radiator, the oil cooler and the charge air cooler as the fan
rotates.
A water cooling system maintains the temperature of the cylinder wall and lubricant at an optimum level so that the
engine can be operated at maximum efficiency. Coolant is force circulated through the radiator, cylinder head and
cylinder block by the internally mounted water pump.
Coolant will not circulate through the radiator until the engine reaches operating temperature. When the
thermostat reaches 83 °C (181 °F), it will open, allowing flow from the head to the radiator.
The hydraulic oil cooler and the charge air cooler are installed to the radiator frame.
WARNING
Before removing the radiator cap, stop the engine and let it cool down sufficiently. When removing it, turn it slowly
to release the pressure.
Service Information

Cooling system, operation 260 Service Information 27/11/2019
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EW145B Volvo
Cooling system, operation


The cooling circuit of the D6D engine is closed circuit (forced circulation cooling), continuous-flow cooling is not permitted.
Figure 1
Cooling system
1 Cooling fan 5 Thermostat 9 Coolant inlet pipe

2 Radiator 6 Fan belt 10 Water pump
3 Air vent hose 7 Cylinder cooling chamber 11 Make up hose
4 Coolant outlet hose 8 Engine filter and oil cooler 12 Coolant filter (option)
NOTE!
Tightening torque (clamp): 0.12 ~ 0.17 kgf·m (0.87 ~ 1.23 lbf·ft)
Coolant
Liquid-cooled engines are to be filled with a treated coolant as otherwise serious engine damage can occur as a
result of freezing, cavitation and corrosion.
The water used must meet the following requirements:
Water quality Minimum Maximum
ph value at 20 °C 6.5 8.5
Chloride ion content (mg/dm3) - 100
Sulfate ion content (mg/dm3) - 100
Total hardness (°dGH) 3 12
The coolant is prepared by adding a cooling system conditioner to the cooling water. A cooling system conditioner
which is free from nitrite, a mine and phosphate is available in 5-liter containers from your Volvo Construction
Equipment dealer through the spare parts service. The suitability of other cooling system conditioners should be
expressly confirmed by Volvo Construction Equipment Service.
The concentration of the cooling system conditioner must not fall below or exceed the following values:
Cooling system conditioner Protection against freezing down to °C (°F)

Maximum 45% -35 (-31)
Maximum 40% -28 (-18.4)
Minimum 35% -22 (-7.6)
The concentration of the coolant is checked with commercially available testers.
Draining cooling system
Figure 2
Draining cooling system
Draining
For draining the cooling system remove screw at the left side of the crankcase and catch coolant in a suitable container and
dispose of according to regulations.
Thereafter tighten screw again.
Service Information

Cooling system, 260 Service Information 27/11/2019
specifications
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EW145B Volvo
Cooling system, specifications


Specifications
Item Unit Specifications

Radiator Core type – 1–Row CF (Wave fin)
Core size mm 496 × 770 × 94
(W × H × D) in 19.5 × 30.3 × 3.7
Dry weight kg (lb) 39 (86)
Hydraulic oil cooler Core type – 1–Row CF (Wave fin)
Core size mm 653 × 570 × 63
(W × H × D) inch 25.7 × 22.4 × 2.48
Dry weight kg (lb) 26 (57)
Service Information

Electrical system, special 300 Service Information 27/11/2019
instructions for servicing,
general
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EW145B Volvo
Electrical system, special instructions for servicing, general


EW145B Volvo
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

electronic components
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Electrical system, special instructions for servicing, electronic

components

EW145B Volvo
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

electrical components,
batteries
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EW145B Volvo
Electrical system, special instructions for servicing, electrical

components, batteries

EW145B Volvo
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

Electrical system, 300 Service Information 27/11/2019
description
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Electrical system, description


EW145B Volvo
This section of the service manual describes the design and construction of the electrical system and all included
components. This section also contains functional description, 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 and
Contronic service display unit. User instructions for VCADS Pro are available in a separate user’s manual while instructions for
the Contronic service display unit are included in the section dealing with the information system.
WARNING
For all servicing of the electrical system, the general instructions must be strictly followed.
Service Information

electrical components,
alternator and charging
regulator
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EW145B Volvo
Electrical system, special instructions for servicing, electrical

components, alternator and charging regulator

EW145B Volvo
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. At correct
belt tension, the belt should "give" when pressure is applied to it, measurement according to figure.
Figure 1
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

Instrument control unit I- 300 Service Information 27/11/2019
ECU, functional description
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EW145B Volvo
Instrument control unit I-ECU, functional description


EW145B Volvo
Figure 1
I-ECU, position
The Instrument electronic control unit (I-ECU) is located in the cab on the right side of the steering wheel.
The I-ECU displays the information received from the sensors and switches of the machine to alert the operator of any
abnormality.
All control lamps should be checked daily and replaced if burnt-out because the indicators alert the operator of a failure in
the machine.
The I-ECU contains a coolant temperature gauge, fuel gauge and alert indicators to show machine conditions.
Figure 2
I-ECU
The I-ECU receives information on the data bus. The information is processed and presented on the information display.
Functions
The engine speed and the actual work mode (P-, T-, W-mode) are shown on the display window.
Values for battery voltage, hammer operating hour (option) and error codes can also be shown on the display
window and in some cases changed.
I-ECU, checking
Before engine starting
Before starting the engine, if you turn the start switch to the ON position all lamps are turned ON for 3 seconds. At
the same time the buzzer is operated 2 times with the cycle of 1.0 second ON and 1.0 second OFF.
Check if all indicator lights come on, and if not, check for burnt-out light bulbs, and the plug–in connectors
(connector A, B) of the printed circuit board.
After engine starting
Before start–up, the battery charge warning lamp and engine oil pressure warning lamp remain ON.
Once the engine starts, the above indicators should go out.
When the engine is run at very low speed, the battery charge warning lamp may remain ON. If this happens,
increase the engine speed, and check if the light goes off. If it remains ON, it is necessary to check the charging
system.
If the engine oil pressure warning lamp remains ON for 2 ~ 3 seconds after the engine is running, stop the engine
and check the engine lubricating system.
Service Information

Software parameters, 301 Service Information 27/11/2019
description
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Software parameters, description


EW145B Volvo
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 Titles in VCADS Pro Default set Set range

Description in VCADS Pro Additional explanation
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.
YA Idle target engine speed 730 rpm 0–2000 rpm
Idle speed, desired value Normal value: 700-900 rpm
Instrument control unit (I-ECU, MID 140)

ABP Anti-theft protection – 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'.
ITR Theft Deterrent Time Delay 30 sec 0–9000 sec

After shutdown, the vehicle can be restarted within this –
time limit without identification.
Caretrack control unit (W-ECU, MID 142)

IGU Satellite Modem – OFF/ON
The parameter activates satellite modem function for –
Caretrack. This function also needs hardware to be
installed.
ON: Satellite modem installed.
OFF: Satellite modem not installed.
IHA GSM Modem – OFF/ON
The parameter activates GSM Modem function for –
Caretrack.
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.
Vehicle control unit (V-ECU, MID 187)

ABP Anti-theft protection – OFF/ON
Activates the anti-theft device that prevent starting of This parameter is also valid for I-ECU.
the vehicle.
ARO Automatic idle delay 5 sec 3–10 sec
The parameter activates/deactivates automatic idling The idling delay is the time after that the engine is
delay. idling mode when the automatic idling condition is full
filled.
BFJ 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.
BFN Auto cruise control – OFF/ON
Connect cruise control
BFQ Connect travel alarm – OFF/ON
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.
BNJ Float position, function – OFF/ON
Option equipment Float position function installed YES The option must be installed.
= 1; NO = 0
FYV Connect X1 proportional control – OFF/ON
Connect X1 proportional valve control This parameter is always set with proportional switch
control lever (IKM)
FYZ Connect X3 proportional control – OFF/ON
Connect X3 proportional valve control This parameter is always set with proportional switch
control lever (IKM)
HNI Connect X1 single acting - OFF/ON
Connect X1 single acting The option must be installed.
HOQ Boost remaining time 9 sec 3–255 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.
LLR Steering servo pressure low - OFF/ON

Steering servo pressure low can be divided into 2
types.
0: Steering servo pressure low will not be adapted.
1:Steering servo pressure low will be adapted.
LUH Engine control mode with power max switch - 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.
MXD China GPS installed - OFF/ON
Next engine start prevent function works if China GPS-
ECU is installed in the machine.
0: China GPS-ECU is not installed in the machine.
1: China GPS-ECU is installed in the machine.
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Troubleshooting, general 302 Service Information 27/11/2019
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Troubleshooting, general

EW145B Volvo
WARNING
When troubleshooting in the electrical system, read through and follow the work instructions and safety instructions
in the concerned method sections.
This section of the Service Manual describes how to troubleshoot the electrical system. The section contains flow charts that
describe the various steps, and tables that show the signal routes and terms for the various functions.
A special service display unit can be used when troubleshooting, see Service display unit.
Other assistive devices for troubleshooting the electrical system:
¡ Wiring diagram and component lists

¡ Operator's Manual
¡ Possible component manuals
¡ Parts Catalogue
The first step in troubleshooting is to gather as much information as possible about how the malfunction is manifested.
NOTE!
The functions in the electronic system may vary depending on which software versions are installed in the electronic units.
Therefore, always check which software versions are installed before starting to troubleshoot.
See current service bulletins for information on updates and differences between software versions.
Malfunctions/errors may be indicated by:
central warning flashing

buzzer sounds
error messages are shown on machine display unit and on message center display unit for I-ECU equipped
machine.
an error/malfunction symptom is obtained.
When any malfunction is suspected or confirmed it is important to determine the cause as soon as possible.
The first step in troubleshooting is to gather information from the operator regarding the error/malfunction symptom. Then,
attempt to pinpoint the cause by performing checks in a certain order, see Troubleshooting strategy.
To facilitate troubleshooting and to make it more effective, there are a number of assistive devices available, for example,
VCADS Pro service tool and the service display unit, see Troubleshooting tools.
WARNING
Continued operation following a malfunction indication may result in damage to persons and property.
Service Information

Collection of basic data Service Information 27/11/2019
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Collection of basic data


EW145B Volvo
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

Troubleshooting tools Service Information 27/11/2019
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Troubleshooting tools

EW145B Volvo
Service manual
Service information for troubleshooting is available in the service manual. The different types of information are listed below:
Instructions for checking electrical cables and connectors

A general description of these checks can be found in Electrical cables and connectors, checking.
Wiring diagrams
Wiring diagrams are of great help during troubleshooting. Wiring diagrams provide cable designations, cable colors
as well as 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 of machine components.
VCADS Pro
Figure 1
VCADS Pro computer
The name VCADS Pro is an abbreviation of Volvo Computer Aided Diagnostics System Professional.
VCADS Pro is a PC-based tool used for, among other things, downloading programs, facilitating and making
troubleshooting more effective.
Complete documentation for VCADS Pro can be found in separate user’s manual.
NOTE!
The start switch must be turned ON before VCADS Pro is connect to the machine.
Contronics service display unit (SDU)
Figure 2
Contronics service display unit
The contronics service display unit can be used to read out error codes and parameters, etc.
Machine display unit (MDU)
Figure 3
Machine display unit
The machine display unit can be used to read out error codes.
It is possible to select any menu or function you would like to see on the display unit.
Message center display
Figure 4
Message center display on I-ECU
The message center display unit can be used to read out error codes.
It is possible to select any menu or function you would like to see on the screen.
Service Information

128 PID45 Service Information 27/11/2019
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EW145B Volvo
128 PID45

Description and measuring
RE2501 Induction air preheating relay

Function Activates the preheating coil.
Wiring diagram
VCADS Pro
EB5, diagnostic signal

EB31, preheating relay signal
Control unit/ Control cable 86 ≈ U bat (relay not
cable harness: - Frame ground activated)
≈ 0 V (relay
activated)
1) 2) 3)
Supply cable 85
- Frame ground ≈ U bat
1) 2) 3)
Supply cable 30
- Frame ground ≈ U bat
1) 2) 3)
Component: (a) 85 - 86 ≈ 30 Ω
1) 2) 3) 4)
Specific part of EB5 - EB9 ≈ 0.55 x U bat
system (b) (closed circuit)
≈ 0 V (open
circuit)
1) 2) 3)
≈ U bat (relay not

EB31 - EB9 activated)
≈ 0 V (relay
activated)
a. Blue/red cable to relay disconnected (cable goes towards control unit).

b. Blue/red cable and black cable connected to relay on respective connections.
Service Information

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128 PID94

SE2301 Fuel pressure sensor

Function Defects fuel pressure of engine
Wiring diagram
VCADS Pro See test 28407-3 Sensor values, monitoring
EB18, frame ground

EB16, fuel pressure signal
EB17, supply (5 V)
Control unit/ Frame ground
cable harness: cable 4 ≈0Ω
- Frame ground
1) 2) 3) 4)
Supply cable 1
- Frame ground ≈5V
1) 2) 3)
Signal line 2
- Frame ground ≈ 100 KΩ
1) 2) 3) 4)
Specific part of 2 - 4 ≈ 0.5 V
system: (engine
stationary)
1) 2) 3)
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128 PID97

SE2302 Water in fuel sensor

Function Detects high water level of separator.
Wiring diagram
EB8, signal line

EB10, frame ground
Control unit/ Frame ground cable
cable harness: 2 ≈0Ω
- Frame ground
1) 2) 3) 4)
Signal line 1 - EB8
≈0Ω
1) 2) 3) 4)
Component 1-2
≈ ∞ Ω (normal
level)
≈ 0 Ω (low
level) 1) 2) 3) 4)
Service Information

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128 PID98

SE2205 Engine oil level sensor

Function Detects low oil level of engine
Wiring diagram
EB4, signal line

EB3, frame ground
Control unit/ 1 - Frame ground
cable harness: - Frame ground ≈ 3 MΩ
1) 2) 3) 4)
2 - Frame ground
≈ 2 ~ 4.5 V
1) 2) 3)
Component 1-2
≈ ∞ Ω (normal
level)
≈ 0 Ω (low
level) 1) 2) 3) 4)
Service Information

Profile:
EW145B Volvo
128 PID100

SE2203 Engine oil pressure sensor

Function Detects low engine oil pressure
Wiring diagram
EA5, frame ground

EA14, oil pressure signal
EA4, supply (5 V)
- Frame ground
1) 2) 3) 4)
Supply cable 1
1) 2) 3)
Signal line 2
1) 2) 3) 4)
system: (engine
stationary)
1) 2) 3)
Service Information

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128 PID102

SE2508 Charge-air (Boost) pressure sensor

Function Measures charged-air (boost) pressure (combined sensor).
Wiring diagram
EA5, frame ground

EA3, charge-air pressure signal
EA4, supply (5 V)
- Frame ground
1) 2) 3) 4)
Supply cable 1
1) 2) 3)
Signal line 2
1) 2) 3) 4)
system: (engine
stationary)
1) 2) 3)
Service Information

Profile:
EW145B Volvo
128 PID105

SE2507 Charge-air (Boost) temperature sensor

Function Measures charged-air (boost) temperature (combined sensor).
Wiring
diagram
EA5, frame ground

EA2, charge-air temperature signal
- Frame ground
1) 2) 3) 4)
Signal line 3
- Frame ground ≈ 5.7 KΩ
1) 2) 3)
Specific part 3 - 4 See table
of system: below
1) 2) 3) 4)
Sensor specification
Air temperature, ºC (ºF) Resistance Air temperature, ºC (ºF) Resistance

–40 (–40) 168 ± 13 kΩ +60 (140) 1240 ± 42 Ω
–30 (–22) 88 ± 6 kΩ +70 (158) 873 ± 33 Ω
–20 (–4) 48 ± 3 kΩ +80 (176) 627 ± 26 Ω
–10 (–14) 27 ± 2 kΩ +90 (194) 458 ± 20 Ω
0 (32) 16 ± 1 kΩ +100 (212) 339 ± 15 Ω
+10 (50) 9.9 ± 0.5 kΩ +110 (230) 255 ± 12 Ω
+20 (68) 6.2 ± 0.3 kΩ +120 (248) 195 ± 10 Ω
+30 (86) 4.0 ± 0.2 Ω +130 (266) 150 ± 8 Ω
+40 (104) 2648 ± 97 Ω +140 (284) 117 ± 7 Ω
+50 (122 1793 ± 58 Ω +150 (302) 93 ± 6 Ω
Service Information

Profile:
EW145B Volvo
128 PID107

SE2502 Air filter pressure drop sensor

Function Detects that air filter is clogged (combined sensor) after air
filter.
Wiring diagram
EB8, frame ground

EB17, air filter pressure signal
- Frame ground
1) 2) 3) 4)
Signal line 1
- Frame ground ≈ 0.8 × U bat
1) 2) 3)
Specific part of 1 - 2 ≈ 330 Ω
system:
1) 2) 3) 4)
Service Information

Profile:
EW145B Volvo
128 PID110

SE2606 Engine coolant temperature sensor

Function Senses coolant temperature in engine.
Wiring
diagram
EA25, signal line
EA5, frame ground
- Frame ground
1) 2) 3) 4)
Signal line 1
- Frame ground ≈ 1.4 KΩ
1) 2) 3) 4)
Supply cable 1
1) 2) 3)
Specific part 1–2 See table below
of system:
1) 2) 3) 4)
Sensor specification
Air temperature, ºC (ºF) Resistance Air temperature, ºC (ºF) Resistance

–30 (–22) 27.5 ± 3.2 kΩ +60 (140) 376 ± 20 Ω
–20 (–4) 15.0 ± 1.6 kΩ +70 (158) 267 ± 13 Ω
–10 (–14) 8.5 ± 0.82 kΩ +80 (176) 191.1 ± 8.5 Ω
0 (32) 4.9 ± 0.44 kΩ +90 (194) 139.7 ± 8.5 Ω
+10 (50) 3.0 ± 0.25 kΩ +100 (212) 103.7 ± 3.7 Ω
+20 (68) 1.9 ± 0.14 kΩ +110 (230) 78.0 ± 2.8 Ω
+30 (86) 1205 ± 85 Ω +120 (248) 59.5 ± 2.4 Ω
+40 (104) 798 ± 52 Ω +130 (266) 45.9 ± 2.0Ω
+50 (122 542 ± 32 Ω
Service Information

MID 128 PID 164 Injection Service Information 27/11/2019
control pressure
Profile:
EW145B Volvo
MID 128 PID 164 Injection control pressure


SE2309 Sensor, common rail pressure

Function Measures the fuel pressure in the common rail.
Wiring
diagram
Installing/ Tightening torque:
Adjusting: VCADS Pro:
Control unit/ ≈0Ω

cable harness: 1–
≈5V
3–
A19–2 ≈0Ω
Component: ≈∞Ω
1–
3–
A19–A11 ≈ 0.5 V
Service Information

MID 128 PID 174 Fuel Service Information 27/11/2019
temperature
Profile:
EW145B Volvo
MID 128 PID 174 Fuel temperature


SE2306 Fuel temperature sensor

Function Measures fuel temperature
Wiring diagram
EA5, frame ground

EA13, fuel temperature signal
- Frame ground
1) 2) 3) 4)
Supply cable 1
1) 2) 3)
Signal line 3
- Frame ground ≈ 1.4 kΩ (20 °
C / 68 °F)
1) 2) 3) 4)
Component: 3 - 4 (EA13 - EA5) ≈ 1.9 kΩ (20 °
C / 68 °F)
≈ 798 Ω (40 °
C / 104 °F) 1) 2) 3) 4)
1 - Frame ground ≈∞Ω
Specific part of 3 - 4 (EA13 - EA5) ≈ 3 V (20 °C /
system: 68 °F)
≈ 2 V (40 °C /
104 °F)
1) 2) 3)
Fuel temperature sensor(SE2306) resistance values
Fuel temperature, ºC (ºF) Resistance Fuel temperature, ºC (ºF) Resistance

–30 (–22) 27.5 ± 3.1 kΩ +60 (140) 376 ± 20 Ω
–20 (–4) 15.0 ± 1.6 kΩ +70 (158) 267 ± 13 Ω
–10 (–14) 8.5 ± 0.8 kΩ +80 (176) 191 ± 9 Ω
0 (32) 4.9 ± 0.4 kΩ +90 (194) 140 ± 6 Ω
+10 (50) 3.0 ± 0.25 kΩ +100 (212) 104 ± 4 Ω
+20 (68) 1.9 ± 0.1 kΩ +110 (230) 78 ± 3 Ω
+30 (86) 1205 ± 85 Ω +120 (248) 60 ± 3 Ω
+40 (104) 798 ± 52 Ω +130 (266) 46 ± 2 Ω
+50 (122) 541 ± 32 Ω
Service Information

128 SID21 Service Information 27/11/2019
Profile:
EW145B Volvo
128 SID21

SE2703 Engine position sensor (camshaft)

Function Measure speed camshaft.
Wiring diagram
EA7, engine speed (+)

EA18, engine speed (-)
Signal line (+) 1 - ≈75 ~ 110 Ω
Frame ground
1) 2) 3) 4)
Component 1-2 ≈ 3.5 kΩ
2 - Frame ground ≈∞Ω 1) 2) 3) 4)

Service Information

Profile:
EW145B Volvo
128 SID240

Error codes
SAE-code: MID128 SID240 FMI2

E-ECU controller, intermittent or incorrect data
Conditions: Engine control unit (E-ECU) registers incorrect checksum in program memory.
Possible cause: Reaction from control unit:
¡ Checksum error in flash memory of the ¡ Error code is set.

main software (Internal error in the control
unit).
¡ Fault when programming.
Noticeable symptom/malfunction: Troubleshooting information:
¡ The engine does not start. ¡ Change the control unit or reprogram using the VCADS
Pro.
Service Information

Profile:
EW145B Volvo
128 SID253

Error codes

E-ECU controller, intermittent or incorrect data
Conditions: If engine control unit (E-ECU) registers incorrect checksum in calibration memory.
¡ Internal error in the control unit (erased ¡ Error code is set.

data set 1 or data set 2 in EEPROM from
some reason).
¡ The engine does not start. ¡ Change the control unit or reprogram using the VCADS
Pro.
Service Information

MID 187 PID 91 Accelerator Service Information 27/11/2019
pedal position
Profile:
EW145B Volvo
MID 187 PID 91 Accelerator pedal position


EW145B Volvo
SE4217 Sensor, travel pedal pressure

Function Measures the travel pedal pressure for travelling.
Wiring Wiring diagram SCH09
diagram
VA62: Signal
VA4: Feed 5V
VA63: Ground
Control unit/ Frame ground cable ≈0Ω
cable harness:
2–
Feed cable ≈5V
1–
Signal cable ≈0Ω

3–VA62
1–
3–
Subsystem: 2–3 0.5–4.5 V
Service Information

187 PPID1122 Service Information 27/11/2019
Profile:
EW145B Volvo
187 PPID1122

MA9105 Conflux cutoff solenoid

Function Controls conflux cutoff solenoid
Wiring
diagram
MA9105, Boom conflux cutoff sol

MA9106, Arm conflux cutoff sol
cable harness:
2–
Feed cable ≈ 24 V
1–
1–
2
1–2 ≈ 28 Ω (20 °C)
Subsystem: ≈ 24 V (active)
A37–
Service Information

187 PPID1133 Service Information 27/11/2019
Profile:
EW145B Volvo
187 PPID1133

EW145B Volvo
SW2701 Engine speed control switch

Function The switch is used to select the engine speed.
Wiring diagram
JA14, frame ground

JA39, signal line
JB11, power supply cable
Control unit/ Frame ground cable ≈ 0 Ω
cable harness: 1
- Frame ground
1) 2) 3) 4)
Supply cable 3 ≈ U bat
- Frame ground
1) 2) 3)
Specific part of JA39 - JA14 ≈ 0.3–4.5 V
system:
Engine speed I2 mode: 0.3 V
control switch to
move variable H mode: 4.5 V 1) 2) 3)
position.
Checking speed
control switch 1) Electrical system of SDU 2) Analog inputs 3) check the
mode position switch step 1~9 of speed control sw
using by SDU.
Service Information

MID 187 PPID 1194 Cruise Service Information 27/11/2019
solenoid
Profile:
EW145B Volvo
MID 187 PPID 1194 Cruise solenoid


EW145B Volvo
MA4211 Solenoid valve, Cruise

Function Activates the cruise control.
diagram
Adjusting: VCADS Pro: C51, Signal

cable harness:
2–
Control cable ≈0Ω

1–C51
Component: 1–2 ≈ 30 Ω
Subsystem: 1–2 ≈ UbatV

(active)
≈ 0V
(inactive)
Service Information

MID 187 PPID 1290 Creep Service Information 27/11/2019
speed solenoid
Profile:
EW145B Volvo
MID 187 PPID 1290 Creep speed solenoid


MA4214 Solenoid valve, Creep speed

Function Control the travel motor with creep speed.
diagram
Adjusting: VCADS Pro: VA59, Signal creep speed
cable harness:
2–

1–VA59
Subsystem: 1–2 ≈ UbatV

(active)
≈ 0V
(inactive)
Service Information

MID 187 PPID 1319 Service Information 27/11/2019
Hammer solenoid
Profile:
EW145B Volvo
MID 187 PPID 1319 Hammer solenoid


EW145B Volvo
MA9103 Solenoid valve, X1 hammer

Function Controls X1, Hammer
diagram
VA37, X1 Hammer
cable harness:
2–

1–VA37
Subsystem: 1–2 Ubat V

(active)
0V
(inactive)
Service Information

Profile:
EW145B Volvo
187 SID231

SID231 SAE J1939 control link, failure

Function Checks if the communication between ECUs is down.
Wiring
diagram
Subsystem U ≈2.5 ~ 3.0 V
CAN H -
U ≈ 2.0 ~ 2.5 V
CAN L -
CAN H - L U≈0~1V
Voltage levels J1939 CAN-bus
Service Information

Profile:
EW145B Volvo
187 SID250

SID250 SAE J1587 information link, failure

Wiring
diagram
Subsystem U ≈ 3.5 ~ 4.5 V
J1587 A -
U ≈ 0 ~ 1.5 V
J1587 B -
J1587 A - B U ≈ 2.5 ~ 4.0 V

Voltage levels J1587 bus
Service Information

Profile:
EW145B Volvo
187 SID253

Error codes

V-ECU controller, intermittent or incorrect data
Conditions: If vehicle control unit (V-ECU) registers incorrect checksum in calibration memory.
¡ Erased data set 1 or data set 2 in EEPROM ¡ Error code is set.

from some reason.
¡ The engine operate only idle condition. ¡ Change the control unit or reprogram using the VCADS
Pro.
Service Information

Profile:
EW145B Volvo
187 SID254

Error codes

V-ECU controller, defective unit or component
Conditions: Vehicle control unit (V-ECU) registers internal error.
¡ Internal error in the control unit ¡ Error code is set.

¡ Supply cable short-circuited to Ubat or
open circuit.
¡ The engine speed controller does not work ¡ See " Checking electrical cabling and connectors
¡ Change the engine control unit
Service Information

Profile:
EW145B Volvo
140 SID231

SID231 SAE J1939 control link, failure

Wiring
diagram
Subsystem U ≈2.5 ~ 3.0 V
CAN H -
U ≈ 2.0 ~ 2.5 V
CAN L -
CAN H - L U≈0~1V
Voltage levels J1939 CAN-bus
Service Information

Profile:
EW145B Volvo
140 SID240

Error codes
SDEDcodeD MID140 SID240 FMI2

I-ECU controller, intermittent or incorrect data
Conditions: Instrument control unit (I-ECU) registers incorrect checksum in program memory.
¡ Checksum error in flash memory of the ¡ Error code is set.

main software ( internal error in the control
unit)
¡ Instrument control unit does not work ¡ Change the instrument control unit
Service Information

Profile:
EW145B Volvo
140 SID250

SID250 SAE J1587 information link, failure

Wiring
diagram
Subsystem U ≈ 3.5 ~ 4.5 V
J1587 A -
U ≈ 0 ~ 1.5 V
J1587 B -
J1587 A - B U ≈ 2.5 ~ 4.0 V

Voltage levels J1587 bus
Service Information

Profile:
EW145B Volvo
140 SID253

Error codes

I-ECU controller, intermittent or incorrect data
Conditions: Instrument control unit (I-ECU) registers incorrect checksum in calibration memory.
¡ Internal error in the control unit ¡ Error code is set.
¡ Instrument control unit does not work ¡ Change the instrument control unit
Service Information

E-ECU (MID128) Engine Service Information 27/11/2019
control unit, passive
measuring conditions
Profile:
EW145B Volvo
E-ECU (MID128) Engine control unit, passive measuring conditions


Figure 1
resistance measurement against cable harness, engine control unit (E-ECU) disconnected
Conditions
1) Control unit disconnected
2) Multi-pin breaker box connected between control unit and cable harness
3) Inter-connecting cable connected to the other connector.
NOTE!
For measuring resistance, the following applies:
4b)Turn start switch to OFF position,
turn battery disconnector switch to OFF position and
measure resistance measurement with multimeter.
NOTICE
The battery disconnect switch must be off during all resistance measurements.
5) Engine off
Abbreviation Explanation
U Direct voltage in volts (V)
Ubat Battery voltage
Ulow Voltage near to 0 volt or 0 volt
R Resistance in ohm (Ω)
E-ECU Passive measuring
Pin Signal / component Measuring Correct value Miscellaneous

points
EA1 Not connected
EA2 SE2507, Boost temperature sensor Not applicable
EA3 SE2508, Boost pressure sensor Not applicable
EA4 SE2203, Engine oil pressure sensor Not applicable
(voltage supply)
EA5 Ground sensors EA5 - EB9 R=0Ω
EA6 Not connected
EA7 SE2703 Engine position sensor EA7 - EA18 R ≈ 3.9 kΩ
(camshaft)
EA8 Not connected
EA9 Not connected
EA10 Not connected
EA11 MA2301, Injector 1 solenoid valve EA11 - EA12 R ≈ 1.5-2.0 Ω
EA12 Ground injectors 1-3
EA13 SE2306, Fuel temperature sensor Not applicable
EA14 SE2203, Engine oil pressure sensor Not applicable
EA15 Not connected
EA16 Not connected
EA17 Not connected
EA18 SE2703 Engine position sensor EA7 - EA18 R ≈ 3.9 kΩ
(camshaft)
EA19 Not connected
EA20 Not connected
EA21 Not connected
EA24 Ground injectors 4-6
EA25 SE2601, Engine coolant temperature Not applicable
sensor
EA26 Not connected
EA27 Not connected
EA28 Not connected
EA29 Not connected
EA30 SE2701, Engine speed sensor EA30 - EA31 R ≈ 3.9 kΩ
(flywheel)
EA31 SE2701, Engine speed sensor EA30 - EA31 R ≈ 3.9 kΩ
(flywheel)
EA32 Not connected
EA33 Not connected
EB1 CAN H (J1939) EB1 - EB2 R ≈ 110 Ω
EB2 CAN L (J1939) EB2 - EB1 R ≈ 110 Ω
EB3 SE2501, Ambient temperature sensor Not applicable
EB4 SW2704, Emergency switch (Limp Not applicable
home position)
EB5 HE2501, Air heater EB5 - EB9 R≈0Ω
EB6 Not connected
EB7 SE2603, Coolant level sensor EB7 - EB8 R = 0 Ω (low level)
R = ∞ Ω (normal level)
EB8 SE2502, Pressure switch inlet air Not applicable
pressure
EB9 Ground EB9 - EB10 R=0Ω
EB10 Ground EB9 - EB10 R=0Ω
EB11 Power supply EB11 - EB12 R=0Ω
EB12 Power supply EB11 - EB12 R=0Ω
EB13 SE2501, Ambient temperature sensor Not applicable
(ground)
EB14 Not connected
EB15 Not connected
EB16 Not connected
EB17 SE2502, Pressure switch inlet air EB17 - EB8 R = 2,2 kΩ (clogged)
pressure R = 330 Ω (not clogged)
EB18 Not connected
EB19 Not connected
EB20 Not connected
EB21 Not connected
EB22 Not connected
EB23 Not connected
EB24 Not connected
EB25 J1587 A Not applicable
EB26 J1587 B Not applicable
EB27 Not connected
EB28 Not connected
EB29 Not connected
EB30 Not connected
EB31 RE2501, Air heater relay EB31 - EB11 R = 132 Ω
EB32 Not connected
EB33 Not connected
EB34 Not connected
EB35 Not connected
EB36 Not connected
Service Information

V-ECU (MID187) Vehicle Service Information 27/11/2019
control unit, active
Profile:
EW145B Volvo
V-ECU (MID187) Vehicle control unit, active measuring conditions


Figure 1
voltage measurement with multi-pin breaker box and adapter cable connected between cable harness and vehicle
control unit (V-ECU)
Conditions
1) Control unit connected
2) Multi-pin breaker box connected between control unit and cable harness
3) Inter-connecting cable connected to the other connector.
NOTE!
For measuring voltage, the following applies:
4a) Turn battery disconnector switch to the ON position,
turn start switch to the ON position and
measure the voltage with the multimeter.

5) Engine off
V-ECU Active measuring

points
JA1 Contronics key “V” JA1 - JB8 U ≈ Ubat (key: ON)
U ≈ 0 V (key: OFF)
JA2 Contronics clock JA2 - JB8 U ≈ Ubat (SDU install)
U ≈ 0 V (SDU uninstall)
JA3 SW4202, Auto cruise switch JA3 - JB8 U ≈ Ubat (switch: ON)
U ≈ 0 V (switch: OFF)
JA4 SE5203, Travel pedal press sensor JA4 - JB8 U≈5V
power
JA5 PWM9101, power shift proportional JA5 - JB8 U ≈ 0–1.0 V
valve ground
JA6 SE5201, brake oil pressure low switch JA6 - JB8 U ≈ 0 V (switch: OFF)
U ≈ 5 V (switch: ON)
JA7 Al3201, Alternator "L" signal JA7 - JB8 U ≈ 12 V
JA8 SW3512, Hi beam switch JA8 - JB8 U ≈ Ubat (switch: ON)
JA9 SW4202, F/R lever switch (reverse) JA9 - JA8 U ≈ Ubat (switch: ON)
JA10 , Travel speed switch JA10 - JA8 U ≈ Ubat (switch: ON)
JA11 MA4101, Auto cruise solenoid valve JA11 - JA8 U ≈ Ubat
JA12 Not connected
JA13 RE3701, EMS power cut off relay JA13 - JB8 U ≈ Ubat
JA14 SW2701, Rotary switch ground JA14 - JB8 U≈0V
JA15 SE2303, Fuel level sensor JA15 - JB8 U≈5V
JA16 SW9160, Quickfit switch (buzzer stop) JA16 - JB8 U ≈ 0 V (switch: OFF)
JA17 Not connected
JA18 Not connected
JA19 SE9154, Attach pilot pressure switch JA19 - JB8 U ≈ 0 V (switch: OFF)
JA20 SW9151, Safety lever switch JA20 - JB8 U ≈ Ubat (switch: ON)
JA21 Not connected
JA22 Not connected
JA23 SW9105, Quickfit switch JA23 - JB8 U ≈ Ubat (switch: ON)
JA24 Contronics key “#” JA24 - JB8 U ≈ Ubat (key: ON)
JA25 Contronics key “>” JA25 - JB8 U ≈ Ubat (key: ON)
JA26 Contronics data JA26 - JB8 U ≈ Ubat (SDU install)
JA27 SW3512, F/R lever switch (Forward) JA27 - JB8 U ≈ Ubat (switch: ON)
JA28 SE5204, Brake 2nd pressure switch JA28 - JB8 U ≈ Ubat (switch: ON)
JA29 Not connected
JA30 Not connected
JA31 SW3613, PTW mode switch (T mode) JA31 - JB8 U ≈ Ubat (switch: ON)
JA32 PWM9101, Power shift proportional See passive
valve signal measuring.
JA33 FU25, Fuse for proportional valve JA33 - JB8 U ≈ Ubat
JA34 Not connected See passive
measuring.
JA35 FU27, Fuse for conflux shut off, Auto JA35 - JB8 U ≈ Ubat
cruise
JA36 MA9107, Power boost solenoid valve U ≈ Ubat See passive
measuring.
JA37 MA9106, Conflux shut off solenoid U ≈ Ubat See passive
valve measuring.
JA38 RE5203, Travel pedal pressure sensor U ≈ 0 - 1.0 V
ground
JA39 SW2701, Engine speed control switch JA39 - JB8 U ≈ 0.3–4.5 V
signal
JA40 Not connected
JA41 Not connected
JA42 SW9105, Quickfit switch (confirm) JA42 - JB8 U ≈ 0 V (switch: ON)
JA43 Not connected
JA44 Not connected
JA45 Not connected
JA46 Not connected
JA47 SW2706, Emergency RPM control and See passive
stop switch (IVS) measuring.
JA48 Contronics key "*” JA48 - JB8 U ≈ Ubat (key: ON)
JA49 Contronics enable JA49 - JB8 U ≈ Ubat (SDU install)
JA50 SW9151, Axle lock switch JA50 - JB8 U ≈ Ubat (switch: ON)
JA51 Not connected - -
JA52 Not connected - -
JA53 SW3613, PTW mode switch (W mode) JA53 - JB8 U ≈ Ubat (switch: ON)
JA54 Not connected
JA55 Not connected
JA56 Not connected
JA57 Not connected
JA58 Not connected
JA59 Not connected
JA60 FU27, Fuse for power boost solenoid JA60 - JB8 U ≈ Ubat
valve, VECU status
JA61 RE3101, Battery relay cut off signal JA61 - JB8 U ≈ Ubat
JA62 SE5203, Travel pedal pressure sensor
signal
JA63 SE2303, Fuel level sensor ground JA63 - JB8 U ≈ 0 V - 1.0 V
JA64 Not connected
JA65 Not connected
JA66 SE9102, Hammer pilot pressure switch JA66 - JB8 U ≈ 0 V (switch: ON)
JA67 SW2704, auto idle select switch JA67 - JB8 U ≈ 0 V (switch: ON)
JA68 Not connected
JA69 Not connected
JA70 Not connected
JB1 SW9109, boost switch JB1 - JB8 U≈0V

U ≈ Ubat (boost select only)
JB2 SW3301, engine start key (R2) JB2 - JB8 U ≈ Ubat (engine cranking only)
U ≈ 0 V (other condition)
JB3 Not connected
JB4 J1587 B (white color) JB4 - JB8 U ≈ 0–5 V
JB5 Shield ground (J1939)
JB6 CAN L (J1939 L, green color) JB6 - JB8 U ≈ 0–3 V
JB7 Battery ground
JB8 Battery ground
JB9 SW3301, engine start key (ACC) JB9 - JB8 U ≈ Ubat
JB10 Not connected
JB11 SW2701, Rotary switch power JB11 - JB8 U ≈ Ubat
JB12 J1587 A (red color) JB12 - JB8 U ≈ 0–5 V
JB14 CAN H (J1939 H, yellow color) JB14 - JB8 U ≈ 2–5 V
JB15 Battery +24 V JB15 - JB8 U ≈ Ubat
JB16 Battery +24 V JB16 - JB8 U ≈ Ubat
Service Information

V-ECU (MID187) Vehicle Service Information 27/11/2019
control unit, passive
Profile:
EW145B Volvo
V-ECU (MID187) Vehicle control unit, passive measuring conditions


Figure 1
resistance measurement against cable harness, vehicle control unit (V-ECU) disconnected
Conditions
1) Control unit disconnected
2) Multi-pin breaker box connected against cable harness

NOTE!
For measuring resistance, the following applies:
3b)Turn start switch to the OFF position,

turn battery disconnector switch to the OFF position and
measure the resistance with the multimeter.
NOTICE
During all resistance measurements, the master switch must be turned OFF.
4) Engine off
V-ECU Passive measuring

points
JA1 Contronics key “V” See active
measuring
JA2 Contronics clock See active
measuring
JA3 SW4202, Auto cruise switch See active
measuring
JA4 SE5203, Travel pedal press sensor See active
power measuring
JA5 PWM9101, power shift proportional JA5 - JA32 R ≈ 15 - 20 Ω
valve ground
JA6 SE5201, brake oil pressure low switch See active
measuring
JA7 Al3201, Alternator "L" signal See active
measuring
JA8 SW3512, Hi beam switch JA8 - JB8 See active
measuring
JA9 SW4202, F/R lever switch (reverse) JA9 - JA8 See active
measuring
JA10 , Travel speed switch See active
measuring
JA11 MA4101, Auto cruise solenoid valve See active
measuring
JA12 Not connected See active
measuring
JA13 RE3701, EMS power cut off relay JA13 - JB8 R ≈ 315 Ω ± 10 %
JA14 SW2701, Rotary switch ground
JA15 SE2303, Fuel level sensor JA15 - JA63 R ≈ 3 ~ 110 Ω
JA16 SW9160, Quickfit switch (buzzer stop) See active
measuring
measuring
measuring
JA19 SE9154, Attach pilot pressure switch See active
measuring
JA20 SW9151, Safety lever switch See active
measuring
JA21 Not connected
JA22 Not connected
JA23 SW9105, Quickfit switch See active
measuring
JA24 Contronics key “#” See active
measuring
JA25 Contronics key “>” See active
measuring
JA26 Contronics data See active
measuring
JA27 SW3512, F/R lever switch (Forward) See active
measuring
JA28 SE5204, Brake 2nd pressure switch See active
measuring
JA29 Not connected
JA30 Not connected
JA31 SW3613, PTW mode switch (T mode) See active
measuring
JA32 PWM9101, Power shift proportional JA32 - JA5 R ≈ 15 ~ 20 Ω
valve signal
JA33 FU25, Fuse for proportional valve See active
measuring
JA34 Not connected
JA35 FU27, Fuse for conflux shut off, Auto See active
cruise measuring
JA36 MA9107, Power boost solenoid valve JA36 - JB8 R ≈ 20 ~ 30 Ω
JA37 MA9106, Conflux shut off solenoid JA36 - JB8 R ≈ 10 ~ 15 Ω
valve
JA38 RE5203, Travel pedal pressure sensor See active
ground measuring
JA39 SW2701, Engine speed control switch JA39 - JA14 R ≈ 46.5 ~ 47.5 KΩ
signal
JA40 Not connected
JA41 Not connected
JA42 SW9105, Quickfit switch (confirm) See active
measuring
JA43 Not connected
JA44 Not connected
JA45 Not connected
JA46 Not connected
JA47 SW2706, Emergency RPM control and JA47 - JB8 R ≈ 2.89 ~ 2.91 KΩ
stop switch (IVS)
JA48 Contronics key "*” See active
measuring
JA49 Contronics enable See active
measuring
JA50 SW9151, Axle lock switch See active
measuring
JA51 Not connected
JA52 Not connected
JA53 SW3613, PTW mode switch (W mode) See active
measuring
JA54 Not connected
JA55 Not connected
JA56 Not connected
JA57 Not connected
JA58 Not connected
JA59 Not connected
JA60 FU27, Fuse for power boost solenoid See active
valve, VECU status measuring
JA61 RE3101, Battery relay cut off signal See active
measuring
JA62 SE5203, Travel pedal pressure sensor
signal
JA63 SE2303, Fuel level sensor ground See active
measuring
JA64 Not connected
JA65 Not connected
JA66 SE9102, Hammer pilot pressure switch See active
measuring
JA67 SW2704, auto idle select switch See active
measuring
JA68 Not connected
JA69 Not connected
JA70 Not connected
JB1 SW9109, boost switch See active

measuring
JB2 SW3301, engine start key (R2) See active
measuring
JB3 Not connected
JB4 J1587 B (white color) See active
measuring
JB6 CAN L (J1939 L, green color) JB6 ~ JB14 R ≈ 60 Ω
JB7 Battery ground
JB8 Battery ground
JB9 SW3301, Engine start key (ACC) See active
measuring
JB10 Not connected
JB11 SW2701, Rotary switch power See active
measuring
JB12 J1587 A (red color) See active
measuring
JB14 CAN H (J1939 H, yellow color) JB14 - JB8 R ≈ 60 Ω
JB15 Battery +24 V JB15 - JB8 U ≈ Ubat See active
measuring
JB16 Battery +24 V JB16 - JB8 U ≈ Ubat See active
measuring
Service Information

Power transmission, 400 Service Information 27/11/2019
description
Profile:
EW145B Volvo
Power transmission, description


Hydraulic system:
¡ Main pump directly driven by the diesel engine supplies the working -, travel - and swing hydraulic system with oil.
¡ Main pump is electronically controlled by the V-ECU (Vehicle Electronic Control Unit), that means the maximum
available hydraulic power is matched to the engine speed.
¡ Servo -, brake - and steering systems are supplied with oil from separate pumps.
¡ Machine is driven by a travel motor which acts directly on the gearbox.
¡ The superstructure is slewed by a swing motor with automatic swing brake and anti-rebound valve.
The swing ring connects the superstructure with the undercarriage and is lubricated with grease.
¡ A centre passage connects the superstructure and undercarriage hydraulically and electrically.
Brake system
¡ Service brake with two separate brake circuits.

¡ Service brake is also used for digging brake with mechanical lock system.
¡ The two circuit travel brakes are supplied with two accumulators in the event of failure in the brake system.
¡ Parking brake is a negative brake system in the gear housing, spring applied and pressure released.
Drive train:
¡ Gearbox with two gears distributes the force via propeller shafts to the front and rear axle.
¡ Front axle with automatic or operator controlled oscillation lock.
¡ Front and rear axle with self adjusting wet multi discs in the hub reductions.
Service Information

Power train, description 400 Service Information 27/11/2019
Profile:
EW145B Volvo
Power train, description


Pressurized oil from main hydraulic pump (2) flows through main control valve (4), center passage (5), to travel motor (6)
that drives the transfer gearbox (9).
Rotational force of the travel motor is reduced through transfer gearbox (9), then transferred through propeller shafts (10)
and reduced again at the differential and reduction gear of the front and rear axles (11, 12).
High torque is transmitted via the planetary hubs to each wheel.
Vehicle speed is controlled by a travel speed adjust valve connected to pedal (7) in the cab, that controls engine speed and
pump flow.
Figure 1
Power train system
1 Engine 6 Travel motor 11 Front axle

2 Main pump 7 Remote control valve (pedal) 12 Rear axle
3 Servo hydraulic pump 8 Forward/reverse select valve 13 Tire
4 Main control valve 9 Transfer gearbox
5 Center passage 10 Propeller shaft
Service Information

Power train, schematic 400 Service Information 27/11/2019
diagram
Profile:
EW145B Volvo
Power train, schematic diagram


Figure 1
Power train, schematic diagram
1 Engine 7 Center passage 13 Brake valve

2 Main pump 8 Travel motor 14 Steering unit
3 1st / 2nd solenoid valve 9 Transfer gearbox 15 Gear pump
4 Travel pedal 10 Rear axle 16 Brake pump
5 Forward / reverse solenoid valve 11 Front axle 17 Steering pump
6 Main control valve 12 Steering cylinder
Service Information

Power train, mechanism 400 Service Information 27/11/2019
Profile:
EW145B Volvo
Power train, mechanism


Motive force from the engine is transmitted via the flywheel to the pump coupling, where it alleviates torsional vibration and
transfers engine power to the hydraulic pump.
Travel direction Forward / Reverse is achieved through main control valve oil flow to the travel motor ports which cause
clockwise / counter clockwise rotation of the motor output shaft.
This rotational force is transferred to the gearbox, axles, and wheels.
Therefore this system is a 4WD power train driven by a hydraulic motor.
Figure 1
Power train, mechanism
A Engine E Transfer gearbox

B Main pump F Propeller shaft
C Main control valve G Axle
D Travel motor H Wheel
Engine speed control mechanism

Travel speed is controlled by the travel remote control valve (pedal) which controls engine speed and pump flow.
Set the travel mode switch at “T” position, the engine speed selection rotary switch to step 1 and depress the travel remote
control valve (pedal) to control travel speed.
Figure 2
Engine speed control mechanism
1. Travel control lever

2. Forward
3. Neutral
4. Reverse
5. Engine rpm control rotary switch
6. Travel mode switch
7. Travel mode switch "T" position
8. Control receives "T" mode signal
9. Depress travel remote control valve (pedal)
10. Pressure sensor senses travel remote control valve secondary pilot pressure, based on pedal stroke and signals the
controller.
11. V-ECU receives signal from pressure sensor and sends signal to E-ECU.
12. E-ECU receives signal from V-ECU and sends signal to engine.
13. Change engine throttle lever angle
14. Engine rpm, pump flow varies
15. Travel speed varies
Service Information

Power train, travel 400 Service Information 27/11/2019
interlock
Profile:
EW145B Volvo
Power train, travel interlock


System diagram
Figure 1
Travel interlock, system diagram
1 Engine speed control switch 6 Pressure sensor 11 Main control valve

2 V-ECU 7 Servo hydraulic pump 12 Travel motor
3 E-ECU 8 Forward / reverse solenoid valve 13 Transfer gearbox
4 Engine 9 Power shift valve 14 Axle
5 Remote control valve (pedal) 10 Main pump
Mode selection and travel interlock

The controller compares related engine speed which are set by the engine speed control switch and travel remote control
valve (pedal), then selects the larger value to control engine speed and pump flow.
¡ If the remote control valve (pedal) is not actuated then engine speed and pump flow is controlled by the engine
speed control switch.
¡ If the engine rpm selected by remote control valve (pedal) is larger than rotary switch value engine speed and
pump flow is controlled by the remote control valve (pedal).
¡ If the engine speed selected by control switch is larger than remote control valve (pedal) value then the engine
speed and pump flow is controlled by the control switch.
¡ If the control switch is set at step 1 then engine speed and pump flow is totally controlled by the remote control
valve (pedal).
Service Information

Power train, related 400 Service Information 27/11/2019
components
Profile:
EW145B Volvo
Power train, related components


Figure 1
Power train, related components (1)
1 Air breather 5 Rear axle

2 Front axle 6 Oil drain plug
3 Inlet and oil level plug 7 Transfer gearbox
4 Propeller shaft (front) 8 Oscillating pin
Figure 2
Power train, related components (2), machine serial no.: ~ 10899
1 Inlet oil level plug 8 2nd pressure connector (P1 port)

2 Down shift protection device 9 Air breather
3 Measuring plug for lubricant pressure 10 1st pressure connector (P2 port)
4 Air breather 11 Oil filler and oil level check plug
5 Leakage oil plug 12 Oil drain plug
6 1st pressure check (M14 × 1.5) 13 Suction filter (in travel motor governor)
7 2nd pressure check (M14 × 1.5) 14 Transfer gearbox
Tightening torque, unit : kgf m (lbf ft)

a 26.7 ± 2.7 (192.8 ± 19.5)
b 90.2 ± 9.0 (651.2 ± 65)
c 14.2 ± 0.7 (102.5 ± 5.1)
d 52.2 ± 5.2 (376.9 ± 37.5)
e 44 ± 2 (317.7 ± 14.4)
Figure 3
Power train, related components (2), machine serial no.: 10900 ~
1 Inlet oil level plug EB Bleed valve (brake)

2 Connection for clutch pressure (for low speed) K port EK Bleed valve (clutch)
3 Connection for brake pressure (for high speed) B port EN Bleed valve (emergency parking brake)
4 Transfer gearbox PN Emergency actuation parking brake
5 Oil drain plug UN Pressure relief valve
6 Oil filler and oil level check plug M Low speed (clutch)
J High speed (brake)
S Lubrication pressure
Tightening torque, unit : kgf m (lbf ft)
a 26.7 ± 2.7 (192.8 ± 19.5)
b 90.2 ± 9.0 (651.2 ± 65)
c 14.2 ± 0.7 (102.5 ± 5.1)
d 52.2 ± 5.2 (376.9 ± 37.5)
e 44 ± 2 (317.7 ± 14.4)
Service Information

Power train, upper piping 400 Service Information 27/11/2019
Profile:
EW145B Volvo
Power train, upper piping


Port connection
Port connection
Part name Port Part name Port Remark

Gear pump 2 PL Filter IN Brake supply
Service brake valve BR1 Center passage E Service brake (front)
BR2 F Service brake (rear)
T1 Tank Tr6 Service brake (return)
T2
Center passage C Tank TR5 Travel gearbox leakage
G Return pipe R5 Axel locking return
D Solenoid valve (1) A3 Axel locking supply
Brake supply valve P Filter OUT Brake supply
T Return pipe R6 -
BC Service brake valve P1 Service brake (front)
AC P2 Service brake (rear)
Gear shifting control valve A Center passage B Gear shift high speed
B A Gear shift low speed
P Accumulator block S1 -
T Suction pipe - Return
PS Block A -
Steering unit P Gear pump 1PL Steering supply
R Center passage N Steering (right)
L M Steering (left)
T Return pipe R4 Steering return
Figure 1
Power train, upper piping (1)
Figure 2
Power train, upper piping (2)
1 Forward 15 Accumulator
2 Neutral 16 PS: to block "A"
3 Reverse 17 Travel motor control valve
4 Nut 18 Screw
Tightening torque: 4 ± 0.5 kgf·m (28.9 ± 3.6 lbf·ft) Tightening torque: 4.5 ± 0.5 kgf·m (32.5 ± 3.6 lbf·ft)
5 Washer 19 T: to suction pipe
6 Shuttle valve 20 P: from servo hydraulic block "S1"
7 Pressure sensor 21 A: to center passage "B"
8 From pump "2PL" 22 B: to center passage "A"
9 To brake supply valve "P" 23 Brake valve assembly
10 AC: to service brake valve "P2" 24 Pressure switch
11 BC: to service brake valve "P1" 25 A: from control valve "PS"
12 Brake supply valve 26 R6: to brake supply valve "T"
13 T: to return pipe "R6" 27 R5: from center passage "G"
14 P: from filter "OUT" 28 R4: from steering unit "T"
Service Information

Power train, lower piping 400 Service Information 27/11/2019
Profile:
EW145B Volvo
Power train, lower piping


Port connection (machine serial no.: ~ 10899)

Port connection

Center passage A Transfer gearbox P2 Low speed
B P1 High speed
C D Leakage
D Axle locking cylinder In -
G Axle locking cylinder Drain -
E Front axle Right -
Left -
F Rear axle Right -
Left -
N Steering cylinder Right -
M Steering cylinder Left -
Travel motor X2 Transfer gearbox M Retard
Port connection (machine serial no.: 10900 ~ )

Port connection

Center passage A Transfer gearbox K Low speed
B B High speed
C D -
D Axle locking cylinder In -
G Axle locking cylinder Drain -
E Front axle Right -
Left -
F Rear axle Right -
Left -
N Steering cylinder Right -
M Steering cylinder Left -
Travel motor X2 Transfer gearbox M Retard
Figure 1
Power train, lower piping (machine serial no.: ~ 10899)
Tightening torque:
1 6.5 ± 0.7 kgf m (46.9 ± 5.1 lbf ft)
2 6.5 ± 0.7 kgf m (46.9 ± 5.1 lbf ft)
3 2.85 ± 0.25 kgf m (20.6 ± 1.8 lbf ft)
Figure 2
Power train, lower piping (machine serial no.: 10900 ~ )
Tightening torque:
1 6.5 ± 0.7 kgf m (46.9 ± 5.1 lbf ft)
2 6.5 ± 0.7 kgf m (46.9 ± 5.1 lbf ft)
3 2.85 ± 0.25 kgf m (20.6 ± 1.8 lbf ft)
Service Information

Power train, 400 Service Information 27/11/2019
troubleshooting
Profile:
EW145B Volvo
Power train, troubleshooting


Troubleshooting
System line Function Phenomenon Troubleshooting Remark

Control and related Travel Does not operate. Operate at manual mode. Manual mode
circuit interlock (Set auto/manual switch at manual Travel, work possible
mode and control engine speed with
throttle linkage).
Forward/reverse/ Forward/ Forward/reverse - Check forward/reverse solenoid valve
neutral select reverse function does not and related circuit.
related circuit operate. Replace faulty part.
Pressure sensor Travel Engine speed is not Replace sensor. Travel and work
faulty interlock controllable. Set travel mode at ″T″ and control possible
engine rpm with engine speed control
rotary switch.
Engine control unit Travel Engine speed is not Check related circuit.
(ECU) interlock controllable. Replace faulty part.
Operate at manual mode.
Service Information

Swing gearbox, description Service Information 27/11/2019
Profile:
EW145B Volvo
Swing gearbox, description


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.
Model code (RGS 050-19D)
Symbol Description
RGS Type number (ex. S = Slew gearbox)
050 Size number
(Theoretical output, ex. 050 = 500 kgf·m)
19 Reduction ratio code
D Serial number
Slew gearbox, sectional view

Figure 1
Slew gearbox, sectional view
1 Case 13 No. 2 planetary gear 25 No.1 planetary gear

2 Shaft 14 Bushing 26 Thrust washer
3 Collar 15 Thrust washer 27 Snap ring
4 O-ring 16 No. 2 pin 28 Thrust washer
5 Taper roller bearing 17 Spring pin 29 No. 1 sun gear
6 Seal 18 No. 2 sun gear 30 Snap ring
7 Taper roller bearing 19 No. 1 planetary gear assembly 31 Screw
8 Split collar 20 No. 1 carrier 32 Pipe
9 Parallel pin 21 No. 1 pin 33 Level gauge
10 Ring gear 22 Spring pin 34 Adapter
11 No. 2 planetary gear assembly 23 Thrust washer 35 Valve assembly
12 No. 2 carrier 24 Needle bearing
Slew gearbox, exploded view

Figure 2
Slew gearbox, exploded view
Function
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 slew ring inner
circumference gear to rotate the superstructure.
Operation
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, 1st planetary gear, 1st pin and the 1st carrier. In the same way, power is transmitted to output shaft through the
splines of the 2nd planetary gear, 2nd pin and the 2nd carrier.
Figure 3
Slew gearbox
A. Torque flow
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) × (Zr / ZS2 + 1)
i = Total reduction ratio
Service Information

Slew gearbox, lubrication Service Information 27/11/2019
Profile:
EW145B Volvo
Slew gearbox, lubrication


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. Use a thermometer to measure. Do not touch directly by hand
to prevent a burn injury.
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.
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
Check, oil level
A. Level
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.
The level gauge also serves as an air breather for the gearbox.
Gear oil replacement procedure
Op nbr 16721
Figure 2
Refilling, gear oil
1. Oil level gauge

2. Filling port
3. Adapter
4. Valve assembly
5. Drain hose
NOTE!
Drain the gear oil while it is still warm to flush out any contaminants.
1. Connect drain hose (5) to valve assembly (4) and open valve assembly and drain the oil into a suitable container.
2. After completely draining, remove drain hose (5) and close valve assembly (4).
3. Refill the gearbox through the oil level gauge stand pipe using a funnel that allows the pipe to breathe.
NOTE!
Oil capacity: 3.9 Liter (1.03 gal)
Service Information

Swing gearbox, Service Information 27/11/2019
maintenance standard
Profile:
EW145B Volvo
Swing gearbox, maintenance standard


EW145B Volvo
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.
Seals
Replace the oil seal and o-ring, 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.
Wear limit
Item Part name Condition Standard value Allowable value

No.
29 No.1 sun gear Pitting on gear teeth surface. Diameter : within φ 1
18 No.2 sun gear mm
25 No.1 planetary gear Area ratio : within 5%
13 No.2 planetary gear
10 Ring gear
25 No.1 planetary gear Flaking on the needle bearing
21 No.1 pin sliding surface.
24 Needle bearing Partial wear
13 No.2 planetary gear Wear on outer diameter and inner Diameter clearance Diameter clearance
14 Bushing diameter of bushing. - Inner diameter: - Inner diameter: 0.1
16 No.2 pin 0.049 ~ 0.078 mm mm
- Outer diameter: - Outer diameter:
0.050 ~ 0.11 mm within 0.3 mm
27 Retaining ring Abnormal wear on the face area. Oil groove depth:
30 Retaining ring within 0.5 mm
15 Thrust washer Abnormal wear on the face area.
23 Thrust washer Severe damage in the exterior
26 Thrust washer
28 Thrust washer
5 Taper roller bearing Pitting/flaking of the race or rollers.
Severe wear in the inner race
7 Taper roller bearing Does not rotate smoothly by hand.
Worn powders stick in the roller.
6 Oil seal Severe wear and damage in the
seal lip
Service Information

Swing unit, replacing Service Information 27/11/2019
Profile:
EW145B Volvo
Swing unit, replacing


EW145B Volvo
Op nbr 431-053
Total procedure time (hr): 6.50
Tools:
14360000 Vacuum pump / 24V
WARNING
Risk of crushing injury.
The hydraulic system could respond slowly at low temperatures and could cause unexpected machine movements.
Operate carefully until the hydraulic system has reached operating temperature.
1. Replacing the swing unit. See Swing gearbox, replacing (See No1 ~ N10).
2. Lift the swing unit with the sling, and lower to the workbench safely.
Figure 1
Swing unit
3. Remove the screws, lift the swing motor with sling, and install it to a new swing unit.
NOTE!
Before installing the swing unit, thoroughly remove the sealing compound on the mounting surface.
NOTE!
Apply sealing compound to the mounting surface of the new swing unit.
4. Transfer valve assembly and dowel pins to the new swing unit.
Figure 2
Sealing compound
5. Replacing the swing unit. See Swing gearbox, replacing (See No.13 ~ No.22).
Service Information

Swing gearbox, replacing Service Information 27/11/2019
Profile:
EW145B Volvo
Swing gearbox, replacing


EW145B Volvo
Op nbr 431-021
1. Park the machine in the service position.
Figure 1
Service position
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 3-4 times with the
ignition switch at "ON" position. Turn the ignition switch to "OFF" position.
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
3. Remove the under cover.
Figure 2
Removal, under cover
4. Open oil drain valve cap and install the oil drain hose. Drain the gearbox oil into a suitable container.
Remove the clamp.
Figure 3
Draining, gearbox oil
1. Drain hose
2. Clamp
5. Remove the anti-cavitation hoses.

NOTE!
When a hose has been disconnected, plug both the hose and the connection immediately. The hoses should be
marked for correct connection.
Figure 4
Removal, hoses
6. Remove the swing gearbox mounting screws.

The take the bucket and shake the attachment from left to right (over the 10 times)
Figure 5
Removal, screws
7. Hold the swing unit with sling. and remove the swing unit.
WARNING
Risk of personal injury. Very heavy object.
Figure 6
Removal, swing unit
1. Sling
2. Swing unit
8. Remove the screws, lift the swing motor with sling, and install it to a new swing gearbox.
NOTE!
Before installing the swing motor, thoroughly remove the sealing compound on the mounting surface.
NOTE!
Apply sealing compound to the mounting surface of the new swing gearbox and then install the swing motor.
Figure 7
Removal, swing motor
1. Screws
2. Swing motor
3. Swing gearbox
9. Install a new swing unit in reverse order of the removal procedure.
NOTE!
Swing unit mounting screws tightening torque. See Swing gearbox, description.
Apply loctite (#277 or 609) on the gearbox and screws.
10. Fill the gearbox oil through the oil filling pipe. See Oil capacity Swing gearbox, specifications.
11. Bleed air from the hydraulic circuit at the swing motor before operating.
12. After completion of the work, start the engine and check for leaks.
Service Information

Swing gearbox, Service Information 27/11/2019
disassembly
Profile:
EW145B Volvo
Swing gearbox, disassembly


Op nbr 00000
Precautions for disassembly
Clean the gearbox and inspect for faults before and during disassembly.
Perform the disassembly work in a clean area .
Match mark attached components to indicate proper positioning during reassembling.
Take care not to mix parts of sub assemblies.
Prepare a collecting container (4 l).
Disassemble following outlined procedures, the number in ( ) indicates number of sectional view and part name.
1. Drain the oil inside of slew reduction through plug (36).

Remove screws (31).
Remove the motor.
NOTE!
Clean off any dirt to prevent entry into slew reduction prior to draining oil.
NOTE!
Match mark attached components to indicate proper positioning for assembly of pipe (35) and level gauge (34)
before disassembly.
¡ Tools: allen wrench 10 mm (M12), 14 mm (PT 1/2)

Figure 1
Oil drain and motor disassembly
2. Remove 1st sun gear (29).
Figure 2
Removal, 1st sun gear
3. Remove 1st planetary gear assembly (19) from ring gear (10). And disassemble the 1st planetary gear assembly,
refer to following procedures.
Remove snap ring (27), thrust washer (26), 1st planetary gear (25), needle bearing (24) and thrust washer
(23).
Remove thrust washer (28).
Remove spring pin (22) from 1st carrier (20).
NOTE!
Match mark attached components to indicate proper positioning for reassembly in 3 points on 1st planetary gear
(25) and 1st carrier (20).
NOTE!
If there is no fault with 1st pin (21), do not disassemble it from 1st carrier (20).
NOTE!
When removing 1st pin (21), do not reuse spring pin (22).
¡ Tools: snap ring pliers (expansion φ 30)

Figure 3
Removal, 1st planetary gear assembly
4. Remove dowel pin (9) and ring gear (10).
5. Remove 2nd sun gear.
Figure 4
Removal, 2nd sun gear
6. Remove 2nd planetary gear assembly (11) from shaft (2).

Disassemble 2nd planetary gear assembly, refer to following procedures.
¡ Push 2nd pin (16) into inside on spring pin (17) using a hammer.
¡ Remove 2nd pin (16) from 2nd carrier (12) using a hammer.
Remove spring pin (17) after 2nd pin disassembly.
¡ Remove 2nd planetary gear (13), bushing (14) and thrust washer (15) from 2nd carrier (12).
NOTE!
Match mark attached components to indicate proper positioning for reassembly in 3 points on 2nd planetary gear
and 2nd carrier.
NOTE!
Don’t reuse the removed spring pin.
Figure 5
Removal, 2nd planetary gear assembly
7. Remove collar (8).

Figure 6
Removal, collar
8. Shift the direction of slew reduction.

Remove shaft (2) from case (1) using a hammer.
Figure 7
Removal, shaft
9. Remove collar (3) and bearing cone (5) from shaft (2) using puller.
NOTE!
Take care not to damage the collar (3) by applying excessive pressure.
Figure 8
Removal, collar and bearing cone
10. Remove o-ring (4) from collar (3).
NOTE!
Do not reuse removed o-ring.
Figure 9
Removal, o-ring
11. Remove oil seal (6) using (-) driver.

NOTE!
Do not reuse removed oil seal.
¡ Tools: (-) driver bearing puller
Figure 10
Removal, oil seal
12. Remove taper roller bearing cup (5, 7) from case (1) using puller.
¡ Tools: (-) driver bearing puller
Figure 11
Removal, taper roller bearing cup
Service Information

Swing gearbox, assembly Service Information 27/11/2019
Profile:
EW145B Volvo
Swing gearbox, assembly


Op nbr 00000
Precaution
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 seal.
Use a torque wrench to tighten the screws and plugs to the specified torque.
Tightening torque
Tightening torque, unit: kgf·m (lbf·ft)
Item No. Part name Thread size Tightening torque

31 Screw M12 12 ~ 13 (87 ~ 94)
35 Pipe PT 1/2 6.5 ~ 7 (47 ~ 50)
36 Plug PT 1/2 6.5 ~ 7 (47 ~ 50)
33 Pipe PT 3/4 7 ~ 8 (50 ~ 58)
1. Shaft assembly
Install o-ring (4) into collar (3) and slide it onto shaft (2).
Press taper roller bearing cone onto shaft using jig.
¡ Tools: Bearing assembly jig (Part no. 8932-00320)
NOTE!
Apply grease (NLGI 2) to o-ring.
NOTE!
Heat taper roller bearing to 110 °C (230 °F) prior to installation.
Figure 1
Installation, o-ring and roller bearing
2. Bearing assembly
Press taper roller bearing cup (7) into case using jig.
NOTE!
Cool taper roller bearing using nitrogen prior to installation.
Figure 2
Installation, taper roller bearing cup
Figure 3
Installation, bearing cup
Turn over case (1).

Press bearing cup into the case.
NOTE!
Cool taper roller bearing using nitrogen prior to installation.
3. Seal
Press seal (6) into case (1) using the seal pressing jigs.
¡ Tools: Bearing assembly jig (Part no. 8933-00420, 8933-00430)
NOTE!
Apply loctite (#680) onto the outer diameter of the seal.
Take care to get any loctite on the seal lip.
Figure 4
Installation, seal
4. Case
Install shaft (2) assembly into case (1) using an eye bolt (M 12).
¡ Tools: Eye bolt (M 12)
NOTE!
The shaft is heavy, take appropriate safety precautions when handling.
NOTE!
Pay attention to case and shaft center alignment to prevent seal lip damage.
Figure 5
Installation, shaft assembly
5. Bearing
Block case (1) as shown.

Press–fit taper roller cone (17) onto case (2).

NOTE!
Heat treatment roller bearing to 110 ºC (230 ºF) prior to installation.
Figure 6
Installation, bearing
6. Collar
Install collar (8) onto shaft (2).
NOTE!
Check if shaft (2) rotates specified rolling torque after assembling the bearing and retaining ring.
¡ Shaft rolling torque: 150 ~ 220 kgf·cm (130 ~ 191 in·lb)
Figure 7
Installation, collar
7. 2nd planetary gear assembly
Insert thrust washers (15) and planetary gear (13) into carrier (12).
Insert pin (16) and bushing (14).
Tap spring pin (17) into the pin hole of carrier (12). After inserting, stake both sides of spring pin (17).
¡ Tools: Hammer
NOTE!
Align the spring pin holes in pin assembly (16) and carrier (12).
NOTE!
Apply a dab of grease to hold thrust washers (15) to gear (3).
NOTE!
Install spring pin (17) with the slit facing the end of pin (16).
NOTE!
Ensure that gears (3) rotate smoothly.
A. Stake
Figure 8
Assembly, thrust washer, planetary gear and pin etc.
8. 1st planetary gear assembly.
Press–fit pins (21) into carrier (20) and install spring pins (22). After inserting, stake both sides of spring
pins (22).
Put thrust washer (28) on the surface of carrier (20).
Onto pin (21) install thrust washer (23), gear (29) including bearing (24), thrust washer (26) and retaining
ring (27).
¡ Tools: Snap ring pliers (expansion φ 42)
NOTE!
Check if the gears rotate smoothly after assembling the retaining ring.
A. Stake
Figure 9
Installation, thrust washer, gear and retaining ring etc.
WARNING
The parts are heavy. Take appropriate safety precautions.
9. Ring gear and 2nd planetary assembly.
Insert dowel pins (29) at four places on case (1).

Insert ring gear (10) onto case (1).
Insert 2nd planetary gear assembly (11) into ring gear (10).
¡ Tools: Hammer
NOTE!
Coat the mating surface of case (1) with liquid gasket loctite #5699.
NOTE!
Support case (1).
Figure 10
Installation, ring gear and 2nd planetary gear assembly
10. 1st planetary gear assembly and 1st sun gear
Install 1st planetary gear assembly (19) into ring gear (10).
Install sun gear (29) into 1st planetary gear assembly (25).
NOTE!
Confirm that shaft (2) rotates smoothly by turning the 1st sun gear.
Figure 11
Installation, 1st planetary gear assembly and sun gear
11. Motor
Assemble the motor on ring gear (10) and tighten screws (31).
Assemble adapter and valve assembly to case.
Assemble pipe (32) to motor and insert level gauge (33).
¡ Tools: Plier (expansion φ 30), Hexagon L wrench (M 16), Torque wrench, Spanner 17× 19 mm
NOTE!
Insure the drain pipe of drain port is downward.
NOTE!
Apply loctite # 577 to thread of pipes and plugs.
NOTE!
Align the match marks when assembling.
NOTE!
Apply loctite # 5699 to mating surface.
NOTE!
Apply loctite # 277 on the screws.
Figure 12
Assembly, motor
Service Information

Slew gearbox, Service Information 27/11/2019
troubleshooting
Profile:
EW145B Volvo
Slew gearbox, troubleshooting


EW145B Volvo
Slew gearbox troubleshooting
Gearbox does not rotate. Motor overloaded. Reduce the load.
Gearbox is damaged. Replace the gearbox.
Oil leakage from mating joint Liquid gasket improperly applied. Disassembly and re-apply.
surfaces.
Mating surface damaged. Repair or replace.
Loosen screws. Tighten to specified torque.
Loosen plug. Tighten to specified torque.
Casing leakage. Cracks or pin holes. Replace the housing.
Cover damaged. Replace the cover.
Floating seal leakage. Sliding surface worn. Replace the floating seal
assembly.
O-ring distorted.
Abnormal operating temperature. Insufficient gear oil. Refill to specified level.
Gear or bearing damaged. Replace the gearbox.
Hydraulic and gear oil mixed. Replace the motor oil seal.
Abnormal operating sound. Gearbox is damaged. Replace the gearbox.

Service Information

Transfer gearbox, Service Information 27/11/2019
specifications
Profile:
EW145B Volvo
Transfer gearbox, specifications


EW145B Volvo
Specifications
Item Unit Specification

Machine serial no.: ~ 10899 Machine serial no.: 10900 ~
Model - 2 HL 100 2 HL 270
Make - ZF
Type - 2-stage power shift, negative
Input torque N·m (lbf·ft) 770 (570)
Output torque N·m (lbf·ft) 4120 (3049) 3750 (2775)
Gear ratio (1st/2nd) - 5.35/1.39 4.89/1.2
Input speed rpm 4500 4200
Installation - Direct vertical
Lubrication oil - Engine oil SAE 15W-40
Gear oil capacity liter (gal) 3.8 (1.0) 2.5 (0.7)
Weight (dry) kg (lb) 136 (300)
Service Information

description
Profile:
EW145B Volvo
Transfer gearbox, description


Machine serial no.: ~ 10899

Hydraulic diagram, schematic
Figure 1
Transfer gearbox, hydraulic diagram
No. Item Specification Function

1 Gear pump 10 cc/rev. To supply pressurized oil necessary for gear speed change
(0.61 cu·in/rev) and other lines.
2 Filter 10µ To filter the pressurized oil supply.
3 Relief valve 40 kgf/cm2 To control system pressure and protect the hydraulic
(569 psi) circuit components.
4 Control valve Reducing valve 32 +3/-2 kgf/cm2 To reduce system pressure to maintain required gearbox
(455 +42/-28 psi) inner or outer clutch pressure.
5 Check valve - To prevent back flow of pressurized oil.
6 Relief valve 14 ± 1.5 bar (200 ± Controls clutch pressure drop to ensure smooth
(Brake valve) 21 psi) application of both clutches when operating as
emergency brake.
7 Solenoid valve - For parking.
8 Solenoid valve - For gear shifting.
9 Accumulator 8 ~ 33 bar To protect the equipment from shock by supplying
(144 ~ 469 psi) pressurized oil exerting back pressure in gearbox in case
of gear shifting or emergency brake working.
10 Pressure check 32 +3/-2 kgf/cm2 Check port for gearbox inner or outer clutch pressure.
port (455 +42/-28 psi)
11 Pressure switch 26.5 ± 2.5 bar (377 ± Pressure switch for power of forward/reverse solenoid
35 psi) valve. (When pressure drops to 26.5 bar forward/reverse
solenoid power cuts off. The valve goes to neutral
position, Travel motor flow is cut and the unit stops.)
12 Swivel joint - A rotary manifold transfers oil flow to/from the upper/
lower structures.
P1 Pressure supply port - Connection port for outer clutch pressure supply line.
(Equipment speed: high speed travelling).
P2 Pressure supply port - Connection port for inner clutch pressure supply line.
(Equipment speed: low speed travelling).
J Pressure check port 32 +3/-2 kgf/cm2 Pressure check port for outer clutch (at oil temperature
(455 +42/-28 psi) 50°C) (Inner clutch pressure is 0.5 kgf/cm2 or less at this
time).
M Pressure check port 32 +3/-2 kgf/cm2 Pressure check port for inner clutch (at oil temperature
(455 +42/-28 psi) 50°C) (Outer clutch pressure is 0.5 kgf/cm2 or less at this
time).
L Pressure check port 2.8 ~ 3.5 kgf/cm2 Lubrication pressure check port. (At engine speed ≥1500
(40 ~ 50 psi) rpm, gearbox oil temperature 50°C).
E Gearbox Leakage oil Max: 1.0 Liter/min. For 1st step (low speed travelling), oil supplied to P2
leakage port quantity (0.26 gpm) applies to inner clutch piston to disengage inner clutch
Max. allowable 0.8kgf/cm2(11psi) and some oil lubricates bearing parts by internal leakage
pressure of output side piston ring, before returning to tank.
13 Throttle check valve - To make the clutch engage slowly, but release quickly.
14 Accumulator 4.5 cc/rev. Installed to reduce time in speed change since the
(0.27 cu·in/rev) application area of 1st speed clutch is larger than that of
2nd speed.
15 1st speed clutch - Power shift device applied by cone type piston spring and
16 1st speed cone type piston spring - released by hydraulic pressure controlled by the speed
shift solenoid. To transmit power, and perform parking
17 2nd speed clutch -
and auxiliary brake function as well.
18 2nd speed cone type piston -
spring
19 Lubrication line ø1.6mm Line for lubricating clutch parts.
20 Governor Pump 3.4 cc/rev. A rotor pump driven by the gearbox output shaft,
(0.20 cu·in/rev) supplies pressurized oil for lubrication and pilot valve
operation.
21 Non return - When downshift, if machine speed is higher than
changeover valve specification then this valve routes the oil for inner clutch
to outer clutch.
22 Relief valve 6.5 ± 1.5 kgf/cm2 To maintain oil pressure required for gearbox lubrication
(92.5 ±21.3 psi) and pilot valve working.
23 Shift piston - To perform gearshift and shift lock function
simultaneously.
24 Non return valve - At downshift, if the machine speed is above the downshift
point, the shift piston moving against the spring force
displaces oil. The oil volume is fed to P2 through the non
return valve.
25 Leakage oil non - When the 1st gear is preselected, the leakage oil at the
return valve shift piston and from the non return valve is fed from the
pressure side P2 to the tank P1 through the leakage oil
non return valve. As a further function, the valve blocks
the control pressure to the inner and outer clutch.
26 Travel mode - Parking brake control switch (Located in cab).
selection switch
27 Travel control - Gearbox control switch (Located in cab).
lever
28 Suction filter - To filter the pressurized oil supply.
Gearbox, external view
Figure 2
1 Pressure line form the governor (shift lock) to the outer clutch
2 Bleeder-outer clutch
3 Travel motor mounting
4 Connection for inductive transmitter (option, M18 x 1.5)
5 Suction line for the rotor pump
6 Pressure line from the governor control valve (shift lock) to the inner clutch
7 Connection leak oil control valve (shift lock) to the inner clutch
8 Gearbox mounting hole (M20)
9 Output flange
10 Pressure port-1st speed (M16 x 1.5): inner clutch
11 Pressure port-2nd speed (M16 x 1.5): outer clutch
12 Oil level check plug (M26 x 1.5)
13 Oil drain plug (M26 x 1.5)
14 Name plate
15 Parking brake emergency release lever
16 Pressure measuring port - 1st speed
17 Pressure measuring port - 2nd speed
18 Governor control valve (shift lock valve)
19 Lubrication pressure check port
Gearbox, sectional view
Figure 3
1 Gearbox input flange 10 Cup spring for clutch

2 Accumulator to control pressure in the outer clutch 11 Throttle valve
3 Inner clutch - LK 12 Drive shaft (Input) - AN
4 Outer clutch - LB 13 Drive (AN)
5 Planetary gear drive - PT 14 Output (AB)
6 Emergency parking brake release device 15 Output (AB)
7 Governor control valve (Shift lock) 16 1st gear (low speed)
8 Rotor pump 17 2nd gear (high speed)
9 Helical gear drive - ST 18 Parking (brake)
Function
The 2 HL100 is a 2 stage power shift gearbox consisting of a helical drive, planetary, dual counter shafts, an integrated multi-
disc brake and a multi-disc clutch. The power shift device consists of a planetary drive composed of the outer clutch (multi-
disc brake) which is splined to the gearbox housing, and the inner clutch multi-disc pack which is splined to the input shaft.
Both clutches are actuated by cup springs and released hydraulically. When both clutches are actuated the planetary can not
rotate and functions as an auxiliary and parking brake.
Parking brake emergency release device
A mechanically operated dog clutch is located between the planetary and helical gear output drive.
When the park brake emergency release lever is unlocked and shifted to the “OFF” position (dog clutch disengaged) the
power flow to the output shafts is disconnected. Since the gearbox input/output is mechanically disconnected the machine
can be towed without the gearbox restricting the towing speed.
WARNING
Block the wheels to prevent accidental machine movement.
When the emergency parking release lever is in the “OFF” position the machine has no parking brake function.
Always block the wheels prior to disconnecting the parking brake!
NOTE!
Prior to towing, check the gearbox oil level. Do not exert excessive force when shifting the lever. After towing, return the
lever to the “ON” position (dog clutch engaged) and tighten the locking screw to specified torque.
Shift lock
The governor control valve operation delays downshifting from 2nd gear into 1st gear, if a danger of overspeeding exists
(vehicle speed of 1st gear above normal), until the gearbox has reached a predetermined rotating speed. This prevents
overspeed damage to the hydraulic travel motor and gearbox. (Gearbox output shaft speed approximately 800 rpm).
NOTE!
Shift lock functions only when down shifting from 2nd to 1st speed.
Shift lock valve, sectional view

Figure 4
Shift lock valve, sectional view
1 Drain oil check valve P1 Shift oil for 2nd speed

2 Shuttle valve P2 Shift oil for 1st speed
3 Check valve B Inner clutch
4 Relief valve K Outer clutch
5 Filter R Planetary gear drive
6 Suction pipe
7 Pump
Shift lock valve, exploded view

Figure 5
Shift lock valve, exploded view
1. Pump
2. Filter
3. Oil
Operation, shift lock

Low speed (1st gear)
At gearbox stop, shift piston (5) is pushed up by piston spring (6) force. When 1st speed is selected oil flow from the
solenoid valve is supplied through P2 port. The oil flows through a passage under the shift piston and K port to release the
inner clutch while the outer clutch is engaged by spring force. The gearbox is at 1st speed state by the clutches. The rotor
pump oil is supplied to SH port according to machine speed, increasing but P2 port supply oil pressure holds the shift piston
so it does not move and the machine is at 1st speed state.
Figure 6
Operation, shift lock (low speed - 1st gear)
a High pressure oil b Return oil c Rotor pump oil d Rotor pump suction oil
1 Throttle check valve 5 Outer clutch 9 Rotor pump 13 Shift piston
2 Outer clutch air breather 6 Parking release 10 Relief valve 14 Non return valve
3 Inner clutch 7 Output 11 Leakage oil non return valve
4 Travel motor 8 Output 12 Non return changeover valve
Low speed (2nd gear)

When 2nd speed is selected oil flow from the solenoid valve is supplied through P1 port. The oil flows through passage S of
the shift piston, check valve (2) and B port to release the outer clutch while the inner clutch is engaged by spring force. The
gearbox is at 2nd speed state by the clutches.
Figure 7
Operation, shift lock (low speed - 2nd gear)
High speed (2nd gear)
The rotor pump oil is supplied to SH port according to the machine speed increasing. The supplied oil pressure pushes down
the shift piston against spring force and passage S of the shift piston is blocked, but oil supplied through check valve (2)
keeps the gearbox at 2nd speed state.
Figure 8
Operation, shift lock (high speed - 2nd gear)
3 Inner clutch 7 Output 11 Leakage oil non return valve 15 Accumulator
High speed (2nd to 1st gear)

At 2nd gear high speed the rotor pump oil is pushing the shift piston against spring force. At this time if 1st speed is
selected the solenoid valve cuts off oil to P1 port and supplies oil to P2 port. The oil flows through S1 passage, opens check
valve (2) and port B. Outer clutch is disengaged by the oil supplied through port B and the gearbox is at 2nd speed state.
According to machine speed (decreasing) rotor pump flow is decreased and the pressure against the spring force is
decreased. By the spring force the shift piston is pushed up, the oil flow supplied through B port is disconnected and P2 oil
flow through SL passage, K port and the gearbox is at 1st speed state.
Figure 9
Operation, shift lock (high speed - 2nd to 1st gear)
3 Inner clutch 7 Output 11 Leakage oil non return valve
Operation, clutch
Figure 10
Operation, clutch (low speed - 1st gear)
Shift control hydraulic pressure routed to the inner clutch piston compresses the cup springs releasing clutch (LK). Outer
clutch (LB) is spring applied and holds ring gear (A) stationary. The torque flow from the hydraulic motor is transmitted to
input shaft (AN) through sun gear (s) to planetary gear drive (PT) through gear (B) to gear drive (ST) and the output shafts
(AB) rotate.
Figure 11
Operation, clutch (high speed - 2nd gear)
Shift control hydraulic pressure routed to the outer clutch piston compresses the cup springs releasing clutch (LB). Inner
clutch (LK) is spring applied and locks ring gear (A) to input shaft (AN) through the clutch pack. The torque flow from the
hydraulic motor is transmitted to input shaft (AN) through clutch (LK) to ring drive (PT) and gear (B) to gear drive (ST) and
the output shafts (AB) rotate.
Inner clutch - throttle check valve / Outer clutch - throttle check valve
Figure 12
Throttle check valve
1 Fitting 5 Pin A Inner clutch - throttle check valve

2 Spring 6 Ball B Outer clutch - throttle check valve
3 O-ring 7 Orifice (0.8 mm)
4 Seat 8 Orifice (1.0 mm)
NOTE!
If the orifice is clogged 2nd speed will malfunction. (inner clutch)
NOTE!
If the orifice is clogged 1st speed will malfunction. (outer clutch)
Operation, gear shift complex valve

Travel control valve is composed of parking brake solenoid valve (1), 1st/2nd speed solenoid valve (2) and clutch pressure
reducing valve (3).
Parking brake solenoid valve
According to parking brake switch, the gearbox can be locked and unlocked. When the solenoid valve is not operating the
parking brake can be released by using screw (4).
Solenoid valve abnormal: After disassembling the nut (5), pull the screw (4) out and turn 90° to the left or right.
Figure 13
Control valve
1st/2nd speed solenoid valve
According to 1st/2nd speed selection switch the solenoid valve supplies oil to disengage 1st/2nd speed clutch in gearbox.
Reducing valve
The reducing valve reduces gear pump output pressure (1st pressure) to secondary pressure which activates gearbox clutch.
Figure 14
Reducing valve
1 Cap 5 Seat
2 Adjustment screw 6 Valve
3 Body 7 Spool
4 Sealing 8 Spring
Machine serial no.: 10900 ~

Description
The transmission is composed of a 2-speed powershift transmission in planetary design, a spur gear drive in double-shaft
arrangement with output flanges to the front and rear axle respectively. a rear-mounted bevel gear set at direct mounting
on a axle. Easy removal of the axle is ensured by a separate cover.
The powershift device for the planetary drive is composed of a rotating multi-disk clutch and a case-stationary multi-disk
brake, fitted upon it. Both are closed by spring force and hydraulically released.
In low speed, the internal gear of the planetary drive is backing upon the closed, caserigid brake. In this speed the piston
chamber of the brake is unpressurized, so that the elastic force and additionally the hydraulic pressure of the clutch piston is
acting upon the disk pack. At this time the clutch is open, i.e. hydraulically released. In the high speed, the clutch is closed by
elastic force and the brake is hydraulically released.
The powershift devices have also the function of a parking brake. At the braking, the brake piston is pushing with aid of the
spring on the brake disks and is thus clamping the planetary drive. The dynamically stressed and large-capacity brake
absorbs the braking energy, since the clutch remains closed at the braking and is only subject to the static friction
conditions. When braking the hydrostatics and transmission brake are acting in common.
The hydraulic downshift interlock avoids the downshifting at high driving speed and therefore the overspeed of the travel
motor. If the low speed is selected at a high driving speed, this speed remains locked and will be automatically shifted
respectively released only after the downshifting point has been reached. The downshifting is realized at about 75% of the
maximum speed in the low speed. Upshiftings are independent from the driving speed. The downshift interlock is effective
in both directions. The downshift interlock does not avoid the possible overspeed at coasting of the vehicle. For this
purpose, a brake valve is to be provided on the travel motor. As alternative to the hydraulic downshift interlock an electric
version by means of a speed sensor and an electronic unit is possible. These signals can be also used for the driving speed
display.
The emergency actuating device is to interrupt the power flow between input and output in case of a control pressure failure
or a travel motor defect and thus allows an emergency towing of the vehicle. For this purpose grease is pumped by means
of a commercial grease gun (in the tool kit) into the grease nipple of the emergency actuation on the transmission until it
comes visibly out of the pressure relief valve. Thus it is ensured that both pistons in the transmission are sufficiently released
for towing of the vehicle. Observe the towing distance and speed since there is no transmission lubrication. In order to
deactivate the emergency actuating device again, the bleeder of the emergency actuation has to be opened and then the
high speed to be shifted (apply control pressure 30 to 35 bar to the connection at the brake). Then close the bleeder again.
The protection of the transmission against an insufficient control pressure is realized by the pressure valve on the valve
block. No pressure lower than 26 bar is applied to the gearshift valve, so that the parking brake is always effective. In case of
a control pressure exceeding 32 bar at the valve block, it is reduced to 32 bar by means of an integrated pressure reducing
function.
Depending on the current application the gearshift valve of the valve block shifts into the high speed or the low speed. If no
current is applied to the solenoids the parking brake is engaged.
The vehicle manufacturer must ensure that with the engaged parking brake the drive valve of the travel motor is in Neutral.
Thus, it cannot be driven when the parking brake is closed.
Figure 15
1 Pressure line from shift interlock to multi-disk brake 7 Oil drain plug
2 Pressure line from shift interlock to multi-disk clutch 8 Model identification plate
3 Transmission housing 9 Transmission suspension
4 Connection travel motor 10 Output flange – rear axle
5 Oil filler plug 11 Shift interlock
6 Output flange – front axle
Measuring points – transmission/shift interlock: Connections – Transmission/shift interlock:

J High speed (brake) K Clutch
M Low speed (clutch) B Brake
S Lubrication pressure PN Emergency actuation parking brake
Speed transmitter and valve at transmission:

N Speed transmitter Out speed (option)
EB Bleed valve Brake
EK Bleed valve Clutch
EN Bleed valve Emergency actuation parking brake
UN Pressure relief valve Emergency actuation parking brake

Figure 16
1 Cup springs for multi-disk brake and multi-disk clutch 9 Output flange – front axle
2 Input shaft 10 Attachment travel motor
3 Multi-disk brake 11 Input (AN)
4 Multi-disk clutch 12 Output (AB)
5 Planetary drive 13 Output (AB)
6 Lube oil pump 14 1st gear (low speed)
7 Spur gear drive 15 2nd gear (high speed)
8 Output flange – rear axle 16 Parking (brake)
Installation of the transmission
1. For the transmission suspension (separate mounting), three fixing bolts M20, property class 8.8. have to be used.
Thread screw-in length min. 26 max. 30 mm. Torque limit of screws 430 Nm.
Minimum material length for screw head seat 750 N/mm2.
Fixing plate must be torsion-free.
Deformations of the vehicle frame must not influence the transmission fixing.
Admissible flatness tolerance over the total transmission mounting face max. 0.3 mm.
In case of separate transmission installation, pay attention to the highest possible ground clearance to protect the
transmission against external damages. If necessary, provide a guard.
2. Mount the enclosed O-Ring sealing on the mounting face of the travel motor. Fixing of the travel motor with
screws of the property class 8.8.
If travel motors with 2-hole flange pattern are used please consult the responsible Application Engineering Dept.
3. Provide universal shafts with greasable length compensation profile. Max. three-dimensional shaft angle is 10°,
because of the admissible load of the output shaft bearing.
The specifications of the universal shaft manufacturer have to be considered.
4. Pay attention to easy accessibility of the bleeders, oil filling and oil drain, measuring connections, pressure ports
and emergency actuating device.
5. In the whole transmission control system, exclusively commercial oil lines and fittings of the standard hydraulics
have to be used.
6. For all hydraulic and measuring connections on the transmissions, threaded pins according to DIN 3852, Shape B
with O-Ring have to be used.
7. Because of the aluminium material of the shift interlock, the torque limit of 30 Nm for the screw-in sleeve B and K is
mandatory to be met.
When mounting the lines to the screw-in sleeves, these must be hold up with a wrench.
8. Rinse hose lines, pipes and screw-in sleeves carefully prior to the installation.
At the installation of all oil-leading parts, also on the connection holes and connection surfaces, pay attention to
utmost cleanliness!
9. At welded pipes must be no welding residues - carry out a 100% - cleaning.
10. The pressure losses in the control lines for the transmission control must be as low as possible.
For this reason, pay attention to the following:
- Short control lines between control pump, valve block, rotary up to the transmission.
- Control lines with internal diameter of min. 10 mm.
- Rotary with diameter of min. 8 mm.
- Calculate ample dimensions for elbows and screw joints with as low as possible throttle losses.
11. The residual pressure in the tank line must be max. 1 bar.
Measurement is made in the tank-relieved control line B and K on the transmission or on the shift interlock resp. on
Port T on the valve block attached to the transmission.
For this reason, pay attention to the following:
- Short tank line from valve block transmission control to hydraulic tank.
- Do not join this tank line with other tank lines.
- Pass the return oil (transmission control) directly into the hydraulic tank, i.e. oil flow not via the return flow filter.
- Tank lines with internal diameter of min. 15 mm.
- Calculate ample dimensions for elbows and screw joints, with as low as possible throttle losses.
NOTE!
The vehicle manufacturer is responsible for the correct installation!
Installation of the valve block

There are 3 installation possibilities for the valve block
Direct attachment to the transmission
The valve block is directly bolted to the transmission housing. Only the control line has to be attached to Port P ( M16x1.5 )
and the tank line to Port T ( M18x1.5 ). For this system the electric signal for the gear changes must be led through the
rotary.
Separate installation in the upper chassis
The valve block is fastened at an adequate place in the upper chassis by means of 2 screws M8x50 or M8x55; Property Class
10.9; Tightening torque 23 Nm. Attachment point is to be selected in a way that the two screw plugs protruding from the
mounting face of the valve block for the Ports P and T ( M10x1 ) are uncovered.
Attach the control line to Port P ( M16x1.5 ) and the tank line to Port T (M18x1.5 ). Attach the pressure lines to the Ports B
and K ( M16x1.5 ) and lead them via the rotary to the transmission.
Mounting to the control block
Through the two contact bores P and T ( M10x1 ) the valve block can also be mounted directly to the control block. In this
case remove the two screw plugs M10x1. Put the O-Rings 14x3 into the recess on the ports P and T. Fasten the valve block
with 2 screws M8x50 or M8x55; Property class 10.9. Tightening torque 23 Nm.
Use the two screw holes being located next to these contact bores. The sealing surface on the control block must be carried
out to ensure the sealing effect and the contact bores of both parts must be matching accordingly.
Attach the pressure lines to the Ports B and K ( M16x1.5 ) and lead them via the rotary to the transmission.
In principle, no installation position is specified for the valve block.
By opening of the locking nut the solenoids can be rotated in its position as requested. For splash water purposes the plug
connecting should always show downwards. Tightening torque: locking nut 2.5 Nm.
Electrical connections
Rated voltage 24 V.
Deutsch plug DT 06-02S EP06.
With contact bush, female, nickel-plated, according to 0460 201 1641.
Interlock: W2S
Both connections are carried out of the same kind (without coding).
The wiring harness must be fastened as close as possible to both plugs to avoid that the plug connection gets loosened or
damaged due to vibrations.
Function of the gearshift valve
If current is applied to Solenoid M1, it is shifted into the low speed.
If current is applied to Solenoid M2, it is shifted into the high speed.
If no current is applied to the solenoids, the parking brake is engaged.
Function of the pressure valve
The pressure valve protects the transmission from a too low control pressure. It does not allow a pressure being lower than
26 bar to the gearshift valve, so that the parking brake is always effective.
If the control pressure exceeds 32 bar it will be reduced to 32 bar by the integrated pressure reducing function.
The control pressure existing at the pressure valve can be measured on Measuring Connection M ( M10x1 ).
Figure 17
Connections valve block
M1 Solenoid valve (low speed)
M2 Solenoid valve (high speed)
DV Pressure valve
P* System pressure (top)
T* Tank (top)
K Clutch (low speed)
B Brake (high speed)
P System pressure (lateral)
T Tank (lateral)
M Measuring point system pressure
Commissioning of production vehicles

The following measures and checks have to be carried out one time on the first production vehicle:
Commissioning
Fill up the transmission (and axle) with oil of the specified oil grade, if no oil filling was made in the factory.
Transmission and axle have a separate oil supply.
Check of the control pressure on the valve block
Measurement on the Measuring Connection M of the valve block at warmed-up condition in lower and upper idling speed
of the combustion engine.
p min 30 bar; p max 50 bar.
Check of the shifting cycles and the residual pressure
Pressure measurement on the measuring connection clutch and measuring connection brake of the transmission at warmed-
up condition in lower and upper idling speed of the combustion engine.
Measurement of up- and downshifting.
Scanning rate min. 50 / sec.
Filling time of clutch and brake max. 0.4 sec.
Residual pressure at emptied condition max. 1 bar.
Check of the downshifting point
Driving in high speed with an input speed exceeding 1200 min-1. Preselect the low speed and reduce the speed slowly.
Downshifting must occur at an input speed below 1000 min-1 (at warmed-up condition). This is applicable to the hydraulic
and electric downshift interlock.
Check of the high pressure adjustment on the travel motor and of the max. speed specified values.
Measurements upon consultation with hydrostatics manufacturer.
At "Excavator operation" the parking brake must not be effective.
At the engagement of the parking brake and simultaneously applied accelerator, the vehicle drive must be without action
(drive valve in Neutral).
Operation
General:
The exact instructions for the operation of the vehicle have to be taken from the operating and maintenance instructions of
the vehicle manufacturer.
Commissioning:
Prior to commissioning of the transmission, fill in the correct quantity of the specified oil grade.
NOTE!
Place the vehicle onto a support. Release the parking brake.
Bleed the transmission control system carefully, as otherwise functional failures may occur at the gear changes.
Bleeding of the transmission control system at running control pump by means of bleeder on brake and clutch. Use a
transparent plastic hose to assess the air content in the oil.
Bleeding:
1. Shift into the high speed, open the bleeder of the brake and bleed it for approx. 20 sec.
Figure 18
1. Brake
2. Clutch
3. Emergency actuation
2. When the brake is bleeded the first time, additionally open also the bleeder of the emergency actuating device to
bring it into its initial position. In this case no oil flows out.
3. Close both bleeders.
4. Shift into the low speed, open the bleeder of the clutch and bleed it for approx. 20 sec.
5. Close the bleeder on the clutch.
6. Bleed the brake and the clutch still 2 times each for approx. 20 sec.
7. At the last bleeding procedure no air bubbles are allowed to be visible in the oil any more.
¡ Check whether it has been sufficiently bled:

NOTE!
Upshiftings 1 - 2 at a lower Diesel speed and the drive must not lock!
¡ The same measures have also to be carried out for a transmission or travel motor replacement.
¡ Upon the commissioning check all screw connections for leakage.
Driving and shifting:

The combustion engine start has always to be carried out in parking brake position.
After the start and preselection of the driving direction and the speed respectively. release of the parking brake, the vehicle
can be set in motion by actuating the accelerator pedal.
Independently of the speed upshiftings are always possible.
If the low speed is selected at a high driving speed, this speed remains locked and will be only then automatically shifted
respectively released when the downshifting point is reached.
The downshifting is realized at about 75% of the maximum speed in the low speed. Reversing is possible in all speeds and
independently of the driving speed.
Parking brake:
General
NOTE!
When leaving the vehicle we recommend to activate, at the application of the parking brake, additionally also the service
brake. This safety measure is then necessary when the vehicle is parked on a gradient or on a slope where the holding force
of the parking brake is no more sufficient.
¡ The parking brake covers only the parking brake function. This means that for the compliance with the national and
international regulations concerning the brake systems, the vehicles have to be equipped with a dual-circuit brake
system.
At excavator operation, i.e. when working with the implements at stationary vehicle, only the service brake is allowed to be
applied. In this case the parking brake is not allowed to be engaged to avoid damages in the driveline due to tearing forces.
¡ It must be ensured by the vehicle manufacturer that with an engaged parking brake the application of the
accelerator pedal is not effective (drive valve in Neutral position). Otherwise the drive motor could tear up the
parking brake, damage it and move the vehicle.
Function
The parking brake is put into function by actuation of the parking brake switch.
The parking brake position of the gearshift valve in the valve block is shifted by not applying any current to both of the
solenoids M1 and M2. This means in case of a power failure, the parking brake is engaged automatically.
If the control pressure on the valve block is too low (lower than 26 bar) the parking brake remains automatically in function.
Emergency braking
At a service brake failure, a dynamic braking is also possible by means of the parking brake. In this case the braking effect of
the hydrostatic drive is additionally also acting.
This braking is not adjustable and cannot be influenced by the driver. Therefore it should only be applied when all service
brake functions have failed.
Towing:
The emergency actuating device is to interrupt the power flow between input and output in case of a control pressure failure
or a travel motor defect and thus allows an emergency towing of the vehicle.
¡ Towing speed: max. 10 km/h

¡ Towing distance: max. 5 km
Since there is no transmission lubrication, damages may occur due to lacking oil supply if the instructions are no observed!
For a longer distance it is best to have transported the defective vehicle on a low loader.
Activate the emergency actuation:
Engine is switched off

NOTE!
Block the vehicle against rolling away!
Figure 19
1. Grease nipple
2. Bleeder
3. Emergency actuation
By means of a grease gun pump in the grease on the grease nipple (1) until it comes visibly out at the pressure
relief valve of the emergency actuation (3). (Commercial grease gun in the tool kit – scope of supply of the vehicle
manufacturer).
Deactivate the emergency actuation:
The bleeder (2) of the emergency actuation must be opened and then shift into the high speed (apply a control
pressure of 30 to 35 bar at the connection of the brake).
Then close the bleeder again.
Figure 20
A Emergency actuation deactivated B Emergency actuation activated

1 Set of springs (plate spring) for multi-plate clutch 7 Pressure ring for the emergency actuation
2 Clutch piston 8 Ring for the emergency actuation
3 Multi-plate clutch 9 Multi-plate brake
4 Set of springs (plate spring) for multi-plate brake 10 Grease
5 Brake piston 11 Grease nipple
6 Pin
Grease is applied to the pressure ring (1) pushing the brake piston (2) to the input housing until contact and thus the clutch
piston (4) is driven over 2 pins (3).
NOTE!
No braking effect of the parking brake, when the release device is actuated.
Operation, shift lock

Figure 21
Operation, shift lock (low speed - 1st gear)
1 Shift modulation valve 7 Gearshift piston 13 Output

2 Pressure valve 8 Changeover check valve 14 Output
3 Gearshift valve 9 Leakage check valve 15 Transmission
4 Valve block 10 Pressure limiting valve 15 Travel motor
5 Rotary upper chassis/ 11 Pump for lube oil & control
undercarriage pressure shift interlock
6 Check valve 12 Shift interlock
EB Bleed valve – brake a Pressure line transmission control

EK Bleed valve – clutch b Tank line transmission control
Nab Speed transmitter – output speed (option) c Lubrication pressure
K Oil pipe from shift interlock to clutch d Suction line lube oil pump
B Oil pipe from shift interlock to brake e Transmission lubricating oil
LK Multi-disk clutch f Emergency actuation parking brake
LB Multi-disk brake
S Sump oil circuit – selector gearbox
Measuring points – transmission/shift interlock: Measuring points – valve block:

J High speed (brake) M System pressure transmission control
M Low speed (clutch)
Connections – Transmission/shift interlock: Connections – valve block:
K Clutch K Clutch
B Brake B Brake
PN Emergency actuation parking brake T Tank
P System pressure transmission control
Solenoid valves – valve block:

Figure 22
Operation, shift lock (high speed - 2nd gear)
1 Shift modulation valve 5 Rotary upper chassis/ 9 Transmission

undercarriage
2 Pressure valve 6 Travel motor 10 Lube oil pump
3 Gearshift valve 7 Output 11 Pump for lube oil
4 Valve block 8 Output 12 Pressure limiting valve

Nab Speed transmitter – output speed (option) c Suction line lube oil pump
LK Multi-disk clutch d Transmission lubricating oil
LB Multi-disk brake e Emergency actuation parking brake
Measuring points – transmission/lube oil pump: Measuring points – valve block:

Connections – Transmission: Connections – valve block:

K Clutch K Clutch
B Brake B Brake

M1 Solenoid valve (clutch)
M2 Solenoid valve (brake)
High speed (2nd to 1st gear)
Figure 23
Operation, shift lock (high speed - 2nd to 1st gear)
1 Shift modulation valve 5 Travel motor 9 Lube oil pump

2 Pressure valve 6 Output 10 Pump for lube oil
3 Gearshift valve 7 Output 11 Pressure limiting valve
4 Valve block 8 Transmission

Nab Speed transmitter – output speed (option) c Suction line lube oil pump
LK Multi-disk clutch d Transmission lubricating oil
LB Multi-disk brake e Emergency actuation parking brake
Measuring points – transmission/lube oil pump: Measuring points – valve block:

Connections – Transmission: Connections – valve block:


Operation, clutch
Figure 24
Operation, clutch (low speed - 1st gear)
Shift control hydraulic pressure routed to the inner clutch piston compresses the cup springs releasing clutch (LK). Outer
clutch (LB) is spring applied and holds ring gear (A) stationary. The torque flow from the hydraulic motor is transmitted to
input shaft (AN) through sun gear (s) to planetary gear drive (PT) through gear (B) to gear drive (ST) and the output shafts
(AB) rotate.
Figure 25
Operation, clutch (high speed - 2nd gear)
Shift control hydraulic pressure routed to the outer clutch piston compresses the cup springs releasing clutch (LB). Inner
clutch (LK) is spring applied and locks ring gear (A) to input shaft (AN) through the clutch pack. The torque flow from the
hydraulic motor is transmitted to input shaft (AN) through clutch (LK) to ring drive (PT) and gear (B) to gear drive (ST) and
the output shafts (AB) rotate.
Service Information

Travel gearbox, removing Service Information 27/11/2019
Profile:
EW145B Volvo
Travel gearbox, removing


Op nbr 431-012
1. Park the machine in the service position C. See Service positions.

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. Turn the ignition key to "OFF" position.
WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries
WARNING
Risk of crushing injuries
NOTICE
NOTE!
Mount the vacuum pump on hydraulic tank, and maintain a vacuum.
NOTE!
Prepare container for collecting hydraulic oil.
2. Remove the screw and front propeller shaft from the travel gearbox. (No.4 See Propeller shaft, replacement).
Figure 1
Front propeller shaft, removal
1. Screws
2. Front propeller shaft (gearbox)
3. Travel gearbox
3. Remove the screw and rear propeller shaft from the travel gearbox. (No.4 See Propeller shaft, replacement).
Figure 2
Rear propeller shaft, removal
1. Screws
2. Rear propeller shaft (gearbox)
3. Travel gearbox
4. Remove the hydraulic hose from the travel gearbox.
Figure 3
Hydraulic hose, removal
5. Remove the hydraulic hose from the travel motor.
Figure 4
Hydraulic hose, removal
6. Drain off oil from drain port of gearbox.

NOTE!
Figure 5
Oil drain
7. Remove the screws and gearbox protecting guard.

Place a jack (A) with a lowering height of >200 mm between the travel motor and the gearbox.
Remove the screws from the gearbox mount, and lower to work area safely.
Figure 6
Gearbox, removal
1. Gearbox protecting guard

2. Gearbox fixing bracket
3. Screw (gearbox protecting guard)
4. Screw (gearbox fixing bracket)
8. Remove the screws and bracket from the gearbox.
Figure 7
Bracket, removal
1. Screw
3. Travel motor
4. Gearbox
9. Remove the screws and gearbox from the travel motor.
Figure 8
Gearbox, removal
1. Screw
2. Travel motor
3. Gearbox
Service Information

Travel gearbox, installing Service Information 27/11/2019
Profile:
EW145B Volvo
Travel gearbox, installing


Op nbr 431-013
1. Park the machine in the service position C. See Service positions.

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. Turn the ignition key to "OFF" position.
WARNING
WARNING
WARNING
Risk of crushing injuries
NOTICE
NOTE!
Mount the vacuum pump on hydraulic tank, and maintain a vacuum.
NOTE!
2. Install the gearbox and screws at the travel motor.

Tightening torque. See Tightening torque, specifications.
Figure 1
Gearbox, installation
1. Screw
2. Travel motor
3. Gearbox
3. Install the bracket and screws at the gearbox.

Figure 2
Bracket, installation
1. Screw
3. Travel motor
4. Gearbox
4. Place a jack (A) with a lowering height of >200 mm between the travel motor and the gearbox.
Install the gearbox mount and screws.
Install the gearbox protecting guard and screws.
Figure 3
Gearbox, installation
1. Gearbox protecting guard

3. Screw (gearbox protecting guard)
4. Screw (gearbox fixing bracket)
5. Install the hydraulic hose from the travel motor.
Figure 4
Hydraulic hose, installation
6. Install the hydraulic hose from the travel gearbox.
Figure 5
Hydraulic hose, installation
7. Fill new gear oil on the gearbox.

Oil capacity. See Transfer gearbox, specifications.
Figure 6
New oil filling
8. Install the rear propeller shaft and screw at the travel gearbox. (No.6 See Propeller shaft, replacement).
Figure 7
Rear propeller shaft, installation
1. Screws
2. Rear propeller shaft (gearbox)
3. Travel gearbox
9. Install the front propeller shaft and screw at the travel gearbox. (No.6 See Propeller shaft, replacement).
Figure 8
Front propeller shaft, installation
1. Screws
2. Front propeller shaft (gearbox)
3. Travel gearbox
10. Check the operation of the machine.

Service Information

Transfer gearbox, tools Service Information 27/11/2019
Profile:
EW145B Volvo
Transfer gearbox, tools



General tools
General tools
No. Description Size Quantity Remark

1 Allen wrench 3, 5, 6, 8, 10, 12 1
2 Spanner Set
3 Snap ring pliers
4 Air gun
5 Driver
6 Hammer
7 Torque wrench 100 N·m
8 Feeler gauge
9 Socket wrench Set
10 Eye bolt M12 1 Drive shaft gear
11 Punch 1 Shift lock valve
Special tools
Special tools
No. Part no. Description Quantity Remark

1 8933 - 00020 Adjustment screw (M12) 1 Set Shift lock valve
2 8933 - 00030 Offset screwdriver 1
4 8933 - 00050 Internal puller 1 Planetary gear
8933 - 00060 Jig 1
5 - Puller 1 Planetary gear inner race
6 8933 - 00070 Pry bar set 1 Parking lever
7 8933 - 00080 Internal puller 1 Shaft needle bearing
8933 - 00090 1
8 8933 - 00100 Internal puller 1 Governor shuttle valve
8933 - 00110 Sliding hammer 1
9 8933 - 00120 Driver 1 Lock washer
10 8933 - 00130 Sleeve 1 Helical bearing
11 8933 - 00140 Driver 1 Needle bearing
12 8933 - 00150 Oil seal insert 1 Clutch shaft seal
13 8933 - 00160 Connector 1 Measure pressure
14 8933 - 00170 Connector 1
15 8933 - 00180 Hand priming pump 1
17 8933 - 00200 Calipers 1 Measuring outer clutch
18 8933 - 00210 Inserter 1 Shift piston seal
19 8933 - 00220 Measuring sleeve 1

Special tools
Special tools
No. Part no. Description Remark

8 5870 400 001 Resetting device 2 pcs. required
10 5870 240 025 Fixture
12 5873 012 021 Rapid grip
13 5873 002 001 Basic tool
23 5870 058 073 Mounting tool
24 5870 260 002 Handle
30 5870 654 049 Clamping bar
33 5870 656 004 Spanner
36 5870 506 150 Pressure piece
Service Information

disassembly
Profile:
EW145B Volvo
Transfer gearbox, disassembly



Instructions
1. Remove the travel motor from the gearbox.

2. Clean the gearbox thoroughly before the disassembly to prevent the possibility of dirt and foreign matter entering.
3. Use the special tools, see the manual.
4. Cleaning and inspection.
Cleaning
Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be immersed in
cleaning fluid and moved up and down slowly until all old lubricant and foreign material is dissolved and
parts are thoroughly cleaned.
¡ Bearings
Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood to
dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles.
Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture free
compressed air. Be careful to direct air stream across the bearings to avoid spinning. Do not spin
bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process.
¡ Housings
Clean interior and exterior of housings, bearing caps, etc. thoroughly. Cast parts may be cleaned
in hot solution tanks with mild alkali solutions providing these parts do not have ground or
polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and
heated. This will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in
solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast parts
may also be cleaned with steam cleaner.
All part cleaned must be thoroughly dried immediately by using moisture free compressed air or
soft lintless absorbent wiping rags free of abrasive materials such as metal filings, contaminated
oil or lapping compound.
Inspection
The importance of careful and thorough inspection of all parts cannot be overstressed. Replacement of all
parts showing indication of wear or stress will eliminate costly and avoidable failures at a later date.
¡ Bearings
Carefully inspect all rollers, cages and cups for wear, chipping or nicks to determine fitness of
bearings for further use. Do not replace a bearing cone or cup individually without replacing the
mating cup or cone at the same time. After inspection, dip bearings in clean light oil and wrap in
clean lintless cloth or paper to protect them until installed.
¡ Oil seals, gaskets and retaining rings

Replacement of spring load oil seals, o-rings, metal sealing rings, gaskets and snap rings is more
economical when unit is disassembled than premature overhaul to replace these parts at a future
time. Further loss of lubricant through a worn seal may result in failure of other more expensive
parts of the assembly. Sealing members should be handled carefully, particularly when being
installed. Cutting, scratching, or curling under of lip of seal seriously impairs its efficiency. Apply a
thin coat of permatex No. 2 on the outer diameter of the oil seal to assure an oil tight fit into the
retainer. When assembling metal type sealing rings, lubricate with grease to stabilize rings in their
grooves for ease of assembly of mating members. Lubricate all o-rings and seals with
recommended type engine oil before assembly.
¡ Gears and shafts

If magna-flux process is available, use process to check parts. Examine teeth on all gears carefully
for wear, pitting, chipping, nicks, cracks or scores. If gear teeth show spots where case hardening
is worn through or cracked, replace with new gear. Small nicks may be removed with suitable
hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines twisted, and
that shafts are true.
¡ Housing, covers, etc.

Inspect housings, covers and bearing caps to be certain they are thoroughly cleaned and that
mating surfaces, bearing bores, etc., are free from nicks or burrs. Check all parts carefully for
evidence of cracks or condition which would cause subsequent oil leaks or failures.
Mounting
¡ Use standard quality (manufacturer furnished) o-ring when mounting hydraulic travel motor to
the gearbox casing.
¡ Control lines shall not be twisted. Use standard products for oil and fittings, etc.
¡ Whenever connecting hydraulic oil components (hose, fitting, pipe...), take extreme care to avoid
ingression of any contaminant. (To make absolutely sure, clean with compressed air.)
¡ Align the drive shaft yoke.
¡ When mounting gearbox torque requirement should be met. (52.3 ± 5.2 kgf·m, 377 ± 37 lbf·ft)
¡ Always use the recommended gearbox oil and fill with specified amount.
Op nbr 00000
Precautions for disassembly
Before disassembly clean the gearbox and prepare the required tools, manual and a bench for the parts.
WARNING
Mount the gearbox on the maintenance stand vertically.

Figure 2
Removal, plug
¡ Tools: allen wrench (12 mm)

¡ Oil reservoir: 4 liter
Put an oil reservoir below the gearbox.

Remove the plug and drain the oil.
1. Remove all hoses and pipes.
Figure 3
Removal, hoses and pipes
¡ Tools: spanner (19, 27 mm)
2. Remove the four screws and remove the shift lock valve.
Figure 4
Removal, screw and shift lock valve
3. Remove screws and remove cover with gasket.
Figure 5
Removal, screws and cover
4. Remove screws and pump cover out of housing.
Figure 6
Removal, screws and pump cover
5. Remove pump shaft.
Figure 7
Removal, pump shaft
6. Remove internal rotor out of pump shaft.

Figure 8
Removal, internal rotor
7. Disassemble control case and outer rotor from pump shaft and remove spring and ball from pump cover and
remove ball out of pump shaft.
NOTE!
When disassembling outer rotor, be careful spring against ball.
Figure 9
Removal, control case and outer rotor
8. Remove snap ring out of cover and remove shaft and bearing. Remove snap ring from shaft and remove bearing.
Figure 10
Removal, snap ring, shaft and bearing
9. Remove needle bearing out of case using puller.

Figure 11
Removal, needle bearing
10. Remove check valve, spool, spring out of valve body.

NOTE!
Mark assembly position of each valve.
Figure 12
Removal, check valve, spool and spring
11. Disassemble the accumulator valve from the housing.
Figure 13
Removal, accumulator valve
¡ Tools: spanner (24 mm)
12. Remover circlip out of guide bushing.

Figure 14
Removal, circlip
¡ Tools: snap ring pliers (expansion)
13. Loosen the 10 screws evenly and than remove.
Figure 15
Loosen, screws
¡ Tools: allen wrench socket (10 mm)
14. Install two adjusting screws and separate the drive casing from the gearbox.
Figure 16
Removal, drive casing
¡ Tools: setscrew 2 (M12), spanner (24 mm), pry bar
15. Remove the housing.

Figure 17
Removal, housing
16. Remove the cup spring.
Figure 18
Removal, cup spring
17. Close the supply line and press the piston out of the housing bore, using compressed air.
Figure 19
Close the supply line and press the piston
18. Remove the piston.

Figure 20
Removal, piston
19. Remove the breather and the plug.
Figure 21
Removal, breather and plug
¡ Tools: spanner (11 mm), allen wrench (5 mm)
20. Remove the seal ring and back-up ring from the ring groove of the housing.
Figure 22
Removal, seal ring and back-up ring
21. Squeeze out snap ring.

Figure 23
Squeeze out snap ring
22. Pull the gasket out of the housing bore, using offset screwdriver.
Figure 24
Pull out the gasket
¡ Tools: offset screwdriver
23. Remove o-ring from the housing.
Figure 25
Removal, o-ring
24. Remove the outer clutch pack.

Figure 26
Removal, outer clutch pack
25. Remove the backing plate.
Figure 27
Removal, backing plate
26. Squeeze out circlip.
Figure 28
Squeeze out circlip
¡ Tools: snap ring pliers (compression)
27. Remove the inner clutch unit.

Figure 29
Removal, inner clutch unit
28. Fix the sun gear axially by means of an assembly jig.
Figure 30
Fix the sun gear
29. Remove circlip.
Figure 31
Removal, circlip
30. Remove the ring, washer and the sun gear.

Figure 32
Removal, ring, washer and sun gear
31. Separate the internal ring gear from the drive shaft.
Figure 33
Separate the internal ring gear
Figure 34
Squeeze out circlip
33. Remove center ring disc.

Figure 35
Removal, center ring disc
34. Remove the snap ring, press the ball bearing out of the centering disc.
Figure 36
Removal, snap ring
35. Ring, bearing, centering disc, ring gear (components).
Figure 37
Components
36. Remove the inner clutch discs and plates.

Figure 38
Removal, inner clutch disc and plates
37. Remove the backing plate.
Figure 39
Removal, backing plate
38. Pry the inner plate carrier out of the piston.
Figure 40
Removal, inner plate carrier
¡ Tools: screwdriver
39. Remove the seal from the carrier.
Figure 41
Removal, seal
40. Remove the piston from the drive shaft.

Figure 42
Removal, piston
41. Remove the cup springs.
Figure 43
Removal, cup springs
42. Remove o-ring and seal.
Figure 44
Removal, o-ring and seal
43. Remove support shim.
Figure 45
Removal, support shim
Figure 46
Squeeze out circlip
¡ Tools: snap ring pliers (expansion)
45. Remove the ring from the guide bushing.
Figure 47
Removal, ring
¡ Tools: snap ring pliers
46. Separate the guide bushing from the shaft.
Figure 48
Separate the guide bushing
47. Remove the seal from the guide bushing after squeezing out snap ring.
Figure 49
Removal, seal
48. Remove the snap ring.
Figure 50
Removal, snap ring
49. Remove the snap ring from the shaft to the bearing.
Figure 51
Removal, snap ring
50. Press the bearing from the shaft.

Figure 52
Press the bearing
51. Remove the throttle valve from the center of the shaft.
Figure 53
Removal, throttle valve
52. Remove o-ring from throttle valve.
Figure 54
Removal, o-ring
53. Squeeze out circlip and remove the planetary drive assembly.
Figure 55
Removal, planetary drive assembly
54. Tilt the gearbox for 90°.

Separate and remove the planetary carrier from the helical gear using an internal puller.
Figure 56
Removal, planetary carrier
55. Squeeze out circlip from the planetary gear shaft.
Figure 57
Squeeze out circlip
56. Pry off the planetary gear using 2 offset screwdrivers.

Figure 58
Removal, planetary gear
¡ Tools: offset screwdriver
57. Remove the washer, planetary gear, and the bearing from the gear shaft.
Figure 59
Removal, washer, planetary gear and bearing
58. Pull off the bearing inner race of the planetary gear.
Figure 60
Pull off bearing inner race
¡ Tools: two-leg puller
59. Turn over the planetary drive and squeeze out the snap ring.
Figure 61
Turn over the planetary drive
60. Remove the bearing.
Figure 62
Removal, bearing
61. Remove the screw locking the park brake emergency release lever.
Figure 63
Removal, screw
62. Remove the dog clutch sliding collar.

Figure 64
Removal, dog clutch sliding collar
63. Remove the plug (10 mm) from the housing.
Figure 65
Removal, plug
64. Drive the roll pin from the plug hole.
Figure 66
Drive the roll pin
¡ Tools: punch, hammer
65. Pry the parking brake emergency release lever out of the housing bore.
Figure 67
Removal, parking brake emergency release lever
¡ Tools: pry bar
66. Remove the dog clutch shift fork and two sliding pads.
Figure 68
Removal, dog clutch shift fork
67. Remove the snap ring and o-ring.
Figure 69
Removal, snap ring and o-ring
68. Remove the snap ring fixing the helical gear.

Figure 70
Removal, snap ring
69. Remove helical gear from the housing.
Figure 71
Removal, helical gear
¡ Tools: plastic hammer
70. Remove the snap ring from the helical gear.
Figure 72
Removal, snap ring
71. Remove the snap ring, washer, and clutch dog.

Figure 73
Removal, snap ring, washer and clutch dog
72. Disassemble the needle bearing from the gear shaft using an internal puller.
Figure 74
Removal, needle bearing
¡ Tools: internal puller
73. Disassemble the helical gear and the bearing cap using a press.
Figure 75
Removal, helical gear and bearing cap
¡ Tools: plastic hammer
74. Squeeze out circlip from the bearing cap.

Figure 76
Removal, circlip
75. Remove the bearing.
Figure 77
Removal, bearing
76. Pry off the bearing from the helical gear.
Figure 78
Removal, bearing
¡ Tools: pry bar (2)
77. Rotate the gearbox so the travel motor mount flange faces downward. Remove the lock plate on the output flange
for the rear axle.
Figure 79
Removal, lock plate
¡ Tools: screwdriver, hammer
78. Remove the flange screws.
Figure 80
Removal, screws
¡ Tools: socket wrench (17 mm)
79. Remove the washer and o-ring.
Figure 81
Removal, washer and o-ring
80. Pry off the output flange.

Figure 82
Removal, output flange
¡ Tools: pry bar (2)
81. Pry the flange seal out of the housing bore.
Figure 83
Removal, flange seal
82. Remove the cover screws.
Figure 84
Removal, screws
83. Install two long screws to the cover.

Figure 85
Installation, two long screws
84. Reverse the mounting position.

Remove the lock plate on the output flange for front axle.
Figure 86
Removal, lock plate
¡ Tools: screwdriver, hammer
85. Remove the flange mounting screws.
Figure 87
Removal, screws
86. Remove the washer and o-ring.

Figure 88
Removal, washer and o-ring
87. Pry off the output flange.
Figure 89
88. Pry the flange seal out of the housing bore.
Figure 90
Removal, flange seal
¡ Tools: screwdriver
89. Using a brass drift, drive the shaft until the cover contacts the screw head.
Figure 91
Drive the shaft
¡ Tools: brass drift, hammer
90. Reverse the mounting position.

Remove the screws and install an eye bolt in the shaft.
Figure 92
Removal, screws
91. Using the eye bolt lift out the gear assembly.
Figure 93
Removal, gear assembly
92. Separate the cover from the drive gear.

Figure 94
Removal, cover
93. Separate the oil baffle from the drive gear.
Figure 95
Removal, oil baffle
94. Squeeze out circlip fixing the bearing to the cover.
Figure 96
Squeeze out circlip
95. Press ball bearing out of the cover.

Figure 97
Removal, ball bearing
96. Pull o-ring out of the ring groove.
Figure 98
Removal, o-ring
97. Pry off the cover and screws from the flange (front and rear). If there is no need to change screws or cover, do not
disassemble.
Figure 99
Removal, cover and screws
¡ Tools: pry bar
98. Remove the oil baffle from the housing.

Figure 100
Removal, oil baffle
99. Using a brass drift drive the ball bearing out of the housing.
Figure 101
100. Disassemble the mounting screw of the lubrication suction pipe.
Figure 102
Removal, screw
101. Remove the mounting nut from the lubrication oil pipe.
Figure 103
Removal, nut
102. Disassemble throttle valve and plugs.

Figure 104
Removal, throttle and plugs
¡ Tools: spanner (27 mm), allen wrench (6, 8, 12 mm)
Put the disassembled parts in order and prepare the assembly.

Op nbr
1. Mount the transmission to the assembly truck.
Figure 105
Mounting, transmission
2. Loosen the screw plug and drain the oil using a suitable collector.
Figure 106
Removal, screw plug
3. Loosen the screw connection and pull off the lube oil pump.
Figure 107
Removal, lube oil pump
4. Loosen the cover screw connection, remove cover (1) with gasket (2) and filter (3) from housing (4).
Figure 108
Removal, cover and filter
5. Remove the pressure limiting valve and both O-rings.
Figure 109
Removal, pressure limiting valve
6. Loosen the pump cover screw connection, keep the housing in vertical position.
Figure 110
Removal, screw
7. Keep pump to contact and rotate it by 180 degree.

Then pull the pump in vertical position out of the housing.
NOTE!
Pay attention to possibly release balls and compression springs!
Figure 111
Removal, pump
8. Remove outer (1) and internal rotor (2) and take released ball (3) out of control housing (4).
Outer, internal and control housing = rotor set
Figure 112
Removal, rotors and ball
9. Remove the control housing and the released balls and compression spring (3 pieces each).
Figure 113
Removal, control housing
10. Unsnap the retaining ring.
Figure 114
Removal, retaining ring
11. Pull the pump shaft out of the pump cover.
Figure 115
Removal, pump shaft
12. Unsnap the retaining ring and press the ball bearing from the shaft.
Figure 116
13. Pull the needle sleeve out of the housing boret.
Figure 117
Removal, needle sleeve
14. Loosen the screw and pull off the speed transmitter.
Figure 118
Removal, speed transmitter
15. Remove the bleeder.

Figure 119
Removal, bleeder
16. Remove the compression spring and the ball.
Figure 120
Removal, spring and ball
17. Remove the threaded element with O-ring from the bore.
Figure 121
Removal, threaded element
18. Remove the lubrication nipple, both screw plugs and the bleeder valve.
Figure 122
Removal, nipple, plugs and bleeder valve
19. Loosen the screw connection of the input housing equally. The input housing is subject to a cup spring and
compression spring preload!
Figure 123
Removal, screw
20. Take off the input housing and remove the O-ring.
Figure 124
Removal, housing and O-ring
21. Remove the compression spring and the O-ring.

Figure 125
Removal, spring and O-ring
22. Pull the complete piston out of the bore.
Figure 126
Removal, piston
23. Remove the cup spring from the brake.
Figure 127
Removal, cup spring
24. Remove the cup spring from the clutch.

Figure 128
Removal, cup spring
25. Remove the piston.
Figure 129
Removal, piston
26. Pull off both cylinder pins.
Figure 130
Removal, cylinder pins
27. Attach two eyebolts and pull the piston cautiously out of the housing.
NOTE!
When disassembling the piston, take care of not to damage.
Figure 131
Removal, piston
28. Remove both seals from the piston.
Figure 132
Removal, seals
29. Remove the axial roller cage with both thrust washers.
Figure 133
Removal, axial roller cage
30. Remove the pressure piece and the compression spring.

Figure 134
Removal, pressure piece and spring
31. Remove the pressure ring with ring.

NOTE!
Ring can also remain in the housing — disassemble the ring separately.
Figure 135
Removal, pressure piece and spring
32. Remove the pressure ring from the ring cautiously by means of lever action.
NOTE!
When disassembling the ring take care not to damage the sealing surfaces.
Figure 136
Removal, pressure ring
33. Remove the gasket and O-rings from the pressure ring and ring.
Figure 137
Removal, gasket and O-rings
34. Take the disc set of the brake with end shims out of the housing.
Figure 138
Removal, disc set
Figure 139
36. Remove the snap ring and the shim.

Figure 140
Removal, snap ring and shim
37. Take the disc set of the clutch with end shims out of the internal gear.
Figure 141
Removal, snap ring and shim
38. Remove the input shaft with internal gear from the housing.
Figure 142
Removal, input shaft

Figure 143
40. Press the input shaft out of the ball bearing and internal gear.
Figure 144
Removal, input shaft
Figure 145
42. Press the centering disc from the input shaft.

Figure 146
Removal, centering disc
43. Unsnap the retaining ring and remove the ball bearing.
Figure 147
Removal, retaining ring and ball bearing
44. Remove the axial needle cage with both thrust washers.
Figure 148
Removal, axial needle cage
45. Loosen the screw connection and remove the washer.

Fasten the output flange by means of the fixture
Figure 149
Removal, screw and washer
46. Press the planet carrier out of the roller bearing.

NOTE!
Pay attention to the released planet carrier and the bearing inner ring!
Figure 150
Removal, planet carrier
47. Pull the second bearing inner ring from the planet carrier.
Figure 151
Removal, inner ring
48. If required, expel both bearing outer rings from the bearing bore.
NOTE!
If the taper roller bearings are reused, pay attention to the bearing location, i.e. respective bearing inner ring to
bearing outer ring!
Figure 152
Removal, bearing outer rings
Figure 153
50. Remove the planetary gear by means of lever action.

NOTE!
Pay attention to the released shim and the cylindrical rollers!
Figure 154
Removal, planetary gear
51. Pull off the bearing inner ring.

In case of an extremely fixed seat heat the bearing inner ring.
Figure 155
Removal, bearing inner ring
52. Remove both seals (1).

Remove both bleeder valves (2) and all screw plugs (3) with sealing and O-ring respectively.
Figure 156
Removal, seals, bleeder valves and screw plugs
53. Loosen the countersunk screws and remove the screen sheet.
NOTE!
Countersunk screws are installed with locking compound (Loctite) — heating for disassembly, if necessary!
Figure 157
Removal, seals, bleeder valves and screw plugs
54. Remove the screen (2) from the planet carrier (1).
Figure 158
Removal, screen
55. Fasten the output flange by means of the fixture.

Loosen the screw connection and then pull off washer, O-ring and flange.
Figure 159
56. Press off the shaft seal by lever action.

NOTE!
Install the second output flange and the shaft seal analogously!
Figure 160
Removal, shaft seal
57. Loosen the screw connection.
Figure 161
Removal, screw
58. By means of lifting tackle separate the output gear with cover from the transmission housing.
Figure 162
Removal, output gear
59. Press the output gear out of the ball bearing/cover.

Remove the released oil baffle plate.
Figure 163
Removal, output gear
60. Unsnap the retaining ring and expel the ball bearing from the cover.
Figure 164
Removal, retaining ring and ball bearing
61. Remove both O-rings from the cover.
Figure 165
Removal, O-rings
62. Remove the screen sheet from the transmission housing.

Figure 166
Removal, screen sheet
63. Expel the ball bearing from the housing bore.
Figure 167
Service Information

Main control valve, Service Information 27/11/2019
description
Profile:
EW145B Volvo
Main control valve, description


This valve block consists of a 4 - spool block and a 3 - spool block connected by screws, main spool, main relief valve, port
relief valves, boom · arm holding valve, boom · arm regenerating valve, arm parallel valve, boom priority logic valve, flow
sensing 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, construction
1. Main relief valve

2. Boom raise port relief valve
3. Boom lower port relief valve
4. Arm in port relief valve
5. Arm out port relief valve
6. Bucket dump port relief valve
7. Bucket curl port relief valve
8. Option port relief valve
Main control valve, sectional view
Figure 2
Main control valve, sectional view (1)
Figure 3
Main control valve, sectional view (2)
1 Main relief valve 44 Spring 87 Check

2 O-ring 45 Cap 88 Spring
3 Back-up ring 46 Check 89 Poppet
4 Cap 47 Sleeve 90 Spring
5 Back-up ring 48 O-ring 91 Cover assembly
6 O-ring 49 Cap 92 Housing
7 Check 50 Piston 93 Bool spool assembly
8 Spring 51 Spring 94 Bucket spool assembly
9 O-ring 52 Sleeve 95 Dozer spool assembly
10 Piston 53 Spool assembly 96 Overload relief valve assembly
11 Cap 54 Spring 98 Port relief valve
12 Piston 55 Check 99 Cap
13 Sleeve 56 Poppet 100 Spring
14 O-ring 57 Sleeve 101 Poppet
15 Sleeve 58 Spring 102 Spool
16 Spring 59 O-ring 103 Spring guide
17 Poppet 60 Spring guide 104 Spool cap
18 Spring 61 Cover 105 Spring
19 Cap 62 Screw 106 Check
20 O-ring 63 Cap 107 Spring
21 Check 64 O-ring 108 O-ring
22 O-ring 65 Spring 109 Cap
23 Housing 66 Spool 110 Cap
24 Travel spool assembly 67 O-ring 111 Back-up ring
25 Slew spool assembly 68 O-ring 112 O-ring
26 Arm spool assembly 69 O-ring 113 Boom spool
27 Option spool assembly 70 Orifice 114 Bucket spool
28 Cover 71 Screw 115 Dozer spool
29 Screw 72 Spring washer 116 Travel spool
30 Cap 73 Poppet 117 Slew spool
31 O-ring 74 Spring 118 Arm spool
32 Cap 75 Spring guide 119 Option spool
33 Nut 76 Back-up ring 120 Cap
34 Spring guide 77 Cover assembly 121 Cap
35 O-ring 78 Screw 122 Plug
36 Spring 79 Manifold 123 Back-up ring
37 Spool 80 O-ring 124 O-ring
38 O-ring 81 Back-up ring 125 Cap
39 Retainer 82 O-ring 126 Union
40 Cap 83 Overload relief valve assembly 127 O-ring
41 Cap 84 Cap
42 Nylon chip 85 Cap
43 Check 86 Spring
Port size
Port size
Symbol Port size Symbol Port size Symbol Port size

Pg1, Pg2 PF 1/4 br1 ~ 3 PF 1/4 AL1 ~ 4 PF 3/4
3Pi PF 1/4 Rs2 PF 3/4 bl1 ~ 4 PF 1/4
Po PF 3/8 ar1 ~ 3 PF 1/4 4Pi PF 1/4
PR PF 3/4 a, b PF 1/4 FL PF 1/4
AR1 ~ 3 PF 3/4 Pa PF 1/4 Pi PF 3/8
BR1 ~ 3 PF 3/4 al1 ~ 4 PF 1/4 Px PF 1/4
FR PF 1/4 Ps PF 1/4 Py PF 1/4
dr1 ~ 6 PF 1/4 PL PF 3/4 Pb PF 1/4
Rs1 PF 1 BL1, 2, 4 PF 3/4
Service Information

Pressure relief valve, Service Information 27/11/2019
troubleshooting
Profile:
EW145B Volvo
Pressure relief valve, troubleshooting


EW145B Volvo
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 Check for contamination on the poppet.
sticking and valve is open. Confirm that each component slides
There is contamination on the smoothly.
poppet or seat. Clean all the components thoroughly.
Unstable relief pressure.

Damaged main poppet seat or Replace damaged component.
servo hydraulic poppet seat of relief Clean all the components thoroughly.
valve.
Main poppet is sticking.
Relief pressure is
incorrect. Wear due to foreign matter. Disassemble and clean the valve.
Damaged pilot seat due to foreign Adjust the relief pressure.
matter.
Loosened lock nut or adjusting
screw.
Oil leak
Damaged main poppet seat or pilot Replace damaged or worn component.
poppet seat due to foreign matter. Confirm that each component operates
Worn O-ring. smoothly before reassembling.
Sticking component due to foreign Confirm that there are no scratches,
matter. nicks, or contamination present before
reassembling.
Service Information

Main spool, disassembly Service Information 27/11/2019
and assembly
Profile:
EW145B Volvo
Main spool, disassembly and assembly


EW145B Volvo
(For assembly, reverse disassembly procedures)

When disassembling, mark each part to indicate original location and position during assembly.
1. Remove screw (1), and remove cover (2).
¡ Tools: Allen wrench 8 mm

¡ Tightening torque: 6 kgf·m (43.3 lbf·ft)
NOTE!
When assembling, make sure that the O-ring is installed before assembling the cover.
Figure 1
Main spool
2. Pull out the spool sub assembly.
NOTE!
Pull out the spool slowly confirming the housing condition.
Figure 2
Removal, spool
3. Hold spool with holder (4) and vise, and loosen spool cap (3).

Figure 3
Disassembly, spool
NOTE!
Remove oil from spool and holder.
NOTE!
When assembling, take care spring guide direction.
4. Remove spool cap (3) and remove spring guide (4) and spring (5).
Figure 4
Removal, spring etc.
5. Only for arm and boom spool, remove cap (6) and pull out spring (7) and check valve (8).
Figure 5
Removal, check valve etc.
Service Information

Main relief valve, Service Information 27/11/2019
description
Profile:
EW145B Volvo
Main relief valve, description


EW145B Volvo
Normal pressure (330 kgf/cm2)

Py servo hydraulic signal: OFF
Hydraulic oil supplied from the pump flows to chamber (3) through orifice (2) of main poppet A.
As section area d1> d2, main poppet A will not move.
Figure 1
Main relief valve
If the pressure reaches set value of spring C, servo hydraulic poppet B will open so that the oil flows to tank passage C
through hole (4). The pressure in chamber (3) will be lowered.
Figure 2
When the pressure reaches set value
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 C.
Figure 3
Hydraulic oil flow to tank passage
Pressurized (350 kgf/cm2)
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
Pressure setting is raised
Service Information

Main pressure relief valve, Service Information 27/11/2019
replacing
Profile:
EW145B Volvo
Main pressure relief valve, replacing


EW145B Volvo
Op nbr 912-067
WARNING
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.
1. Remove hose (2) and main relief valve (1).
Figure 1
2. Install a new main relief valve.

NOTE!
Tightening torque : 147.1 ±14.7 N m (108.3 ±10.8 lbf ft)
3. Adjust the main pressure and test the machine. See : Main relief valve, adjustment
Service Information

Boom holding valve, Service Information 27/11/2019
description
Profile:
EW145B Volvo
Boom holding valve, description


EW145B Volvo
Spool in neutral
3pi servo hydraulic signal: OFF
The position of piston A is as illustrated and servo hydraulic pressure (Pg2) is isolated from chamber Y. Therefore, the
positions of piston B and poppet C become as shown, and passage (5) and (6) will be isolated from poppet C. As chamber
(1) is connected to chamber (2) through orifice (4), pressure Pc is obtained. As poppet E is closed because section area d1 >
d2, chamber (2) and (3) are completely isolated.
Figure 1
Structure, boom holding valve
A Piston F Boom spool

B Piston P Boom cylinder head side
C Poppet H High pressure supply passage
D Check valve T Tank passage
E Poppet
Spool operating
Boom raising [Pv > Pc] (3pi servo hydraulic signal: OFF)
As chamber (1) is connected to chamber (2) through orifice (4), pressure (Pc) is obtained and poppet E will open. The oil in
high pressure supply passage flows to cylinder, piston side.
Figure 2
Boom raising
H High pressure oil supply passage

E Poppet
P Boom cylinder piston side
T Tank passage
Boom lowering [Pc > Pv] (3pi servo hydraulic signal: ON)
When servo hydraulic pressure (3pi) is applied, piston A moves up and servo hydraulic pressure (Pg2) flows to chamber Y.
Piston B and poppet C move to the right, so passage (5) and (6) are connected.
As chamber (3) is connected to the tank passage (by spool moving to left), the oil in chamber (1) opens check valve D
through passage (5) and (6), and then flows to tank passage through passage (7). Therefore, pressure Pc is applied to (area
d1 – area d2). Poppet E is opened and the oil returned from the cylinder, piston side, now flows to tank passage.
Figure 3
Boom lowering
A Piston E Poppet
B Piston G Drain port
C Poppet P Boom cylinder piston side
D Check valve T Tank passage
Service Information

Arm holding valve, Service Information 27/11/2019
description
Profile:
EW145B Volvo
Arm holding valve, description


Spool in neutral
4pi servo hydraulic signal: OFF
Spool A is positioned as shown, and chamber (1) and drain (dr3) are isolated. As chamber (1) is connected to chamber (2)
through orifice (4), the pressure in chamber (1) will be Pc. As area d1 > d2, poppet B will not move, and chamber (2) and
chamber (3) are isolated to hold the arm in position.
Figure 1
Arm holding valve
A Spool
B Poppet
C Arm spool
D Servo hydraulic signal port
R Arm rod
T Tank passage
Spool operating
Arm out [Pv > Pc] (4pi servo hydraulic signal: OFF)
As chamber (1) is connected to chamber (2) through orifice (4), the pressure will be Pc and poppet B will open. The oil (Pv) in
high pressure supply passage is supplied to cylinder rod side through chamber (3).
Figure 2
Arm out
A Spool
B Poppet
R Arm rod
T Tank passage
Arm in [Pc > Pv] (4pi servo hydraulic signal: ON)
When servo hydraulic pressure (4pi) is applied, spool A moves left. As the oil is drained when chamber (1) and drain (dr3) is
connected, the pressure in chamber (2) becomes low. When the pressure Pc is applied by (area d1 – area d2), poppet B will
open and the oil returned from the cylinder, rod side, flows to tank passage.
Figure 3
Arm in
A Spool
B Poppet
R Arm rod
T Tank passage
Service Information

Arm regenerating and arm Service Information 27/11/2019
conflux check valve,
disassembly and assembly
Profile:
EW145B Volvo
Arm regenerating and arm conflux check valve, disassembly and

assembly

EW145B Volvo
(For assembly, reverse disassembly procedure)

When disassembling, mark each part to make assembling easier.
Figure 1
Arm regenerating and arm conflux check valve
1. Remove cap (1) and pull out spring (2) and spool (3).
¡ Tools: Socket wrench, spanner 27 mm

Figure 2
Removal, cap and spring etc.
¡ Tightening torque: 10 kgf·m (72 lbf·ft)
2. Remove sleeve (4) and pull out piston (5), spring (6) and check valve (7).
3. Remove cap (8) and pull out piston (9) and spring (12).

Service Information

Load check valve, Service Information 27/11/2019
Profile:
EW145B Volvo
Load check valve, disassembly and assembly


EW145B Volvo

1. Remove cap (1) and pull out spring (2), poppet (3) and check valve (4).
Figure 1
Load check valve
A. Boom (single)
B. Slew, arm, bucket, dozer blade, option (double)
Figure 2
Removal, spool etc.
Service Information

Center bypass valve, Service Information 27/11/2019
Profile:
EW145B Volvo
Center bypass valve, disassembly and assembly


EW145B Volvo

1. Remove cap (1) and pull out spool assembly.
Figure 1
Center bypass valve
2. Hold spool with holder and vise and loosen nut (2). (Refer to the main spool.)

Figure 2
Removal, spring
¡ Tightening torque: 2.5 kgf·m (18 lbf·ft)
NOTE!
Tighten nuts prior to assembling.
NOTE!
Note that the spool notches in 3 – series and 4 – series side are different.
3. Remove nut (2) and pull out spring seat (3), spring (4).
Service Information

Hydraulic pump, 913 Service Information 27/11/2019
specifications
Profile:
EW145B Volvo
Hydraulic pump, specifications


Specifications
Item Unit Specification

Function – Full horsepower control
Type – Variable displacement, swash plate type, piston pump
Displacement cc/rev 2 x 80
Flow-rate lpm (gpm) 160 x 2 (42.2 x 2)
Pressure MPa (kgf/cm2) (psi) 32.3/34.3 (330 / 350 (4694 / 4980) (323.6/343.2)
(normal / boost) (bar)
Service Information

Hydraulic pump, 913 Service Information 27/11/2019
description
Profile:
EW145B Volvo
Hydraulic pump, description


Model code (K5V80DT-1PDR - 9N02/9NOJ)

Model code
Symbol Description Remark

K5V Series
80 Size (Displacement: cm3/rev)
DT Tandem type double pump
1PX Design series number
R Shaft rotation view from shaft end R: Clockwise
L: Counterclockwise
9NXX Regulator type
For more details refer to the section for the regulator.
Structure
Figure 1
Structure, main pump
1. Set screw minimum flow
2. Eye bolt
3. Set screw maximum flow
Port connection
Port Port name Port size

A1, 2 Delivery SAE 6000 3/4″
B1 Suction SAE 2500 2 1/2″
Dr Drain PF 1/2 – 19
Pi1, 2 Servo hydraulic PF 1/4 – 15
a1, 2 Gauge PF 1/4 – 15
a3, 4 Gauge PF 1/4 – 15
A3 Gear pump delivery PF 1/2 – 19
B3 Gear pump suction PF 3/4 – 20.5
P1 Power shift valve PF 1/4 – 15
Pump, sectional view

Figure 2
Main pump, sectional view
111 Driving shaft (F) 312 Valve block 725 O-ring
113 Driving shaft (R) 313 Valve plate (R) 728 O-ring
114 Spline coupling 314 Valve plate (L) 732 O-ring
123 Roller bearing 401 Screw 774 Seal
124 Needle bearing 406 Screw 789 Back-up ring
127 Bearing spacer 466 Plug 792 Back-up ring
141 Cylinder block 467 Plug 808 Lock nut
151 Piston 490 Plug 809 Lock nut
152 Shoe 531 Tilting pin 824 Snap ring
153 Set plate 532 Servo piston 885 Valve plate pin
156 Spherical bushing 534 Stopper 886 Spring pin
157 Cylinder spring 535 Stopper 901 Eye bolt
211 Shoe plate 548 Feedback pin 953 Adjusting screw
212 Swash Plate 702 O-ring 954 Adjusting screw
214 Tilting bushing 710 O-ring 981 Name plate
251 Swash plate support 717 O-ring 983 Pin
261 Seal cover 719 O-ring
271 Pump casing 724 O-ring
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 pumps.
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 (a).
The valve block group consists of valve block (312), valve plate (313) 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.
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 3
Moving, swash plate
1. Servo piston
2. Tilting pin
Adjustment of maximum flow

Adjust it by loosening nut (809) and by tightening (or loosening) adjusting screw (954).
Only the maximum flow is adjusted without changing other control characteristics.
Figure 4
Adjustment of maximum flow
X Servo hydraulic pressure, Pi

Y Delivery flow, Q
Adjustment of minimum flow

Adjust it by loosening 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 5
Adjustment of minimum flow
X Servo hydraulic pressure, Pi

Y Delivery flow, Q
Service Information

Pump, disassembly 913 Service Information 27/11/2019
Profile:
EW145B Volvo
Pump, disassembly

EW145B Volvo
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 re-assembly.
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 analyse all failures. Determine the root cause!
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.
3. Remove drain port plug (467) 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.

Refer to the regulator section for disassembly.
Figure 1
Removal, regulator
NOTE!
Mark each regulator to match the pump.
5. Remove screws (401) which hold swash plate support (251), pump casing (271) and valve block (312).
NOTE!
If a gear pump is fitted to the rear face of the pump, remove it before starting this work.
6. Place the pump horizontally on a workbench with regulator-fitting surface facing down, and separate pump casing
(271) from valve block (312).
Figure 2
Removal, pump casing
NOTE!
Spread a rubber sheet on the workbench to prevent this surface from being damaged.
7. Pull cylinder (141) out of pump casing (271) straight over drive shaft (111). Pull out piston (151), set plate (153),
spherical bushing (156) and cylinder springs (157) simultaneously.
Figure 3
Removal, cylinder
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.
8. Remove screws (406) and front seal cover (261).
Figure 4
Removal, seal cover
NOTE!
Fit screws into pull-out tapped holes (M 6) of seal cover (F), so it can be removed easily.
NOTE!
Since an seal is fitted to the seal cover, take care not to damage it during disassembly.
9. Remove screws (408).

10. 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
Tapping, swash plate support
11. Remove shoe plate (211) and swash plate (212) from pump casing (271).
Figure 6
Removal, shoe plate and swash plate
12. Tap lightly the ends of drive shafts (111, 113) with a plastic hammer to remove them from the swash plate supports.
Figure 7
Removal, shaft
13. Remove valve plates (313, 314) from valve block (312).
Figure 8
Removal, valve plate
14. If necessary, remove stopper (534), stopper (535), servo piston (532) and tilting pin (531) from pump casing (271),
and needle bearing (124) and splined coupling (114) from valve block (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.
NOTE!
Do not loosen nuts (808) and set screws (953, 954). If loosened, the flow setting will be changed.
Service Information

Pump, installation 913 Service Information 27/11/2019
Profile:
EW145B Volvo
Pump, installation

Precautions, start-up
Fill the pump casing 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
Tightening torque
Tightening torque, unit : N.m (kgf·m) (lbf·ft)
Symbol Description Specification Remark

A M16 × 2.0 × 60L 215.7 ± 21.6 (22 ± 2.2) (158.9 ± 15.9) Apply loctite #277
B M16 × 2.0 × 50L 215.7 ± 21.6 (22 ± 2.2) (158.9 ± 15.9)
C M16 (10.9 and more, JIS) 235 ± 19.6 (24 ± 2) (173 ± 14)
E M8 17 (1.7) (12.6)
F M10 × 30 63.7 ± 6.9 (6.5±0.7) (46.9 ± 5.1))
Service Information

Hydraulic pump (removed), 913 Service Information 27/11/2019
changing shaft seal
Profile:
EW145B Volvo
Hydraulic pump (removed), changing shaft seal


EW145B Volvo
Op nbr 913-007
1. Remove screws (1) and front seal cover (2).
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

Hydraulic pump, replacing 913 Service Information 27/11/2019
Profile:
EW145B Volvo
Hydraulic pump, replacing


EW145B Volvo
Op nbr 913-010
WARNING
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 vessel. Disconnected hoses and connections must be
plugged.
NOTE!
Container capacity : 300 liters Drain hose : The hose for engine oil draining can be used.
WARNING
1. Place the machine in the service position B. See : Service positions
2. Remove screws (1) and under covers (2)
WARNING
When the last bolt has been removed, the cover plate falls down.
Figure 1
3. Connect drain hose (1) supplied with the machine to the drain valve and drain the hydraulic oil into an oil barrel
Disconnect drain hose (1), after draining hydraulic oil.
Figure 2
NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
4. Open the hood.

Remove screws (3) and cover (4).
Remove screws (1) and cover (2).
Figure 3
5. Remove screws (1,2, 3, 4, 5) and bracket (6).

Figure 4
6. Remove hoses (1), screws (2) and servo hydraulic drain oil filter.
Figure 5
7. Remove sensor wire harness (3).
8. Remove screws (4) and engine oil filter.
9. Remove screws (1), (2) & (3) and hoses (4, 5).
Figure 6
10. Remove screws (6) and fuel filter.
11. Remove screws (7) and water separator.
12. Remove screws and clamp (1).
Figure 7
13. Remove screws (1, 2).
Figure 8
14. Remove muffler with hoist (1).
Figure 9
15. Disconnect wire harness and hoses (1, 2, 3).

Figure 10
16. Remove screws (1) and the suction tube.

NOTE!
Before removing screws, hold the suction tube not to drop down.
Figure 11
17. Install eye bolts and slings (3), hold with hoist (1) and remove mounting screws (4).
Figure 12
18. Remove the hydraulic pump with flange (2).
19. Remove screws (1), hub (2) and insert (3) assembly from hydraulic oil pump shaft (4).
Figure 13
20. Remove the flange (4) from hydraulic oil pump.
Figure 14
21. Fit the flange to a new hydraulic pump.
22. Transfer connectors (1) and plate (2) to new hydraulic pump from old hydraulic pump.
NOTE!
O-rings disassembled should be replaced with new ones.
Transfer hydraulic oil pressure sensor (3) to new hydraulic pump from old hydraulic pump.
23. Fit hub (2), insert (3) assembly and tighten screws (1) to new hydraulic oil pump shaft (4).
NOTE!
Apply loctite # 277 onto the threads of screws (1).
Tightening torque : 10 ~ 12 kg m (72 ~ 87 lbf ft)

Figure 15
24. Install the hydraulic pump assembly.
Figure 16
25. Install flange mounting screws (4).
26. Install screws (1) and the suction tube.
Figure 17
27. Install servo pump hoses and hoses (1, 2, 3)and the wire harness.
Figure 18
28. Install muffler with hoist (1).
Figure 19
29. Install screws (1, 2).
Figure 20
30. Tightening screws and clamp (1).

Figure 21
31. Install fuel filter mounting screws (6) and hoses (4).
Figure 22
32. Install water separator mounting screws (7) and hoses (5).
33. Install hoses clamp screws (1. 2, 3).
34. Install engine oil filter mounting screws (4)and screws.
Figure 23
35. Install sensor wire harness (3).

36. Install servo hydraulic drain oil filter mounting screws (2) and hoses (1) .
37. Install bracket (6) and screws (1, 2, 3, 4, 5).
Figure 24
38. Install covers (2, 4) and screws (1, 3).

Close the hood.
Figure 25
39. Install under covers (2) and screws (1).
Figure 26
40. Remove plug (1).

Fill the oil tank with hydraulic oil through the return filter.
Install plug (1).
Figure 27
41. Start the engine and test the machine.

Service Information

Hydraulic circuits, neutral 990 Service Information 27/11/2019
Profile:
EW145B Volvo
Hydraulic circuits, neutral


Servo hydraulic circuit (safety lever in unlocked position)

Servo hydraulic pressure circuit
Oil discharged by the gear pump passes through the relief valve and servo hydraulic filter (8) and enters the following
components, completing the servo hydraulic pressure circuit :
Remote control valve for operating digging units (19, 20)

Remote control valve for travel (25)
Dozer blade remote control valve (23)
Slew brake valve (PG)
Power shift valve (for pump control)
Auto idle circuit (Pg1)
Solenoid valve for main pressure boost, safety, axle locking, breaker, boom and arm conflux
Travel 1st/2nd speed clutch release circuit, cruise solenoid valve circuit
Negative control signal circuit

The advantage of this circuit is minimizing pump discharge under no–load, thereby eliminating wasteful energy
consumption (for energy conservation), and reducing fuel costs.
The operating principle is the negative control type in which the increase in main return oil pressure (Fl, Fr) reduces the
discharge from the pump.
Negative control pressure (Fl, Fr) rises when in neutral because all the oil discharged from the pump is directed through the
throttle of the flow sensing valve (56), increasing the flow through it.
In the negative control circuit for the A1 pump, oil from port Fl of the control valve passes and enters port Pi1 (Fl) of the
pump.
In the negative control circuit for the A2 pump, oil from port Fr of the control valve passes and enters port Pi2 (Fr) of the
pump.
Main circuit
Hydraulic oil cleaned by tank strainer (37) is drawn in by the variable displacement pumps.
This oil is then discharged by A1, A2 pump and enters the main control valve.
When the flow sensing valve in the control valve is actuated, the oil drains through tank port (R).
The returning oil passes through the oil cooler and return filter (34) where any contaminates are removed as it is drained to
tank.
Service Information

Hydraulic circuits, standard 990 Service Information 27/11/2019
Profile:
EW145B Volvo
Hydraulic circuits, standard


1 Main pump 31 Bypass check valve

2 Main control valve 32 Hydraulic oil cooler
3 Slew motor 33 Hydraulic oil tank
4 Travel motor 34 Return element
5 Boom cylinder 35 Bypass valve
6 Arm cylinder 36 Quick drain valve
7 Bucket cylinder 37 Strainer
8 Center passage 38 Air breather
9 Block 39 Shuttle valve
10 Dozer blade cylinder 40 Quick coupler
11 Double servo hydraulic check valve 41 Connector filter
12 Double servo hydraulic check valve 42 Connector filter
13 Servo hydraulic filter 43 Connector filter
14 Accumulator block 44 Connector orifice
15 Accumulator 45 Pressure switch
16 Solenoid valve (1) 46 Pressure switch
17 Solenoid valve (2) 47 Pressure sensor
18 Block (1) 48 Quickfit valve
19 Remote control valve (lever) - left 49 Quickfit
20 Remote control valve (lever) - right 50 Boom holding valve
21 Shuttle valve 51 Logic valve (Boom conflux)
22 Servo hydraulic selector valve 52 Main relief valve
23 Dozer blade lever 53 Center bypass valve - 3 series
24 Remote control valve - X1 pedal 54 Arm parallel conflux valve
25 Remote control valve - pedal 55 Center bypass valve - 4 series
26 Travel solenoid valve 56 Flow sensing valve
27 Shuttle valve 57 Arm regeneration valve
28 Cruise solenoid valve 58 Arm holding valve
29 Drain filter 59 Back pressure check valve
30 Bypass check valve 60 Orifice
Figure 1
Hydraulic circuits
Service Information

Hydraulic circuits, boom 990 Service Information 27/11/2019
raise conflux (internal)
Profile:
EW145B Volvo
Hydraulic circuits, boom raise conflux (internal)


When joystick (20) is operated to “BOOM RAISE”, secondary servo hydraulic pressure oil from the remote control
valve flows to port (br1, Ps, b) and (pb) through servo hydraulic selector valve (22).
(br1) flows to the main control valve pilot port (br1), moving the boom spool to the right, routing A2 pump flow
(PR) to the piston side of the cylinders extending the rods raising the boom.
(Ps) flows to arm conflux valve (54) servo hydraulic port (Ps), controlling the valve blocking A2 pump flow (PR) to
the arm cylinder. (Refer Arm in/Boom raise)
(b) flows to center bypass valve (55) and (BU2) flows to (Pb) through servo hydraulic selector valve (22).
(pb) moves logic valve (51) spool to the right blocking (A1) oil to the logic valve, allowing the logic valve poppet to
open.
(b) moves center bypass valve (55) to the left, blocking (A1) oil to tank and opens logic valve poppet (51). A1
combines with A2 flow in the main control valve, then is routed to the piston side of the cylinders raising the boom.
The oil from the rod side flows to the hydraulic filter and oil cooler, then is drained to tank.
Negative signal (Fr) of A2 pump is disconnected by the boom spool and negative signal (Fl) of A1 pump is
disconnected by the spool of center bypass valve (55). So A1, A2 pump discharge is increased.
Line color index

Red High pressure oil
Blue Low pressure, servo hydraulic primary pressure oil
Brown Servo hydraulic secondary pressure oil
Green Drain circuit, pump suction oil
Figure 1
Hydraulic circuits, boom raise conflux
Service Information

Hydraulic circuits, arm in 990 Service Information 27/11/2019
conflux
Profile:
EW145B Volvo
Hydraulic circuits, arm in conflux


When joystick (19) is operated to “ARM IN” secondary pilot oil from the remote control valve flows to ports (al3,
sh2, Al2, AM, a, 4Pi).
(al3) oil flows to the main control valve moving the arm spool to the right, routing A1 pump flow to the arm
cylinder piston side, moving the arm in.
(sh2) oil flows through shuttle valve (39) shifting the brake valve spool, routing primary pilot oil (PG) to release the
slew brake.
(Al2) oil flows to servo hydraulic selector valve (22) shifting the spool, draining servo hydraulic signal (pb) at the
spool valve of logic valve (51). Then A1 (PL) pump oil flows through the check valve and spool valve to the logic
valve upper side. Due to the surface area differential valve (51) is held closed.
(AM) oil flows to A3 solenoid valve in block (17) and is routed to port (a) at center bypass valve (53) moving the
spool, block A1 pump flow to tank and the negative flow signal (Fr) ; therefore A2 pump flow increas es and is
routed through arm conflux valve (54) via port (Po) to merge with A1 pump flow in the main control valve, and is
routed to the cylinder piston side moving the arm in (confluent flow).
(4Pi) oil flows to the arm holding spool valve, shifting the spool, draining the oil from the upper side of arm holding
valve (58). This enables return oil from the cylinder rod side to open the holding valve (58) and flow through the
main control valve, hydraulic filter and oil cooler to tank.
When supply flow is sufficient, regenerating valve is pushed to the right and the return circuit is unrestricted.
When the engine rotates at low rpm or the supply flow is not sufficient due to combined operation, the pressure
will drop. In this case, regenerating valve is pushed to the left and the return circuit is restricted. Arm regenerating
check valve in the center of the arm spool is opened and some return oil is merged with supply flow, to the arm
cylinder.
This prevents cavitation and any sudden change of cylinder speed.
Line color index

Figure 1
Hydraulic circuits, arm in conflux
Service Information

Hydraulic circuits, bucket 990 Service Information 27/11/2019
curl
Profile:
EW145B Volvo
Hydraulic circuits, bucket curl


Bucket curl (Depicted in schematic)
When joystick (20) is operated to “ BUCKET CURL” secondary servo hydraulic oil from the remote control valve flows
to port (br2) on the main control valve moving the bucket spool to the left, routing A2 pump flow (PR) to the
cylinder piston side extending the rod, curling the bucket.
Since center bypass valve (55) is open, A1 pump flow (PL) returns to tank.
Flow sensing valve (56) restricts the return flow, raising the oil pressure in passage (Fl) shifting the servo piston of
A1 pump decreasing pump delivery.
Bucket dump
When joystick (20) is operated to “ BUCKET DUMP” secondary servo hydraulic oil from the remote control valve
flows to port (ar2) on the main control valve moving the bucket spool to the right, routing A2 pump flow (PR) to the
cylinder rod side retracting the rod, dumping the bucket.
As the bucket spool shifts it blocks the negative flow signal (Fr) and A2 pump flow (PR) increases.
Since center bypass valve (55) is open, A1 pump flow (PL) returns to tank.
Flow sensing valve (56) restricts the return flow, raising the oil pressure in passage (Fl) shifting the servo piston of
A1 pump decreasing pump delivery.
Return oil from the piston side flows through the main control valve to the hydraulic filter and oil cooler, then is
drained to tank.
Line color index

Figure 1
Hydraulic circuits, bucket curl
Service Information

Hydraulic circuits, travel 990 Service Information 27/11/2019
Profile:
EW145B Volvo
Hydraulic circuits, travel


When the travel pedal is operated secondary pilot pressure from remote control valve (25) flows to (bl1) according
to forward/reverse solenoid valve control (26). And pilot pressure from pilot pump flows to parking solenoid valve,
1st/2nd speed clutch in the transfer gearbox.
(bl1) flows to the main control valve pilot port (bl1), moving the travel spool to the left, routing A1 pump flow (PL)
to port (B) of travel motor (4).
The boom conflux logic valve (51) blocks A1 pump oil (PL) from merging with A2 pump oil (PR).
The A2 pump oil (PR) flows through the center bypass valve (53) and returns to tank. Flow sensing valve (56)
restricts the return flow, raising the oil pressure in passage (Fr) shifting the servo piston of A2 pump decreasing
pump delivery.
Travel mode select switch has 3 steps.
(P : Park, W : Work, T: Travel)
Auto-decel function is not available while in travel mode.
When the machine starts, the travel motor swash plate angle is increased to achieve enough torque to start moving
the machine.
Line color index

Figure 1
Hydraulic circuits, travel
Service Information

Wiring diagram 1 370 Service Information 27/11/2019
Profile:
EW145B Volvo
Wiring diagram 1

EW145B Volvo
Figure 1
Designation Component Comment

AL3201 Alternator
BA3101 Battery 1
BA3102 Battery 2
DI3301 Diode, Battery relay
FU3101 Slow blow Fuse 40 A
FU3201 Slow blow Fuse 80 A
FU16 Feed, Start switch
IM3812 Hour counter
MO3301 Starter motor
RE3101 Relay, Battery
RE3301 Relay, Safety
SW3101 Battery disconnector
SW3301 Start switch
V-ECU Vehicle control unit
Service Information

Profile:
EW145B Volvo
Wiring diagram 2

EW145B Volvo
Figure 1
DI3302 Diode, Safety
DI3101 Diode, Work mode
DI3201 Diode, Travel mode
DI5501 Diode, Parking solenoid
MA9108 Safety solenoid
MA5501 Parking solenoid
SE9160 Limit switch ( control box)
SW9151 Safety lever
SW3613 Mode switch
FU23 Feed, Parking solenoid 10 A
Service Information

Profile:
EW145B Volvo
Wiring diagram 3

EW145B Volvo
Figure 1
I-ECU Instrument control unit
E-ECU Engine control unit
SW2706 Emergency engine control & stop switch
FU1 Feed, Front instrument panel (I-ECU) 10 A
FU16 Feed, Start switch 15 A
FU10 Feed, V-ECU (1) 10 A
FU24 Feed, Engine RPM manual control 5A
Service Information

Profile:
EW145B Volvo
Wiring diagram 4

EW145B Volvo
Figure 1

SW3301 Start switch
SW2706 Emergency engine speed control & stop switch
FU15 Feed, Engine electronic control unit relay 20 A
FU24 Feed, Emergency engine speed control & stop switch 5A
RE2701 Relay, Engine electronic control unit data record
RE2702 Relay, Engine electronic control unit power
Service Information

Profile:
EW145B Volvo
Wiring diagram 5

EW145B Volvo
Figure 1

LC3801 Indicator light, Central warning
LC5201 Indicator light, Brake oil low pressure
LC2201 Indicator light, Engine oil low pressure
LC2601 Indicator light, Engine coolant temperature warning
LC2602 Indicator light, Engine coolant level gauge
LC2501 Indicator light, Air filter
SE2303 Sensor, Fuel level gauge
SE5201 Sensor, Brake oil low pressure
SE2606 Sensor, Engine coolant temperature
SE2203 Sensor, Engine oil low pressure
SE2501 Sensor, Air filter pressure
SE2603 Sender, Engine coolant level
IM3811 Engine coolant temperature gauge
IM3803 Fuel level gauge
Service Information

Profile:
EW145B Volvo
Wiring diagram 6

EW145B Volvo
Figure 1

SW2701 Engine control switch
SW2703 Automatic idling switch
SE9154 Sensor, Attach pressure
Service Information

Profile:
EW145B Volvo
Wiring diagram 7

EW145B Volvo
Figure 1

DI4208 Diode, Low speed solenoid
DI4201 Diode, Forward solenoid
DI4202 Diode, Backward solenoid
DI4203 Diode, Forward
DI4204 Diode, Backward
RE3601 Alarm relay
SW4202 Transmission switch
SW9151 Axle locking switch
SA3603 Back-up alarm
SE5203 Sensor, Travel pedal pressure
SE4216 Sensor, Transmission oil low pressure
MA9152 Axle locking solenoid
MA4202 Forward/backward solenoid
MA4101 Auto cruise solenoid
FU21 Feed, Back up alarm 10 A
Service Information

Profile:
EW145B Volvo
Wiring diagram 8

EW145B Volvo
Figure 1

LA3501 Right hand headlight (High/Low)
LA3502 Left hand headlight (High/Low)
LA3512 Clearance light, Left hand rear
LA3522 Clearance light, Left hand headlight
LA3526/LA3527 Licence plate lights
LA3515 Clearance, Right hand headlight
LA3523 Clearance, Right hand rear
RE3501 Relay, Illumination
RE3502 Relay, Light
FU2 Feed, Lights (2) 10 A
FU3 Feed, Headlights 15 A
FU12 Feed, Lights (1) 20 A
FU26 Feed, Clearance light ( LH rear) 10 A
FU27 Feed, Clearance light ( RH rear) 15 A
FU28 Feed, Headlights (High) 15 A
FU29 Feed, Headlights (Low) 15 A
Service Information

Profile:
EW145B Volvo
Wiring diagram 9

EW145B Volvo
Figure 1

DI9101 Diode, Quickfit
RE9105 Relay 1, Quickfit
RE9104 Relay 2, Quickfit
RE9106 Relay, Safety pressure
SE9151 Sensor, Safety pressure
SE9152 Sensor, Hammer pilot pressure
SW9104 Quickfit solenoid 1
SW9105 Quickfit solenoid 2
SW9108 Boost switch- Right hand RCV
SW9109 Boost rocker switch
SW9160 Warning signal, confirm & turn off switch
MA9107 Boost solenoid
MA9104 Hammer solenoid
MA9105 Boom pilot shutoff solenoid
MA9106 Arm pilot shutoff solenoid
FU17 Feed, Quickfit 10 A
Service Information

Profile:
EW145B Volvo
Wiring diagram 10

EW145B Volvo
Figure 1

SE9102 Sensor, Hammer pressure
SW2704 Auto/manual select switch
MM3903 Resistor, Pump
PWM9101 Proportional valve, Pump control
Service Information

Profile:
EW145B Volvo
Wiring diagram 11

EW145B Volvo
Figure 1

LA3519 Turning signal rear, Right hand
LA3518 Turning signal front, Right hand
LA3517 Turning signal rear, Left hand
LA3516 Turning signal front, Left hand
RFX Flash unit
RERFX Flash unit relay
SW3512 Multi function switch
SW3513 Hazard switch
FU6 Feed, Hazard light 10 A
FU18 Feed, Turn signal light 10 A
Service Information

Profile:
EW145B Volvo
Wiring diagram 12

EW145B Volvo
Figure 1

LA3523 Tail/stop, Right hand
LA3512 Tail/stop, Left hand
LA3524 Back-up light, Right hand
LA3522 Back-up light, Left hand
LA3504 Boom work light, Right hand
LA3503 Boom work light, Left hand
RE3524 Relay, Stop light
RE3503 Relay, Work light
SE5204 Sensor, Stop pressure
SW3501 Work light switch
FU13 Feed, Boom work lights 20 A
FU22 Feed, Stop lights 10 A
Service Information

Profile:
EW145B Volvo
Wiring diagram 13

EW145B Volvo
Figure 1

CU3601 Control unit, Windshield wiper
DI3605 Diode, Washer pump
LA3509 Room light
MO3601 Motor, Washer
MO3602 Motor, Upper wiper
SW3602 Switch, Windshield wiper
SW3601 Switch, Washer motor
SW3503 Switch, Room light
SE3602 Position monitor, Upper wiper
FU4 Feed, Wiper & washer 10 A
FU20 Feed, Room lights 10 A
Service Information

Profile:
EW145B Volvo
Wiring diagram 14

EW145B Volvo
Figure 1

DI3603 Diode 1, Horn
DI3604 Diode 2, Horn
HE3801 Cigarette lighter
HE8501 Seat heater
MO8501 Motor, Air suspension
RE3604 Relay, Horn
SA3601 Horn
SA3602 Horn
SW3606 Switch, Horn
SW3512 Switch, Multi function
SW8501 Switch, Seat heating
FU4 Feed, Multifunction switch 10 A
FU7 Feed, Horn 10 A
FU9 Feed, Cigarette light 10 A
FU11 Feed, Seat heating 10 A
Service Information

Profile:
EW145B Volvo
Wiring diagram 15

EW145B Volvo
Figure 1

ANT3901 Antenna
CA6(SA3901) Speaker, Left hand
CA7(SA3902) Speaker, Right hand
CRR3901 Cassette/radio
PO3902 Power socket
SO3901 DC-DC converter
SO3902 DC-DC converter
SW3901 Mute switch
FU5 Feed, Cassette & radio 10 A
FU20 Feed, Power outlet 10 A
Service Information

Profile:
EW145B Volvo
Wiring diagram 16

EW145B Volvo
Figure 1

LS(IS) Service socket
FU14 Feed, Service socket 5A
Service Information

Profile:
EW145B Volvo
Wiring diagram 17

EW145B Volvo
Figure 1

CU8701 Air conditioner
SE8705 Ambient air pressure
SE2504 Sensor, Recirculation air temperature
SW3301 Start switch
FU8 Feed, Air conditioner 20 A
Service Information

Profile:
EW145B Volvo
Wiring diagram 18

EW145B Volvo
Figure 1
DI8702 Diode, Air conditioner receiver dryer pressure
MO8702 Motor, Air conditioner compressor
SE8701 Sensor, Air conditioner receiver dryer pressure
Service Information

Profile:
EW145B Volvo
Wiring diagram 19

EW145B Volvo
Figure 1

SE2606 Sensor, Coolant temperature
SE2507 Sensor, Boost air temperature
SE2203 Sensor, Oil pressure
SE2508 Sensor, Boost pressure
SE2306 Sensor, Fuel temperature
Service Information

Profile:
EW145B Volvo
Wiring diagram 20

EW145B Volvo
Figure 1

SE2701 Sensor, Flywheel speed
SE2703 Sensor, Camshaft speed
SE2603 Sensor, Coolant level
SE2501 Sensor, Ambient air temperature
SE2502 Sensor, Air filter pressure
Service Information

Profile:
EW145B Volvo
Wiring diagram 21

EW145B Volvo
Figure 1

MA2301 Unit injector 1
Service Information

Profile:
EW145B Volvo
Wiring diagram 22

EW145B Volvo
Figure 1

RE2501 Relay, Preheater
HE2501 Coil, Preheater
Wiring diagram SCH03
Show All Profiles

EW145B Volvo
Engine starting and speed control system
Figure 1
Wiring diagram SCH03
Marking Designation Marking Designation

HE2301 Fuel warmer SE2701 Engine speed sensor, crankshaft
MA2301 Injector 1 SE2703 Engine speed sensor, camshaft
MA2302 Injector 2 SW2301 Fuel warmer switch
MA2303 Injector 3 SW2701 Engine speed control switch
MA2304 Injector 4 SW2703 Auto idle switch
MA2305 Injector 5 SW2704 Emergency engine speed control and
stop switch
MA2306 Injector 6 SW3301 Engine start switch
MA2504 Internal exhausted gas recirculation RE2501 Preheater relay
MO3301 Starter motor RE3301 Starter motor relay
PWM2303 Actuator-MPROP common rail RE3302 Starter motor power relay
Figure 2

EW145B Service Information

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Document Title: Function Group: Information Type: Date:

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Engine, description (Deutz D6D EOE2)

Valid for serial numbers

1. Coolant inlet (from radiator)

Engine, front side view

1. Air inlet (from charge air cooler)

Engine, top side view

1 Fuel suction port 9 Coolant make up port

Engine, rear side view

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Engine, tightening torques

Valid for serial numbers

Engine, tightening torque

Document Title: Function Group: Information Type: Date:

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1 Engine oil filler 10 Oil dipstick

19 Crankcase bleeding valve 26 Turbocharger

Document Title: Function Group: Information Type: Date:

Determining cylinder head gasket

Valid for serial numbers

Measuring piston projection

 A dial gauge with a fixture is needed to measure the piston projection.

Piston projection Identification of cylinder head gasket

Document Title: Function Group: Information Type: Date:

Fitting cylinder head

Valid for serial numbers

2. Lightly oil the cylinder head bolts.

¡ 1st step: 30 N·m (22.2 lbf·ft, 3.1 kgf·m)

Document Title: Function Group: Information Type: Date:

Valid for serial numbers

Document Title: Function Group: Information Type: Date:

Piston rings, description

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Document Title: Function Group: Information Type: Date:

Valid for serial numbers

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Valve system specifications

Valid for serial numbers

Document Title: Function Group: Information Type: Date:

Internal Exhaust Gas Recirculation (IEGR), description

Valid for serial numbers

Checking and adjusting

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Go back to Index Page

Valid for serial numbers

1. Remove rocker cover.

¡ Tightening torque: 9 N·m (6.6 lbf·ft)

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Valid for serial numbers

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Connecting rod, description

Valid for serial numbers

Document Title: Function Group: Information Type: Date:

Valid for serial numbers

¡ Front (fan end): yellow and white

Tightening torque, unit: kgf·m (lbf·ft)

No. Part name Thread size Tightening torque

Document Title: Function Group: Information Type: Date:

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Lubrication system, description

Valid for serial numbers

Lubrication oil flow diagram

A dial gauge with a fixture is needed to measure the piston projection.

The concentration of the coolant is checked with commercially available testers.