Volvo ECR38 Compact Excavators Service Repair Manual
Complete repair service manual with Electrical Wiring Diagrams for Volvo ECR38 Compact Excavators, with technical information to maintain, diagnose, and repair like professional mechanics.
Volvo Constructions ECR38 Compact Excavators workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Volvo ECR38 Compact Excavators Service Repair Manual.PDF
MAIN SECTIONS
0 - GENERAL
1 - STANDARD PARTS, SERVICE
2 - ENGINE WITH MOUNTING AND EQUIPMENT
3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
4 - POWER TRANSMISSION
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM
PRODUCT DETAILS:
Total Pages: 891
File Format: PDF
Language: English
TABLE OF CONTENTS
0 - GENERAL.....2
00 - DESCRIPTION; COMPLETE MACHINE.....3
Description; general.....4
Product plate; description.....5
03 - SPECIFICATIONS.....7
Tightening torques.....9
Location of components.....20
Dimensions.....22
Weight.....25
Technical data.....26
Capacities.....28
Others; standard tightening torque.....29
Conversion tables.....32
Engine; specifications_{22-29}.....37
Engine; specifications_{22-11}.....38
Fuel system; specifications .....39
Fuel injection pump; specifications .....40
Cooling system; specifications .....41
Electrical system; specifications .....42
Battery; specification .....43
Alternator; specifications .....44
Starter motor; specifications .....45
Fuse box; specifications .....46
Instrument panel; specifications .....47
Fuel; lubricant and filling capacities .....48
Track motor; specifications_{18-31}.....49
Track motor; specifications_{18-13}.....50
Slew motor; specifications_{17-45}.....51
Slew motor; specifications_{17-27}.....52
Slewing ring; tightening torques .....53
Frame; technical data.....54
Drive gear; tightening torque.....55
Top track roller; tightening torque.....56
Bottom track roller; tightening torque.....57
Cab; specifications.....58
Hydraulic system; specifications_{14-48}.....59
Hydraulic system; specifications_{14-30}.....60
Hydraulic tank; specifications.....61
Hydraulic cylinder specifications.....62
Bucket; specifications.....63
Hammer; specification.....64
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION.....65
Transporting and lifting the machine.....66
07 - STANDARD TIME.....69
Operation numbers for additional work.....70
08 - TOOL.....72
Infrared Thermometer.....73
09 - MISCELLANEOUS.....77
Service positions.....78
Service position 2.....80
Service position 3.....81
Hydraulic cylinders; dieseling.....82
1 - STANDARD PARTS; SERVICE.....84
16 - LUBRICANT; FUEL; OTHER FLUID.....85
Lubricants; specifications.....86
Alternative fuels.....88
17 - SERVICE.....91
Service and maintenance.....92
Cleaning of the machine.....94
Paint and Finish.....95
Service points.....96
Engine; changing oil and filter.....98
Fuel level; checking.....102
Fuel filter; replacing-.....103
Fuel line; water separator; check and drain.....105
Engine; air cleaner maintenance.....107
Cooling system; maintenance.....109
Coolant; changing.....111
Fan belt and_or alternator belt; checking and adjusting tension.....114
Fan belt and_or alternator belt; replacing.....116
Track tension; checking.....118
Track tension; adjusting.....119
Checking the hydraulic oil level.....121
Hydraulic oil tank; changing oil.....123
Hydraulic oil filter; replacing.....126
Cleaning the oil cooler.....128
Periodic maintenance.....129
Measuring condition.....136
Cylinder speed.....137
Travel Speed.....140
Towing; measures.....142
Starting engine with booster cables.....143
19 - GENERAL.....145
Safety concerns everybody!.....146
General precautions.....148
Preparations for work.....151
Safety measures during operation.....154
Move and operate machine safely.....159
2 - ENGINE WITH MOUNTING AND EQUIPMENT.....161
20 - GENERAL.....162
Engine; description_{44-41}.....163
Engine; description_{44-21}.....164
Precautions.....167
Periodic maintenance chart.....168
Periodic inspection and maintenance procedure.....170
Troubleshooting chart.....204
Maintenance standards.....210
Tightening torque.....214
21 - ENGINE.....216
Engine; specifications_{41-18}.....217
Engine; specifications_{41-00}.....218
Compression pressure inspection.....219
Adjusting operation.....222
Engine; removing.....223
Engine; installing.....231
Cylinder head; description-48.....239
Cylinder head; description.....240
Valve cover; description and operation.....241
Exploded view; cylinder head.....244
Cylinder head; disassembly_assembly.....247
Cylinder head; parts inspection and measurement.....252
Cylinder block; description.....261
Exploded view; cylinder block.....263
Cylinder block; disassembly and assembly.....265
Cylinder block; parts inspection and measurement.....272
Pistons; description.....284
Valve mechanism; description.....287
Timing gear; description.....289
Camshaft; description.....291
Gear train and camshaft; description.....293
Gear train and camshaft; disassembly and assembly.....296
Gear train and camshaft; parts inspection and measurement.....300
Crankshaft; description.....304
Engine; changing oil and filter.....306
Engine mounting.....310
Engine mounts; removing.....312
Engine mounts; replacing.....315
22 - LUBRICATING SYSTEM.....318
Lubricating system; description.....319
Lubrication system; disassembly and assembly.....321
Lubrication system; parts inspection and measurement.....323
Oil pump; description.....325
23 - FUEL SYSTEM.....327
Fuel system; specifications.....328
Fuel system; description.....329
Fuel; recommendation.....331
Fuel injection pump; specifications.....332
Fuel injection pump; description.....333
Fuel injection pump; disassembly and assembly.....335
Adjustment of fuel injection pump.....339
Fuel injection nozzle.....340
Fuel pump; description.....343
Fuel pump; removing.....344
Fuel pump; installing.....347
Fuel filter; description.....349
Fuel filter; replacing.....350
Fuel tank; description.....352
Fuel level; checking.....355
Fuel tank; removing.....356
Fuel tank; installing.....359
Fuel lines; description.....361
Fuel filter_water separator; description.....363
Fuel line; water separator; check and drain.....364
Idling speed; checking and adjusting.....366
Injectors; description.....368
25 - INLET & EXHAUST SYSTEM.....370
Intake and exhaust system; description.....371
Exhaust system; description.....373
Silencer; removing.....375
Silencer; installing.....377
Air cleaner; description.....379
Engine; air cleaner maintenance.....380
Air cleaner; removing.....382
Air cleaner; installing.....384
26 - COOLING SYSTEM.....386
Cooling system; description.....387
Coolant; changing.....389
Cooling system; disassembly_assembly.....392
Cooling system; maintenance.....394
Cooling system; flushing.....396
Cooling system; specifications.....399
Radiator; removing.....400
Radiator; installing.....403
Coolant pump; removing.....406
Coolant pump; installing.....409
Thermostat; replacing.....411
Fan belt and_or alternator belt; checking and adjusting tension.....415
Fan belt and_or alternator belt; replacing.....417
27 - ENGINE CONTROL.....419
Cold start device; description.....420
Auto idling device; description.....422
Automatic idling device; removing.....424
Automatic idling device; installing.....426
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....428
30 - GENERAL.....429
Troubleshooting guide_{53-37}.....430
Troubleshooting guide_{53-19}.....432
Electrical system; specifications.....434
31 - BATTERY.....435
Battery; description.....436
Battery; specification.....438
Battery condition; checking.....439
Batteries; replacing.....443
32 - ALTERNATOR; CHARGE REGULATOR.....445
Alternator; specifications.....446
Alternator; description.....447
Alternator; removing.....449
Alternator; installing.....450
Alternator; inspection.....452
35 - LIGHTING.....453
Starter motor; specifications.....454
Starter motor; description.....455
Starter motor; removing.....457
Starter motor; installing.....459
36 - OTHER ELECTRICAL EQUIPMENT.....461
Instrument control unit I-ECU; description.....462
Vehicle control unit V-ECU; description_{45-13}.....464
Vehicle control unit V-ECU; description_{44-52}.....467
Antitheft device; first activation of a new A-ECU.....470
V-ECU; replacing.....472
Option anti-theft; instruction.....474
37 - CABLE; FUSE; RELAY.....478
Electrical symbols and designation.....479
Cable and component marking explanations.....481
Components list_{41-10}.....483
Components list_{40-50}.....488
Wiring diagram; general_{40-15}.....493
Wiring diagram; general_{39-57}.....494
Wiring diagram; cab and accessories.....498
Wiring diagram; engine part.....501
Wiring diagram; electronic system.....506
Wiring diagram; working lights.....511
Wiring diagram; hydraulic system.....514
Wiring diagram; safety and service.....518
Wiring diagram 1.....521
Wiring diagram 2.....524
Wiring diagram 3.....527
Wiring diagram 4.....530
Wiring diagram 5.....533
Wiring diagram 6.....536
Wiring diagram 7.....539
Wiring diagram 8.....542
Wiring diagram 9.....545
Relays and fuses in engine compartment_{32-42}.....548
Relays and fuses in engine compartment_{32-22}.....551
Fuse box; description.....554
Fuse box; specifications.....556
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....557
Instrument panel; description.....558
Instrument panel; specifications.....560
Instrument panel; operation.....561
Instrument panel; electrical circuit.....563
Instrument console; removing .....566
Instrument console; installing .....568
39 - MISCELLANEOUS.....571
CareTrack W-ECU; description.....572
4 - POWER TRANSMISSION.....573
40 - GENERAL.....574
General notes to be observe when working on power transmission assemblies.....575
Track motor; specifications_{24-36}.....577
Track motor; specifications_{24-18}.....578
Fuel; lubricant and filling capacities.....579
44 - HYDROSTATIC DRIVE.....580
Track tension; adjusting.....581
Slew motor; specifications_{22-42}.....583
Slew motor; specifications_{22-25}.....584
Slew motor; description_{21-53}.....585
Slew motor; description_{21-32}.....592
Swing motor; removing_{21-02}.....595
Swing motor; removing_{20-42}.....598
Swing motor; installing_{20-12}.....601
Swing motor; installing_{19-52}.....604
Travel motor; description.....607
Removing the travel motor.....615
Assembling the travel motor.....618
Travel motor; exploded view.....621
Automatic kick-down.....623
Travel gear; dismantling.....625
Travel gear; mounting.....634
Gear motor; exploded view.....645
Swing motor; replacing counterbalance valve.....647
Slew motor; break release valve.....650
Travel lever throttle cable; adjusting.....651
Swivel joint; description.....653
Hydraulic swivel joint; removing.....655
Hydraulic swivel joint; installing.....657
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....658
71 - FRAME.....659
Frame; technical data.....660
Slewing ring; tightening torques.....661
Counterweight; description.....662
Counterweight; removing.....664
Counterweight; installing.....667
Undercarriage; description.....670
Removing the superstructure.....671
Assembling the superstructure.....673
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....674
Drive gear; tightening torque.....675
Top track roller; tightening torque.....676
Bottom track roller; tightening torque.....677
Removing the guide sprocket .....678
Assembling the guide sprocket .....680
Removing the guide sprocket.....682
Sprocket; measurement of wear.....683
Assembling the guide sprocket.....684
Adjusting the Track Tension.....685
Removing the crawler tracks.....687
Assembling the crawler track.....689
Removing the rubber track.....691
Assembling the rubber track.....693
Removing the top roller.....694
Assembling the top roller.....695
Removing the track roller.....696
Assembling the track roller.....698
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....699
81 - CAB; NAKED; CANOPY.....700
Cab; specifications.....701
Cab; description.....702
Cab; removing.....704
Cab; installing.....706
82 - ENGINE HOOD; MUDGUARD; FOOT STEP.....708
Engine hood; removing.....709
Engine hood; installing.....711
83 - DOORS; HATCH; COVER PLATE; (all).....713
Door; replacing.....714
Cab door; changing door catch.....715
85 - CAB INTERIOR; UPHOLSTERY.....718
Operator's seat; removing.....719
Operator's seat; installing.....721
87 - AIR CONDITIONING UNIT.....723
Heater core; replacing.....724
88 - INTERIOR EQUIPMENT.....727
Instrument console; removing.....728
Instrument console; installing.....730
Seat safety belt; replacing.....733
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....735
90 - GENERAL.....736
Hydraulic diagram; component list-01.....738
Hydraulic diagram; component list-02.....739
Hydraulic diagram; component list-03.....740
Hydraulic diagram; component list-04.....741
Hydraulic diagram; component list-05.....742
Hydraulic diagram; component list-06.....743
Hydraulic diagram; component list-07.....744
Hydraulic diagram; component list-08.....745
Hydraulic diagram; component list-09.....746
Hydraulic diagram; component list-10.....747
Hydraulic diagram; complete_{43-28}.....748
This information is not valid for serial number range_{43-08}.....751
Hydraulic diagram 1.....752
Hydraulic diagram 2.....755
Hydraulic diagram 3.....758
Hydraulic diagram 4.....761
Hydraulic diagram 5.....764
Hydraulic diagram 6.....767
Hydraulic diagram 7.....770
Hydraulic diagram 8.....773
Hydraulic diagram 9.....776
Hydraulic diagram 10.....779
Hydraulic circuit (EU)_{38-39}.....782
Hydraulic circuit (EU)_{38-21}.....786
Hydraulic circuit (US).....789
Hydraulic diagram; swing system_{37-28}.....792
This information is not valid for serial number range_{37-08}.....794
Hydraulic circuit; slewing gear and offset.....795
Hydraulic circuit; boom.....797
Hydraulic diagram; control pattern selector valve.....799
Hydraulic circuit; accessories.....802
Hydraulic circuit; bucket.....804
Hydraulic circuit; dozer blade.....806
Hydraulic circuit; dipper arm.....808
Hydraulic circuit; travel motors.....811
Hydraulic system; specifications_{33-32}.....813
Hydraulic system; specifications_{33-14}.....814
Hydraulic cylinder specifications.....815
Hydraulic oil; description.....816
Hydraulic oil; storage and handling.....817
Hydraulic components; storing and transporting.....818
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....819
Hydraulic tank; specifications.....820
Hydraulic tank; description.....821
Hydraulic oil tank; removing.....823
Hydraulic oil tank; installing.....826
Checking the hydraulic oil level.....829
Hydraulic oil tank; changing oil.....831
Return line filter - description and operation.....834
Hydraulic oil filter; replacing.....837
Hydraulic oil cooler; description.....839
Hydraulic oil cooler; removing.....842
Hydraulic oil cooler; installing.....844
Cleaning the oil cooler.....846
Shuttle valve; swing brake.....847
Main control valve; description.....850
Main control valve; removing.....852
Main control valve; installing.....856
Hose rupture valve on boom cylinder.....859
Hose rupture valve on dipper arm cylinder.....860
Balancing valve on offset cylinder.....861
Tests and adjustments of the power control.....863
Pilot pressure; checking and adjusting.....866
Stand-by pressure.....869
FR pressure control valve; checking and adjusting.....871
LS pressure relief valve; checking and adjusting.....873
Adjustment of secondary valves.....875
Hydraulic pump; description.....876
Hydraulic pump; replacing.....878
92 - MECHANICAL EQUIPMENT_ATTACHMENT.....884
Boom support; pivot play.....885
Hammer; specification.....890
97 - UNIT; DIGGING.....891
Bucket; specifications.....892
Bucket cylinder; removing.....893
Bucket cylinder; installing.....896
Volvo ECR38 Compact Excavators Service Repair Manual
