Volvo ECR40D Compact Excavators Service Repair Manual
Complete repair service manual with electrical wiring diagrams for Volvo ECR40D Compact Excavators, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo ECR40D 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.
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
Volvo ECR40D Compact Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,301
File Format: PDF
TABLE OF CONTENTS
000 - Foreword.....2
000 - GENERAL.....3
00 - DESCRIPTION; COMPLETE MACHINE.....4
Component locations.....5
Description, general.....6
Product plate, description.....8
03 - SPECIFICATIONS.....10
Capacities.....11
Conversion tables.....12
Lifting capacities.....17
Tightening torques-[0748].....18
Weight.....27
07 - STANDARD TIME.....28
Operation numbers for additional work.....29
08 - TOOL.....31
Infrared Thermometer.....32
09 - MISCELLANEOUS.....36
Hydraulic cylinders, dieseling.....37
Welding on the machine.....39
001 - STANDARD PARTS, SERVICE.....40
16 - LUBRICANT; FUEL; OTHER FLUID.....41
Alternative fuels.....42
Coolant.....45
Fuel, recommendation.....47
Lubricants, specifications.....48
17 - SERVICE.....51
Air inlet hose, checking.....54
Arrival Inspection, according to Inspection Programme.....55
Attachment quick coupler, checking.....56
Cab main filter, replacing.....57
Cleaning prior to repair.....59
Cleanliness, braking and hydraulic system.....60
Coolant freezing point, checking.....61
Coolant level, checking.....63
Coolant, changing-[5523].....65
Crankcase ventilation separator, checking.....68
Creeping of hydraulic cylinder.....70
Cylinder speed.....72
Delivery Inspection, according to Inspection Programme.....76
Deviation when travelling straight ahead.....77
Engine air cleaner primary filter, cleaning.....80
Engine air cleaner primary filter, replacing.....83
Engine air cleaner secondary filter, replacing.....86
Engine oil and filter, changing.....88
Engine oil level, checking.....91
Exhaust manifold, checking.....93
Fan_alternator belt, checking.....94
Fuel filter, replacing.....96
Fuel hoses, checking.....98
Fuel injectors, checking.....99
Hydraulic hoses, checking.....108
Hydraulic oil level, checking.....109
Hydraulic oil return filter, replacing.....111
Hydraulic oil, changing.....113
Hydraulic pressure, checking.....116
Hydraulic system, pressure release.....120
Injection pump, checking.....122
Injection timing, checking-[5202].....128
Leakage oil filter element, replacing.....134
Lubrication and service schedules.....136
Lubrication.....139
Machine condition, checking.....141
Maintenance of Stored Machines, according to Inspection Programme.....142
Maintenance service, daily.....143
Maintenance service, every 1000 hours.....145
Maintenance service, every 1500 hours.....149
Maintenance service, every 2000 hours.....150
Maintenance service, every 250 hours.....152
Maintenance service, every 3000 hours.....155
Maintenance service, every 50 hours.....157
Maintenance service, every 500 hours.....159
Maintenance service, first 50 hours.....162
Measuring condition.....164
Radiator and hydraulic oil cooler, cleaning.....165
Radiator hoses, checking.....167
Repairing hydraulic system.....169
Seat belt, replacing.....170
Service and maintenance.....173
Service position 1-[0038].....175
Service position 2-[0018].....176
Service position 3-[5956].....178
Service.....180
Slewing speed.....183
Starting with booster batteries-[3007].....185
Test running and checking.....187
Thumb pivot pin, lubricating.....188
Towing, measures.....190
Track running speed.....192
Track tension and condition, checking.....194
Travel Speed.....197
Travel gearbox oil level, checking.....199
Travel gearbox oil, changing.....201
Values, creeping of hydraulic cylinder.....203
Values, cylinder speed.....204
Values, deviation when travelling straight ahead.....205
Values, slewing speed.....206
Values, track running speed.....207
Values, travel speed.....208
Valves, adjusting-[5551].....209
Water separator, checking.....213
Water separator, cleaning.....215
19 - GENERAL.....217
CE marking and declaration of conformity.....218
Checklist after a fire or heat exposure.....220
Decontamination.....221
Environmental handling for the future.....222
Environmentally hazardous fluids.....224
Environmentally safe handling.....225
Fire prevention measures.....227
Health hazards with paint, plastics and rubber.....230
Pressure setting and leak detection.....232
Safety concerns everybody!.....233
Safety for work on hydraulic systems.....235
Safety rules when servicing.....237
Safety when handling oils and fuel.....240
Safety when handling the machine.....241
Safety when lifting and supporting the machine.....246
Safety when working with air conditioning refrigerant.....248
Safety when working with batteries.....251
Service position 1.....254
Service position 2.....256
Service position 3.....258
Starting with booster batteries.....260
Waste handling.....262
Working in environmentally contaminated areas.....266
Working on the electrical system of the machine.....269
002 - ENGINE WITH MOUNTING AND EQUIPMENT.....271
20 - GENERAL.....272
Engine, capacities.....273
Engine, description.....274
Engine, tighten torques_{08-19-30}.....277
Engine, tighten torques_{08-19-42}.....279
Troubleshooting chart.....281
21 - ENGINE.....284
Crankshaft front oil seal, replacing.....285
Crankshaft rear oil seal, replacing.....291
Crankshaft, description.....295
Cylinder head, description.....297
Cylinder head, installing.....299
Cylinder head, removing.....305
Engine mounts, replacing.....311
Engine, installing.....313
Engine, removing.....319
Engine, specifications_{08-18-07}.....326
Engine, specifications_{08-18-18}.....328
Engine, specifications_{08-18-30}.....329
Engine, specifications_{08-18-42}.....331
Oil sump, replacing.....332
Timing gear case new gasket, installing.....334
Valve cover, installing.....347
Valve cover, removing.....349
Valve mechanism, description.....351
Valve system specifications.....353
Valves, adjusting.....354
22 - LUBRICATING SYSTEM.....359
Lubricating system, description.....360
Lubrication oil pressure, checking with pressure gauge.....363
Lubrication system, component locations.....366
Lubrication system, specifications.....368
Lubrication system, tightening torques.....369
Oil pump, description.....370
Oil pump, replacing.....371
23 - FUEL SYSTEM.....375
Fuel feed pump, description.....376
Fuel feed pump, specifications.....377
Fuel filter_water separator, description.....378
Fuel pipes, replacing.....379
Fuel pump, installing.....386
Fuel pump, removing.....388
Fuel system, description.....391
Fuel system, general specifications_{08-07-03}.....393
Fuel system, general specifications_{08-07-15}.....394
Fuel tank, description.....395
Fuel tank, installing.....396
Fuel tank, removing.....399
Fuel tank, specifications.....403
Idling speed, checking and adjusting.....404
Injection pump gasket shims, description.....407
Injection pump, description.....409
Injection pump, fitting incl setting injection timing.....412
Injection pump, removing.....417
Injection timing, checking.....420
Injectors, checking.....425
Injectors, description.....428
Injectors, replacing.....430
Injectors, specification.....433
25 - INLET & EXHAUST SYSTEM.....434
Air cleaner, description.....435
Air cleaner, installing.....437
Air cleaner, primary filter replacing.....438
Air cleaner, removing.....441
Air cleaner, secondary filter replacing.....443
Air cleaner, specification.....445
Exhaust pipe, replacing.....446
Intake and exhaust system, description.....449
Silencer, installing.....451
Silencer, removing.....454
26 - COOLING SYSTEM.....457
Coolant anti-freeze resistance, checking.....458
Coolant pump, replacing.....460
Coolant, changing.....464
Cooling system, description.....467
Cooling system, specification.....469
Expansion tank, installing.....470
Expansion tank, removing.....471
Fan belt and_or alternator belt, checking and adjusting tension.....473
Fan belt and_or alternator belt, replacing.....476
Radiator hoses all, replacing.....479
Radiator, installing.....481
Radiator, removing.....482
Thermostat, replacing.....483
27 - ENGINE CONTROL.....485
Auto idling device, description.....486
Automatic idling device, installing.....488
Automatic idling device, removing.....490
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....492
30 - GENERAL.....493
11 666 140 Multimeter.....496
8883 0028 Adapter cable.....497
88890040 Oscilloscope for VCADS Pro.....498
999 0062 Extension cable.....499
999 3894 Template.....500
999 8699 Multi-pin breaker box.....501
AL3201, description and measuring.....502
BA3101, description and measuring.....505
CU2504, description and measuring.....507
Checking electrical cabling and connectors.....510
Collection of basic data.....515
Communication with data buses.....517
Component descriptions.....519
Component troubleshooting, checking component.....522
Component troubleshooting, checking subsystem (circuit).....524
Component troubleshooting, checking wiring harness and input_output on ECU.....526
Component troubleshooting, structure, description.....528
Conditions when checking.....530
Connecting special tools.....535
DC current measurement.....538
DC voltage measurement.....542
Data buses, function.....545
Data links, fault tracing with Oscilloscope.....551
Diode check procedure.....561
Electrical cables and connectors, checking.....564
Electrical system, special instructions for servicing, electronic components_{07-46-53}.....569
Electrical system, special instructions for servicing, electronic components_{07-47-05}.....571
Electrical system, special instructions for servicing, electronic components_{07-47-20}.....572
Electrical system, special instructions for servicing, general.....574
Electronic control system, description.....576
Error code information, description.....578
Error code information, general.....580
Error codes, build-up-[4100].....582
Error codes, build-up.....587
FX1056, description and measuring.....591
FX1057, description and measuring.....593
General fault diagnosis information.....595
Information display, check.....596
Lead and connector checks.....597
MA2307, description and measuring.....603
MA4228, description and measuring.....605
MA8704, description and measuring.....607
MA9109, description and measuring.....609
MA9186, description and measuring.....611
Measuring components.....613
Measuring symbols, description.....614
Measuring, general.....617
RE3301, description and measuring.....618
Resistance measurement.....620
SAE J1708_1587 Information link, description and measuring.....623
SAE J1939_CAN control link, description and measuring.....625
SAE J1939_CAN2 Control link, description and measuring.....628
SE8702, description and measuring.....631
Service connection and programming connection.....634
Software parameters, description.....636
Special tools for troubleshooting.....639
Tech Tool, operations.....640
Troubleshooting strategy.....641
Troubleshooting tips.....643
Troubleshooting tools.....645
Troubleshooting, assistant devices.....646
Troubleshooting, general.....648
VCADS Pro service tool.....650
VCADS Pro, connecting problems.....654
31 - BATTERY.....657
Batteries, replacing.....658
Battery condition, checking.....661
Battery, description.....665
Battery, specifications.....666
32 - ALTERNATOR; CHARGE REGULATOR.....667
Alternator, installing.....668
Alternator, removing.....671
Alternator, specifications.....674
33 - STARTING SYSTEM.....675
Glow plug, installing.....676
Glow plug, removing.....678
Glow plugs, testing.....680
Preheating, specifications_{07-01-16}.....681
Preheating, specifications_{07-01-28}.....682
Starter motor, installing.....683
Starter motor, removing.....685
Starter motor, specification.....687
35 - LIGHTING.....688
Light bulb, replacing.....689
Light bulbs, specification.....693
36 - OTHER ELECTRICAL EQUIPMENT.....694
Horn, replacing.....695
I-ECU, replacing.....698
Instrument control unit I-ECU, functional description.....700
Theft protection.....702
Travel alarm, replacing.....703
V-ECU, replacing.....705
Vehicle control unit V-ECU, functional description.....707
37 - CABLE; FUSE; RELAY.....708
Antennas (Caretrack), component locations.....711
Cable and component marking explanations.....712
Cables, description.....714
Component list Alternator, batteries, capacitors, electronic units, voltage outlet_{06-54-39}.....715
Component list Alternator, batteries, capacitors, electronic units, voltage outlet_{06-54-51}.....716
Component list Fuses_{06-53-41}.....718
Component list Fuses_{06-53-52}.....720
Component list Motors, resistors, monitoring system_{06-53-00}.....722
Component list Motors, resistors, monitoring system_{06-53-10}.....723
Component list Relays_{06-52-28}.....724
Component list Relays_{06-52-39}.....725
Component list Solenoid valves_{06-51-25}.....726
Component list Solenoid valves_{06-51-37}.....727
Component list Switches_{06-50-28}.....728
Component list Switches_{06-50-39}.....729
Component list, Antennas (Care Track)_{06-54-10}.....730
Component list, Antennas (Care Track)_{06-54-22}.....731
Component list, Heating coils.....732
Component list, Sounders_{06-50-57}.....733
Component list, Sounders_{06-51-08}.....734
Component list, sensors_{06-51-54}.....735
Component list, sensors_{06-52-05}.....736
Component location, alternator, batteries, capacitors, electronic units, voltage outlet_{06-39-53}.....737
Component location, alternator, batteries, capacitors, electronic units, voltage outlet_{06-40-05}.....739
Component location, fuses_{06-39-21}.....741
Component location, fuses_{06-39-33}.....742
Component location, motors_{06-38-50}.....743
Component location, motors_{06-39-03}.....744
Component location, relays_{06-38-19}.....746
Component location, relays_{06-38-31}.....747
Component location, sensors_{06-37-47}.....749
Component location, sensors_{06-37-59}.....751
Component location, solenoid valves_{06-37-12}.....753
Component location, solenoid valves_{06-37-27}.....755
Component location, switches_{06-36-36}.....758
Component location, switches_{06-36-49}.....760
Electrical distribution box, circuit board replacing.....762
Electrical distribution box.....764
Electrical symbols and designation.....765
Electrical system component locations.....767
Explanation of wiring diagrams.....768
I-ECU, I_O list_{06-50-00}.....772
I-ECU, I_O list_{06-50-11}.....773
K-ECU, I_O list.....775
V-ECU, I_O list.....776
Wiring diagram 10_{06-43-56}.....778
Wiring diagram 10_{06-44-09}.....781
Wiring diagram 11_{06-43-23}.....784
Wiring diagram 11_{06-43-37}.....786
Wiring diagram 12_{06-42-40}.....788
Wiring diagram 12_{06-42-53}.....790
Wiring diagram 13.....792
Wiring diagram 14.....794
Wiring diagram 15.....796
Wiring diagram 1_{06-48-55}.....798
Wiring diagram 1_{06-49-06}.....799
Wiring diagram 2_{06-48-24}.....800
Wiring diagram 2_{06-48-38}.....803
Wiring diagram 3_{06-47-51}.....806
Wiring diagram 3_{06-48-04}.....809
Wiring diagram 4_{06-47-18}.....811
Wiring diagram 4_{06-47-32}.....814
Wiring diagram 5_{06-46-45}.....816
Wiring diagram 5_{06-46-59}.....818
Wiring diagram 6_{06-46-06}.....820
Wiring diagram 6_{06-46-20}.....823
Wiring diagram 7_{06-45-33}.....826
Wiring diagram 7_{06-45-46}.....828
Wiring diagram 8_{06-45-01}.....830
Wiring diagram 8_{06-45-14}.....832
Wiring diagram 9_{06-44-28}.....834
Wiring diagram 9_{06-44-41}.....836
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....838
Keypad, description.....839
Service mode.....842
39 - MISCELLANEOUS.....849
CareTrack W-ECU, description.....850
CareTrack system, description.....854
W-ECU, MID142, changing non-programmed ECU_{06-34-06}.....856
W-ECU, MID142, changing non-programmed ECU_{06-34-19}.....859
W-ECU, MID142, changing pre-programmed ECU_{06-33-33}.....861
W-ECU, MID142, changing pre-programmed ECU_{06-33-46}.....864
004 - POWER TRANSMISSION.....866
40 - GENERAL.....867
General notes to be observe when working on power transmission assemblies.....868
Power transmission, description.....870
44 - HYDROSTATIC DRIVE.....871
Centre passage, description.....872
Centre passage, installing.....875
Centre passage, removing.....879
Swing motor, description.....883
Swing motor, installing.....888
Swing motor, removing.....891
Swing motor, specifications.....894
Track motor, installing.....895
Track motor, removing.....899
Track motor, specifications.....903
Track motor, tightening torques.....904
Travel motor, description.....905
Travel motor, exploded view.....911
49 - MISCELLANEOUS.....913
Swing ring gear, description.....914
Swing ring, installing.....916
Swing ring, removing.....920
Tightening torques.....925
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....926
70 - GENERAL.....927
Frame and track unit, specifications.....928
Frame, tightening torque.....929
71 - FRAME.....930
Additional counterweight, description.....931
Additional counterweight, installing.....932
Additional counterweight, removing.....934
Counterweight, description.....936
Counterweight, installing.....938
Counterweight, removing.....941
Counterweight, specifications.....945
Undercarriage, description.....946
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....947
Bottom roller, installing.....948
Bottom roller, removing.....950
Front idler, installing.....952
Front idler, removing.....954
Rubber track, installing.....956
Rubber track, removing.....957
Sprocket, removing.....960
Top roller, installing.....961
Top roller, removing.....964
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....967
81 - CAB, NAKED; CANOPY.....968
Cab platform, installing.....969
Cab platform, removing.....977
Cab, installing.....984
Cab, position 1, restoring.....988
Cab, position 1.....991
Cab, removing.....994
Cab, roof panel, installing.....998
Cab, roof panel, removing.....1000
Cab, tightening torques.....1002
Cab, weight.....1003
82 - ENGINE HOOD; MUDGUARD; FOOT STEP.....1004
Engine hood, changing gas spring.....1005
Engine hood, replacing.....1007
85 - CAB INTERIOR; UPHOLSTERY.....1009
Operator's seat, installing.....1010
Operator's seat, removing.....1012
87 - AIR CONDITIONING UNIT.....1014
Air conditioning unit, specifications.....1015
Cooling unit, performance test.....1017
88 - INTERIOR EQUIPMENT.....1023
Seat safety belt, replacing.....1024
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....1027
90 - GENERAL.....1028
Cleanliness when working on hydraulic components.....1029
General notes when working on hydraulic system.....1030
Hydraulic components, storing and transporting.....1032
Hydraulic oil, storage and handling.....1033
Hydraulic system, description.....1034
Hydraulic system, repair of hydraulic components in workshop.....1038
Hydraulic system, specification.....1039
Hydraulic system, tightening torques.....1040
Pressure adjustment and leaks checking.....1041
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....1042
Accumulator, description.....1044
Accumulator, replacing.....1045
Control levers, maintenance standard.....1047
Control levers, repairing.....1049
Control pattern selector valve, description.....1057
Control pattern selector valve, installing.....1061
Control pattern selector valve, removing.....1062
Control valve, tightening torques.....1064
Explanations to hydraulic diagram.....1066
FR pressure control valve, checking and adjusting.....1073
Hose rupture valve, installing.....1076
Hose rupture valves.....1078
Hydraulic diagram, X1 line.....1080
Hydraulic diagram, complete_{06-07-34}.....1085
Hydraulic diagram, complete_{06-07-47}.....1088
Hydraulic diagram, control pattern selector valve.....1091
Hydraulic diagram, schematic.....1094
Hydraulic oil cooler, description.....1096
Hydraulic oil cooler, installing.....1097
Hydraulic oil cooler, removing.....1099
Hydraulic oil tank, installing.....1101
Hydraulic oil tank, removing.....1104
Hydraulic pump, description.....1107
Hydraulic pump, power control, adjusting.....1122
Hydraulic pump, power control, checking.....1125
Hydraulic pump, standby pressure, checking and adjusting.....1131
Hydraulic tank, specifications.....1134
LR pressure relief valve, checking and adjusting.....1135
LS (load sense) pressure, checking.....1139
LS system, bleeding.....1142
LS-pressure relief valve, replacing.....1144
Left control lever, installing.....1147
Left control lever, removing.....1150
Main control valve, assembling.....1153
Main control valve, description.....1157
Main control valve, disassembling.....1160
Main control valve, installing.....1163
Main control valve, removing.....1166
Port relief valve pressure, checking and adjusting.....1170
Pump, installing.....1173
Pump, removing.....1176
Pump, specifications_{06-01-05}.....1178
Pump, specifications_{06-01-16}.....1180
Pump, troubleshooting.....1182
Right control lever, installing.....1184
Right control lever, removing.....1187
Secondary pressure limiting valve, replacing.....1190
Servo pressure, checking and adjusting.....1194
Servo valve, installing.....1197
Servo valve, removing.....1200
Tiltrotator control system, description.....1202
Tiltrotator display main menu.....1210
Tiltrotator, specifications.....1220
Travel valve (pedal), installing.....1221
Travel valve (pedal), removing.....1223
Working pressure, checking and adjusting.....1226
92 - MECHANICAL EQUIPMENT_ATTACHMENT.....1229
Boom support, pivot play.....1230
Quickfit, function check.....1235
Steelwrist quick coupler.....1237
Thumb kit, description.....1242
97 - UNIT, DIGGING.....1244
Adjustable boom cylinder, specifications.....1245
Boom cylinder, installing.....1246
Boom cylinder, removing.....1250
Boom lifting cylinder, specifications.....1254
Boom, installing.....1255
Boom, removing.....1262
Bucket cylinder, installing.....1269
Bucket cylinder, removing.....1273
Bucket cylinder, specifications.....1277
Dipper arm cylinder, installing.....1278
Dipper arm cylinder, removing.....1282
Dipper arm cylinder, specifications.....1286
Dipper arm, installing.....1287
Dipper arm, removing.....1291
Dozer blade cylinder, specifications.....1296
98 - FUNCTION FOR ROAD CONSTRUCTION.....1297
Dozer blade cylinder, replacing.....1298
Volvo ECR40D Compact Excavators Service Repair Manual
