Volvo EC15E Compact Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EC15E Compact Excavators, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo Constructions EC15E 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.
PRODUCT DETAILS:
Total Pages: 997 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo EC15E Compact Excavators Service Repair Manual.pdf
MAIN SECTIONS
0 - Foreword.....2
0 - GENERAL.....3
00 - DESCRIPTION; COMPLETE MACHINE.....4
Component locations .....5
Description, general .....7
Product plate, description.....9
03 - SPECIFICATIONS.....11
Conversion tables.....12
Lifting capacities.....17
Tightening torques .....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
1 - 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.....65
Crankcase ventilation separator, checking.....70
Creeping of hydraulic cylinder.....72
Cylinder speed.....74
Delivery Inspection, according to Inspection Programme.....78
Deviation when travelling straight ahead.....79
Engine air cleaner primary filter, cleaning.....82
Engine air cleaner primary filter, replacing.....85
Engine air cleaner secondary filter, replacing.....88
Engine oil and filter, changing.....89
Engine oil level, checking.....92
Exhaust manifold, checking.....94
Fan_alternator belt, checking.....95
Fuel filter, replacing.....97
Fuel hoses, checking.....99
Fuel injectors, checking.....100
Hydraulic hoses, checking.....106
Hydraulic oil level, checking.....107
Hydraulic oil return filter, replacing.....109
Hydraulic oil, changing.....111
Hydraulic pressure, checking.....115
Hydraulic system, pressure release.....119
Injection pump, checking.....121
Injection timing, checking.....128
Leakage oil filter element, replacing.....137
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.....151
Maintenance service, every 250 hours.....153
Maintenance service, every 3000 hours.....156
Maintenance service, every 50 hours.....158
Maintenance service, every 500 hours.....160
Maintenance service, first 50 hours.....164
Measuring condition.....166
Radiator and hydraulic oil cooler, cleaning.....167
Radiator hoses, checking.....169
Repairing hydraulic system.....171
Seat belt, replacing .....172
Service and maintenance.....175
Service position 1 .....177
Service position 2 .....178
Service position 3 .....180
Service.....182
Slewing speed.....185
Starting engine with booster cables.....187
Starting with booster batteries-[0811].....190
Test running and checking.....192
Towing, measures.....193
Track gearbox oil level, checking.....194
Track gearbox oil, changing.....196
Track running speed.....198
Track tension and condition, checking.....200
Travel Speed.....203
Values, creeping of hydraulic cylinder.....205
Values, cylinder speed.....206
Values, deviation when travelling straight ahead.....207
Values, slewing speed.....208
Values, track running speed.....209
Values, travel speed.....210
Valves, adjusting .....211
Water separator, checking.....220
19 - GENERAL.....222
CE marking and declaration of conformity.....223
Checklist after a fire or heat exposure.....225
Decontamination.....226
Environmental handling for the future.....227
Environmentally hazardous fluids.....229
Environmentally safe handling.....230
Fire prevention measures.....232
Health hazards with paint, plastics and rubber.....235
Pressure setting and leak detection.....237
Safety concerns everybody!.....238
Safety for work on hydraulic systems.....240
Safety rules when servicing.....242
Safety when handling oils and fuel.....245
Safety when handling the machine.....246
Safety when lifting and supporting the machine.....251
Safety when working with air conditioning refrigerant.....253
Safety when working with batteries.....256
Service position 1.....259
Service position 2.....261
Service position 3.....263
Starting with booster batteries.....265
Waste handling.....267
Working in environmentally contaminated areas.....271
Working on the electrical system of the machine.....274
2 - ENGINE WITH MOUNTING AND EQUIPMENT.....276
20 - GENERAL.....277
Component locations.....278
Engine trouble shooting.....280
Engine, capacities.....283
Engine, tighten torques.....284
21 - ENGINE.....286
Crankcase ventilation, description.....287
Crankshaft, description.....289
Cylinder compression, testing.....291
Cylinder head, description.....294
Engine mounts, replacing.....296
Engine, installing.....300
Engine, mounting in work stand.....307
Engine, removing.....309
Oil sump, replacing.....316
Pistons, description.....319
Timing gear, description.....321
Valve mechanism, description.....323
Valve mechanism, specifications.....325
Valves, adjusting.....326
22 - LUBRICATING SYSTEM.....328
Lubricating system, description.....329
Lubrication system, specifications.....332
23 - FUEL SYSTEM.....333
Fuel feed pump, description.....334
Fuel feed pump, specifications.....336
Fuel pump, installing.....337
Fuel pump, removing.....340
Fuel system, description.....344
Fuel system, general specifications.....347
Fuel system, tightening torques.....348
Fuel tank, description.....350
Fuel tank, installing.....352
Fuel tank, removing.....354
Fuel tank, specifications.....357
Idling speed, checking and adjusting.....358
Injection pump, replacing.....361
Injectors, checking.....366
Injectors, description.....368
Injectors, replacing.....370
Injectors, specification.....377
Injectors, tightening torques.....378
25 - INLET & EXHAUST SYSTEM.....380
Air cleaner, description.....381
Air cleaner, installing.....383
Air cleaner, removing.....385
Exhaust manifold, replacing.....387
Induction manifold gasket, replacing.....391
Intake and exhaust system, description.....394
Silencer, installing.....396
Silencer, removing.....398
26 - COOLING SYSTEM.....400
Coolant anti-freeze resistance, checking.....401
Coolant pump, replacing.....403
Cooling package, installing.....408
Cooling package, removing.....412
Cooling system, description.....416
Cooling system, specification.....420
Expansion tank, installing.....421
Expansion tank, removing.....422
Fan belt and_or alternator belt, replacing.....424
Radiator hose upper, replacing.....427
Radiator hoses lower, replacing.....430
Thermostat, inspecting.....433
Thermostat, replacing.....435
27 - ENGINE CONTROL.....439
Stop magnet, replacing.....440
Throttle control cable, installing.....441
Throttle control cable, removing.....444
Throttle controls, setting.....448
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....451
30 - GENERAL.....452
Checking electrical cabling and connectors.....453
Collection of basic data.....458
DC current measurement.....460
DC voltage measurement.....464
Diode check procedure.....468
Electrical system, special instructions for servicing, electronic components_{02-17-27}.....471
Electrical system, special instructions for servicing, electronic components_{02-17-50}.....473
Electrical system, special instructions for servicing, electronic components_{02-18-17}.....474
Electrical system, special instructions for servicing, general.....476
Measuring components.....478
Resistance measurement.....479
Troubleshooting tips.....483
Troubleshooting, assistant devices.....485
Troubleshooting, general.....487
31 - BATTERY.....488
Batteries, replacing.....489
Battery condition, checking.....493
Battery, specifications.....497
32 - ALTERNATOR; CHARGE REGULATOR.....498
Alternator, installing.....499
Alternator, removing.....501
Alternator, specifications.....504
33 - STARTING SYSTEM.....505
Glow plug, installing.....506
Glow plug, removing.....508
Glow plugs, testing.....510
Preheating, specifications.....511
Starter motor, replacing.....512
Starter motor, specification.....515
35 - LIGHTING.....516
Light bulb, replacing.....517
Light bulbs, specification.....522
36 - OTHER ELECTRICAL EQUIPMENT.....523
A-ECU (anti theft), replacing_{01-59-28}.....524
A-ECU (anti theft), replacing_{01-59-55}.....528
Antitheft device, first activation of a new A-ECU.....531
Horn, replacing.....534
I-ECU, replacing.....537
Switch, replacing.....541
Travel alarm, replacing.....545
Travel alarm, specifications.....548
V-ECU, replacing.....549
Windscreen wiper front motor, replacing.....552
37 - CABLE; FUSE; RELAY.....559
Cable and component marking explanations.....560
Cables, description.....563
CareTrack.....565
Component list Alternator, batteries, capacitors, electronic units, voltage outlet.....568
Component list Fuses.....570
Component list Heating coils, instruments, service socket.....574
Component list Lights.....575
Component list Relays.....577
Component list Solenoid valves.....579
Component list Switches.....581
Component list, Sounders.....583
Component list, diodes.....584
Component list, motors.....587
Component list, sensors.....588
Electrical distribution box, circuit board replacing.....590
Electrical symbols and designation.....594
Fuse, description.....597
Wiring diagram 1.....599
Wiring diagram 10.....600
Wiring diagram 11.....603
Wiring diagram 2.....606
Wiring diagram 3.....609
Wiring diagram 4.....612
Wiring diagram 5.....615
Wiring diagram 6.....618
Wiring diagram 7.....621
Wiring diagram 8.....624
Wiring diagram 9.....627
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....630
Instrument panel, description.....631
4 - POWER TRANSMISSION.....633
40 - GENERAL.....634
General notes to be observe when working on power transmission assemblies.....635
Power transmission, description.....637
44 - HYDROSTATIC DRIVE.....638
Center passage, description.....639
Centre passage, installing.....641
Centre passage, removing.....645
Swing motor, description.....650
Swing motor, installing.....656
Swing motor, removing.....659
Swing motor, specifications.....662
Track motor, installing.....663
Track motor, removing.....667
Track motor, tightening torques.....672
Travel motor, description.....673
Travel motor, specifications.....676
49 - MISCELLANEOUS.....677
Swing ring gear, description.....678
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....680
70 - GENERAL.....681
Frame and track unit, specifications.....682
71 - FRAME.....684
Counterweight, description.....685
Counterweight, replacing.....686
Counterweight, specifications.....690
Superstructure covering, description.....691
Undercarriage, description.....693
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....695
Bottom roller, installing.....696
Bottom roller, removing.....698
Chain guide, installing.....700
Chain guide, removing.....702
Front idler, installing.....705
Front idler, removing.....707
Rubber track, installing.....709
Rubber track, removing.....710
Sprocket, installing.....713
Sprocket, removing.....715
Track tension, adjusting.....717
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....719
81 - CAB, NAKED; CANOPY.....720
Cab platform, installing.....721
Cab platform, removing.....729
Cab, installing.....737
Cab, position 1, restoring.....741
Cab, position 1.....744
Cab, removing.....748
Cab, tightening torques.....753
Cab, weight.....754
82 - ENGINE HOOD; MUDGUARD; FOOT STEP.....755
Engine hood, replacing.....756
85 - CAB INTERIOR; UPHOLSTERY.....760
Operator's seat, installing.....761
Operator's seat, removing.....764
Seat belt, replacing.....767
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....768
90 - GENERAL.....769
General notes when working on hydraulic system.....770
Hydraulic components, storing and transporting.....773
Hydraulic oil, description.....774
Hydraulic oil, storage and handling.....775
Hydraulic system, description.....776
Hydraulic system, specification.....780
Pressure adjustment and leaks checking.....781
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....783
Accumulator, description.....785
Accumulator, discarding.....787
Anti-cavitation check valve, replacing.....789
Control lever, installing.....792
Control lever, removing.....797
Control levers, description.....802
Control levers, repairing.....807
Control pattern selector valve, description.....815
Control pattern selector valve, installing.....818
Control pattern selector valve, removing.....820
Control valve, tightening torques.....822
Explanations to hydraulic diagram.....823
Flow regulation valve, changing.....830
Flushing valve, replacing.....833
Hose rupture valve, installing.....837
Hose rupture valve, removing.....839
Hose rupture valves.....842
Hydraulic diagram, complete.....844
Hydraulic diagram, component locations.....847
Hydraulic oil cooler, description.....848
Hydraulic oil cooler, installing.....849
Hydraulic oil cooler, removing.....850
Hydraulic oil tank, installing.....851
Hydraulic oil tank, removing.....854
Hydraulic oil tank, tightening torques.....858
Hydraulic pump, power control, checking.....859
Hydraulic tank, specifications.....864
LS (load sense) pressure, checking.....865
LS-pressure relief valve, replacing.....868
Main control valve, assembling.....871
Main control valve, description.....874
Main control valve, disassembling.....876
Main control valve, installing.....879
Main control valve, removing.....881
Pump, installing.....884
Pump, removing.....886
Pump, specifications.....888
Secondary pressure limiting valve, replacing.....889
Servo accumulator, installing.....892
Servo accumulator, removing.....895
Servo pressure, checking and adjusting.....898
Servo valve, description.....901
Servo valve, installing.....903
Servo valve, removing.....905
Six way valve, offset_optional equipment.....907
Solenoid valve, offset_optional equipment.....909
Tightening torques.....911
Travel valve (pedal), installing.....912
Travel valve (pedal), removing.....916
Working pressure, checking and adjusting.....919
X1 and X3 hydraulic with flow control, calibrating.....922
92 - MECHANICAL EQUIPMENT_ATTACHMENT.....925
Boom support, pivot play.....926
Quickfit, function check.....931
97 - UNIT, DIGGING.....933
Adjustable boom cylinder, specifications.....934
Boom cylinder, installing.....935
Boom cylinder, removing.....939
Boom cylinder, specifications.....943
Boom swing cylinder, installing.....944
Boom swing cylinder, removing.....948
Boom, installing.....952
Boom, removing.....957
Boom, specifications.....961
Bucket cylinder, installing.....962
Bucket cylinder, removing.....966
Bucket cylinder, specifications.....970
Dipper arm cylinder, installing.....971
Dipper arm cylinder, removing.....975
Dipper arm cylinder, specifications.....979
Dipper arm, installing.....980
Dipper arm, removing.....984
Dipper arm, specifications.....987
Dozer blade cylinder, specifications.....988
98 - FUNCTION FOR ROAD CONSTRUCTION.....989
Dozer blade cylinder, replacing.....990
99 - MISCELLANEOUS.....995
Description, general.....997
