Volvo EW55B Compact Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EW55B Compact Excavators, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo Constructions EW55B 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: 1,275 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo EW55B Compact Excavators Service Repair Manual.pdf
TABLE OF CONTENTS
0 - Foreword....2
0 - GENERAL....3
03 - SPECIFICATIONS....4
Air cleaner restriction switch, specifications....4
Air conditioning unit, specifications_....5
Air preheater, specifications_....7
Alternator, specifications_....8
Battery disconnector switch, specifications_....9
Battery, specifications_....10
Brake pump, specifications_....11
Brake supply valve, specifications_....12
Brake valve, specification_....13
Cab, specifications_....14
Combination lamp, specifications_....15
Compressor, specifications_....16
Coolant temperature sender for needle gauge, specifications_....17
Cooling system, specifications_....19
Cylinder, specifications_....21
Dozer blade cylinder, specifications_....25
Drying filter, specifications_....26
Electric horn, specifications_....27
Electrical system, specifications_....28
Engine oil pressure switch, specifications....29
Engine, specifications_....30
Flasher side lamp, specifications_....35
Frame and wheel, specifications_....36
Front axle, specification_....37
Fuel filler pump, specifications_....38
Fuel injection pump, specifications_....39
Fuel level sender for needle gauge, specifications_....40
Fuel system, specifications_....41
Fuse box, specifications_....42
Hydraulic pressure, specifications_....44
Hydraulic tank, specifications_....45
Injectors, specification_....46
Location of components....47
Lubrication system, specifications_....49
Main control valve, specifications_{10-05-45}....50
Measurement conversion tables....51
Overload warning pressure switch, specifications_....60
Pivot axle lock cylinder, specifications_....61
Preheating relay, specifications_....62
Pump, specifications (Serial no. 30314 ~ )_{10-05-27}....63
Pump, specifications (Serial no. ~ 30313)_{10-05-15}....64
Radio with tape player, specifications_....65
Recommended hydraulic oil, specifications_....67
Relay, specifications_....70
Relief valve, specifications_{10-05-57}....71
Remote control valve (Lever), specifications_....72
Remote control valve (dozer blade), specifications_....73
Safety limit switch, specifications_....74
Safety start relay, specifications_....75
Servo pump, specifications (Serial no. 30314 ~ )_....76
Slew gearbox, specifications....77
Slow blow fuse, specifications_....78
Solenoid valve, specifications_....79
Start switch, specifications_....80
Starter motor, specifications_....81
Steering pump, specifications_....82
Steering unit, specification_....83
Swing motor, specifications_....84
Swing ring gear, specifications_....85
Tightening torques....86
Tire and rim, specifications_....95
Transfer gearbox, specifications_....97
Travel alarm pressure switch, specifications....98
Travel motor, specifications_....99
Travel selection switch, specifications_....100
Valve system specifications_....101
Warning buzzer, specifications_....102
Water temperature switch, specifications_....103
Window limit switch, specifications_....104
Wiper controller, specifications_....105
Wiper motor, specifications_....106
Work lights and headlights, specifications_....107
07 - STANDARD TIME....108
Operation numbers for additional work....108
08 - TOOL....110
E-tools, NET 8940-00350 Replace tool for the swing motor assembly....110
E-tools, NET 8940-00370 Guide pin for track motor and swing ring gear....111
E-tools, NET 8940-00380 Replacement tool for swing ring gear....112
NET 8940-00200 Replace tool for the remote control valve joint-[0143]....114
NET 8940-00200 Replace tool for the remote control valve joint....115
NET 8940-00360 Replacement tool for the radiator assembly....117
1 - STANDARD PARTS, SERVICE....118
16 - LUBRICANT; FUEL; OTHER FLUID....119
Alternative fuels....119
Recommended lubricants....122
17 - SERVICE....125
Arrival Inspection, according to Inspection Programme....125
Coasting left and right swing....126
Coolant anti-freeze resistance, checking ....128
Creeping of hydraulic cylinder....132
Cylinder speed....133
Delivery Inspection, according to Inspection Programme....136
Maintenance of Stored Machines, according to Inspection Programme....137
Measuring condition....138
Measuring of swing bearing clearance....139
Periodic maintenance....142
Starting engine with booster cables....144
Swing speed....146
Travel Speed....147
19 - GENERAL....148
Cautions during operation....148
General precautions....153
Move and operate machine safely....155
Preparations for work....156
2 - ENGINE WITH MOUNTING AND EQUIPMENT....159
20 - GENERAL....160
Engine, description....161
Engine, tightening torque....168
Maintenance standards....170
Periodic inspection and maintenance procedure....171
Periodic maintenance chart....204
Precautions....206
Special tools....207
21 - ENGINE....212
Adjusting operation....213
Camshaft, description....223
Compression pressure inspection....225
Crankshaft, description....228
Cylinder block, description....230
Cylinder head, description....232
Engine mounting....234
Engine timing gear, description....238
Engine, specifications....240
Pistons, description-[3539]....245
Pistons, description....247
Troubleshooting chart....249
Valve system specifications....255
Valves, adjusting....256
22 - LUBRICATING SYSTEM....263
Lubricating system, description....264
Lubrication system, specifications....267
23 - FUEL SYSTEM....268
Cold start device, description....269
Fuel filler pump, description....271
Fuel filler pump, specifications....273
Fuel injection pump, description....274
Fuel injection pump, specifications....276
Fuel lines, description....277
Fuel system, description....279
Fuel system, specifications....281
Fuel tank, description....282
Injectors, description....284
Injectors, specification....286
Stop solenoid, description....287
25 - INLET & EXHAUST SYSTEM....288
Intake and exhaust system, description....289
26 - COOLING SYSTEM....291
Coolant anti-freeze resistance, checking....292
Cooling system, description....297
Cooling system, specifications....299
Fan belt and_or alternator belt, checking and adjusting tension-....301
Fan belt and_or alternator belt, checking and adjusting tension....303
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....305
30 - GENERAL....306
Auxiliary start....307
Basic check....309
Checking electrical cabling and connectors....311
Collection of basic data....316
DC current measurement....318
DC voltage measurement....322
Diagnosis for malfunction symptoms....325
Diode check procedure....331
Electrical system, special instructions for servicing, action when working on machine....334
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator....335
Electrical system, special instructions for servicing, electrical components, batteries....337
Electrical system, special instructions for servicing, electronic components....339
Electrical system, special instructions for servicing, general....340
Electrical system, specifications....341
Measuring components....342
Precautions when handling plug connectors....343
Resistance measurement....345
Special tools for troubleshooting....348
Troubleshooting, assistant devices....350
Troubleshooting, general....352
31 - BATTERY....353
Battery, charging....354
Battery, description....355
Battery, specifications....356
32 - ALTERNATOR; CHARGE REGULATOR....357
Alternator, description....358
Alternator, inspection....360
Alternator, specifications....361
33 - STARTING SYSTEM....362
Air preheater, description....363
Air preheater, specifications....364
Preheating relay, description....365
Preheating relay, specifications....366
Preheating system, description....367
Safety start relay, description....368
Safety start relay, specifications....371
Start switch, description....372
Start switch, specifications....374
Starter motor, description....375
Starter motor, specifications....376
Starting operation....377
35 - LIGHTING....379
Combination lamp, description....380
Combination lamp, specifications....381
Flasher side lamp, description....382
Flasher side lamp, specifications....384
Work lights and headlights, description....385
Work lights and headlights, specifications....386
36 - OTHER ELECTRICAL EQUIPMENT....387
Connector, configuration....388
Connectors, position....392
Electric horn, description....397
Electric horn, specifications....398
Forward_reverse lever, description....399
Switch panel, description....401
Travel selection switch, specifications....407
Travel speed selection switch, description....408
Window limit switch, description....410
Window limit switch, specifications....411
Windscreen wiper, components location....412
Windscreen wiper, description....415
Wiper controller, description....416
Wiper controller, specifications....418
Wiper motor, description....419
Wiper motor, specifications....421
Work lamp switch, description_{08-44-44}....422
Work lamp switch, description_{08-45-04}....425
37 - CABLE; FUSE; RELAY....427
Battery disconnector switch, description....428
Battery disconnector switch, specifications....429
Components list....430
Electrical symbols and designations....434
Explanation of wiring diagrams....436
Fuse box, description....440
Fuse box, specifications....442
Ground connections....444
Positive feed....445
Relay, description....446
Relay, specifications....447
Slow blow fuse, description....448
Slow blow fuse, specifications....450
Wiring diagram SCH01_{08-38-18}....451
Wiring diagram SCH01_{08-38-33}....454
Wiring diagram SCH02....457
Wiring diagram SCH03....460
Wiring diagram SCH04....463
Wiring diagram SCH05....466
Wiring diagram SCH06....468
Wiring diagram SCH07....470
Wiring diagram SCH08....472
Wiring diagram SCH09_{08-33-43}....474
Wiring diagram SCH09_{08-33-58}....476
Wiring diagram SCH10....478
Wiring diagram SCH11....481
Wiring diagrams....483
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....484
Air cleaner restriction switch, description_{08-24-24}....485
Air cleaner restriction switch, specifications_{08-24-11}....486
Control lockout lever switch, description-[2609]....487
Control lockout lever switch, description....488
Coolant temperature sender for needle gauge, description....489
Coolant temperature sender for needle gauge, specifications....490
Engine oil pressure switch, description_{08-24-55}....492
Engine oil pressure switch, description_{08-25-24}....493
Engine oil pressure switch, specifications_{08-24-43}....494
Engine oil pressure switch, specifications_{08-25-12}....495
Fuel level sender for needle gauge, description....496
Fuel level sender for needle gauge, specifications....497
Instrument panel, description....498
Instrument panel, gauge and indicator....501
Overload warning pressure switch, description....506
Overload warning pressure switch, specifications....507
Safety limit switch, specifications....508
Travel alarm pressure switch, description_{08-23-41}....509
Travel alarm pressure switch, specifications_{08-23-28}....511
Warning buzzer, description....512
Warning buzzer, specifications....513
Water temperature switch for indicator, description....514
Water temperature switch, specifications....515
39 - MISCELLANEOUS....516
Radio with tape player, description....517
Radio with tape player, specifications....519
4 - POWER TRANSMISSION....521
40 - GENERAL....522
Power transmission, description....523
43 - GEARBOX....529
Slew gearbox, description....530
Slew gearbox, precautions for operation....533
Slew gearbox, specifications....535
Swing gearbox, assembly....536
Swing gearbox, disassembly....546
Swing gearbox, maintenance standard....552
Transfer gearbox, description....553
Transfer gearbox, disassembly and assembly....558
Transfer gearbox, filling and checking....569
Transfer gearbox, specifications....571
44 - HYDROSTATIC DRIVE....572
Center passage, description....573
Center passage, disassembly and assembly....578
Flexible coupling....587
Slew motor, precautions for installation....590
Slew motor, troubleshooting....591
Swing motor, assembly....593
Swing motor, description....602
Swing motor, disassembly....615
Swing motor, maintenance standard....622
Swing motor, specifications....623
Travel motor, assembly....624
Travel motor, control_{011-22-37}....631
Travel motor, control_{011-22-50}....635
Travel motor, description....638
Travel motor, disassembly....646
Travel motor, oil leakage flow check....668
Travel motor, specifications....670
45 - PROPELLER SHAFT....671
Propeller shaft, description....672
46 - FRONT AXLE; REAR AXLE....674
Axle, disassembly and assembly....675
Differential, description....707
Front axle, description....709
Front axle, specification....713
Hub reduction, description....714
Rear axle, description....717
49 - MISCELLANEOUS....718
Slew ring gear, installation....719
Slew ring gear, removal....721
Swing ring gear, specifications....723
5 - BRAKE....724
52 - HYDRAULIC BRAKE SYSTEM....725
Axle brake disassembly and assembly....726
Axle brake pressure measure....727
Axle brake system air bleeding....729
Axle brake....731
Brake accumulator, description....733
Brake line, description....735
Brake pump, description....739
Brake pump, specifications....741
Brake supply valve, description....742
Brake supply valve, specifications....747
Brake system, component....748
Brake system, troubleshooting....751
Brake valve, description....754
Brake valve, specification....757
Brake, description....758
Check the internal leakage in brake system....761
Service brake (multi disk brake), assembly....762
Service brake (multi disk brake), disassembly....765
Undercarriage piping....768
55 - PARKING BRAKE....770
Parking brake cylinder, assembly....771
Parking brake cylinder, description....775
Parking brake cylinder, disassembly....777
Parking brake, description....781
6 - STEERING....785
64 - STEERING....786
Priority valve, assembly....786
Priority valve, disassembly....788
Steering column, description....791
Steering pressure, adjustment....792
Steering pump, description....795
Steering pump, specifications....797
Steering system, description....798
Steering system, troubleshooting....808
Steering unit, assembly....811
Steering unit, disassembly....821
Steering unit, maintenance standard....829
Steering unit, specification....830
Steering wheel operation time measurement....831
Steering wheel, description....833
Troubleshooting....834
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....838
70 - GENERAL....839
Frame and wheel, specifications....840
71 - FRAME....841
Additional counterweight or attachment....842
Counterweight, installation....843
Counterweight, removing....845
Superstructure, installation....847
Superstructure, removal....848
76 - SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL_SIDE CONTROL....850
Axle locking cylinder, assembly....851
Axle locking cylinder, disassembly....854
Pivot axle lock cylinder, description....856
Pivot axle lock cylinder, specifications....858
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....859
Tire and rim, specifications....860
Tire, description....862
Tire, handle with care....864
Tire, structure....866
Tire, troubleshooting....867
Tyre, specifications....869
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....870
81 - CAB, NAKED; CANOPY....871
Cab, installation....872
Cab, removal....874
Cab, specifications....875
87 - AIR CONDITIONING UNIT....876
Air conditioning unit, description....877
Air conditioning unit, location of components....879
Air conditioning unit, maintenance....884
Air conditioning unit, refrigerant check and recharging....888
Air conditioning unit, specifications....893
Compressor, description....895
Compressor, specifications....897
Condenser, description....898
Cooling unit, description....899
Drying filter, description....901
Drying filter, specifications....903
Expansion valve and evaporator, description....904
Heater unit, description....907
Heating control valve, description....909
Performance test, AC unit....910
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....916
90 - GENERAL....917
Hydraulic pressure, specifications....918
Recommended hydraulic oil, specifications....919
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....923
Control pattern selector valve, description....925
Control pattern selector valve, hydraulic circuits - Image....930
Control pattern selector valve, hydraulic circuits....934
Control valve, troubleshooting....939
Examples, hydraulic system....941
Examples, power transmission....951
Hydraulic circuits, ports....958
Hydraulic components, description....960
Hydraulic diagram, schematic (Serial no. 30314 ~ )_{10-32-30}....963
Hydraulic diagram, schematic (Serial no. ~ 30313)_{10-32-18}....965
Hydraulic tank, description....967
Hydraulic tank, specifications....969
Lower line....970
Main control valve, assembly....973
Main control valve, description....979
Main control valve, disassembly....992
Main control valve, specifications_{010-28-42}....994
Main control valve, specifications_{010-29-07}....995
Main control valve, specifications_{010-29-34}....996
Main line....997
Main relief valve, adjustment....1000
Port relief valve pressure, measuring and adjusting....1004
Pressure relief valve (main), assembly....1005
Pressure relief valve (main), description....1006
Pressure relief valve (main), disassembly....1008
Pressure relief valve (port), assembly....1009
Pressure relief valve (port), description....1010
Pressure relief valve (port), disassembly....1012
Pressure relief valve, troubleshooting....1014
Pump, assembly (Serial no. 30314 ~ )_{10-18-29}....1015
Pump, assembly (Serial no. ~ 30313)_{10-18-03}....1039
Pump, description (Serial no. 30314 ~ )_{10-21-18}....1043
Pump, description (Serial no. ~ 30313)_{10-21-01}....1050
Pump, disassembly (Serial no. 30314 ~ )_{10-19-07}....1057
Pump, disassembly (Serial no. ~ 30313)_{10-18-50}....1073
Pump, maintenance standard (Serial no. 30314 ~ )_{10-20-37}....1077
Pump, maintenance standard (Serial no. ~ 30313)_{10-20-25}....1080
Pump, specifications (Serial no. 30314 ~ )_{10-21-47}....1082
Pump, specifications (Serial no. 30314 ~ )_{10-22-13}....1083
Pump, specifications (Serial no. ~ 30313)_{10-21-35}....1084
Pump, specifications (Serial no. ~ 30313)_{10-22-02}....1085
Pump, tools (Serial no. 30314 ~ )_{10-19-38}....1086
Pump, tools (Serial no. ~ 30313)_{10-19-26}....1088
Pump, troubleshooting (Serial no. 30314 ~ )_{10-20-06}....1089
Pump, troubleshooting (Serial no. ~ 30313)_{10-19-56}....1090
Relief valve, specifications_{010-28-53}....1091
Relief valve, specifications_{010-29-19}....1092
Relief valve, specifications_{010-29-44}....1093
Remote control valve (Lever), description....1094
Remote control valve (Lever), specifications....1107
Servo hydraulic line....1108
Servo pump, description (Serial no. 30314 ~ )....1112
Servo pump, specifications (Serial no. 30314 ~ )....1113
Solenoid valve, description....1114
Solenoid valve, disassembly and assembly....1121
Solenoid valve, inspection....1123
Solenoid valve, specifications....1124
Solenoid valve, troubleshooting....1125
Troubleshooting, diagnosing procedure....1126
92 - MECHANICAL EQUIPMENT_ATTACHMENT....1131
Attachment quick coupler, description....1132
Attachment quick coupler, operation....1136
Dozer blade cylinder, specifications....1139
Dozer blade, description....1140
Remote control valve (dozer blade), description....1142
Remote control valve (dozer blade), specifications....1144
97 - UNIT, DIGGING....1145
Cylinder, assembly....1146
Cylinder, description....1158
Cylinder, disassembly....1161
Cylinder, inspection and maintenance standard....1167
Cylinder, removal and installation....1170
Cylinder, specifications....1177
Cylinder, tools....1181
Cylinder, troubleshooting....1186
Digging unit, description....1188
Digging unit, maintenance standard, specifications....1193
99 - MISCELLANEOUS....1195
Axle locking, description....1197
Boom slew, description - Image....1200
Boom slew, description....1201
Hammer, description....1204
Hydraulic circuits, arm in (Serial no. 30314 ~ ) - Image....1207
Hydraulic circuits, arm in (Serial no. 30314 ~ )_{10-03-17}....1208
Hydraulic circuits, arm in (Serial no. ~ 30313) - Image....1210
Hydraulic circuits, arm in (Serial no. ~ 30313)_{10-03-01}....1211
Hydraulic circuits, arm out (Serial no. 30314 ~ ) - Image....1213
Hydraulic circuits, arm out (Serial no. 30314 ~ )_{10-02-35}....1214
Hydraulic circuits, arm out (Serial no. ~ 30313) - Image....1216
Hydraulic circuits, arm out (Serial no. ~ 30313)_{10-02-18}....1217
Hydraulic circuits, boom lower (Serial no. 30314 ~ ) - Image....1219
Hydraulic circuits, boom lower (Serial no. 30314 ~ )_{10-03-57}....1220
Hydraulic circuits, boom lower (Serial no. ~ 30313) - Image....1222
Hydraulic circuits, boom lower (Serial no. ~ 30313)_{10-03-41}....1223
Hydraulic circuits, boom raise (Serial no. 30314 ~ ) - Image....1225
Hydraulic circuits, boom raise (Serial no. 30314 ~ )_{10-05-27}....1226
Hydraulic circuits, boom raise (Serial no. ~ 30313) - Image....1228
Hydraulic circuits, boom raise (Serial no. ~ 30313)_{10-05-11}....1229
Hydraulic circuits, boom raise _arm in (Serial no. 30314 ~ ) - Image....1231
Hydraulic circuits, boom raise _arm in (Serial no. 30314 ~ )....1232
Hydraulic circuits, boom raise _arm in (Serial no. ~ 30313) - Image....1234
Hydraulic circuits, boom raise _arm in (Serial no. ~ 30313)....1235
Hydraulic circuits, bucket (Serial no. 30314 ~ ) - Image....1237
Hydraulic circuits, bucket (Serial no. 30314 ~ )_{10-01-55}....1238
Hydraulic circuits, bucket (Serial no. ~ 30313) - Image....1240
Hydraulic circuits, bucket (Serial no. ~ 30313)_{10-01-40}....1241
Hydraulic circuits, dozer blade....1243
Hydraulic circuits, neutral (Serial no. 30314 ~ ) - Image....1246
Hydraulic circuits, neutral (Serial no. 30314 ~ )_{10-05-52}....1247
Hydraulic circuits, neutral (Serial no. ~ 30313) - Image....1251
Hydraulic circuits, neutral (Serial no. ~ 30313)_{10-06-11}....1252
Hydraulic circuits, neutral_{010-06-21}....1256
Hydraulic circuits, slew (Serial no. 30314 ~ ) - Image....1257
Hydraulic circuits, slew (Serial no. 30314 ~ )_{10-00-44}....1258
Hydraulic circuits, slew (Serial no. ~ 30313) - Image....1260
Hydraulic circuits, slew (Serial no. ~ 30313)_{10-00-30}....1262
Hydraulic circuits, travel (Serial no. 30314 ~ ) - Image....1264
Hydraulic circuits, travel (Serial no. 30314 ~ )_{09-59-32}....1265
Hydraulic circuits, travel (Serial no. ~ 30313) - Image....1267
Hydraulic circuits, travel (Serial no. ~ 30313)_{09-59-19}....1268
Hydraulic circuits, travel _ arm in (Serial no. 30314 ~ ) - Image....1270
Hydraulic circuits, travel _ arm in (Serial no. 30314 ~ )....1271
Hydraulic circuits, travel _ arm in (Serial no. ~ 30313) - Image....1273
Hydraulic circuits, travel _ arm in (Serial no. ~ 30313)....1274
Volvo EW55B Compact Excavators Repair Service Manual
