Volvo Compact Excavators EC18D Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Constructions Compact Excavators EC18D, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
EC18D Volvo 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.
EC18D Volvo Compact Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,308 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
000 - Foreword....2
000 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Description; general....5
Product plate; description....7
Component locations....9
03 - SPECIFICATIONS....11
Tightening torques....12
Conversion tables....23
Dimensions....28
Weight....31
Lifting capacities....32
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION....33
Transporting and lifting the machine....34
07 - STANDARD TIME....38
Operation numbers for additional work....39
08 - TOOL....41
Infrared Thermometer....42
09 - MISCELLANEOUS....46
Welding on the machine_{07-21-02}....47
Welding on the machine_{07-20-41}....48
Hydraulic cylinders; dieseling....50
001 - STANDARD PARTS; SERVICE....52
16 - LUBRICANT; FUEL; OTHER FLUID....53
Hydraulic oil....54
Recommended lubricants....59
Fuel; recommendation....62
Coolant ....63
Coolant....68
Alternative....70
17 - SERVICE....73
Cleanliness; braking and hydraulic system....76
Hydraulic system; pressure release....77
Repairing hydraulic system....79
Service and maintenance....80
Cleaning prior to repair....82
Arrival Inspection; according to Inspection Programme....83
Delivery Inspection; according to Inspection Programme....84
Maintenance of Stored Machines; according to Inspection Programme....85
Service positions ....86
Maintenance service; every 10 hours....88
Maintenance service; every 50 hours....89
Maintenance service; every 250 hours....90
Maintenance service; every 500 hours....92
Maintenance service; every 1000 hours....94
Maintenance service; every 1500 hours....97
Maintenance service; every 2000 hours....99
Maintenance service; every 3000 hours....102
Test running and checking....105
Lubrication....106
Valves; adjusting-[0656]....107
Engine oil level; checking....118
Engine oil and filter; changing....119
Water separator; checking....122
Fuel filters; replacing....124
Fuel hoses; checking....126
Injection pump; checking ....127
Injection timing; checking ....133
Fuel injectors; checking....140
Air inlet hose; checking....147
Exhaust manifold; checking....148
Engine air cleaner primary filter; replacing....150
Engine air cleaner secondary filter; replacing....152
Coolant level; checking....153
Coolant; changing....155
Coolant freezing point; checking....159
Fan_alternator belt; checking....161
Radiator; cleaning....163
Radiator hoses; checking....165
Battery; checking....167
Travel gearbox oil level; checking....169
Travel gearbox oil; changing....171
Track tension and condition; checking....173
Cab main filter; replacing....176
Seat belt; replacing ....178
Hydraulic oil level; checking....181
Hydraulic oil; changing....183
Leakage oil filter element; replacing....186
Hydraulic oil return filter; replacing....188
Hydraulic hoses; checking....190
Hydraulic pressure; checking....192
Attachment quick coupler; checking....197
Lubrication and service schedules....199
Measuring condition ....202
Cylinder speed....203
Values; cylinder speed....207
Creeping of hydraulic cylinder....208
Values; creeping of hydraulic cylinder....210
Slewing speed....211
Values; slewing speed....213
Travel Speed....214
Values; travel speed....216
Track running speed....217
Values; track running speed....219
Deviation when travelling straight ahead....220
Values; deviation when travelling straight ahead....223
Towing; measures....224
Starting engine with booster cables....225
19 - GENERAL....228
Safety concerns everybody!....229
Service position 1....231
CE marking and declaration of conformity....233
Safety when handling the machine....235
Safety rules when servicing....240
Safety when lifting and supporting the machine....243
Service positions....245
Fire prevention measures....247
Working on the electrical system of the machine....250
Safety when working with batteries....252
Starting with booster batteries....255
Safety when handling oils and fuel....256
Safety for work on hydraulic systems....258
Safety when handling accumulators....260
Checklist after a fire or heat exposure....261
Health hazards with paint; plastics and rubber....263
Environmental handling for the future....266
Waste handling....268
Environmentally safe handling....272
Environmentally hazardous fluids....275
Safety when working with air conditioning refrigerant....276
Working in environmentally contaminated areas....278
Decontamination....281
002 - ENGINE WITH MOUNTING AND EQUIPMENT....285
20 - GENERAL....286
Engine; description....287
Component locations....289
Engine; capacities....291
Engine; tighten torques....292
Engine trouble shooting....294
21 - ENGINE....297
Engine; specifications....298
Cylinder compression; testing....299
Engine; removing....305
Engine; installing....321
Cylinder head; description....336
Crankcase ventilation; description....338
Pistons; description....340
Valve mechanism; description....342
Valve mechanism; specifications....344
Valves; adjusting....345
Timing gear; description....346
Crankshaft; description....347
Oil sump; replacing....349
Engine mounts; replacing....352
22 - LUBRICATING SYSTEM....357
Lubricating system; description....358
Lubrication system; specifications....361
23 - FUEL SYSTEM....362
Fuel system; description....363
Fuel tank; capacities....366
Fuel system; general specifications....367
Fuel system; tightening torques....368
Fuel feed pump; description....370
Fuel feed pump; specifications....372
Fuel pump; removing....373
Fuel pump; installing....375
Fuel tank; description....377
Fuel tank; removing....379
Fuel tank; installing....391
Idling speed; checking and adjusting....401
Injection timing; checking....403
Injection pump; removing....404
Injection pump; checking....409
Injectors; description....410
Injectors; replacing....412
Injectors; checking....417
25 - INLET & EXHAUST SYSTEM....418
Exhaust manifold; replacing....419
Silencer; removing....423
Silencer; installing....427
Air cleaner; description....430
Air cleaner; removing....432
Air cleaner; installing....434
26 - COOLING SYSTEM....436
Cooling system; description....437
Cooling system; specification....440
Coolant anti-freeze resistance; checking....441
Radiator hose upper; replacing....443
Radiator hoses lower; replacing....446
Radiator; removing....449
Radiator; installing....455
Expansion tank; removing....461
Expansion tank; installing....463
Thermostat; inspecting....464
Thermostat; replacing....466
Coolant pump; replacing....470
Fan belt and_or alternator belt; checking and adjusting tension....478
Fan belt and_or alternator belt; replacing....481
27 - ENGINE CONTROL....484
Throttle controls; setting....485
Throttle control cable; removing....487
Throttle control cable; installing....490
Stop magnet; replacing....493
Auto idling device; description....495
Engine speed control; changing throttle cylinder....497
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....499
30 - GENERAL....500
Electrical system; special instructions for servicing; general....501
Electrical system; special instructions for servicing; electronic components_{05-38-00}....503
Electrical system; special instructions for servicing; electronic components_{05-37-35}....505
Electrical system; special instructions for servicing; electronic components_{05-37-14}....506
Troubleshooting; general....508
Troubleshooting tips....509
Troubleshooting; assistant devices....511
Collection of basic data....513
Measuring components....515
Checking electrical cabling and connectors....516
Resistance measurement....521
DC voltage measurement....525
DC current measurement....529
Diode check procedure....533
31 - BATTERY....536
Battery; specifications....537
Battery condition; checking....538
Batteries; replacing....542
32 - ALTERNATOR; CHARGE REGULATOR....546
Alternator; specifications....547
Alternator; removing....548
Alternator; installing....551
33 - STARTING SYSTEM....554
Starter motor; specification....555
Starter motor; replacing....556
Preheating; specifications....558
Glow plug; removing....559
Glow plug; installing....560
Glow plugs; testing....561
35 - LIGHTING....562
Light bulbs; specification....563
Light bulb; replacing....564
36 - OTHER ELECTRICAL EQUIPMENT....568
Horn; replacing....569
Travel alarm; specifications....571
Travel alarm; replacing....572
Windscreen wiper front motor; replacing....574
Switch; replacing....581
Vehicle control unit V-ECU; description....584
Antitheft device; first activation of a new A-ECU....587
A-ECU (anti theft); replacing....589
I-ECU; replacing....594
V-ECU; replacing....598
Option anti-theft; instruction....600
37 - CABLE; FUSE; RELAY....604
Electrical symbols and designation_{05-12-00}....606
Electrical symbols and designation_{05-11-12}....609
Cable and component marking explanations....612
Cables; description....615
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{05-09-17}....617
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{05-08-53}....619
Component list; diodes_{05-08-17}....621
Component list; diodes_{05-07-53}....623
Component list Fuses_{05-07-17}....625
Component list Fuses_{05-06-53}....627
Component list Heating coils; instruments; service socket_{05-06-17}....629
Component list Heating coils; instruments; service socket_{05-05-53}....631
Component list Lights_{05-05-17}....633
Component list Lights_{05-04-53}....635
Component list; motors_{05-04-12}....637
Component list; motors_{05-03-48}....639
Component list PWM valves_{05-03-12}....640
Component list PWM valves_{05-02-49}....641
Component list Relays_{05-02-13}....642
Component list Relays_{05-01-49}....644
Component list; sensors_{05-01-07}....646
Component list; sensors_{05-00-43}....648
Component list Solenoid valves_{05-00-08}....650
Component list Solenoid valves_{04-59-44}....652
Component list; Sounders_{04-59-08}....654
Component list; Sounders_{04-58-44}....655
Component list Switches_{04-57-57}....656
Component list Switches_{04-57-33}....658
V-ECU inputs and outputs....660
Table of contents; wiring diagrams....662
Wiring diagram 1_{04-56-17}....663
Wiring diagram 2_{04-55-41}....666
Wiring diagram 3_{04-55-05}....669
Wiring diagram 4_{04-54-29}....672
Wiring diagram 5_{04-53-53}....675
Wiring diagram 6_{04-53-16}....678
Wiring diagram 7_{04-52-41}....681
Wiring diagram 7_{04-52-17}....684
Wiring diagram 8_{04-51-41}....687
Wiring diagram 8_{04-51-17}....690
Wiring diagram 9_{04-50-42}....693
Wiring diagram 9_{04-50-17}....696
Wiring diagram 10_{04-49-41}....699
Wiring diagram 10_{04-49-17}....702
Wiring diagram 11_{04-48-42}....705
Wiring diagram 11_{04-48-18}....708
Wiring diagram 12....711
Wiring diagram 13....714
Wiring diagram 14....717
Fuse; description....720
Electrical distribution box; circuit board replacing....722
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....726
Instrument panel; description....727
004 - POWER TRANSMISSION....729
40 - GENERAL....730
General notes to be observe when working on power transmission assemblies....731
44 - HYDROSTATIC DRIVE....733
Travel motor; description....734
Track motor; specifications....739
Track motor; tightening torques....740
Track motor; removing....741
Track motor; installing....746
Travel motor removed; overhaul....750
Slew motor; description....789
Slew motor; specifications....795
Slew motor; tightening torques....796
Slew motor; troubleshooting....797
Swing motor; removing....799
Swing motor; installing....805
Swing motor removed; overhaul....812
Center passage; description....837
Centre passage; removing....839
Centre passage; installing....844
49 - MISCELLANEOUS....848
Swing ring gear; description....849
Swing ring; removing....851
Swing ring; installing....858
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....864
70 - GENERAL....865
Frame and track unit; specifications....866
71 - FRAME....868
Counterweight; specifications....869
Counterweight; replacing....870
Undercarriage; description....872
Superstructure covering; description....874
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....876
Front idler; removing....877
Front idler; installing....880
Sprocket; removing....882
Sprocket; installing....884
Rubber track; removing....886
Rubber track; installing....889
Chain guide; removing....891
Chain guide; installing....894
Bottom roller; removing....896
Bottom roller; installing....898
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....900
81 - CAB; NAKED; CANOPY....901
Cab; weight....902
Cab; tightening torques_{04-11-40}....903
Cab; tightening torques_{04-11-19}....904
Cab; removing_{04-10-35}....905
Cab; removing_{04-10-11}....911
Cab; installing_{04-09-36}....916
Cab; installing_{04-09-12}....922
Cab platform; removing_{04-08-36}....926
Cab platform; removing_{04-08-04}....942
Cab platform; installing_{04-07-24}....957
Cab platform; installing_{04-06-50}....972
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....986
Engine hood; replacing....987
85 - CAB INTERIOR; UPHOLSTERY....991
Operator's seat; removing....992
Operator's seat; installing....995
Seat belt; replacing....999
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....1003
90 - GENERAL....1004
Hydraulic diagram; complete - Image....1006
Explanations to hydraulic diagram....1008
Hydraulic diagram; complete_{004-00-08}....1015
Hydraulic diagram; complete_{003-59-44}....1018
Hydraulic diagram 001....1021
Hydraulic diagram 002....1023
Hydraulic diagram 003....1026
Hydraulic diagram 004....1029
Hydraulic diagram 005....1032
Hydraulic diagram 006....1034
Hydraulic diagram 007....1036
Hydraulic diagram 008....1038
Hydraulic diagram 009....1040
Hydraulic diagram 010....1042
Hydraulic diagram 011....1045
Hydraulic diagram 012....1047
Hydraulic diagram 013....1049
Hydraulic diagram 014....1051
Hydraulic diagram 015....1053
Hydraulic diagram 016....1055
Hydraulic system; description....1057
General notes when working on hydraulic system....1061
Pressure adjustment and leaks checking....1064
Hydraulic oil; description....1066
Hydraulic oil; storage and handling....1067
Hydraulic components; storing and transporting....1068
Hydraulic system; tightening torques....1069
H-ECU (hydraulic); replacing pre-programmed ECU_{003-48-07}....1070
H-ECU (hydraulic); replacing pre-programmed ECU_{003-47-43}....1072
Hydraulic system; specification....1074
Accumulator; discarding....1075
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....1077
LS system; bleeding....1079
Hydraulic tank; specifications....1081
Hydraulic oil cooler; description....1082
Hydraulic oil tank; removing....1084
Hydraulic oil tank; installing....1090
Hydraulic oil cooler; removing....1096
Hydraulic oil cooler; installing....1100
Main control valve; description....1104
Control valve; tightening torques....1107
Main control valve; removing....1108
Main control valve; installing....1116
Main control valve; disassembling....1123
Main control valve; assembling....1126
LS-pressure relief valve; replacing....1130
Flow regulation valve; changing....1134
Flushing valve; replacing....1138
Secondary pressure limiting valve; replacing....1142
Anti-cavitation check valve; replacing....1145
Working pressure; checking and adjusting....1148
Proportional valve; offset_optional equipment_{003-34-20}....1153
Proportional valve; offset_optional equipment_{003-33-56}....1156
Six way valve; offset_optional equipment....1159
Shuttle valve; swing brake....1161
Line rupture valve....1163
Hose rupture valve; removing....1165
Hose rupture valve; installing....1168
Pump; specifications_{003-30-53}....1170
Pump; specifications_{003-30-32}....1171
Pump; removing_{003-30-00}....1172
Pump; removing_{003-29-37}....1177
Pump; installing_{003-29-04}....1182
Pump; installing_{003-28-41}....1186
Hydraulic pump; power control; checking....1190
Accumulator; description....1194
Servo accumulator; removing....1196
Servo accumulator; installing....1199
Travel valve (pedal); removing....1202
Travel valve (pedal); installing....1206
Servo valve; removing....1210
Servo valve; installing....1213
Control levers; description....1216
Control levers; maintenance standard....1223
Control levers; repairing....1225
Left control lever; removing....1233
Right control lever; removing....1237
Left control lever; installing....1241
Right control lever; installing....1244
X001 and X3 hydraulic with flow control; calibrating....1247
92 - MECHANICAL EQUIPMENT_ATTACHMENT....1250
Boom support; pivot play....1251
97 - UNIT; DIGGING....1256
Boom lifting cylinder; specifications....1257
Dipper arm cylinder; specifications....1258
Bucket cylinder; specifications....1259
Adjustable boom cylinder; specifications....1260
Dozer blade cylinder; specifications....1261
Boom; removing....1262
Boom; installing....1268
Boom cylinder; removing....1275
Boom cylinder; installing....1278
Dipper arm; removing....1281
Dipper arm; installing....1287
Dipper arm cylinder; removing....1293
Dipper arm cylinder; installing....1297
Bucket cylinder; removing....1301
Bucket cylinder; installing....1305
Volvo Compact Excavators EC18D Repair Service Manual
