Volvo EC18C Compact Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for EC18C Volvo Compact Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions Compact Excavators EC18C 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.
EC18C Volvo Compact Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,312 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword................2
0 - GENERAL................3
00 - DESCRIPTION; COMPLETE MACHINE................4
Component locations................5
Product plate; description................7
Description; general................10
03 - SPECIFICATIONS................12
Dozer blade cylinder; specifications_{03-00-19}................14
Dozer blade cylinder; specifications_{03-00-41}................15
Adjustable boom cylinder; specifications ................16
Bucket cylinder; specifications ................17
Dipper arm cylinder; specifications ................18
Boom lifting cylinder; specifications ................19
Pump; specifications ................20
Control valve; tightening torques................21
Hydraulic tank; specifications ................22
Hydraulic system; tightening torques ................23
Hydraulic system; specification ................24
Cab; tightening torques ................25
Cab; weight ................26
Counterweight; specifications ................27
Frame and track unit; specifications ................28
Slew motor; tightening torques ................30
Slew motor; specifications ................31
Track motor; tightening torques ................32
Track motor; specifications ................33
Travel alarm; specifications ................34
Light bulbs; specification ................35
Battery; specifications ................36
Preheating; specifications................37
Starter motor; specification................38
Alternator; specifications ................39
Electrical system; tightening torques ................40
Cooling system; specification ................41
Injectors; specification ................42
Fuel feed pump; specifications ................43
Lubrication system; specifications ................44
Valve mechanism; specifications ................45
Engine; tighten torques ................46
Engine; capacities ................48
Engine; specifications ................49
Weight................51
Dimensions................52
Conversion tables................55
Tightening torques................60
07 - STANDARD TIME................71
Operation numbers for additional work................72
08 - TOOL................74
Infrared Thermometer................75
09 - MISCELLANEOUS................79
Hydraulic cylinders; dieseling................80
Welding on the machine................82
1 - STANDARD PARTS; SERVICE................83
16 - LUBRICANT; FUEL; OTHER FLUID................84
Hydraulic oil................85
Lubricants; specifications................90
Fuel; recommendation................92
Coolant................93
Alternative fuels................95
17 - SERVICE................98
Cleanliness; braking and hydraulic system................101
Repairing hydraulic system................102
Service and maintenance................103
Cleaning prior to repair................105
Warranty inspection 100 hours................106
Warranty inspection 1000 hours................110
Service position 1 ................115
Service position 2 ................116
Service position 3 ................118
Maintenance service; daily................120
Maintenance service; every 50 hours................122
Maintenance service; every 250 hours................124
Maintenance service; every 500 hours................127
Maintenance service; every 1000 hours................130
Maintenance service; every 1500 hours................135
Maintenance service; every 2000 hours................140
Maintenance service; every 3000 hours................145
Track tension; checking................150
Track tension; adjusting................151
Coolant; level; check................153
Test-run and check................154
The machine; check for external damages; cracks and wear damages................155
Engine; oil level; check................156
Dust valve; clean................157
Hydraulic oil level; check................158
Lubrication; see lubrication chart................160
Water separator; drain................161
Fuel tank sediment; drain................163
Fan belt and_or alternator belt; checking and adjusting tension ................165
Engine; changing oil and filter................168
Water separator filter element; change................171
Fuel filter; change................173
Engine radiator and hydraulic oil cooler; check (clean when necessary)................175
Engine radiator; oil cooler and condensor (if installed); clean................177
Hydraulic oil filter; changing................179
Hydraulic pressure; checking................181
Loose and loss of bolts; check................185
Air cleaner primary filter; change................186
Air cleaner secondary filter; change................188
Valve clearance; checking and adjusting................190
Battery condition; check................210
Track gearbox oil level; check................211
Travel motor gearbox; changing oil................213
Cab main filter; replacing................215
Hydraulic system; changing oil.................216
Leakage oil filter; filter element replace................221
Fuel injectors; inspect_clean and test................223
Crankcase breather system; inspect................234
Coolant; change................236
Fuel and fuel return hoses; check and replace if necessary................240
Hydraulik pump; suction hose and pressure hose; check and replace if necessary................242
Hoses for boom-; dipper-; and bucket-cylinder; check and replace if necessary................245
Hose on boom for X1; X2; X3; check and replace if neccessary................246
Quick coupler lock mechanism; replace................247
Seat belt; replace................249
Service history (included in the respective Operator's manual); fill in.................253
Lubrication and service schedules ................254
Lubrication and service schedules................257
Measuring condition................260
Cylinder speed................261
Values; cylinder speed................265
Creeping of hydraulic cylinder................266
Values; creeping of hydraulic cylinder................268
Slewing speed................269
Values; slewing speed................271
Travel Speed................272
Values; travel speed................274
Track running speed................275
Values; track running speed................277
Deviation when travelling straight ahead................278
Values; deviation when travelling straight ahead................281
Towing; measures................282
Starting engine with booster cables................283
19 - GENERAL................286
Safety concerns everybody!................287
Service position 1................289
Service position 2................291
Service position 3................293
CE marking and declaration of conformity................295
Safety when handling the machine................297
Safety rules when servicing................302
Safety when lifting and supporting the machine................305
Fire prevention measures................307
Working on the electrical system of the machine................310
Safety when working with batteries................312
Starting with booster batteries................315
Safety when handling oils and fuel................316
Pressure setting and leak detection................318
Safety for work on hydraulic systems................319
Checklist after a fire or heat exposure................321
Health hazards with paint; plastics and rubber................323
Environmental handling for the future................326
Waste handling................328
Environmentally safe handling................332
Environmentally hazardous fluids................335
Working in environmentally contaminated areas................336
Decontamination................339
2 - ENGINE WITH MOUNTING AND EQUIPMENT................343
20 - GENERAL................344
Engine; description................345
Engine; capacities................349
Engine; tighten torques................350
Troubleshooting chart................352
21 - ENGINE................358
Engine; specifications................359
Cylinder compression; testing................361
Engine; removing................365
Engine; installing................382
Cylinder head; description................399
Valve cover; description and operation................400
Cylinder head gasket; replacing................402
Cylinder head; removing................403
Cylinder head; installing................415
Cylinder block; description................428
Pistons; description................430
Valve mechanism; description................432
Valve mechanism; specifications................434
Valve cover; removing................435
Valve cover; installing................440
Valves; adjusting................446
Valve covers; fitting new gasket................458
Timing gear; description................460
Camshaft; description................462
Crankshaft; description................464
22 - LUBRICATING SYSTEM................466
Lubrication system; description................467
Lubrication system; specifications................469
Oil pump; description................470
23 - FUEL SYSTEM................472
Fuel system; general specifications................473
Fuel system; description................474
Fuel feed pump; description................476
Fuel feed pump; specifications................478
Fuel pump; removing................479
Fuel pump; installing................482
Fuel tank; description................485
Fuel tank; removing................487
Fuel tank; installing................500
Injection pump; description................512
Idling speed; checking and adjusting................514
Injection timing; checking................516
Injection pump; removing................526
Injectors; specification................541
Injectors; description................542
Injectors; replacing................543
25 - INLET & EXHAUST SYSTEM................552
Silencer; removing................553
Silencer; installing................557
Air cleaner; description................561
Air cleaner; removing................563
Air cleaner; installing................566
26 - COOLING SYSTEM................568
Cooling system; description................569
Cooling system; specification................571
Radiator hose upper; replacing................572
Radiator hoses lower; replacing................575
Radiator; removing................579
Radiator; installing................585
Expansion tank; removing................591
Expansion tank; installing................593
Thermostat; replacing................595
Coolant pump; replacing................600
Alternator; specifications ................604
Fan belt and_or alternator belt; checking and adjusting tension................605
Fan belt and_or alternator belt; replacing................607
27 - ENGINE CONTROL................614
Throttle controls; setting................615
Throttle control cable; removing................617
Throttle control cable; installing................620
Stop magnet; replacing................623
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS................625
30 - GENERAL................626
Electrical system; special instructions for servicing; general................627
Electrical system; special instructions for servicing; electronic components................629
Electrical system; special instructions for servicing; electrical components; batteries................630
Electrical system; special instructions for servicing; action when working on machine................632
Electrical system; tightening torques................633
Troubleshooting; general................634
Troubleshooting tips................635
Troubleshooting; assistant devices................637
Collection of basic data................639
Measuring components................641
Checking electrical cabling and connectors................642
Resistance measurement................647
DC voltage measurement................651
DC current measurement................655
Diode check procedure................659
31 - BATTERY................662
Battery; specifications................663
Battery condition; checking................664
Batteries; replacing................668
32 - ALTERNATOR; CHARGE REGULATOR................672
Alternator; specifications................673
Alternator; removing................674
Alternator; installing................677
33 - STARTING SYSTEM................680
Starter motor; removing................681
Starter motor; installing................684
Glow plug; removing................687
Glow plug; installing................689
35 - LIGHTING................691
Light bulbs; specification................692
Light bulb; replacing................693
36 - OTHER ELECTRICAL EQUIPMENT................697
Horn; replacing................698
Travel alarm; specifications................702
Travel alarm; replacing................703
Windscreen wiper front motor; replacing................706
Antitheft device; first activation of a new A-ECU................713
A-ECU (anti theft); replacing................715
I-ECU; replacing................720
Option anti-theft; instruction................724
37 - CABLE; FUSE; RELAY................728
Electrical symbols and designation................730
Cable and component marking explanations................733
Cables; description................736
Electrical system component locations................738
Component list Alternator; batteries; capacitors; electronic units; voltage outlet................739
Component list; diodes................740
Component list Fuses................741
Component list Heating coils; instruments; service socket................742
Component list Lights................743
Component list; motors................744
Component list PWM valves................745
Component list Relays................746
Component list; sensors................747
Component list Solenoid valves................748
Component list; Sounders................749
Component list Switches................750
Wiring diagram 1................751
Wiring diagram 2................754
Wiring diagram 3................757
Wiring diagram 4................760
Wiring diagram 5................763
Wiring diagram 6................766
Wiring diagram 7................769
Wiring diagram 8................772
Wiring diagram 9................775
Cable harnesses; description ................778
Cable harnesses; description.................787
Cable harnesses; description................789
Electrical distribution box; circuit board replacing................792
Fuse; description................796
Component location; alternator; batteries; capacitors; electronic units; voltage outlet................798
Component location; diodes................800
Component location; fuses................801
Component location; heating coils; instruments; service-sockets................802
Component location; lights................803
Component location; motors................804
Component location; PWM valves................805
Component location; relays................806
Component location; sensors................807
Component location; solenoid valves................809
Component location; sounders................810
Component location; switches................811
4 - POWER TRANSMISSION................813
40 - GENERAL................814
General notes to be observe when working on power transmission assemblies................815
44 - HYDROSTATIC DRIVE................817
Travel motor; description................818
Track motor; specifications................823
Track motor; tightening torques................824
Track motor; removing................825
Track motor; installing................830
Travel motor removed; overhaul................834
Slew motor; description................873
Slew motor; specifications................879
Slew motor; tightening torques................880
Slew motor; troubleshooting................881
Swing motor; removing................883
Swing motor; installing................889
Swing motor removed; overhaul................896
Center passage; description................921
Centre passage; removing................923
Centre passage; installing................928
49 - MISCELLANEOUS................932
Swing ring; removing................933
Swing ring; installing................940
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT................946
70 - GENERAL................947
Frame and track unit; specifications................948
71 - FRAME................950
Counterweight; specifications................951
Undercarriage; description................952
Superstructure covering; description................954
77 - WHEELS; TRACKS; TYRE; HUB; DRUM................956
Front idler; removing................957
Front idler; installing................960
Sprocket; removing................962
Sprocket; installing................964
Rubber track; removing................966
Rubber track; installing................969
Chain guide; removing................971
Chain guide; installing................974
Bottom roller; removing................976
Bottom roller; installing................978
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE................980
81 - CAB; NAKED; CANOPY................981
Cab; weight................982
Cab; tightening torques................983
Cab; removing................984
Cab; installing................990
Cab platform; removing................996
Cab platform; installing................1012
82 - ENGINE HOOD; MUDGUARD; FOOT STEP................1027
Engine hood; replacing................1028
85 - CAB INTERIOR; UPHOLSTERY................1032
Operator's seat; removing................1033
Operator's seat; installing................1036
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS................1040
90 - GENERAL................1041
Hydraulic diagram; complete - Image................1042
Hydraulic diagram; complete................1043
Hydraulic diagram 1................1047
Hydraulic diagram 2................1050
Hydraulic diagram 3................1053
Hydraulic diagram 4................1056
Hydraulic diagram 5................1059
Hydraulic diagram 6................1062
Hydraulic diagram 7................1065
Hydraulic diagram 8................1068
Hydraulic diagram 9................1071
Hydraulic diagram 10................1074
Hydraulic diagram 11................1077
Hydraulic diagram 12................1080
Hydraulic diagram 13................1083
Hydraulic diagram 14................1086
General notes when working on hydraulic system................1089
Pressure adjustment and leaks checking................1092
Hydraulic oil; description................1094
Hydraulic oil; storage and handling................1095
Hydraulic components; storing and transporting................1096
Hydraulic system; tightening torques................1097
H-ECU (hydraulic); replacing pre-programmed ECU................1098
Hydraulic system; specification................1102
91 - WORKING HYDRAULIC; SERVO HYDRAULICS................1103
LS system; bleeding................1105
Hydraulic tank; specifications................1107
Hydraulic oil cooler; description................1108
Hydraulic oil cooler; removing................1110
Hydraulic oil cooler; installing................1114
Main control valve; description................1118
Control valve; tightening torques_{11-32-29}................1121
Control valve; tightening torques_{11-32-08}................1122
Main control valve; removing................1123
Main control valve; installing................1131
Main control valve; disassembling................1138
Main control valve; assembling................1141
LS-pressure relief valve; replacing................1145
Flow regulation valve; changing................1149
Flushing valve; replacing................1153
Secondary pressure limiting valve; replacing................1157
Anti-cavitation check valve; replacing................1160
Working pressure; checking and adjusting................1163
LS (load sense) pressure; checking................1166
Proportional valve; offset_optional equipment................1169
Six way valve; offset_optional equipment................1172
Shuttle valve; swing brake................1174
Pump; specifications................1176
Pump; removing................1177
Pump; installing................1182
Hydraulic pump; power control; checking................1186
Servo pressure; checking and adjusting................1190
Accumulator; description................1193
Servo accumulator; removing................1195
Servo accumulator; installing................1198
Travel valve (pedal); removing................1201
Travel valve (pedal); installing................1205
Servo valve; removing................1209
Servo valve; installing................1212
Control levers; description................1215
Control levers; maintenance standard................1222
Control levers; repairing................1224
Left control lever; removing................1232
Right control lever; removing................1236
Left control lever; installing................1240
Right control lever; installing................1243
97 - UNIT; DIGGING................1246
Boom lifting cylinder; specifications................1247
Dipper arm cylinder; specifications................1248
Bucket cylinder; specifications................1249
Adjustable boom cylinder; specifications................1250
Dozer blade cylinder; specifications_{11-13-17}................1251
Dozer blade cylinder; specifications_{11-12-56}................1252
Boom; removing_{11-12-20}................1253
Boom; removing_{11-11-56}................1259
Boom; installing_{11-11-20}................1265
Boom; installing_{11-10-57}................1272
Boom cylinder; removing................1279
Boom cylinder; installing................1282
Dipper arm; removing................1285
Dipper arm; installing................1291
Dipper arm cylinder; removing................1297
Dipper arm cylinder; installing................1301
Bucket cylinder; removing................1305
Bucket cylinder; installing................1309
Volvo EC18C Compact Excavators Repair Service Manual
