Volvo EC20E Compact Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for EC20E Volvo Compact Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions EC20E 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.
EC20E Volvo Compact Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,030 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
Description; general.........5
Product plate; description.........7
Component locations .........9
03 - SPECIFICATIONS.........11
Tightening torques .........12
Conversion tables.........23
Weight.........28
Lifting capacities.........29
07 - STANDARD TIME.........30
Operation numbers for additional work.........31
08 - TOOL.........33
Infrared Thermometer.........34
09 - MISCELLANEOUS.........38
Welding on the machine.........39
Hydraulic cylinders; dieseling.........40
1 - STANDARD PARTS; SERVICE.........42
16 - LUBRICANT; FUEL; OTHER FLUID.........43
Hydraulic oil.........44
Recommended lubricants.........49
Fuel; recommendation.........52
Coolant .........53
Coolant.........58
Alternative fuels.........60
17 - SERVICE.........63
Cleanliness; braking and hydraulic system.........66
Hydraulic system; pressure release.........67
Repairing hydraulic system.........69
Service.........70
Service and maintenance.........73
Cleaning prior to repair.........75
Arrival Inspection; according to Inspection Programme.........76
Delivery Inspection; according to Inspection Programme.........77
Maintenance of Stored Machines; according to Inspection Programme.........78
Service position 1-38.........79
Service position 2-13.........80
Service position 3-47.........82
Maintenance service; first 50 hours.........84
Maintenance service; daily.........86
Maintenance service; every 50 hours.........88
Maintenance service; every 250 hours.........90
Maintenance service; every 500 hours.........93
Maintenance service; every 1000 hours.........97
Maintenance service; every 1500 hours.........101
Maintenance service; every 2000 hours.........103
Maintenance service; every 3000 hours.........105
Fuel filter; replacing.........107
Valves; adjusting-.........109
Coolant; changing.........118
Machine condition; checking.........123
Radiator and hydraulic oil cooler; cleaning.........124
Leakage oil filter element; replacing.........126
Seat belt; replacing-14.........128
Injection timing; checking.........131
Injection pump; checking.........140
Test running and checking.........147
Lubrication.........148
Crankcase ventilation separator; checking.........149
Engine oil level; checking.........151
Engine oil and filter; changing.........153
Water separator; checking.........156
Fuel hoses; checking.........158
Fuel injectors; checking.........159
Air inlet hose; checking.........165
Exhaust manifold; checking.........166
Engine air cleaner primary filter; cleaning_{03-27}.........167
Engine air cleaner primary filter; cleaning_{03-04}.........170
Engine air cleaner primary filter; replacing_{02-33}.........173
Engine air cleaner primary filter; replacing_{02-13}.........176
Engine air cleaner secondary filter; replacing_{01-42}.........179
Engine air cleaner secondary filter; replacing_{01-22}.........181
Coolant level; checking.........183
Coolant freezing point; checking.........185
Fan_alternator belt; checking.........187
Radiator hoses; checking.........189
Track gearbox oil level; checking.........191
Track gearbox oil; changing.........193
Track tension and condition; checking.........195
Cab main filter; replacing.........198
Hydraulic oil level; checking.........200
Hydraulic oil; changing.........202
Hydraulic oil return filter; replacing.........206
Hydraulic hoses; checking.........208
Hydraulic pressure; checking.........209
Attachment quick coupler; checking.........213
Service history (included in the respective Operator's manual); fill in..........214
Lubrication and service schedules-11.........215
Lubrication and service schedules.........218
Measuring condition-43.........221
Measuring condition.........222
Cylinder speed.........223
Values; cylinder speed.........227
Creeping of hydraulic cylinder.........228
Values; creeping of hydraulic cylinder.........230
Slewing speed.........231
Values; slewing speed.........233
Travel Speed.........234
Values; travel speed.........236
Track running speed.........237
Values; track running speed.........239
Deviation when travelling straight ahead.........240
Values; deviation when travelling straight ahead.........243
Towing; measures.........244
Starting engine with booster cables.........245
Starting with booster batteries .........248
19 - GENERAL.........250
Safety concerns everybody!.........251
Service position 1.........253
Service position 2.........255
Service position 3.........257
CE marking and declaration of conformity.........259
Safety when handling the machine.........261
Safety rules when servicing.........266
Safety when lifting and supporting the machine.........269
Fire prevention measures.........271
Working on the electrical system of the machine.........274
Safety when working with batteries.........276
Starting with booster batteries.........279
Safety when handling oils and fuel.........281
Pressure setting and leak detection.........282
Safety for work on hydraulic systems.........283
Checklist after a fire or heat exposure.........285
Health hazards with paint; plastics and rubber.........286
Environmental handling for the future.........288
Waste handling.........290
Environmentally safe handling.........294
Environmentally hazardous fluids.........296
Safety when working with air conditioning refrigerant.........297
Working in environmentally contaminated areas.........300
Decontamination.........303
2 - ENGINE WITH MOUNTING AND EQUIPMENT.........304
20 - GENERAL.........305
Engine; description.........306
Component locations.........308
Engine; capacities.........310
Engine; tighten torques.........311
Engine trouble shooting.........313
21 - ENGINE.........316
Engine; specifications.........317
Engine; mounting in work stand.........318
Cylinder compression; testing.........320
Engine; removing.........323
Engine; installing.........330
Cylinder head; description.........337
Crankcase ventilation; description.........339
Pistons; description.........341
Valve mechanism; description.........343
Valve mechanism; specifications.........345
Valves; adjusting.........346
Timing gear; description.........348
Crankshaft; description.........350
Oil sump; replacing.........352
Engine mounts; replacing.........355
22 - LUBRICATING SYSTEM.........359
Lubricating system; description.........360
Lubrication system; specifications.........363
23 - FUEL SYSTEM.........364
Fuel system; description.........365
Fuel system; general specifications.........368
Fuel system; tightening torques.........369
Fuel feed pump; description.........371
Fuel feed pump; specifications.........373
Fuel pump; removing.........374
Fuel pump; installing.........378
Fuel tank; specifications.........381
Fuel tank; description.........382
Fuel tank; removing.........384
Fuel tank; installing.........387
Idling speed; checking and adjusting.........389
Injection pump; replacing.........392
Injectors; specification.........397
Injectors; description.........398
Injectors; tightening torques.........400
Injectors; replacing.........402
Injectors; checking.........409
25 - INLET & EXHAUST SYSTEM.........411
Intake and exhaust system; description.........412
Induction manifold gasket; replacing.........414
Exhaust manifold; replacing.........417
Silencer; removing.........421
Silencer; installing.........423
Air cleaner; description.........425
Air cleaner; removing.........427
Air cleaner; installing.........429
26 - COOLING SYSTEM.........431
Cooling system; description.........432
Cooling system; specification.........436
Cooling package; removing.........437
Cooling package; installing.........441
Coolant anti-freeze resistance; checking.........445
Radiator hose upper; replacing.........447
Radiator hoses lower; replacing.........450
Expansion tank; removing.........453
Expansion tank; installing.........455
Thermostat; inspecting.........456
Thermostat; replacing.........458
Coolant pump; replacing.........462
Fan belt and_or alternator belt; replacing.........467
27 - ENGINE CONTROL.........470
Throttle controls; setting.........471
Throttle control cable; removing.........474
Throttle control cable; installing.........478
Stop magnet; replacing.........481
Auto idling device; description.........482
Automatic idling device; removing.........484
Automatic idling device; installing.........487
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.........490
30 - GENERAL.........491
Electrical system; special instructions for servicing; general.........492
Electrical system; special instructions for servicing; electronic components_{53-05}.........494
Electrical system; special instructions for servicing; electronic components_{52-44}.........496
Electrical system; special instructions for servicing; electronic components_{52-26}.........497
Troubleshooting; general.........499
Troubleshooting tips.........500
Troubleshooting; assistant devices.........502
Collection of basic data.........504
Measuring components.........506
Checking electrical cabling and connectors.........507
Resistance measurement.........512
DC voltage measurement.........516
DC current measurement.........520
Diode check procedure.........524
31 - BATTERY.........527
Battery; specifications.........528
Battery condition; checking.........529
Batteries; replacing.........533
32 - ALTERNATOR; CHARGE REGULATOR.........537
Alternator; specifications.........538
Alternator; removing.........539
Alternator; installing.........542
33 - STARTING SYSTEM.........544
Starter motor; specification.........545
Starter motor; replacing.........546
Preheating; specifications.........549
Glow plug; removing.........550
Glow plug; installing.........552
Glow plugs; testing.........554
35 - LIGHTING.........555
Light bulbs; specification.........556
Light bulb; replacing.........557
36 - OTHER ELECTRICAL EQUIPMENT.........562
Horn; replacing.........563
Travel alarm; specifications.........566
Travel alarm; replacing.........567
Windscreen wiper front motor; replacing.........570
Switch; replacing.........577
Vehicle control unit V-ECU; description.........581
Antitheft device; first activation of a new A-ECU.........584
A-ECU (anti theft); replacing.........587
I-ECU; replacing.........591
V-ECU; replacing.........595
37 - CABLE; FUSE; RELAY.........598
Electrical symbols and designation.........600
Cable and component marking explanations.........603
Cables; description.........606
Component list Alternator; batteries; capacitors; electronic units; voltage outlet.........608
Component list; diodes.........610
Component list Fuses.........613
Component list Heating coils; instruments; service socket.........617
Component list Lights.........618
Component list; motors.........620
Component list PWM valves.........621
Component list Relays.........622
Component list; sensors.........624
Component list Solenoid valves.........626
Component list; Sounders.........628
Component list Switches.........629
V-ECU inputs and outputs.........631
Wiring diagram 1.........633
Wiring diagram 2.........634
Wiring diagram 3.........637
Wiring diagram 4.........640
Wiring diagram 5.........643
Wiring diagram 6.........646
Wiring diagram 7.........649
Wiring diagram 8.........652
Wiring diagram 9.........655
Wiring diagram 10.........658
Wiring diagram 11.........661
CareTrack.........664
Fuse; description.........667
Electrical distribution box; circuit board replacing.........669
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.........673
Instrument panel; description.........674
4 - POWER TRANSMISSION.........676
40 - GENERAL.........677
General notes to be observe when working on power transmission assemblies.........678
Power transmission; description.........680
44 - HYDROSTATIC DRIVE.........681
Track motor; tightening torques.........682
Swing motor; specifications.........683
Swing motor; description.........684
Swing motor; removing.........690
Swing motor; installing.........693
Travel motor; description.........696
Travel motor; specifications.........701
Track motor; removing.........702
Track motor; installing.........707
Center passage; description.........711
Centre passage; removing.........713
Centre passage; installing.........718
49 - MISCELLANEOUS.........722
Swing ring gear; description.........723
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.........725
70 - GENERAL.........726
Frame and track unit; specifications.........727
71 - FRAME.........729
Counterweight; specifications.........730
Counterweight; description.........731
Counterweight; replacing.........732
Undercarriage; description.........736
Superstructure covering; description.........738
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.........740
Front idler; removing.........741
Front idler; installing.........743
Sprocket; removing.........745
Sprocket; installing.........747
Track tension; adjusting.........749
Rubber track; removing.........751
Rubber track; installing.........754
Chain guide; removing.........755
Chain guide; installing.........758
Bottom roller; removing.........760
Bottom roller; installing.........762
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.........764
82 - ENGINE HOOD; MUDGUARD; FOOT STEP.........765
Engine hood; replacing.........766
85 - CAB INTERIOR; UPHOLSTERY.........770
Operator's seat; removing.........771
Operator's seat; installing.........774
Seat belt; replacing.........777
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.........778
90 - GENERAL.........779
Hydraulic diagram; complete - Image.........780
Explanations to hydraulic diagram.........781
Hydraulic diagram; component locations.........788
Hydraulic diagram; complete.........789
Hydraulic system; description.........792
General notes when working on hydraulic system.........796
Pressure adjustment and leaks checking.........799
Hydraulic oil; description.........801
Hydraulic oil; storage and handling.........802
Hydraulic components; storing and transporting.........803
Hydraulic system; specification.........804
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.........805
Hydraulic oil tank; tightening torques.........807
Hydraulic tank; specifications.........808
Hydraulic oil cooler; description.........809
Hydraulic oil tank; removing.........810
Hydraulic oil tank; installing.........814
Hydraulic oil cooler; removing.........817
Hydraulic oil cooler; installing.........818
Main control valve; description.........819
Control valve; tightening torques.........821
Main control valve; removing.........822
Main control valve; installing.........825
Main control valve; disassembling.........827
Main control valve; assembling.........830
LS-pressure relief valve; replacing.........833
Flow regulation valve; changing.........836
Flushing valve; replacing.........839
Secondary pressure limiting valve; replacing.........843
Anti-cavitation check valve; replacing.........846
Working pressure; checking and adjusting.........849
Proportional valve; offset_optional equipment_{38-11}.........852
Solenoid valve; offset_optional equipment_{37-53}.........854
Six way valve; offset_optional equipment.........856
Hose rupture valves.........858
Hose rupture valve; removing.........860
Hose rupture valve; installing.........863
Pump; specifications.........865
Pump; removing.........866
Pump; installing.........869
LS (load sense) pressure; checking.........871
Hydraulic pump; power control; checking.........874
Servo valve; description-36.........879
Servo valve; description.........881
Servo valve; removing.........883
Servo valve; installing.........885
Servo pressure; checking and adjusting.........887
Accumulator; description.........890
Servo accumulator; removing.........892
Servo accumulator; installing.........895
Travel valve (pedal); removing.........898
Travel valve (pedal); installing.........901
Accumulator; discarding.........905
Control levers; description.........907
Control levers; repairing.........912
Control lever; removing.........920
Control lever; installing.........925
Tightening torques.........930
Control pattern selector valve; description.........931
X1 and X3 hydraulic with flow control; calibrating.........934
Control pattern selector valve; removing.........937
Control pattern selector valve; installing.........939
92 - MECHANICAL EQUIPMENT_ATTACHMENT.........941
Boom support; pivot play.........942
Quickfit; function check.........947
Quickfit solenoid valve; replacing.........949
97 - UNIT; DIGGING.........952
Boom cylinder; specifications.........953
Dipper arm cylinder; specifications.........954
Bucket cylinder; specifications.........955
Adjustable boom cylinder; specifications.........956
Dozer blade cylinder; specifications.........957
Boom swing cylinder; removing.........958
Boom swing cylinder; installing.........962
Boom; specifications.........966
Boom; removing.........967
Boom; installing.........971
Boom cylinder; removing.........976
Boom cylinder; installing.........981
Dipper arm; specifications.........986
Dipper arm; removing.........987
Dipper arm; installing.........990
Dipper arm cylinder; removing.........994
Dipper arm cylinder; installing.........998
Bucket cylinder; removing.........1002
Bucket cylinder; installing.........1006
98 - FUNCTION FOR ROAD CONSTRUCTION.........1010
Dozer blade cylinder; replacing.........1011
99 - MISCELLANEOUS.........1016
Hydraulic pump; power control; checking_{15-56}.........1017
Hose rupture valve; removing_{15-20}.........1022
Hose rupture valve; installing_{15-03}.........1025
Exhaust manifold; replacing_{14-45}.........1027
Volvo EC20E Compact Excavators Repair Service Manual
