Volvo EC60D Compact Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EC60D Compact Excavators, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo Constructions EC60D 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: 1,274 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo EC60D Compact Excavators Service Repair Manual.pdf
MAIN SECTIONS
0 - Foreword.....2
0 - GENERAL.....3
00 - DESCRIPTION; COMPLETE MACHINE.....4
Machine view.....5
Product plates.....8
03 - SPECIFICATIONS.....10
Measurement conversion tables.....11
Tightening torques-.....20
07 - STANDARD TIME.....29
Operation numbers for additional work.....30
09 - MISCELLANEOUS.....32
Hydraulic cylinders, dieseling.....33
Service positions.....37
Welding on the machine.....40
1 - STANDARD PARTS, SERVICE.....43
16 - LUBRICANT; FUEL; OTHER FLUID.....44
Alternative fuels.....45
Change capacities.....48
Coolant.....49
Engine oil.....53
Fuel.....56
Grease.....57
Hydraulic oil.....61
17 - SERVICE.....65
Air conditioner compressor belt, checking.....68
Air conditioner main filter, cleaning.....70
Air conditioner main filter, replacing.....72
Air inlet hose, checking.....74
Arrival Inspection, according to Inspection Programme.....75
Bearings.....76
Cleaning prior to repair.....80
Coasting left and right swing.....84
Coolant freezing point, checking.....86
Coolant level, checking.....89
Coolant, changing .....90
Creeping of hydraulic cylinder.....93
Cylinder speed.....94
Delivery Inspection, according to Inspection Programme.....97
Engine air cleaner primary filter, replacing.....98
Engine air cleaner secondary filter, replacing.....100
Engine oil and filter, changing.....103
Engine oil level, checking.....106
Fan_alternator belt, checking.....108
Fuel filter, replacing.....110
Fuel hoses, checking.....112
Fuel injectors, checking.....113
Hoses and tubes.....117
Hydraulic oil level, checking.....121
Hydraulic oil return filter, replacing.....123
Hydraulic oil servo filter, replacing.....126
Hydraulic oil suction strainer, cleaning.....128
Hydraulic oil tank breather filter, cleaning.....130
Hydraulic oil, changing.....132
Injection timing, checking-.....134
Lubrication, every 010 hours.....138
Maintenance of Stored Machines, according to Inspection Programme.....139
Maintenance service, every 010 hours.....140
Maintenance service, every 100 hours.....141
Maintenance service, every 1000 hours.....142
Maintenance service, every 1500 hours.....144
Maintenance service, every 2000 hours.....146
Maintenance service, every 250 hours.....148
Maintenance service, every 3000 hours.....150
Maintenance service, every 500 hours.....152
Maintenance service, every 6000 hours.....154
Maintenance service, first 250 hours.....155
Maintenance service, first 500 hours.....156
Measuring condition.....157
Measuring of swing bearing clearance.....158
Pressure testing.....161
Radiator and hydraulic oil cooler, cleaning.....165
Radiator hoses, checking.....167
Replacement parts.....168
Safety when servicing.....172
Service methods.....176
Service position.....180
Service.....182
Straight traveling performance.....185
Swing bath grease, lubricating.....187
Swing gearbox oil level, checking.....188
Swing gearbox oil, changing.....190
Swing ring gear bearing, lubricating.....193
Swing speed.....195
Test running and checking.....196
Track gearbox oil level, checking.....198
Track gearbox oil, changing.....199
Track running speed.....201
Track shoe bolts, checking.....202
Track tension and condition, checking.....204
Travel Speed.....206
Turbocharger, checking.....208
Valves, adjusting-.....210
Water separator, checking.....217
19 - GENERAL.....219
CE-marking, EMC-directive.....220
Cautions during operation.....224
Checklist after a fire or heat exposure.....231
Decontamination.....232
Environmental handling for the future.....233
Environmentally hazardous fluids.....234
Environmentally safe handling.....235
Fire prevention measures.....237
General precautions.....240
Health hazards with paint, plastics and rubber.....244
Move and operate machine safely.....246
Preparations for work.....249
Safety concerns everybody!.....253
Safety rules when servicing.....254
Safety when handling oils and fuel.....259
Safety when handling the machine.....260
Safety when using lifting equipment.....267
Safety when working with air conditioning refrigerant.....269
Safety when working with batteries.....272
Safety when working with hydraulic systems.....275
Starting with booster batteries.....276
Waste handling.....277
Working in environmentally contaminated areas.....278
2 - ENGINE WITH MOUNTING AND EQUIPMENT.....279
20 - GENERAL.....280
Component locations.....281
Engine belts, replacing.....284
Engine, description.....286
21 - ENGINE.....290
Crankshaft front oil seal, replacing.....291
Crankshaft rear oil seal, replacing.....294
Engine rotation speed sensor (crank shaft), replacing.....297
Engine, specifications.....299
Engine, tightening torques.....300
Valve cover, installing.....301
Valve cover, removing.....305
Valve system specifications.....309
Valves, adjusting.....310
22 - LUBRICATING SYSTEM.....313
Lubricating system, description.....314
Lubrication oil pressure, checking with pressure gauge.....317
Lubrication system, component locations.....320
Lubrication system, specifications.....322
Lubrication system, tightening torques.....323
Oil cooler, replacing.....326
23 - FUEL SYSTEM.....329
Fuel pump unit, replacing.....330
Fuel system, component location.....337
Fuel system, description.....339
Fuel system, specifications.....341
Fuel system, tightening torques.....342
Fuel tank, specifications.....348
Injection pump, checking.....349
Injection timing, checking.....352
Injectors, replacing.....356
Overflow pipe, inspecting.....360
25 - INLET & EXHAUST SYSTEM.....363
Inlet and exhaust system, component location.....364
Inlet and exhaust system, tightening torques.....365
Silencer, replacing.....366
Turbocharger, inspecting.....369
Turbocharger, replacing.....371
Wastegate, checking.....375
26 - COOLING SYSTEM.....377
Coolant anti-freeze resistance, checking.....378
Coolant pump, replacing.....383
Coolant, changing.....386
Cooling system, component location.....389
Cooling system, description.....391
Cooling system, specification.....394
Cooling system, tightening torques.....395
Expansion tank, replacing.....396
Thermostat, checking.....398
Thermostat, replacing.....402
27 - ENGINE CONTROL.....405
Engine control, specifications.....406
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....407
30 - GENERAL.....408
Basic check.....409
Collection of basic data.....411
Communication with data buses.....415
Electrical system, description.....417
Electrical system, special instructions for servicing, action when working on machine.....419
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator.....422
Electrical system, special instructions for servicing, electrical components, batteries.....425
Electrical system, special instructions for servicing, electronic components.....429
Electrical system, special instructions for servicing, general.....432
Electrical system, specifications.....436
Electronic control system, description.....437
Lead and connector checks.....439
Measuring components.....445
Special tools for troubleshooting.....446
Troubleshooting tools.....447
31 - BATTERY.....448
Batteries, replacing.....449
Battery, charging.....451
Battery, description.....452
Battery, specifications.....454
Battery, storage.....455
32 - ALTERNATOR; CHARGE REGULATOR.....458
Alternator, replacing incl function checking.....459
Alternator, specifications.....461
Alternator, testing.....462
33 - STARTING SYSTEM.....464
Starter motor, specifications.....465
Starter relay, replacing.....466
35 - LIGHTING.....468
Work lights and extra lights, specifications.....469
36 - OTHER ELECTRICAL EQUIPMENT.....470
Control unit, description.....471
Electric horn, description.....473
Electric horn, specifications.....474
Horn, replacing.....475
Pre-heating relay, replacing.....477
Rotating beacon, specifications.....479
Start switch, description.....480
Start switch, specifications.....483
Travel alarm, description.....485
Travel alarm, specifications.....486
Windscreen wiper, components location.....487
Windscreen wiper, description.....490
Wiper controller, description.....491
Wiper controller, specifications.....493
Wiper motor, description.....494
Wiper motor, specifications.....496
37 - CABLE; FUSE; RELAY.....497
Battery disconnect switch, description.....499
Battery disconnect switch, specifications.....500
Component list Alternator, batteries, capacitors, electronic units, voltage outlet.....501
Component list, Heating coils.....502
Component list, Miscellaneous.....503
Component list, Solenoid valves_{008-25-58}.....504
Component list, Solenoid valves_{008-26-09}.....505
Component list, Switches.....506
Component list, diodes.....507
Component list, fuses.....508
Component list, lights.....509
Component list, motors.....510
Component list, relays.....511
Component list, sensors.....512
Component location 002.....513
Component location 003.....516
Component location 008.....521
Fuse, description-[1834].....524
Fuse, description-[1848].....525
Fuse, description.....528
Relay, description-[1741].....531
Relay, description.....533
Relay, specifications.....535
Slow blow fuse, description.....536
Wiring diagram WD201.....537
Wiring diagram WD202.....540
Wiring diagram WD203.....543
Wiring diagram WD301.....546
Wiring diagram WD302.....549
Wiring diagram WD303.....552
Wiring diagram WD304.....555
Wiring diagram WD305.....558
Wiring diagram WD306.....561
Wiring diagram WD801.....564
Wiring diagram WD802.....567
Wiring diagram WD901.....570
Wiring diagram WD902.....573
Wiring diagram.....576
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....577
Fuel level sensor, description.....578
Fuel level sensor, specifications.....579
Instrument cluster.....580
39 - MISCELLANEOUS.....581
Radio with CD and MP003 player, description.....582
4 - POWER TRANSMISSION.....583
40 - GENERAL.....584
Power transmission, description.....585
Tightening torque, specifications .....586
43 - GEARBOX.....587
Function description.....588
Slew gearbox, description.....590
Slew gearbox, precautions for operation.....593
Swing gearbox, assembly.....595
Swing gearbox, disassembly.....605
Swing gearbox, maintenance standard.....611
Swing gearbox, specifications.....613
Track gearbox cover, replacing.....614
Track gearbox, assembly.....617
Track gearbox, description.....618
Track gearbox, disassembly.....619
Track gearbox, maintenance standard.....620
Track gearbox, precautions for operation.....621
Track gearbox, specifications.....624
Track unit, replacing.....625
44 - HYDROSTATIC DRIVE.....629
Center passage, assembly.....630
Center passage, description.....636
Center passage, disassembly.....638
Center passage, maintenance standard_{007-57-45}.....641
Center passage, maintenance standard_{007-58-13}.....643
Center passage, specifications.....646
Center passage, tools.....647
Center passage, troubleshooting.....649
Hydraulic pump coupling, description.....650
Manual release of parking brake.....652
Slew motor, precautions for installation.....655
Slew motor, troubleshooting.....657
Swing motor relief valve, replacing.....659
Swing motor, assembly.....661
Swing motor, description_{008-03-01}.....671
Swing motor, description_{008-03-36}.....683
Swing motor, disassembly.....695
Swing motor, maintenance standard.....703
Swing motor, specifications.....704
Track motor relief valve, replacing_{008-05-33}.....705
Track motor relief valve, replacing_{008-05-46}.....707
Track motor, assembly.....709
Track motor, description.....725
Track motor, disassembly.....735
Track motor, maintenance standard.....748
Track motor, specifications.....750
49 - MISCELLANEOUS.....751
Slew ring gear, installation.....752
Slew ring gear, removal.....754
Swing ring gear, description.....756
Swing ring gear, specifications.....758
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....759
70 - GENERAL.....760
Frame and track unit, description.....761
Frame and track unit, specifications.....763
Undercarriage, tightening torque.....764
71 - FRAME.....766
Counterweight, description.....767
Counterweight, replacing.....768
Counterweight, specifications.....772
Counterweight, tightening torques.....773
Machine weight, specifications.....775
Superstructure, installation.....777
Superstructure, removal.....779
Tightening torque, specifications.....781
Undercarriage, description.....783
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....785
Bottom roller, description.....787
Bottom roller, measurement of wear.....789
Bottom roller, replacing one.....792
Front idler, replacing one.....795
Idler, description.....798
Idler, measurement of wear.....799
Rubber pads.....802
Rubber shoe_pad usage.....804
Rubber track, installing.....806
Rubber track, removing.....808
Selection of track shoes.....811
Spring package, measurement of wear.....813
Sprocket, measurement of wear.....815
Sprocket, replacing one.....818
Tools & equipment.....820
Top roller, description.....825
Top roller, measurement of wear.....827
Top roller, replacing one_{007-38-15}.....829
Top roller, replacing one_{007-38-32}.....832
Track chain assembly, installing.....836
Track chain assembly, removing.....840
Track chain, description-[4500].....843
Track chain, description.....844
Track chain, measurement of wear.....846
Track guard, replacing one.....851
Track links, replacing.....853
Track recoil spring (tensioner) assembly, replacing.....857
Track shoe, replacing one.....860
Track tension cylinder, replacing.....862
Track, adjusting track sag.....866
Track, adjusting track sag_{007-44-08}.....867
Track, adjusting track sag_{007-44-23}.....870
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....875
83 - DOORS; HATCH; COVER PLATE, (all).....876
Door, replacing.....877
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.....880
Door window, replacing.....881
Rear window, replacing.....884
Side window, replacing.....889
Windows, general.....894
Windscreen, replacing.....895
87 - AIR CONDITIONING UNIT.....900
Air conditioning unit, maintenance.....901
Air conditioning unit, refrigerant check and recharging.....905
Air conditioning unit, specifications.....910
Condenser.....911
Expansion valve.....912
Heater unit, description.....916
Performance test, AC unit.....918
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....924
90 - GENERAL.....925
Description, general.....926
General notes when working on hydraulic system.....927
Hydraulic oil, description.....930
Hydraulic pressure, specifications .....934
Pressure adjustment and leaks checking.....935
Recommended hydraulic oil, specifications.....937
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....938
Accumulator, replacing.....941
Control valve, replacing.....943
Control valve, troubleshooting.....947
Hydraulic components, description.....949
Hydraulic diagram, ports.....951
Hydraulic oil cooling system, description.....953
Hydraulic oil cooling system, specifications.....954
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump.....955
Hydraulic pressure, measuring and adjustment.....958
Hydraulic pressure, specifications.....960
Hydraulic pump (removed), changing shaft seal.....962
Hydraulic pump, maintenance standard, Specifications.....964
Hydraulic pump, replacing.....968
Hydraulic pump, specifications.....973
Hydraulic system, position of main components.....974
Hydraulic system, work instructions.....977
Hydraulic tank, description.....982
Hydraulic tank, specifications.....984
Main control valve, assembly.....985
Main control valve, description.....992
Main control valve, disassembly.....996
Main control valve, operation.....998
Main pressure relief valve, replacing.....1011
Main relief valve, adjustment.....1014
Main relief valve, assembly.....1016
Main relief valve, description.....1017
Main relief valve, disassembly.....1019
Oil level gauge, replacing.....1021
Port relief valve pressure, measuring and adjusting.....1024
Port relief valve, assembly.....1026
Port relief valve, description.....1027
Port relief valve, disassembly.....1030
Pressure accumulator, description.....1032
Pressure accumulator, specifications.....1035
Pressure relief valve, troubleshooting.....1036
Pump, assembly.....1037
Pump, description.....1057
Pump, disassembly.....1065
Pump, installation.....1080
Pump, tools.....1082
Pump, troubleshooting.....1084
Remote control valve (Lever), assembly.....1086
Remote control valve (Lever), description.....1093
Remote control valve (Lever), disassembly.....1102
Remote control valve (Lever), maintenance standard, Specifications.....1109
Remote control valve (Lever), specifications.....1111
Remote control valve (Lever), troubleshooting.....1113
Remote control valve (lever), replacing.....1114
Servo hydraulic block.....1121
Servo pressure, checking and adjusting.....1122
Servo pump, description.....1124
Servo pump, replacing.....1126
Servo pump, specifications.....1130
Solenoid valve, description .....1131
Solenoid valve, description.....1134
Solenoid valve, disassembly and assembly.....1137
Solenoid valve, inspection.....1139
Solenoid valve, replacing.....1140
Solenoid valve, specifications-.....1143
Solenoid valve, specifications.....1144
Stop valve.....1145
Tightening torques-.....1148
X001 Line, description.....1151
92 - MECHANICAL EQUIPMENT_ATTACHMENT.....1155
Control lever (dozer blade), replacing.....1156
Dozer blade cylinder, description.....1161
Dozer blade cylinder, replacing.....1163
Dozer blade cylinder, specifications.....1168
Dozer blade, description.....1169
Dozer blade, specifications.....1171
Remote control valve (dozer blade), description.....1172
Remote control valve (dozer blade), specifications.....1175
Tightening torques .....1176
97 - UNIT, DIGGING.....1178
Boom cylinder, description.....1179
Boom cylinder, replacing.....1181
Boom cylinder, specifications.....1185
Boom, description.....1186
Boom, replacing.....1188
Boom, specifications.....1194
Bucket cylinder, description.....1195
Bucket cylinder, replacing.....1197
Bucket cylinder, specifications.....1201
Connecting rod yoke, replacing.....1202
Cylinder, description.....1207
Cylinder, disassembly and assembly.....1209
Cylinder, troubleshooting.....1220
Digging unit, maintenance standard, specifications.....1224
Dipper arm connecting rod, replacing.....1226
Dipper arm cylinder, description.....1231
Dipper arm cylinder, replacing.....1233
Dipper arm cylinder, specifications.....1238
Dipper arm, description.....1239
Dipper arm, replacing.....1241
Dipper arm, specifications.....1247
Link, description-[4934].....1248
Link, description.....1250
Tightening torques.....1252
99 - MISCELLANEOUS.....1257
Explanations to hydraulic diagram.....1258
Hydraulic circuits, standard.....1269
Hydraulic circuits, with option components.....1272
Volvo EC60D Compact Excavators Repair Service Manual
