Volvo EC20D Compact Excavators Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EC20D Compact Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
EC20D Volvo Constructions 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.
EC20D Volvo Compact Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,311 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - GENERAL....2
00 - DESCRIPTION; COMPLETE MACHINE....3
Description; general....4
Product plate; description....6
Component Locations....8
03 - SPECIFICATIONS....10
Tightening torques....11
Conversion tables....22
Dimensions....27
Weight....30
Lifting capacities....31
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION....32
Transporting and lifting the machine....33
07 - STANDARD TIME....37
Operation numbers for additional work....38
08 - TOOL....40
Infrared Thermometer....41
09 - MISCELLANEOUS....45
Welding on the machine_{56-30}....46
Welding on the machine_{56-16}....47
Hydraulic cylinders; dieseling....49
1 - STANDARD PARTS; SERVICE....51
16 - LUBRICANT; FUEL; OTHER FLUID....52
Hydraulic oil....53
Recommended lubricants....58
Fuel; recommendation....61
Coolant....62
Alternative fuels....64
17 - SERVICE....67
Cleanliness; braking and hydraulic system....70
Hydraulic system; pressure release....71
Repairing hydraulic system....73
Service and maintenance....74
Cleaning prior to repair....76
Arrival Inspection; according to Inspection Programme....77
Delivery Inspection; according to Inspection Programme....78
Maintenance of Stored Machines; according to Inspection Programme....79
Service Positions....80
Maintenance service; every 10 hours....82
Maintenance service; every 50 hours....83
Maintenance service; every 250 hours....84
Maintenance service; every 500 hours....86
Maintenance service; every 1000 hours....88
Maintenance service; every 1500 hours....91
Maintenance service; every 2000 hours....93
Maintenance service; every 3000 hours....96
Test running and checking....99
Lubrication....100
Valves; Adjusting....101
Engine oil level; checking....112
Engine oil and filter; changing....113
Water separator; checking....116
Fuel filters; replacing....118
Fuel hoses; checking....120
Injection pump; Checking....121
Injection timing; Checking....127
Fuel injectors; checking....134
Air inlet hose; checking....141
Exhaust manifold; checking....142
Engine air cleaner primary filter; replacing....144
Engine air cleaner secondary filter; replacing....146
Coolant level; checking....147
Coolant; changing....149
Coolant freezing point; checking....153
Fan_alternator belt; checking....155
Radiator; cleaning....157
Radiator hoses; checking....159
Battery; checking....161
Travel gearbox oil level; checking....163
Travel gearbox oil; changing....165
Track tension and condition; checking....167
Cab main filter; replacing....170
Seat belt; Replacing....172
Hydraulic oil level; checking....175
Hydraulic oil; changing....177
Leakage oil filter element; replacing....180
Hydraulic oil return filter; replacing....182
Hydraulic hoses; checking....184
Hydraulic pressure; checking....186
Attachment quick coupler; checking....191
Lubrication and service schedules....193
Measuring condition....196
Cylinder speed....197
Values; cylinder speed....201
Creeping of hydraulic cylinder....202
Values; creeping of hydraulic cylinder....204
Slewing speed....205
Values; slewing speed....207
Travel Speed....208
Values; travel speed....210
Track running speed....211
Values; track running speed....213
Deviation when travelling straight ahead....214
Values; deviation when travelling straight ahead....217
Towing; measures....218
Starting engine with booster cables....219
19 - GENERAL....222
Safety concerns everybody!....223
Service position 1....225
CE marking and declaration of conformity....227
Safety when handling the machine....229
Safety rules when servicing....234
Safety when lifting and supporting the machine....237
Service positions....239
Fire prevention measures....241
Working on the electrical system of the machine....244
Safety when working with batteries....246
Starting with booster batteries....249
Safety when handling oils and fuel....250
Safety for work on hydraulic systems....252
Safety when handling accumulators....254
Checklist after a fire or heat exposure....255
Health hazards with paint; plastics and rubber....257
Environmental handling for the future....260
Waste handling....262
Environmentally safe handling....266
Environmentally hazardous fluids....269
Safety when working with air conditioning refrigerant....270
Working in environmentally contaminated areas....272
Decontamination....275
2 - ENGINE WITH MOUNTING AND EQUIPMENT....279
20 - GENERAL....280
Engine; description....281
Component locations....283
Engine; capacities....285
Engine; tighten torques....286
Engine trouble shooting....288
21 - ENGINE....291
Engine; specifications....292
Cylinder compression; testing....293
Engine; removing....299
Engine; installing....315
Cylinder head; description....330
Crankcase ventilation; description....332
Pistons; description....334
Valve mechanism; description....336
Valve mechanism; specifications....338
Valves; adjusting....339
Timing gear; description....340
Crankshaft; description....341
Oil sump; replacing....343
Engine mounts; replacing....346
22 - LUBRICATING SYSTEM....351
Lubricating system; description....352
Lubrication system; specifications....355
23 - FUEL SYSTEM....356
Fuel system; description....357
Fuel tank; capacities....360
Fuel system; general specifications....361
Fuel system; tightening torques....362
Fuel feed pump; description....364
Fuel feed pump; specifications....366
Fuel pump; removing....367
Fuel pump; installing....369
Fuel tank; description....371
Fuel tank; removing....373
Fuel tank; installing....385
Idling speed; checking and adjusting....395
Injection timing; checking....397
Injection pump; removing....398
Injection pump; checking....403
Injectors; description....404
Injectors; replacing....406
Injectors; checking....411
25 - INLET & EXHAUST SYSTEM....412
Exhaust manifold; replacing....413
Silencer; removing....417
Silencer; installing....421
Air cleaner; description....424
Air cleaner; removing....426
Air cleaner; installing....428
26 - COOLING SYSTEM....430
Cooling system; description....431
Cooling system; specification....434
Coolant anti-freeze resistance; checking....435
Radiator hose upper; replacing....437
Radiator hoses lower; replacing....440
Radiator; removing....443
Radiator; installing....449
Expansion tank; removing....455
Expansion tank; installing....457
Thermostat; inspecting....458
Thermostat; replacing....460
Coolant pump; replacing....464
Fan belt and_or alternator belt; checking and adjusting tension....472
Fan belt and_or alternator belt; replacing....475
27 - ENGINE CONTROL....478
Throttle controls; setting....479
Throttle control cable; removing....481
Throttle control cable; installing....484
Stop magnet; replacing....487
Auto idling device; description....489
Engine speed control; changing throttle cylinder....491
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....493
30 - GENERAL....494
Electrical system; special instructions for servicing; general....495
Electrical system; special instructions for servicing; electronic components_{46-41}....497
Electrical system; special instructions for servicing; electronic components_{46-27}....499
Electrical system; special instructions for servicing; electronic components_{46-14}....500
Troubleshooting; general....502
Troubleshooting tips....503
Troubleshooting; assistant devices....505
Collection of basic data....507
Measuring components....509
Checking electrical cabling and connectors....510
Resistance measurement....515
DC voltage measurement....519
DC current measurement....523
Diode check procedure....527
31 - BATTERY....530
Battery; specifications....531
Battery condition; checking....532
Batteries; replacing....536
32 - ALTERNATOR; CHARGE REGULATOR....540
Alternator; specifications....541
Alternator; removing....542
Alternator; installing....545
33 - STARTING SYSTEM....548
Starter motor; specification....549
Starter motor; replacing....550
Preheating; specifications....552
Glow plug; removing....553
Glow plug; installing....554
Glow plugs; testing....555
35 - LIGHTING....556
Light bulbs; specification....557
Light bulb; replacing....558
36 - OTHER ELECTRICAL EQUIPMENT....562
Horn; replacing....563
Travel alarm; specifications....565
Travel alarm; replacing....566
Windscreen wiper front motor; replacing....568
Switch; replacing....575
Vehicle control unit V-ECU; description....578
Antitheft device; first activation of a new A-ECU_{32-16}....581
Antitheft device; first activation of a new A-ECU_{32-03}....583
A-ECU (anti theft); replacing_{31-39}....586
A-ECU (anti theft); replacing_{31-24}....591
I-ECU; replacing....595
V-ECU; replacing....599
Option anti-theft; instruction....601
37 - CABLE; FUSE; RELAY....605
Electrical symbols and designation_{28-17}....607
Electrical symbols and designation_{27-46}....610
Cable and component marking explanations....613
Cables; description....616
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{26-37}....618
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{26-22}....620
Component list; diodes_{25-59}....622
Component list; diodes_{25-44}....624
Component list Fuses_{25-11}....626
Component list Fuses_{24-57}....628
Component list Heating coils; instruments; service socket_{24-36}....630
Component list Heating coils; instruments; service socket_{24-21}....632
Component list Lights_{24-00}....634
Component list Lights_{23-45}....636
Component list; motors_{23-24}....638
Component list; motors_{23-09}....640
Component list PWM valves_{22-48}....641
Component list PWM valves_{22-34}....642
Component list Relays_{22-13}....643
Component list Relays_{21-59}....645
Component list; sensors_{21-39}....647
Component list; sensors_{21-24}....649
Component list Solenoid valves_{21-03}....651
Component list Solenoid valves_{20-49}....653
Component list; Sounders_{20-28}....655
Component list; Sounders_{20-14}....656
Component list Switches_{19-54}....657
Component list Switches_{19-39}....659
V-ECU inputs and outputs....661
Table of contents; wiring diagrams....663
Wiring diagram 1_{18-46}....664
Wiring diagram 1_{18-31}....667
Wiring diagram 2_{18-10}....670
Wiring diagram 2_{17-56}....673
Wiring diagram 3_{17-34}....676
Wiring diagram 3_{17-20}....679
Wiring diagram 4_{16-56}....682
Wiring diagram 4_{16-41}....685
Wiring diagram 5_{16-18}....688
Wiring diagram 5_{16-03}....691
Wiring diagram 6_{15-42}....694
Wiring diagram 6_{15-28}....697
Wiring diagram 6_{15-13}....700
Wiring diagram 7_{14-52}....703
Wiring diagram 7_{14-39}....706
Wiring diagram 8_{14-18}....709
Wiring diagram 8_{14-04}....712
Wiring diagram 9_{13-37}....715
Wiring diagram 9_{13-25}....718
Wiring diagram 10_{12-58}....721
Wiring diagram 10_{12-44}....724
Wiring diagram 11_{12-23}....727
Wiring diagram 11_{12-08}....730
Wiring diagram 12....733
Wiring diagram 13....736
Wiring diagram 14....739
Fuse; description....742
Electrical distribution box; circuit board replacing....744
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....748
Instrument panel; description....749
4 - POWER TRANSMISSION....751
40 - GENERAL....752
General notes to be observe when working on power transmission assemblies....753
44 - HYDROSTATIC DRIVE....755
Travel motor; description....756
Track motor; specifications....761
Track motor; tightening torques....762
Track motor; removing....763
Track motor; installing....768
Travel motor removed; overhaul....772
Slew motor; description....811
Slew motor; specifications....817
Slew motor; tightening torques....818
Slew motor; troubleshooting....819
Swing motor; removing....821
Swing motor; installing....827
Swing motor removed; overhaul....834
Center passage; description....859
Centre passage; removing....861
Centre passage; installing....866
49 - MISCELLANEOUS....870
Swing ring gear; description....871
Swing ring; removing....873
Swing ring; installing....880
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....886
70 - GENERAL....887
Frame and track unit; specifications....888
71 - FRAME....890
Counterweight; specifications....891
Counterweight; description....892
Counterweight; replacing....893
Undercarriage; description....895
Superstructure covering; description....897
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....899
Front idler; removing....900
Front idler; installing....903
Sprocket; removing....905
Sprocket; installing....907
Rubber track; removing....909
Rubber track; installing....912
Chain guide; removing....914
Chain guide; installing....917
Bottom roller; removing....919
Bottom roller; installing....921
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....923
81 - CAB; NAKED; CANOPY....924
Cab; weight....925
Cab; tightening torques_{50-54}....926
Cab; tightening torques_{50-41}....927
Cab; removing_{50-21}....928
Cab; removing_{50-07}....934
Cab; installing_{49-46}....939
Cab; installing_{49-32}....945
Cab platform; removing_{49-10}....949
Cab platform; removing_{48-52}....965
Cab platform; installing_{48-26}....980
Cab platform; installing_{48-07}....995
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....1009
Engine hood; replacing....1010
85 - CAB INTERIOR; UPHOLSTERY....1014
Operator's seat; removing....1015
Operator's seat; installing....1018
Seat belt; replacing....1022
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....1026
90 - GENERAL....1027
Hydraulic diagram; complete - Image....1029
Explanations to hydraulic diagram....1031
Hydraulic diagram; complete_{58-25}....1035
Hydraulic diagram; complete_{58-11}....1038
Hydraulic diagram 1....1041
Hydraulic diagram 2....1043
Hydraulic diagram 3....1046
Hydraulic diagram 4....1049
Hydraulic diagram 5....1052
Hydraulic diagram 6....1054
Hydraulic diagram 7....1056
Hydraulic diagram 8....1058
Hydraulic diagram 9....1060
Hydraulic diagram 10....1062
Hydraulic diagram 11....1065
Hydraulic diagram 12....1067
Hydraulic diagram 13....1069
Hydraulic diagram 14....1071
Hydraulic diagram 15....1073
Hydraulic diagram 16....1075
Hydraulic system; description....1077
General notes when working on hydraulic system....1081
Pressure adjustment and leaks checking....1084
Hydraulic oil; description....1086
Hydraulic oil; storage and handling....1087
Hydraulic components; storing and transporting....1088
Hydraulic system; tightening torques....1089
H-ECU (hydraulic); replacing pre-programmed ECU_{50-38}....1090
H-ECU (hydraulic); replacing pre-programmed ECU_{50-23}....1092
Hydraulic system; specification....1094
Accumulator; discarding....1095
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....1097
LS system; bleeding....1099
Hydraulic tank; specifications....1101
Hydraulic oil cooler; description....1102
Hydraulic oil tank; removing....1104
Hydraulic oil tank; installing....1110
Hydraulic oil cooler; removing....1116
Hydraulic oil cooler; installing....1120
Main control valve; description....1124
Control valve; tightening torques....1127
Main control valve; removing....1128
Main control valve; installing....1136
Main control valve; disassembling....1143
Main control valve; assembling....1146
LS-pressure relief valve; replacing....1150
Flow regulation valve; changing....1154
Flushing valve; replacing....1158
Secondary pressure limiting valve; replacing....1162
Anti-cavitation check valve; replacing....1165
Working pressure; checking and adjusting....1168
Proportional valve; offset_optional equipment....1173
Six way valve; offset_optional equipment....1176
Shuttle valve; swing brake....1178
Line rupture valve....1180
Hose rupture valve; removing....1182
Hose rupture valve; installing....1185
Pump; specifications....1187
Pump; removing....1188
Pump; installing....1193
Hydraulic pump; power control; checking....1197
Accumulator; description....1201
Servo accumulator; removing....1203
Servo accumulator; installing....1206
Travel valve (pedal); removing....1209
Travel valve (pedal); installing....1213
Servo valve; removing....1217
Servo valve; installing....1220
Control levers; description....1223
Control levers; maintenance standard....1230
Control levers; repairing....1232
Left control lever; removing....1240
Right control lever; removing....1244
Left control lever; installing....1248
Right control lever; installing....1251
X1 and X3 hydraulic with flow control; calibrating....1254
92 - MECHANICAL EQUIPMENT_ATTACHMENT....1257
Boom support; pivot play....1258
97 - UNIT; DIGGING....1263
Boom lifting cylinder; specifications....1264
Dipper arm cylinder; specifications....1265
Bucket cylinder; specifications....1266
Adjustable boom cylinder; specifications....1267
Dozer blade cylinder; specifications....1268
Boom; removing....1269
Boom; installing....1275
Boom cylinder; removing....1282
Boom cylinder; installing....1286
Dipper arm; removing....1290
Dipper arm; installing....1296
Dipper arm cylinder; removing....1302
Dipper arm cylinder; installing....1306
Bucket cylinder; removing....1310
Bucket cylinder; installing....1314
Volvo EC20D Compact Excavators Repair Service Manual
