Volvo EC20C Excavator Service Repair Manual PDF

Volvo EC20C Excavator Service Repair Manual PDF

Size: 76.60 MB
Language: English
Make: Volvo
Machine: Excavator
Document: Service Repair Manual, Electrical Diagram, Hydraulic Diagram
Model: Volvo EC20C
Page: 4451 Pages

Detail Contents:
1 Volvo EC15C,EC17C,EC18C,EC20C
Description

• Accumulator, description
  Air cleaner, description
  Antitheft device, first activation of a new A-ECU
  Cable and component marking explanations
  Cable harnesses, description Ground and battery cable
  Cable harnesses, description Starter cables
  Cable harnesses, description Wiring loom, cab platform
  Cables, description
  Camshaft, description
  Center passage, description
  Checking electrical cabling and connectors
  Cleaning prior to repair
  Cleanliness, braking and hydraulic system
  Collection of basic data
  Component location, alternator, batteries, capacitors, electronic units, voltage outlet
  Component location, diodes
  Component location, fuses
  Component location, heating coils, instruments, service-sockets
  Component location, lights
  Component location, motors
  Component location, PWM valves
  Component location, relays
  Component location, sensors
  Component location, solenoid valves
  Component location, sounders
  Component location, switches
  Component locations
  Control levers, description
  Coolant
  Cooling system, description
  Crankshaft, description
  Cylinder block, description
  Cylinder head, description
  DC current measurement
  DC voltage measurement
  Description, general
  Diode check procedure
  Electrical symbols and designation
  Electrical system, special instructions for servicing, action when working on machine
  Electrical system, special instructions for servicing, electrical components, batteries
  Electrical system, special instructions for servicing, electronic components
  Electrical system, special instructions for servicing, general
  Engine, description
  Fuel feed pump, description
  Fuel system, description
  Fuel tank, description
  Fuel, recommendation
  Fuse, description
  General notes to be observe when working on power transmission assemblies
  General notes when working on hydraulic system
  Hydraulic components, storage and transport
  Hydraulic cylinders, dieseling
  Hydraulic oil cooler, description
  Hydraulic oil, description
  Hydraulic oil, storage and handling
  Infrared Thermometer
  Injection pump, description
  Injectors, description
  Lubricants, specifications
  Lubrication system, description
  Main control valve, description
  Measuring components
  Oil pump, description
  Option anti-theft, instruction
  Pistons, description
  Pressure adjustment and leaks checking
  Product plate, description
  Proportional valve, offset optional equipment
  Repairing hydraulic system
  Resistance measurement
  Service and maintenance
  Shuttle valve, swing brake
  Six way valve, offset optional equipment
  Slew motor, description
  Starting engine with booster cables
  Superstructure covering, description
  Swing motor removed, overhaul
  Timing gear, description
  Towing, measures
  Travel motor, description
  Troubleshooting chart
  Troubleshooting tips
  Troubleshooting, assistant devices
  Troubleshooting, general
  Undercarriage, description
  Valve cover, description and operation
  Valve mechanism, description
  Welding on the machine

Diagrams

• Hydraulic diagram 1 Main control valve, inlet element – hydraulic oil tank – leakage oil filter
  Hydraulic diagram 2 Swing motor
  Hydraulic diagram 3 Left track motor
  Hydraulic diagram 4 Right track motor
  Hydraulic diagram 5 Arm extension cylinder
  Hydraulic diagram 6 Dozer blade cylinder – Chassis width adjustment cylinder
  Hydraulic diagram 7 Bucket cylinder
  Hydraulic diagram 8 Extra equipment
  Hydraulic diagram 9 Arm cylinder – ladder breakage protector
  Hydraulic diagram 10 Extension cylinder – ladder breakage protector
  Hydraulic diagram 11 Main control valve outlet element – electric proportional valve
  Hydraulic diagram 12 Joystick right
  Hydraulic diagram 13 Joystick left
  Hydraulic diagram 14 Travel control (foot pedals)
  Hydraulic diagram, complete Figure 1
  Hydraulic diagram, complete
  Wiring diagram 1 Alternator – battery – control block lever – starter – engine preheater
  Wiring diagram 2 Engine shutdown – engine oil pressure switch – temperature sensor – fuel level display – fuel feed pump
  Wiring diagram 3 Hydraulic function – driving speed – switch arm extension attachment – width-adjustable chassis – max. flow – joystick right
  Wiring diagram 4 Work lights – beacon – horn – power socket 1
  Wiring diagram 5 Cab lighting – windshield cleaner – power socket 2 – cassette CD radio – loudspeaker – cab ventilation
  Wiring diagram 6 Immobilizer
  Wiring diagram 7 Care Track
  Wiring diagram 8 Immobiliser – Care Track
  Wiring diagram 9 Canopy – working lights – beacon

Installation Instruction

• Anti theft device, installing new
  CareTrack with anti theft device, installing new
  CareTrack, installing new
  FOG (Falling Object Guard), installing new1
  FOG (Falling Object Guard), installing new2
  Hammer shear selection valve, installing new
  Hose rupture valve, installing new
  Protecting screen, installing new
  Radio, installing new
  Rotating beacon, installing new
  Work light on mono boom, installing new

Repair

• A-ECU (anti theft), replacing
  Air cleaner primary filter, change
  Air cleaner secondary filter, change
  Air cleaner, installing
  Air cleaner, removing
  Alternator, installing
  Alternator, removing
  Anti-cavitation check valve, replacing
  Batteries, replacing
  Battery condition, check
  Battery condition, check1
  Boom cylinder, installation
  Boom cylinder, removal
  Boom, installation
  Boom, removal
  Bottom roller, installing
  Bottom roller, removing
  Bucket cylinder, installation
  Bucket cylinder, removal
  Cab platform, installation
  Cab platform, removal
  Cab, installing
  Cab, main filter, replacing
  Cab, removing
  Centre passage, installing
  Centre passage, removing
  Chain guide, installing
  Chain guide, removing
  Component list Alternator, batteries, capacitors, electronic units, voltage outlet
  Component list Diodes
  Component list Fuses
  Component list Heating coils, instruments, service socket
  Component list Lights
  Component list PWM valves
  Component list Relays
  Component list Solenoid valves
  Component list Switches
  Component list, Motors
  Component list, Sensors
  Component list, Sounders
  Compression test
  Control lever, installation1
  Control lever, installation2
  Control lever, removal1
  Control lever, removal2
  Control levers, maintenance standard
  Control levers, repairing
  Coolant pump, replacing
  Coolant, change
  Coolant, level, check
  Crankcase breather system, inspect
  Creeping of hydraulic cylinder
  Cylinder head, fitting
  Cylinder head, removing
  Cylinder head, replacing gasket
  Cylinder speed
  Deviation when travelling straight ahead
  Dipper arm cylinder, installation
  Dipper arm cylinder, removal
  Dipper arm, installation
  Dipper arm, removal
  Dust valve, clean
  Electrical distribution box, circuit board replacing
  Engine hood, replacing
  Engine radiator and hydraulic oil cooler, check (clean when necessary)
  Engine radiator, oil cooler and condensor (if installed), clean
  Engine, changing oil and filter
  Engine, installing
  Engine, oil level, check
  Engine, removing
  Expansion tank, installing
  Expansion tank, removing
  Fan belt and or alternator belt, checking and adjusting tension
  Fan belt and or alternator belt, checking and adjusting tension1
  Fan belt and or alternator belt, replacing
  Flow regulation valve, changing
  Flushing valve, replacing
  Front idler, installing
  Front idler, removing
  Fuel and fuel return hoses, check and replace if necessary
  Fuel filter, change
  Fuel injectors, inspect clean and test
  Fuel pump, installing
  Fuel pump, removing
  Fuel tank sediment, drain
  Fuel tank, installing
  Fuel tank, removing
  Glow plug, installation
  Glow plug, removal
  H-ECU (hydraulic), replacing pre-Programd ECU
  H-ECU (hydraulic), replacing pre-Programd ECU1
  Horn, replacing
  Hose on boom for X1, X2, X3, check and replace if neccessary
  Hoses for boom-, dipper-, and bucket-cylinder, check and replace if necessary
  Hydraulic oil cooler, installing
  Hydraulic oil cooler, removing
  Hydraulic oil filter, changing
  Hydraulic oil level, check
  Hydraulic pressure, check
  Hydraulic pump, power control checking
  Hydraulic system, changing oil.
  Hydraulik pump, suction hose and pressure hose, check and replace if necessary
  Idling speed, checking and adjusting
  I-ECU, replacing
  Injection pump, removing
  Injection timing, checking
  Injectors, replacing all
  Lamp bulb, replacing
  Loose and loss of bolts, check
  LS (load sense) pressure, checking
  LS-pressure relief valve, replacing
  Lubrication and service schedules
  Lubrication, see lubrication chart
  Main Control Valve – Assembly
  Main Control Valve – Disassembly
  Main control valve, installation
  Main control valve, removal
  Maintenance service, daily
  Maintenance service, every 50 hours
  Maintenance service, every 250 hours
  Maintenance service, every 500 hours
  Maintenance service, every 1000 hours
  Maintenance service, every 1500 hours
  Maintenance service, every 2000 hours
  Maintenance service, every 3000 hours
  Measuring condition
  Operator’s seat, installing
  Operator’s seat, removing
  Pump, installation
  Pump, removal
  Quick coupler lock mechanism, replace
  Radiator hose upper, replacing
  Radiator hoses lower, replacing
  Radiator, installing
  Radiator, removing
  Rubber track, installing
  Rubber track, removing
  Seat belt, replace
  Secondary pressure limiting valve, replacing
  Service history (included in the respective Operator’s manual), fill in.
  Servo accumulator, installation
  Servo accumulator, removal
  Servo pressure, checking and adjusting
  Servo valve, installation
  Servo valve, removal
  Silencer, installing
  Silencer, removing
  Slew motor, troubleshooting
  Sprocket, installation
  Sprocket, removal
  Starter motor, installing
  Starter motor, removing
  Stop magnet, replacing
  Swing motor, installing
  Swing motor, removing
  Swing ring, installing
  Swing ring, removing
  Swing speed
  Test-run and check
  The machine, check for external damages, cracks and wear damages
  Thermostat, replacing
  Throttle control cable, installing
  Throttle control cable, removing
  Throttle controls, setting
  Track gearbox oil level, check
  Track motor, installing
  Track motor, removing
  Track running speed
  Track tension, adjusting
  Track tension, checking
  Travel alarm, replacing
  Travel motor gearbox, changing oil
  Travel motor removed, overhaul
  Travel Speed
  Travel valve (pedal), installing
  Travel valve (pedal), removing
  Values, creeping of hydraulic cylinder
  Values, cylinder speed
  Values, deviation when travelling straight ahead
  Values, slewing speed
  Values, track running speed
  Values, travel speed
  Valve clearance, checking and adjusting
  Valve cover, installing
  Valve cover, removing
  Valve covers, fitting new gasket
  Valves, adjusting
  Warranty inspection 100 hours
  Warranty inspection 1000 hours
  Water separator filter element, change
  Water separator, drain
  Windscreen wiper front, replacing motor
  Working pressure, checking and adjusting

Safety

• CE marking and declaration of conformity
  Checklist after a fire or heat exposure
  Decontamination
  Environmental handling for the future
  Environmentally hazardous fluids
  Environmentally safe handling
  Fire prevention measures
  Health hazards with paint, plastics and rubber
  Pressure setting and leak detection
  Safety concerns everybody!
  Safety for work on hydraulic systems
  Safety rules when servicing
  Safety when handling oils and fuel
  Safety when handling the machine
  Safety when lifting and supporting the machine
  Safety when working with batteries
  Service position 1
  Service position 2
  Service position 3
  Starting with booster batteries
  Waste handling
  Working in environmentally contaminated areas
  Working on the electrical system of the machine

Service Bulletins

• Battery maintenance guideline for long term stock machines
  Capilarity leakage at the hose crimpings
  Fuel gauge
  Fuel sampling, method
  Identification plate support
  Lateral play equipment
  Maintenance of Stored Machines
  New boom design
  New dipper arm
  New hydraulic fluid filter
  New product
  New starter switch
  New TechTool VCADS Pro interface
  Pivot play tolerance and instruction
  Play on variable track
  Portable refillable O-ring kits
  Pump companion
  Reporting of product misuse & near-miss report
  Rotating beacon improvement
  Secondary relief valve on bucket function
  Volvo Product incident accident report & Interview Form

Special Tools, Misc

• Special tool catalog
  Special Tools Recommendations
  Time Guide Current generation
  Time Guide Old generation
  Time Guide Previous generation

Specifications

• Adjustable boom cylinder, specifications
  Alternator, specifications
  Alternator, specifications1
  Battery, specifications
  Boom lifting cylinder, specifications
  Bucket cylinder, specifications
  Cab, tightening torques
  Cab, weight
  Control valve, torque value1
  Control valve, torque value2
  Cooling system, specification
  Counterweight, specifications
  Dipper arm cylinder, specifications
  Dozer blade cylinder, specifications1
  Dozer blade cylinder, specifications2
  Electrical system, tightening torques
  Engine, capacities
  Engine, specifications
  Engine, tighten torques
  Frame and track unit, specifications
  Fuel feed pump, specifications
  Fuel system, general specifications
  Hydraulic system, specification
  Hydraulic system, tightening torques
  Hydraulic tank, specifications
  Injectors, specification
  Light bulbs, specification
  Lubrication system, specifications
  Pump, specifications
  Slew motor, specifications
  Slew motor, tightening torques
  Track motor, specifications
  Track motor, tightening torques
  Travel alarm, specifications
  Valve mechanism, specifications
  VOLVO standard tightening torques

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