Volvo EC220D N Excavator Service Repair Manual PDF

Volvo EC220D N Excavator Service Repair Manual PDF

Size: 486.81 MB
Language: English
Make: Volvo
Machine: Excavator
Document: Service Repair Manual, Electrical Diagram, Hydraulic Circuit
Model: Volvo EC220D N
Page: 6630 Pages

Detail Contents:
1.EC220D N
Descriptions

• Adjustable boom (1st boom), description
  Adjustable boom (2nd boom), description
  Adjustable boom cylinder, description
  Adjustable boom valve, description
  Air conditioning unit, description
  Air distribution, description
  Alternator, description
  Alternator, test
  Anti-theft system
  Audio remote controller, description
  Auto Manual pump control switch description
  Auxiliary heater, description
  Auxiliary heater, principles’
  Auxiliary start
  Battery charging capacity, checking
  Battery, description
  Boom cylinder, description
  Boom float position, description
  Boom, description
  Bottom roller, description
  Bucket cylinder, description
  Cab suspension, description
  Center passage, description
  Check valve, description
  Communication with data buses
  Component designations
  Component list Alternator, batteries, capacitors, electronic units, voltage outlet
  Component list, Heating coils
  Connectors, overview
  Control lockout lever switch, description
  Control pattern selector valve, description
  Cooling fan clutch, description
  Cooling system, component location
  Cooling system, description
  Crankcase ventilation, description
  Cylinder, description
  Cylinder, troubleshooting
  Data buses, function
  Dipper arm cylinder, description
  Dipper arm, description
  Display unit
  Driver’s seat, description
  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
  Electrical system
  Electronic climate control unit ECC, description
  Electronic control system, description
  Emergency operation, description
  Engine characteristic curve
  Engine control unit E-ECU, function description
  Engine limp home switch, description
  Engine oil
  Engine system
  Engine, description
  Exhaust Aftertreatment System, component location
  Exhaust Aftertreatment System, description
  Exhaust gas recirculation (EGR), component location
  Exhaust Gas Recirculation (EGR), description
  Falling object protection structure (FOPS), description
  Fan motor, description
  Fan motor, troubleshooting
  Fan pump, description
  Fire suppression system, component description
  Fuel system, component location
  Fuel system, description
  Fuel tank, description
  Function description
  Heating system, description
  HVAC system
  Hydraulic components, description
  Hydraulic components, storage and transport
  Hydraulic cylinders, dieseling
  Hydraulic diagram, schematic
  Hydraulic oil cooler, description
  Hydraulic oil cooling system, description
  Hydraulic oil, description
  Hydraulic oil, storage and handling
  Hydraulic pump coupling, description
  Hydraulic pump, description
  Hydraulic quickfit, description
  Hydraulic system, cleanliness when handling hydraulic components
  Hydraulic system, description
  Hydraulic system, position of main components
  Hydraulic system, repair of hydraulic components in workshop
  Hydraulic system, work instructions
  Hydraulic system
  Hydraulic tank, description
  Idler, description
  Inlet and exhaust system, description
  Instrument control unit I-ECU, function description
  Instruments and controls, left instrument panel
  Instruments and controls, rear instrument panel
  Instruments and controls, right instrument panel
  Keypad, description
  Link, description
  Lubricating system, description
  MA9109 Quickfit solenoid valve, description
  Main control valve, description 1
  Main control valve, description
  Main control valve, port size and tightening torque
  Preheating, description
  Pressure accumulator, description
  Product plates
  Proportional relief valve, description
  Proportional solenoid valve, description
  Pump, troubleshooting
  Quickfit system, operation
  Radiator, description
  Radio with CD and MP3 player, description’
  Radio, description
  Radio, replacing
  Regeneration process, description
  Regulator, description
  Regulator, disassembly and assembly
  Remote control valve (Lever), description
  Rotating beacon, description
  Rotating beacon, replacing
  Rotator (X3 Line option), description
  Selection of track shoes
  Service connection and programming connection
  Service mode
  Service positions
  Service
  Servo hydraulic block
  Servo pump, description
  Shuttle valve block, description
  Single pedal stopper position
  Slew motor, adjustment
  Spring package, assembly dimension
  Start switch, description
  Starter motor, description
  Starter switch, testing
  Starting engine with booster cables
  Starting operation
  Straight travel pedal, description
  Swing gearbox, description
  Swing motor, description
  Swing motor, principle of operation
  Swing ring gear, description
  Tightening torque, specifications
  Top roller, description
  Track chain, description
  Track gearbox, description
  Track guards
  Track motor, adjustment
  Track motor, description
  Track motor, maintenance standard
  Travel alarm, replacing
  Troubleshooting hvac
  Turbocharger, description
  Vehicle control unit V-ECU, function description
  Vehicle information
  Welding on the machine
  Wire harness layout
  Wiring harnesses
  X1 Line, description

Diagrams

• Control system diagram
  Electrical distribution box, circuit board replacing
  Electrical distribution box
  Electrical symbols and designations
  Explanations to hydraulic diagram
  Fuse, description
  Hydraulic diagram, standard 1
  Hydraulic diagram, standard
  Hydraulic diagram, with option 4
  Hydraulic diagram, with option
  Hydraulic diagram, with option 1
  Hydraulic diagram, with option 2
  Hydraulic diagram, with option components
  Instruments and controls, front instrument panel
  Instruments and controls, overview
  Relay, description
  Wiring diagram SCH01
  Wiring diagram SCH02 1
  Wiring diagram SCH02
  Wiring diagram SCH03 1
  Wiring diagram SCH03
  Wiring diagram SCH04
  Wiring diagram SCH05
  Wiring diagram SCH07
  Wiring diagram SCH08
  Wiring diagram SCH10
  Wiring diagram SCH11
  Wiring diagram SCH12
  Wiring diagram SCH13
  Wiring diagram SCH14 1
  Wiring diagram SCH14
  Wiring diagram SCH15
  Wiring diagram SCH16
  Wiring diagram SCH17.1
  Wiring diagram SCH17
  Wiring diagram SCH18
  Wiring diagram SCH20
  Wiring diagram SCH21
  Wiring diagram SCH22
  Wiring diagram SCH23
  Wiring diagram SCH24
  Wiring diagram SCH26
  Wiring diagram SCH30
  Wiring diagram, electrical dist

Repair

• 2 stage port relief valve, adjustment
  3 way selector valve, description
  Accumulator, replacing
  ACM (After treatment control module), replacing, non-Programd
  ACM (After treatment control module), replacing, pre-Programd
  Adjustable boom valve, disassembly
  Air cleaner, cleaning filter element 1
  Air cleaner, cleaning filter element
  Air cleaner, primary filter replacing
  Air cleaner, secondary filter replacing
  Air conditioner compressor belt, check
  Air conditioner main filter, change
  Air conditioner main filter, clean
  Air conditioning unit, maintenance
  Air mix door actuator, replacing
  Air pump, replacing
  Alternator, replacing incl function check
  Antenna, replacing
  Arm parallel conflux check valve, disassembly and assembly
  Arm parallel conflux valve, disassembly and assembly
  Arm regenerating valve, disassembly
  Backrest, replacing
  Batteries, replacing
  Battery condition, check
  Battery disconnector, replacing
  Battery, charging
  Boom and arm holding valve (Boom-1, Arm-1), disassembly
  Boom back pressure check valve, disassembly
  Boom cylinder, installation
  Boom cylinder, removal
  Boom cylinder, replacing
  Boom, installation
  Boom, removal
  Boom, replacing
  Bottom roller, measurement of wear
  Bottom roller, replacing one
  Bottom roller, replacing seal
  Breather, replacing
  Bucket assembly, installation
  Bucket assembly, removal
  Bucket assembly, replacing
  Bucket cylinder bushing lever-link, replacing
  Bucket cylinder bushing on dipper arm, changing
  Bucket cylinder, installation
  Bucket cylinder, removal
  Bucket cylinder, replacing
  Bucket flow control valve, disassembly
  Bucket regenerating valve, disassembly
  Burner, replacing
  Cab filter, replacing
  Cab, installing
  Cab, prefilter, clean
  Cab, prefilter, replace
  Cab, removing 1
  Cab, removing
  Cab; door, covers, hinges, joints and locks, lubricate
  Carbon dioxide in coolant system, checking
  Carbon dioxide in fuel system, check
  CareTrack antenna, replacing
  CareTrack battery, replacing
  CareTrack W-ECU, description
  Center bypass valve, disassembly and assembly
  Center passage, assembly
  Center passage, disassembly
  Center passage, maintenance standard
  Center passage, replacing seal kit
  Center passage, replacing
  Coasting left and right swing
  Component locations engone
  Compressor, replacing incl draining and filling
  Compressor, replacing magnetic clutch (compressor removed)
  Condenser, replacing incl draining and filling
  Connecting rod yoke, installation
  Connecting rod yoke, removal
  Connecting rod yoke, replacing
  Control lockout lever switch, replacing
  Control types for X1 and X3 operation
  Control valve, replacing
  Coolant level, check
  Coolant, changing 1
  Coolant, changing
  Coolant, checking anti-freeze resistance 1
  Coolant, checking anti-freeze resistance
  Cooler and Heater assembly, replacing
  Counterweight, description
  Counterweight, replacing
  Creeping of hydraulic cylinder
  Cylinder speed
  Cylinder, disassembly and assembly
  Diesel particulate filter, checking and cleaning 1
  Diesel particulate filter, checking and cleaning
  Digging unit, maintenance
  Dipper arm connecting rod, installation
  Dipper arm connecting rod, removal
  Dipper arm connecting rod, replacing
  Dipper arm cylinder bushing on boom, replacing
  Dipper arm cylinder bushing on dipper arm, replacing
  Dipper arm cylinder, installation
  Dipper arm cylinder, removal
  Dipper arm cylinder, replacing
  Dipper arm, installation
  Dipper arm, removal
  Dipper arm, replacing
  Door window, replacing
  Door, replacing
  Earth lead to battery, replacing
  ECC, MID 146, changing non-Programd ECU
  ECC, MID 146, changing pre-Programd ECU
  Electric pedal control on X1 (on-off), replacing
  Electric pedal control on X1 (proportional), replacing
  Engine hood, replacing
  Engine oil and filter, changing
  Engine oil pressure sensor, replacing
  Engine rotation speed sensor (camshaft), replacing
  Engine rotation speed sensor, replacing
  Engine speed control switch, replacing
  Engine temperature sensor, replacing
  Engine wire harness, replacing
  Engine, installing
  Engine, oil level, check
  Engine, removing
  Evaporator, replacing incl draining and filling
  Exhaust pipe, flexible tube, replacing
  Expansion tank, replacing
  Expansion valve, replacing incl draining and filling
  Fan belt and belt tension, check
  Fan belt and or alternator belt, replacing
  Fan belt and or alternator-, compressor belt, replacing all belts
  Fan motor, assembly
  Fan motor, disassembly
  Fan motor, replacing
  Fan motor, tools
  Fan pump, assembly
  Fan pump, disassembly
  Fan pump, parts inspection
  Feed pump, checking feed pressure
  Flow control valve, disassembly and assembly
  Frame and track unit, description
  Front idler, replacing one
  Fuel filling pump, installing
  Fuel filling pump, removing
  Fuel filter, change
  Fuel level sender, replacing
  Fuel system, bleeding
  Fuel tank air ventilation filter, change
  Fuel tank sediment, drain
  Full track guard, replacing
  Function description
  General, precautions
  General, tools
  Hammer and shear pedal valve (RCV), replacing
  Hammer return filter, description
  Heater core, replacing
  High pressure fuel system, pressure relief
  Horn, replacing
  Hour meter, replacing
  Hydraulic oil drain filter, change
  Hydraulic oil level, check
  Hydraulic oil return filter, replacing
  Hydraulic oil servo filter, change
  Hydraulic oil suction strainer, clean
  Hydraulic oil tank breather filter, replacing
  Hydraulic oil tank, replacing
  Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
  Hydraulic oil temperature sensor, replacing
  Hydraulic oil, changing
  Hydraulic pump (removed), changing shaft seal
  Hydraulic pump, replacing
  Idler, assembly
  Idler, disassembly
  Idler, measurement of wear
  I-ECU, MID 140, changing non-Programd ECU
  I-ECU, MID 140, changing pre-Programd ECU
  Ignition switch, replacing
  Inlet and exhaust system, component location
  Instrument panel, replacing (left)
  Instrument panel, replacing (right)
  Intake actuator, replacing
  Intercooler, replacing
  Line rupture valve (arm), assembly
  Line rupture valve (arm), disassembly
  Line rupture valve (boom), assembly
  Line rupture valve (boom), disassembly
  Line rupture valve pressure, checking and adjusting
  Load check valve single, disassembly and assembly
  Longitudinal adjustment cable, replacing
  Longitudinal suspension cable, replacing
  Loose and loss of bolts, check
  Lower boom cylinder bushing, replacing
  Lubrication oil pressure, checking with pressure gauge
  Lubrication system, component locations
  Lubrication, see lubrication chart
  Machine view
  Main pressure relief valve, replacing
  Main relief valve, adjustment
  Main relief valve, disassembly and assembly
  Main spool, disassembly and assembly
  Maintenance service, every 50 hours
  Maintenance service, every 250 hours
  Maintenance service, every 500 hours
  Maintenance service, every 1000 hours
  Maintenance service, every 2000 hours
  Maintenance service, every 3000 hours
  Maintenance service, every 4000 hours
  Maintenance service, every 4500 hours
  Maintenance service, every 6000 hours
  Maintenance service, first 500 hours
  MATRIS, reading, export reading
  Measuring condition
  Measuring of swing bearing clearance
  Mode (foot) actuator, replacing
  NOx sensor, replacing
  Oil cooler line bypass valve (check valve), replacing
  Oil cooler, replacing
  Oil level gauge, replacing
  Oil level sensor, changing
  Oil-bath air cleaner’s reservoir (optional equipment), clean, and oil, change
  Oil-bath air cleaner’s reservoir (optional equipment), filter insert, clean
  Oil-bath air cleaner’s reservoir (optional equipment), oil, check
  Pipe and hose (pump – valve), replacing
  Port relief valve pressure, checking and adjusting
  Port relief valve, disassembly and assembly
  Preheating coil, replacing
  Pre-heating relay, replacing
  Proportional solenoid valve (power shift), replacing
  Proportional solenoid valve, description
  Proportional solenoid valve, measuring and adjustment
  Pump gearbox coupling assembly, replacing
  Pump regulator, replacing
  Pump suction hose and pipe, replacing
  Pump, assembly
  Pump, disassembly
  Pump, installation
  Pump, maintenance standard
  Pump, tools
  Quickfit, installation
  Quickfit, removal
  Quickfit, replacing
  Radiator hoses all, replacing
  Radiator outside hydraulic oil cooler outside, cleaning
  Radiator, replacing
  Rear window, replacing
  Rear-view mirror, changing
  Receiver, replacing incl draining and filling
  Recoil spring cylinder seal kit, replacing
  Remote control valve (Lever), assembly
  Remote control valve (Lever), disassembly
  Remote control valve (Lever), maintenance standard
  Remote control valve (lever), replacing
  Remote control valve (Lever), troubleshooting
  Remote control valve (pedal), assembly
  Remote control valve (pedal), description
  Remote control valve (pedal), disassembly
  Remote control valve (pedal), maintenance standard
  Remote control valve (pedal), replacing
  Remote control valve (pedal), troubleshooting
  Ring gear grease pipe, replacing
  Rotating beacon, replacing
  Rotator valve, adjustment
  Rupture valve, replacing (boom cylinder)
  Rupture valve, replacing (dipper arm cylinder)
  Seat cushion, replacing
  Seat heater, checking
  Seat support, replacing
  Seat, replacing
  Service history (included in the respective Operator’s manual), fill in.
  Servo hydraulic pressure, adjustment
  Servo pump, parts inspection
  Servo pump, replacing
  Side window, replacing
  Solenoid valve (1) for hammer and shear selection
  Solenoid valve, description 1
  Solenoid valve, description
  Solenoid valve, disassembly and assembly
  Solenoid valve, inspection
  Solenoid valve, replacing
  Spark plug, checking
  Spark plug, replacing 1
  Spark plug, replacing
  Speaker, replacing
  Spring package, assembly
  Spring package, disassembly
  Sprocket, measurement of wear
  Sprocket, replacing one
  Starter motor, replacing
  Starter motor, tests
  Starter relay, replacing
  Stop valve
  Straight traveling performance
  Superstructure, installing
  Superstructure, removing
  Swing bath grease, check
  Swing gearbox oil level, check
  Swing gearbox removed, replacing seal
  Swing gearbox removed, replacing shaft
  Swing gearbox, assembly
  Swing gearbox, disassembly
  Swing gearbox, maintenance standard
  Swing gearbox, replacing
  Swing motor gearbox, changing oil
  Swing motor relief valve, replacing
  Swing motor removed, replacing seal
  Swing motor, assembly
  Swing motor, disassembly
  Swing motor, maintenance standard
  Swing motor, replacing brake piston seal
  Swing motor, replacing plate (brake)
  Swing motor, replacing
  Swing ring gear bearing, lubricate
  Swing ring gear cover, installation
  Swing ring gear cover, removal
  Swing ring gear inner seal, replacing
  Swing ring gear outer seal, replacing
  Swing ring gear outer seal, replacing1
  Swing ring gear, replacing
  Swing speed
  Swing unit, replacing
  Test-run and check
  Thermostat, checking
  Thermostat, replacing
  Tool box assembly, replacing
  Tools & equipment
  Top roller, measurement of wear
  Top roller, replacing one
  Track chain assembly, installing
  Track chain assembly, removing
  Track chain, measurement of wear
  Track gearbox (removed), replacing floating seal
  Track gearbox oil level, check
  Track gearbox, assembly
  Track gearbox, disassembly
  Track gearbox, maintenance standard
  Track gearbox, replacing cover
  Track guard, replacing one
  Track link, dimension
  Track links, replacing
  Track motor gearbox, changing oil
  Track motor relief valve, replacing 1
  Track motor relief valve, replacing
  Track motor, assembly 1
  Track motor, assembly
  Track motor, disassembly 1
  Track motor, disassembly
  Track motor, replacing
  Track recoil spring (tensioner) assembly, replacing
  Track running speed
  Track shoe bolts, check
  Track shoe, replacing one
  Track tensio condition, check
  Track unit, replacing
  Track, adjusting track sag
  Travel alarm, replacing
  Travel Speed
  Turbocharger, replacing
  Undercarriage, description
  Upper boom cylinder bushing, replacing
  Valves, adjusting 1
  Valves, adjusting
  VCADS Pro, connecting problems
  VCADS Pro, logged errors, read off
  V-ECU, MID 187, changing non-Programd ECU
  V-ECU, MID 187, changing pre-Programd ECU
  Vent actuator, replacing
  Voltage converter, replacing
  Washer fluid level, check
  Water separator filter element, change
  Water separator, check drain
  W-ECU, MID142, changing non-Programd ECU
  W-ECU, MID142, changing pre-Programd ECU 1
  W-ECU, MID142, changing pre-Programd ECU
  Windows, general
  Windscreen flusher pump, replacing
  Windscreen wiper front, replacing motor
  Windscreen wiper, replacing controller
  Windscreen wiper, replacing switch
  Windscreen, replacing
  Work lighting, replacing one head lamp assy
  X1 Pre-set relief valve, adjusting
  X1 return filter (optional equipment), change

Safety

• CE-marking, EMC-directive
  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
  Safety concerns everybody!
  Safety rules when servicing
  Safety when handling oils and fuel
  Safety when handling the machine
  Safety when handling the waste handler
  Safety when using lifting equipment
  Safety when working with air conditioning refrigerant
  Safety when working with batteries
  Safety when working with hydraulic systems
  Starting with booster batteries
  Waste handling
  Working in environmentally contaminated areas

Service Bulletins

• Air conditioning compressor improvement
  Arm conflux hose improvement
  Attachment shims for clearance adjustment of pin joint
  Auto belt tensioner (D5E, D7E)
  Auxiliary heater
  Battery improvement
  Battery maintenance guideline for long term stock machines
  Biodegradable hydraulic oil
  Blower motor
  Bottom roller improvement
  Bucket cylinder protection improvement
  Cab door latch
  Cab door latch1
  Cab door
  Cabin light operation problem
  Cable harness connector, engine
  Camshaft, hardening process update
  CareTrack Telematics system
  CareTrack, new software version 2008w6
  CD & MP3 player
  Check method on engine oil consumption
  Cigar lighter and ashtray change
  Coolant pump improvement
  Crankshaft and camshaft gear manufacturing improvements
  D4 – D7 Alternator improvement
  D6-D7 Exhaust gas leakage into the cooling system
  D6E and D7E, high pressure pipe leakage
  DEF AdBlue AUS32 sampling, method
  Diesel fuels – quality and function
  Dipstick level gauge improvement for swing gearbox
  ECU, functional check
  Electric connector
  Electric horn improvement
  Electric horn
  Electrical distribution box
  Engine limp home switch wire harness
  Engine oil leakage
  Engine Oil Level
  Engine speed control switch improvement
  Engine starting in the manual mode
  Expansion tank
  Fuel cap improvement
  Fuel Level
  Fuel pump (Tier 3) manufacturing process improvement1
  Fuel pump (Tier 3) manufacturing process improvement2
  Fuel sampling, method
  Fuel tank crack
  Heat-resistant kit for RCV leakage
  Hose leakage
  Hour counter improvement
  Hydraulic hose assembly leakage handling
  Hydraulic oil
  Hydraulic system flushing method
  Hydraulic tank air breather
  Idler wheel and bushing improvement
  I-ECU, clock and rear view camera
  Improved Volvo quick-fit block
  Improvement of grading performance
  Improvement of return check valve
  Injector wire harness for D4E-D6E-D7E
  Injector yoke bolt
  Injector yoke retention bolt loose
  Instrument ECU change
  Instrument ECU Improvement
  Internal modem change
  Leakage at engine oil pump gasket
  Line rupture valve hose, improvement
  Lubrication point change on swing bearing
  Machine model
  Main Control Valve, logic valve
  Modification of CareTrack wire harness
  Muffler bracket improvement
  New engine oil level sensor
  New fan bracket with profile washer
  New oil change interval for Volvo bio hydraulic oil
  New product1
  New product2
  New product3
  New product4
  New slew ring gear seal
  New software for anti-theft and cold starting improvement
  New software for low engine oil level warning
  New software release1
  New software release2
  New software1
  New software2
  New software3
  New TechTool VCADS Pro interface
  New turbo charger for D6E D7E
  Oil analyses
  Oil sampling, method
  Oil sampling, sampling points
  Operating hour parameter
  Pipe leakage
  Plastic shims for Boom Arm pin joints
  Plates
  Poor grading with RCV
  Portable refillable O-ring kits
  Quick fit cylinder hose
  Receiver drier improvement
  Recoil spring grease valve
  Recoil spring package rod
  Recommendations for Oil Sampling Intervals
  Reporting of product misuse & near-miss report
  Reports
  Reversible fan, modes and setting
  Rotating beacon lamp, tightening torque
  Routines for reporting cracks on Boom and Arm
  Sprocket improvement
  Swing ring gear seal improvement
  Swing ring gear seal1
  Swing ring gear seal2
  Thermostat failure (D4, D5, D6 & D7)
  Tool box change
  Tool box improvement
  Travel gearbox floating seal improvement
  Travel motor
  Travel motor1
  Turbocharger
  Volvo Product incident accident report & Interview Form
  Washer pump improvement
  Washer pump improvement1
  Waste handler strobe light
  Water separator drain valve
  Windshield, water and dust entering
  X1 stop valve

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