Volvo EC45 Excavator Service Repair Manual PDF

Volvo EC45 Excavator Service Repair Manual PDF

Size: 62.46 MB
Language: English
Make: Volvo
Machine: Excavator
Document: Service Repair Manual, Electrical Diagram, Hydraulic Diagram
Model: Volvo EC45
Page: 4206 Pages

Detail Contents:
1 Volvo EC45
2 Volvo EC45
Description

• Applying the brake
  Assembling pistons and guide sleeves
  Assembling the brake discs
  Assembling the cylinder block
  Assembling the oil distributor seals
  Assembling the radial seals
  Assembling the roller bearings
  Auxiliary pressure block Figure 1
  Auxiliary pressure block
  Battery, description
  Battery, location and removal
  Boom cabin weather roof Figure 1
  Boom cabin weather roof Figure 2
  Boom cabin weather roof Figure 3
  Boom cabin weather roof Figure 4
  Boom cabin weather roof Figure 5
  Boom cabin weather roof Figure 6
  Boom cabin weather roof
  Brake valve (counter balance valve) Figure 1
  Brake valve (counter balance valve)
  Cabin door, description Figure 1
  Cabin door, description Figure 2
  Cabin door, description
  Change engine oil, replace filter
  Changing the hydraulic oil Figure 1
  Changing the hydraulic oil Figure 2
  Changing the hydraulic oil Figure 3
  Changing the hydraulic oil
  Cleanliness, braking and hydraulic system
  Colour codes
  Complete wiring diagram (part 1)
  Complete wiring diagram (part 2)
  Control valve
  Description fuel
  Description
  Design of axial piston motor Figure 1
  Design of axial piston motor
  Design of travel motor
  Designations of electrical components
  Diagnostics
  Disassembling pistons and guide sleeves Figure 1
  Disassembling pistons and guide sleeves
  Disassembling the roller bearings
  Electric system, trouble shooting
  Electric welding
  Electrical components (hydraulic system side part 1) Figure 1
  Electrical components (hydraulic system side part 1)
  Electrical components (hydraulic system side part 2) Figure 1
  Electrical components (hydraulic system side part 2)
  Electrical system, description
  Electronic multi-function switch PUMA (ECU1) Figure 1
  Electronic multi-function switch PUMA (ECU1)
  Engine air filter unit Figure 1
  Engine air filter unit
  Engine trouble shooting
  error codes
  Fuses for cabin equipment
  Fuses for machine equipment
  General description frame
  General Figure 1
  General
  Hose rupture valve on boom cylinder Figure 1
  Hose rupture valve on boom cylinder Figure 2
  Hose rupture valve on boom cylinder
  Hose rupture valve on dipper Figure 1
  Hose rupture valve on dipper Figure 2
  Hose rupture valve on dipper
  Hydraulic components, storage and transport
  Hydraulic motor – slewing of superstructure Figure 1
  Hydraulic motor – slewing of superstructure
  Hydraulic oil, description
  Hydraulic oil, storage and handling
  Hydraulic safety solenoid valve Figure 1
  Hydraulic safety solenoid valve
  Hydraulic system, description Figure 1
  Hydraulic system, description
  Hydraulic system, replacement of hydraulic filter element Figure 1
  Hydraulic system, replacement of hydraulic filter element Figure 2
  Hydraulic system, replacement of hydraulic filter element Figure 3
  Hydraulic system, replacement of hydraulic filter element
  Jump starting
  Load capacity tables EC 45 Figure 1
  Load capacity tables EC 45
  Lubricating system, description
  Maintenance instructions
  Position of components Figure 1
  Position of components
  Precautions when handling plug connectors Figure 1
  Precautions when handling plug connectors Figure 2
  Precautions when handling plug connectors Figure 3
  Precautions when handling plug connectors
  Precautions
  Pressure regulator (hydraulic control elements) Figure 1
  Pressure regulator (hydraulic control elements) Figure 2
  Pressure regulator (hydraulic control elements)
  Pressure relief valves
  Recharging of batteries
  Recommended lubricants
  Relay
  Releasing the slewing brake
  Removing the brake discs
  Removing the cylinder block Figure 1
  Removing the cylinder block
  Removing the oil distributor seals Figure 1
  Removing the oil distributor seals
  Removing the radial seals
  Repairing hydraulic system
  Schematic
  Service and maintenance
  Swivel joint Figure 1
  Swivel joint
  Tests before disassembly
  Travel gear, oil change Figure 1
  Travel gear, oil change
  Troubleshooting chart
  Valve block for slewing gear
  VOLVO standard tightening torques
  Way valve, control valve Figure 1
  Way valve, control valve
  Windscreen
  Working headlights and main headlights, description
  Working principle of the travel system

Diagrams

• Balancing valve (offset cylinder) Figure 1
  Balancing valve (offset cylinder) Test and adjustment procedure
  Balancing valve (offset cylinder)
  Hose rupture valve on boom cylinder Figure 1
  Hose rupture valve on boom cylinder
  Hydraulic circuit for bucket Figure 1
  Hydraulic circuit for bucket
  Hydraulic circuit, boom Figure 1
  Hydraulic circuit, boom
  Hydraulic circuit, dipper arm Figure 1
  Hydraulic circuit, dipper arm
  Hydraulic circuit, dozer blade Figure 1
  Hydraulic circuit, dozer blade
  Hydraulic circuit, slewing gear offset Figure 1
  Hydraulic circuit, slewing gear offset
  Hydraulic circuit, travel system Figure 1
  Hydraulic circuit, travel system
  Hydraulic diagram EC 45, complete Figure 1
  Hydraulic diagram EC 45, complete
  Hydraulic system, auxiliary pressure block Figure 1
  Hydraulic system, auxiliary pressure block
  Hydraulic system, function diagram Figure 1
  Hydraulic system, function diagram
  Servo hydraulics Figure 1
  Servo hydraulics
  Solenoid valve for hydraulic working unit Figure 1
  Solenoid valve for hydraulic working unit
  Wiring diagram, schematic drawing (part 1) Figure 1
  Wiring diagram, schematic drawing (part 1)
  Wiring diagram, schematic drawing (part 2) Figure 1
  Wiring diagram, schematic drawing (part 2)
  Wiring engine, schematic drawing Figure 1
  Wiring engine, schematic drawing

Installation Instruction

• CareTrack1
  CareTrack2
  Hydraulic quick coupling single acting on 1, 4m arm and tool holder
  Hydraulic quick coupling single acting on 1, 4m arm
  Hydraulic quick coupling single acting on 1, 7m arm and tool holder
  Hydraulic quick coupling single acting on 1, 7m arm
  Safety valve on boom cylinder
  Safety valves on boom and arm cylinder

Repair

• Adjusting the Track Tension
  Assemble the generator
  Assembling the cabin Figure 1
  Assembling the cabin Figure 2
  Assembling the cabin Figure 3
  Assembling the cabin Figure 4
  Assembling the cabin
  Assembling the crawler track
  Assembling the fuel injection line
  Assembling the gear motor
  Assembling the guide sprocket
  Assembling the guide sprocket1
  Assembling the hydraulic motor
  Assembling the rubber track
  Assembling the superstructure
  Assembling the top roller
  Assembling the track roller
  Assembling the travel motor
  Assembling the valve block Figure 1
  Assembling the valve block
  Bleeding the fuel system
  Changing the fuel filter Figure 1
  Changing the fuel filter Figure 2
  Changing the fuel filter
  Changing the V-belt
  Checking and adjusting the breaker (volumetric capacity)
  Checking and adjusting the dipper arm cylinder (volumetric capacity)
  Checking and adjusting the FR pressure control valve Figure 1
  Checking and adjusting the FR pressure control valve Figure 2
  Checking and adjusting the FR pressure control valve
  Checking and adjusting the LS pressure relief valve
  Checking and adjusting the pilot pressure Figure 1
  Checking and adjusting the pilot pressure Figure 2
  Checking and adjusting the pilot pressure Figure 3
  Checking and adjusting the pilot pressure
  Checking the hydraulic oil level Figure 1
  Checking the hydraulic oil level Figure 2
  Checking the hydraulic oil level
  Checking the performance characteristics Figure 1
  Checking the performance characteristics
  Checking the voltage regulation Figure 1
  Checking the voltage regulation
  Compression pressure inspection
  Control valve block for slewing gear, test and adjustment Figure 1
  Control valve block for slewing gear, test and adjustment Figure 2
  Control valve block for slewing gear, test and adjustment
  Cylinder speed
  Disassemble the generator Figure 1
  Disassemble the generator Figure 2
  Disassemble the generator Figure 3
  Disassemble the generator Figure 4
  Disassemble the generator Figure 5
  Disassemble the generator Figure 6
  Disassemble the generator Figure 7
  Disassemble the generator Figure 8
  Disassemble the generator Figure 9
  Disassemble the generator Figure 10
  Disassemble the generator Figure 11
  Disassemble the generator
  Disassembling the fuel injection line
  Disassembling the fuel pump Figure 1
  Disassembling the fuel pump
  Disassembling the hydraulic motor Figure 1
  Disassembling the hydraulic motor Figure 2
  Disassembling the hydraulic motor Figure 3
  Disassembling the hydraulic motor Figure 4
  Disassembling the hydraulic motor Figure 5
  Disassembling the hydraulic motor Figure 6
  Disassembling the hydraulic motor Figure 7
  Disassembling the hydraulic motor Figure 8
  Disassembling the hydraulic motor Figure 9
  Disassembling the hydraulic motor Figure 10
  Disassembling the hydraulic motor Figure 11
  Disassembling the hydraulic motor Figure 12
  Disassembling the hydraulic motor Figure 13
  Disassembling the hydraulic motor Figure 14
  Disassembling the hydraulic motor Figure 15
  Disassembling the hydraulic motor Figure 16
  Disassembling the hydraulic motor Figure 17
  Disassembling the hydraulic motor Figure 18
  Disassembling the hydraulic motor Figure 19
  Disassembling the hydraulic motor Figure 20
  Disassembling the hydraulic motor Figure 21
  Disassembling the hydraulic motor Figure 22
  Disassembling the hydraulic motor Figure 23
  Disassembling the hydraulic motor Figure 24
  Disassembling the hydraulic motor Figure 25
  Disassembling the hydraulic motor Figure 26
  Disassembling the hydraulic motor Figure 27
  Disassembling the hydraulic motor Figure 28
  Disassembling the hydraulic motor Figure 29
  Disassembling the hydraulic motor Figure 30
  Disassembling the hydraulic motor Figure 31
  Disassembling the hydraulic motor Figure 32
  Disassembling the hydraulic motor Figure 33
  Disassembling the hydraulic motor Figure 34
  Disassembling the hydraulic motor Figure 35
  Disassembling the hydraulic motor Figure 36
  Disassembling the hydraulic motor Figure 37
  Disassembling the hydraulic motor
  Dismantling the valve block Figure 1
  Dismantling the valve block
  Foreword
  Hose rupture valve on boom cylinder Test and adjustment procedure Figure 1
  Hose rupture valve on boom cylinder Test and adjustment procedure Figure 2
  Hose rupture valve on boom cylinder Test and adjustment procedure Figure 3
  Hose rupture valve on boom cylinder Test and adjustment procedure
  Hose rupture valve on boom cylinder, leak test Figure 1
  Hose rupture valve on boom cylinder, leak test
  Hose rupture valve on dipper arm cylinder, leakage test Figure 1
  Hose rupture valve on dipper arm cylinder, leakage test
  Hydraulic lock, hose rupture valve
  Hydraulic motor 1, travel gear Figure 1
  Hydraulic motor 1, travel gear
  Idle speed, inspection and adjustment
  Inspection
  Installing the fuel pump
  Installing the generator Figure 1
  Installing the generator Figure 2
  Installing the generator
  Installing the hydraulic pump Figure 1
  Installing the hydraulic pump Figure 2
  Installing the hydraulic pump Figure 3
  Installing the hydraulic pump
  Installing the oil filter
  Installing the oil pressure switch
  Installing the valve block Figure 1
  Installing the valve block Figure 2
  Installing the valve block
  Measuring the play of the slewing bearing
  Oil cooling system
  Removing the cabin
  Removing the coolant pump Figure 1
  Removing the coolant pump Figure 2
  Removing the coolant pump Figure 3
  Removing the coolant pump Figure 4
  Removing the coolant pump Figure 5
  Removing the coolant pump Figure 6
  Removing the coolant pump
  Removing the crawler tracks
  Removing the gear motor
  Removing the generator Figure 1
  Removing the generator
  Removing the guide sprocket
  Removing the guide sprocket1
  Removing the hydraulic oil pump Figure 1
  Removing the hydraulic oil pump Figure 2
  Removing the hydraulic oil pump Figure 3
  Removing the hydraulic oil pump
  Removing the oil cooler
  Removing the oil filter
  Removing the oil pressure switch
  Removing the rubber track
  Removing the superstructure
  Removing the thermostat housing
  Removing the top roller
  Removing the track roller
  Removing the travel motor
  Removing the valve block Figure 1
  Removing the valve block
  Slewing overtravel
  Sprocket, measurement of wear
  Stand-by pressure Figure 1
  Stand-by pressure
  Starter motor, disassembly and assembly
  Swing speed
  Tensioning the V-belt
  Tests and adjustments of the power control Figure 1
  Tests and adjustments of the power control Figure 2
  Tests and adjustments of the power control Figure 3
  Tests and adjustments of the power control Figure 4
  Tests and adjustments of the power control
  Travel gear, dismantling
  Travel gear, mounting
  Travel motor, exploded view Figure 1
  Travel motor, exploded view
  Travel Speed Figure 1
  Travel Speed Figure 2
  Travel Speed
  Valves, adjusting

Safety

• General precautions
  Move and operate machine safely
  Preparations for work
  Safety concerns everybody!
  Safety measures during operation

Service Bulletins

• Boom
  Cab parts, change
  Check valve inside MCV
  Cylinder, improvement
  Fuel sampling, method
  Internal leakage dozer blade, tolerance
  Maintenance of Stored Machines
  New coolant
  New ECU (PUMA) software
  New Puma 3
  New slew motor brake kit
  New TechTool VCADS Pro interface
  Option anti-theft, instruction
  Portable refillable O-ring kits
  Puma programming kit USB port
  PUMA System, trouble shooting guide
  Relief valve, change
  Reporting of product misuse & near-miss report
  Slew motor improvement
  Volvo Product incident accident report & Interview Form

Special Tools, Misc

• 01 Time Guide Current generation
  11 Time Guide Previous generation
  21 Time Guide Old generation
  35 GRD G700B LabourTimeGuide
  40 RM Compaction Time guide old version
  41 RM Compaction ABG Time Guide
  42 RM Paving Systems ABG Time Guide
  Special tool catalog
  Special Tools Recommendations

Specifications

• Basic objects of examination
  Battery, specification
  Cabin, specification
  Cabin, tightening torques
  Caution sign – Diesel engine starting procedure
  Caution sign – Emergency exit
  Caution sign – Lashing
  Caution sign – Lifting the machine
  Caution sign – Operation and maintenance
  Caution sign – Track tension
  COOLING SYSTEM
  Drive gear, tightening torque
  Electrical system, technical data
  Electrical system
  ENGINE
  Fuel, lubricant and filling capacities
  Fuel, lubricant and filling capacities1
  Fuels, lubricants and filling capacities (litres)
  Hydraulic motor 1 – travel system
  Hydraulic oil tank, filling capacity
  Hydraulic system EC 45
  Load capacity tables EC 45
  Lubrication system, specification
  Machine identification
  Main dimensions EC 45 Figure 1
  Main dimensions EC 45
  Mechanical transmission – track gearbox
  Miscellaneous
  Plugs with tapered thread
  Power transmission
  Reach EC 45
  Reach of the working attachment EC 45
  Slewing ring, tightening torques
  Slewing ring, tightening torques1
  Specification, engine
  Specification, filling capacities
  Specification, weight
  Strength class 8.8 Metric coarse and fine threads
  Strength class 10.9 Metric coarse and fine threads
  Technical data
  Technical data1
  Test and adjustment values EC 45
  Tightening torques, engine
  Tightening torques, engine1
  Track pad, tightening torque
  Track roller, tightening torque
  Track supporting idler, tightening torque
  UNC-threads, coarse pitch
  Valve timing
  Warning and information decals
  Warning sign – Open engine hood only with engine stopped
  Warning sign – Safety distance from the movement area
  Warning sign – Safety distance from the work area
  Working headlights and main headlights, specification

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