Volvo ECR48C Excavator Service Repair Manual PDF

Volvo ECR48C Excavator Service Repair Manual PDF

Size: 79.35 MB
Language: English
Make: Volvo
Machine: Excavator
Document: Service Repair Manual, Electrical Diagram, Hydraulic Diagram
Model: Volvo ECR48C
Page: 4866 Pages

Detail Contents:
1 Volvo ECR48C
Description

• Accumulator, description
  Additional counterweight, description
  Air cleaner, description
  Antitheft device, first activation of a new A-ECU
  Auto idling device, description
  Balancing valve on offset cylinder
  Cable and component marking explanations
  Cable harnesses, description
  Cable harnesses, description1
  Cable harnesses, description2
  Cable harnesses, description3
  Cable harnesses, description4
  Cables, description
  Camshaft, description
  Checking electrical cabling and connectors
  Cleaning prior to repair
  Cleanliness, braking and hydraulic system
  Cold start device, description
  Cold start device, description1
  Collection of basic data
  Component locations
  Control levers, description
  Coolant
  Cooling system, description
  Counterweight, 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, description1
  Engine, description2
  Fuel feed pump, description
  Fuel filter water separator, 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 control unit, H-ECU, functions check
  Hydraulic cylinders, dieseling
  Hydraulic oil cooler, description
  Hydraulic oil, description
  Hydraulic oil, storage and handling
  Infrared Thermometer
  Injection pump, description
  Injectors, description
  Instrument panel, description
  Instrument panel, operation
  LR pressure relief valve, checking and adjusting
  Lubricants, specifications
  Lubrication system, description
  Main control valve, description
  Measuring components
  Oil pump, description1
  Oil pump, description2
  Option anti-theft, instruction
  Pistons, description
  Pressure adjustment and leaks checking
  Product plate, description
  Proportional valve, right left selector
  Pump, troubleshooting
  Repairing hydraulic system
  Resistance measurement
  Schematic
  Service and maintenance
  Servo valve, description
  Shuttle valve, swing brake
  Six way valve, offset optional equipment
  Slew motor, break release valve
  Slew motor, description
  Starting engine with booster cables
  Swivel joint, description
  Thumb kit, description
  Timing gear, description
  Towing, measures
  Track motor, troubleshooting
  Transporting and lifting the machine
  Travel motor, description
  Troubleshooting, assistant devices
  Troubleshooting, general
  Undercarriage, description
  Valve cover, description and operation
  Valve mechanism, description
  Vehicle ECU functions, check
  Welding on the machine

Diagrams

• Hydraulic diagram 1
  Hydraulic diagram 2
  Hydraulic diagram 3
  Hydraulic diagram 4
  Hydraulic diagram 5
  Hydraulic diagram 6
  Hydraulic diagram 7
  Hydraulic diagram 8
  Hydraulic diagram 9
  Hydraulic diagram 10
  Hydraulic diagram 11
  Hydraulic diagram 12
  Hydraulic diagram, complete
  Wiring diagram 1
  Wiring diagram 2
  Wiring diagram 3
  Wiring diagram 4
  Wiring diagram 5
  Wiring diagram 6
  Wiring diagram 7
  Wiring diagram 8
  Wiring diagram 9
  Wiring diagram 10
  Wiring diagram 11

Installation Instruction

• 2nd auxiliary, optional arm length, installing new
  2nd auxiliary, standard arm, installing new
  Anti-Theft-Device
  CareTrack, installing new
  FOG (Falling Object Guard), installing new
  FOG (Falling Object Guard), installing new1
  Hose rupture valve, installing new
  Protecting screen, installing new
  Rotating Beacon
  Thumb, quick attachment, installing new
  Thumb, standard bucket, installing new
  Travel alarm
  Wegfahrsperre
  X1 Flow adjustment potentiometer, installing new

Repair

• Air cleaner primary filter, change
  Air cleaner secondary filter, change
  Air cleaner, installing
  Air cleaner, removing
  Alternator, installing
  Alternator, removing
  Automatic idling device, installing
  Automatic idling device, removing
  Batteries, replacing
  Battery condition, check
  Battery condition, check1
  Boom cylinder, installation
  Boom cylinder, removal1
  Boom cylinder, removal2
  Boom, installation
  Boom, removal1
  Boom, removal2
  Bottom roller, installing
  Bottom roller, removing
  Bucket cylinder, installation
  Bucket cylinder, removal
  Bucket cylinder, removal1
  Cab platform, installation
  Cab platform, removal1
  Cab platform, removal2
  Cab, installing
  Cab, main filter, replacing
  Cab, removing
  Cab, roof panel, installing
  Cab, roof panel, removing
  Check the static brake torque
  Compensator valve, replacing1
  Compensator valve, replacing2
  Component list Alternator, batteries, capacitors, electronic units, voltage outlet
  Component list Control lights warning lights
  Component list Fuses
  Component list Relays
  Component list Solenoid valves
  Component list Switches
  Component list, Heating coils
  Component list, Lights
  Component list, Motors
  Component list, Sensors
  Component list, Sounders
  Component location, motors and coils
  Component location, solenoid valve
  Component locations, acoustic signal emitter
  Component locations, fuses
  Component locations, lighting
  Component locations, relays
  Component locations, sensors
  Component locations, switches
  Component locations
  Component locations1
  Compression test
  Control lever, installation
  Control lever, removal1
  Control lever, removal2
  Control levers, maintenance standard
  Control levers, repairing
  Coolant pump, installing
  Coolant pump, removing
  Coolant, change
  Coolant, changing
  Coolant, level, check
  Counterweight, fitting
  Counterweight, removing
  Crankcase breather system, inspect
  Crankshaft, replacing front oil seal
  Creeping of hydraulic cylinder
  Cylinder speed
  Deviation when travelling straight ahead
  Dipper arm cylinder, installation
  Dipper arm cylinder, removal1
  Dipper arm cylinder, removal2
  Dipper arm, installation
  Dipper arm, removal1
  Dipper arm, removal2
  Directional valve, dozer blade, disassembling spool and replacing seals1
  Directional valve, dozer blade, disassembling spool and replacing seals2
  Directional valve, drive, disassembling spool and replacing seals1
  Directional valve, drive, disassembling spool and replacing seals2
  Directional valve, hydraulically operated, disassembling spool and replacing seals1
  Directional valve, hydraulically operated, disassembling spool and replacing seals2
  Dust valve, clean
  Electrical distribution box, circuit board replacing
  Engine hood, changing gas spring
  Engine radiator and hydraulic oil cooler, check (clean when necessary)
  Engine, changing oil and filter
  Engine, installing
  Engine, oil level, check
  Engine, 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, changing1
  Flow regulation valve, changing2
  FR pressure control valve, checking and adjusting
  Front idler, installing
  Front idler, removing
  Fuel and fuel return hoses, replace
  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
  Gear motor, exploded view
  Glow plug, installation
  Glow plug, removal
  H-ECU (hydraulic), replacing pre-Programd ECU
  H-ECU (hydraulic), replacing pre-Programd ECU1
  Horn, replacing
  Hoses for boom-, dipper-, and bucketcylinder, replace
  Hoses on boom for X1, X2, X3, replace
  Hydraulic oil cooler, installing
  Hydraulic oil cooler, removing
  Hydraulic oil filter, changing
  Hydraulic oil level, check
  Hydraulic oil tank, changing oil
  Hydraulic pressure, check
  Hydraulic pump, checking and adjusting standby pressure
  Hydraulic pump, power control adjusting
  Hydraulic pump, power control checking
  Hydraulic pump, suction hose and pressure hose, replace
  Idling speed, checking and adjusting
  Injection pump, removing
  Injection timing, checking
  Instrument console, installing
  Instrument console, removing
  Lamp bulb, replacing
  Load check valve, replacing1
  Load check valve, replacing2
  Loose and loss of bolts, check
  LS (load sense) pressure, checking
  LS-pressure relief valve, replacing1
  LS-pressure relief valve, replacing2
  Lubrication and service schedules
  Lubrication, see lubrication chart
  Main Control Valve – Assembly
  Main Control Valve – Disassembly1
  Main Control Valve – Disassembly2
  Main control valve troubleshooting
  Main control valve, installation
  Main control valve, removal1
  Main control valve, removal2
  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
  Oil pump, replacing1
  Oil pump, replacing2
  Operator’s seat, installing
  Operator’s seat, removing
  Port relief valve pressure, checking and adjusting1
  Port relief valve pressure, checking and adjusting2
  Pump, installation
  Pump, removal
  Quick coupler lock mechanism, replace
  Radiator, installing
  Radiator, removing
  Rubber track, installing
  Rubber track, removing
  Seat belt, replace
  Seat retention cable, replacement
  Seat retention cable, replacement1
  Seat safety belt, replacing
  Secondary pressure limiting valve, replacing1
  Secondary pressure limiting valve, replacing2
  Service history (included in the respective Operator’s manual), fill in.
  Service position 2
  Service position 3
  Service positions
  Servo accumulator, installation1
  Servo accumulator, installation2
  Servo accumulator, removal1
  Servo accumulator, removal2
  Servo pressure, checking and adjusting
  Servo valve, installation
  Servo valve, removal1
  Servo valve, removal2
  Silencer, installing
  Slew motor, troubleshooting
  Sprocket, installation
  Sprocket, removal
  Starter motor, installing
  Starter motor, removing
  Swing motor removed, overhaul
  Swing motor, installing
  Swing motor, removing1
  Swing motor, removing2
  Swing motor, replacing counterbalance valve1
  Swing motor, replacing counterbalance valve2
  Swing speed
  Test-run and check
  The machine, check for external damages, cracks and wear damages
  Thermostat, replacing
  Thumb pivot pin, lubricate
  Top roller, installation
  Top roller, removal
  Track gearbox oil level, check
  Track motor, installing
  Track motor, removing
  Track running speed
  Track tension, adjusting
  Track tension, checking1
  Track tension, checking2
  Travel gear, dismantling
  Travel motor gearbox, changing oil
  Travel motor gearbox, changing oil1
  Travel motor, assembly
  Travel motor, exploded view
  Travel Speed
  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 covers, fitting new gasket1
  Valve covers, fitting new gasket2
  Valves, adjusting
  V-ECU, replacing
  Warranty inspection 100 hours
  Warranty inspection 1000 hours
  Water separator filter element, change
  Water separator, drain
  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 air conditioning refrigerant
  Safety when working with batteries
  Starting with booster batteries
  Waste handling
  Working in environmentally contaminated areas
  Working on the electrical system of the machine

Service Bulletins

• Air conditioning unit
  Battery maintenance guideline for long term stock machines
  Bonnet latch cracks
  Boom offset function, time cycle
  Boom welding quality improvement
  Cab door vibration (especially with steel track option)
  Capilarity leakage at the hose crimpings
  Dipper arm welding improvement
  Engine hunting
  Engine Tier 3 introduction
  Fuel cap seal improvement
  Fuel level gauge indicator
  Fuel sampling, method
  Fuel tank leakage
  Grading
  Maintenance of Stored Machines
  New boom design
  New cabin plastic roof
  New dashboard
  New dipper arm
  New engine hood hinges
  New hydraulic pump pressure hose
  New product
  New starter switch
  New TechTool VCADS Pro interface
  Pilot valve coil
  Pivot play tolerance and instruction
  Platform cracks
  Portable refillable O-ring kits
  Pump companion
  Reporting of product misuse & near-miss report
  Rotating beacon improvement
  Seal between cab and platform
  Starter switch change
  Transport of machines equipped with roof on the cab
  Travel alarm
  Volvo Product incident accident report & Interview Form
  X1 function information

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 Old
  42 RM Paving Systems ABG Time Guide
  Special tool catalog
  Special Tools Recommendations

Specifications

• Adjustable boom cylinder, specifications
  Adjustable boom cylinder, specifications1
  Air conditioning unit, specifications
  Air conditioning unit, specifications1
  Alternator, specifications
  Alternator, specifications1
  Alternator, specifications2
  Battery, specifications
  Battery, specifications1
  Boom lifting cylinder, specifications
  Boom lifting cylinder, specifications1
  Bucket cylinder, specifications
  Bucket cylinder, specifications1
  Cab, tightening torques
  Cab, tightening torques1
  Cab, weight
  Cab, weight1
  Control valve, torque value
  Control valve, torque value1
  Conversion tables
  Cooling system, specification
  Cooling system, specification1
  Counterweight, specifications
  Counterweight, specifications1
  Dimensions
  Dipper arm cylinder, specifications
  Dipper arm cylinder, specifications1
  Dozer blade cylinder, specifications
  Dozer blade cylinder, specifications1
  Engine, capacities
  Engine, capacities1
  Engine, specifications1
  Engine, specifications2
  Engine, tighten torques
  Frame and track unit, specifications
  Frame and track unit, specifications1
  Fuel feed pump, specifications
  Fuel feed pump, specifications1
  Fuel tank, volume
  Fuel tank, volume1
  Hydraulic connections, general
  Hydraulic control unit, H-ECU, inputs and outputs
  Hydraulic control unit, H-ECU, inputs and outputs1
  Hydraulic control unit, H-ECU, value list
  Hydraulic control unit, H-ECU, value list1
  Hydraulic system, specification
  Hydraulic system, specification1
  Hydraulic system, tightening torques
  Hydraulic system, tightening torques1
  Hydraulic tank, specifications
  Hydraulic tank, specifications1
  Injectors, specification
  Injectors, specification2
  Instrument panel, specifications
  Instrument panel, specifications1
  Lifting capacities
  Light bulbs, specification
  Light bulbs, specification1
  Lubrication system, specifications
  Lubrication system, specifications1
  Preheating, specifications1
  Preheating, specifications2
  Preheating, specifications3
  Preheating, specifications4
  Pump, specifications1
  Pump, specifications2
  Pump, specifications3
  Pump, specifications4
  Slew motor, specifications
  Slew motor, specifications1
  Slew motor, tightening torques
  Slew motor, tightening torques1
  Standard tightening torques
  Starter motor, specification
  Starter motor, specification1
  Track motor, specifications
  Track motor, specifications1
  Track motor, specifications2
  Track motor, tightening torques
  Track motor, tightening torques1
  Track motor, tightening torques2
  Valve mechanism, specifications
  Valve mechanism, specifications1
  V-ECU, I-O list
  V-ECU, value list
  V-ECU, value list1
  VOLVO standard tightening torques
  Weight

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