Volvo ECR40D Compact Excavator Workshop Service and Repair Manual PDF Download - MVLVCOECR40D.zip
A full-service repair guide for the Volvo ECR40D Compact Excavator, featuring electrical wiring schematics and every piece of workshop data needed to service, troubleshoot, overhaul, and rebuild the machine just like a trained technician.
Contained within this Volvo ECR40D Compact Excavator workshop service and repair manual:
* 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.
MAIN SECTIONS
0 - GENERAL
1 - STANDARD PARTS, SERVICE
2 - ENGINE WITH MOUNTING AND EQUIPMENT
3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
4 - POWER TRANSMISSION
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM
Volvo ECR40D Compact Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,301
File Format: PDF
TABLE OF CONTENTS
000 - Foreword.....2
000 - GENERAL.....3
00 - DESCRIPTION; COMPLETE MACHINE.....4
Component locations.....5
Description, general.....6
Product plate, description.....8
03 - SPECIFICATIONS.....10
Capacities.....11
Conversion tables.....12
Lifting capacities.....17
Tightening torques-[0748].....18
Weight.....27
07 - STANDARD TIME.....28
Operation numbers for additional work.....29
08 - TOOL.....31
Infrared Thermometer.....32
09 - MISCELLANEOUS.....36
Hydraulic cylinders, dieseling.....37
Welding on the machine.....39
001 - STANDARD PARTS, SERVICE.....40
16 - LUBRICANT; FUEL; OTHER FLUID.....41
Alternative fuels.....42
Coolant.....45
Fuel, recommendation.....47
Lubricants, specifications.....48
17 - SERVICE.....51
Air inlet hose, checking.....54
Arrival Inspection, according to Inspection Programme.....55
Attachment quick coupler, checking.....56
Cab main filter, replacing.....57
Cleaning prior to repair.....59
Cleanliness, braking and hydraulic system.....60
Coolant freezing point, checking.....61
Coolant level, checking.....63
Coolant, changing-[5523].....65
Crankcase ventilation separator, checking.....68
Creeping of hydraulic cylinder.....70
Cylinder speed.....72
Delivery Inspection, according to Inspection Programme.....76
Deviation when travelling straight ahead.....77
Engine air cleaner primary filter, cleaning.....80
Engine air cleaner primary filter, replacing.....83
Engine air cleaner secondary filter, replacing.....86
Engine oil and filter, changing.....88
Engine oil level, checking.....91
Exhaust manifold, checking.....93
Fan_alternator belt, checking.....94
Fuel filter, replacing.....96
Fuel hoses, checking.....98
Fuel injectors, checking.....99
Hydraulic hoses, checking.....108
Hydraulic oil level, checking.....109
Hydraulic oil return filter, replacing.....111
Hydraulic oil, changing.....113
Hydraulic pressure, checking.....116
Hydraulic system, pressure release.....120
Injection pump, checking.....122
Injection timing, checking-[5202].....128
Leakage oil filter element, replacing.....134
Lubrication and service schedules.....136
Lubrication.....139
Machine condition, checking.....141
Maintenance of Stored Machines, according to Inspection Programme.....142
Maintenance service, daily.....143
Maintenance service, every 1000 hours.....145
Maintenance service, every 1500 hours.....149
Maintenance service, every 2000 hours.....150
Maintenance service, every 250 hours.....152
Maintenance service, every 3000 hours.....155
Maintenance service, every 50 hours.....157
Maintenance service, every 500 hours.....159
Maintenance service, first 50 hours.....162
Measuring condition.....164
Radiator and hydraulic oil cooler, cleaning.....165
Radiator hoses, checking.....167
Repairing hydraulic system.....169
Seat belt, replacing.....170
Service and maintenance.....173
Service position 1-[0038].....175
Service position 2-[0018].....176
Service position 3-[5956].....178
Service.....180
Slewing speed.....183
Starting with booster batteries-[3007].....185
Test running and checking.....187
Thumb pivot pin, lubricating.....188
Towing, measures.....190
Track running speed.....192
Track tension and condition, checking.....194
Travel Speed.....197
Travel gearbox oil level, checking.....199
Travel gearbox oil, changing.....201
Values, creeping of hydraulic cylinder.....203
Values, cylinder speed.....204
Values, deviation when travelling straight ahead.....205
Values, slewing speed.....206
Values, track running speed.....207
Values, travel speed.....208
Valves, adjusting-[5551].....209
Water separator, checking.....213
Water separator, cleaning.....215
19 - GENERAL.....217
CE marking and declaration of conformity.....218
Checklist after a fire or heat exposure.....220
Decontamination.....221
Environmental handling for the future.....222
Environmentally hazardous fluids.....224
Environmentally safe handling.....225
Fire prevention measures.....227
Health hazards with paint, plastics and rubber.....230
Pressure setting and leak detection.....232
Safety concerns everybody!.....233
Safety for work on hydraulic systems.....235
Safety rules when servicing.....237
Safety when handling oils and fuel.....240
Safety when handling the machine.....241
Safety when lifting and supporting the machine.....246
Safety when working with air conditioning refrigerant.....248
Safety when working with batteries.....251
Service position 1.....254
Service position 2.....256
Service position 3.....258
Starting with booster batteries.....260
Waste handling.....262
Working in environmentally contaminated areas.....266
Working on the electrical system of the machine.....269
002 - ENGINE WITH MOUNTING AND EQUIPMENT.....271
20 - GENERAL.....272
Engine, capacities.....273
Engine, description.....274
Engine, tighten torques_{08-19-30}.....277
Engine, tighten torques_{08-19-42}.....279
Troubleshooting chart.....281
21 - ENGINE.....284
Crankshaft front oil seal, replacing.....285
Crankshaft rear oil seal, replacing.....291
Crankshaft, description.....295
Cylinder head, description.....297
Cylinder head, installing.....299
Cylinder head, removing.....305
Engine mounts, replacing.....311
Engine, installing.....313
Engine, removing.....319
Engine, specifications_{08-18-07}.....326
Engine, specifications_{08-18-18}.....328
Engine, specifications_{08-18-30}.....329
Engine, specifications_{08-18-42}.....331
Oil sump, replacing.....332
Timing gear case new gasket, installing.....334
Valve cover, installing.....347
Valve cover, removing.....349
Valve mechanism, description.....351
Valve system specifications.....353
Valves, adjusting.....354
22 - LUBRICATING SYSTEM.....359
Lubricating system, description.....360
Lubrication oil pressure, checking with pressure gauge.....363
Lubrication system, component locations.....366
Lubrication system, specifications.....368
Lubrication system, tightening torques.....369
Oil pump, description.....370
Oil pump, replacing.....371
23 - FUEL SYSTEM.....375
Fuel feed pump, description.....376
Fuel feed pump, specifications.....377
Fuel filter_water separator, description.....378
Fuel pipes, replacing.....379
Fuel pump, installing.....386
Fuel pump, removing.....388
Fuel system, description.....391
Fuel system, general specifications_{08-07-03}.....393
Fuel system, general specifications_{08-07-15}.....394
Fuel tank, description.....395
Fuel tank, installing.....396
Fuel tank, removing.....399
Fuel tank, specifications.....403
Idling speed, checking and adjusting.....404
Injection pump gasket shims, description.....407
Injection pump, description.....409
Injection pump, fitting incl setting injection timing.....412
Injection pump, removing.....417
Injection timing, checking.....420
Injectors, checking.....425
Injectors, description.....428
Injectors, replacing.....430
Injectors, specification.....433
25 - INLET & EXHAUST SYSTEM.....434
Air cleaner, description.....435
Air cleaner, installing.....437
Air cleaner, primary filter replacing.....438
Air cleaner, removing.....441
Air cleaner, secondary filter replacing.....443
Air cleaner, specification.....445
Exhaust pipe, replacing.....446
Intake and exhaust system, description.....449
Silencer, installing.....451
Silencer, removing.....454
26 - COOLING SYSTEM.....457
Coolant anti-freeze resistance, checking.....458
Coolant pump, replacing.....460
Coolant, changing.....464
Cooling system, description.....467
Cooling system, specification.....469
Expansion tank, installing.....470
Expansion tank, removing.....471
Fan belt and_or alternator belt, checking and adjusting tension.....473
Fan belt and_or alternator belt, replacing.....476
Radiator hoses all, replacing.....479
Radiator, installing.....481
Radiator, removing.....482
Thermostat, replacing.....483
27 - ENGINE CONTROL.....485
Auto idling device, description.....486
Automatic idling device, installing.....488
Automatic idling device, removing.....490
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....492
30 - GENERAL.....493
11 666 140 Multimeter.....496
8883 0028 Adapter cable.....497
88890040 Oscilloscope for VCADS Pro.....498
999 0062 Extension cable.....499
999 3894 Template.....500
999 8699 Multi-pin breaker box.....501
AL3201, description and measuring.....502
BA3101, description and measuring.....505
CU2504, description and measuring.....507
Checking electrical cabling and connectors.....510
Collection of basic data.....515
Communication with data buses.....517
Component descriptions.....519
Component troubleshooting, checking component.....522
Component troubleshooting, checking subsystem (circuit).....524
Component troubleshooting, checking wiring harness and input_output on ECU.....526
Component troubleshooting, structure, description.....528
Conditions when checking.....530
Connecting special tools.....535
DC current measurement.....538
DC voltage measurement.....542
Data buses, function.....545
Data links, fault tracing with Oscilloscope.....551
Diode check procedure.....561
Electrical cables and connectors, checking.....564
Electrical system, special instructions for servicing, electronic components_{07-46-53}.....569
Electrical system, special instructions for servicing, electronic components_{07-47-05}.....571
Electrical system, special instructions for servicing, electronic components_{07-47-20}.....572
Electrical system, special instructions for servicing, general.....574
Electronic control system, description.....576
Error code information, description.....578
Error code information, general.....580
Error codes, build-up-[4100].....582
Error codes, build-up.....587
FX1056, description and measuring.....591
FX1057, description and measuring.....593
General fault diagnosis information.....595
Information display, check.....596
Lead and connector checks.....597
MA2307, description and measuring.....603
MA4228, description and measuring.....605
MA8704, description and measuring.....607
MA9109, description and measuring.....609
MA9186, description and measuring.....611
Measuring components.....613
Measuring symbols, description.....614
Measuring, general.....617
RE3301, description and measuring.....618
Resistance measurement.....620
SAE J1708_1587 Information link, description and measuring.....623
SAE J1939_CAN control link, description and measuring.....625
SAE J1939_CAN2 Control link, description and measuring.....628
SE8702, description and measuring.....631
Service connection and programming connection.....634
Software parameters, description.....636
Special tools for troubleshooting.....639
Tech Tool, operations.....640
Troubleshooting strategy.....641
Troubleshooting tips.....643