Volvo EC480D EC480DL Excavator Workshop Repair Service Manual PDF Download - MVLVCONEC480D.zip
A full-service repair guide for the Volvo EC480D and EC480DL Excavators, featuring Electrical Wiring Diagrams and every technical detail needed to service, troubleshoot, fix, and rebuild these machines the way professional technicians do.
This workshop service repair manual for Volvo Construction's EC480D and EC480DL Excavators contains:
* 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.
Volvo EC480D, EC480DL Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,890 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
000 - Foreword....2
000 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Machine view_{05-06}....5
Machine view_{04-37}....7
Product plates....9
General description....12
07 - STANDARD TIME....13
Operation numbers for additional work....14
08 - TOOL....16
E-tools; NET 8940-00290 Swing motor guide pin....17
09 - MISCELLANEOUS....19
Service positions....20
Welding on the machine....23
Hydraulic cylinders; dieseling....26
001 - STANDARD PARTS; SERVICE....31
16 - LUBRICANT; FUEL; OTHER FLUID....32
Recommended lubricants....33
Grease....36
Hydraulic oil_{53-59}....41
Hydraulic oil_{53-32}....47
Specification; filling capacities_{52-59}....50
Specification; filling capacities_{52-30}....51
Engine oil_{51-57}....52
Engine oil_{51-31}....54
Engine oil_{51-02}....57
Fuel_{50-30}....59
Fuel_{50-04}....63
Alternative fuels....65
Coolant_49-10....76
Coolant....82
Coolant with freezing and corrosion protection....86
17 - SERVICE....91
Bearings....95
Replacement parts....100
Safety when servicing....105
Service....110
Service methods....114
Pressure testing....119
Hoses and tubes....124
Cleaning prior to repair....129
VCADS Pro; Operations....134
Arrival Inspection; according to Inspection Programme....136
Delivery Inspection; according to Inspection Programme....141
Maintenance of Stored Machines; according to Inspection Programme....146
Measuring condition....151
Cylinder speed_{43-53}....155
Cylinder speed_{43-22}....158
Creeping of hydraulic cylinder....161
Swing speed....163
Coasting left and right swing....164
Measuring of swing bearing clearance....166
Travel Speed_{40-58}....169
Travel Speed_{40-28}....171
Track running speed_{39-53}....173
Track running speed_{39-24}....175
Straight traveling performance....177
Maintenance service; first 500 hours_{04-29}....179
Maintenance service; first 500 hours_{04-01}....180
Maintenance service; daily_{03-29}....181
Maintenance service; daily_{03-04}....182
Maintenance service; every 50 hours_{01-19}....183
Maintenance service; every 50 hours_{00-53}....185
Maintenance service; every 250 hours_{00-21}....187
Maintenance service; every 250 hours_{59-55}....189
Maintenance service; every 500 hours_{59-23}....191
Maintenance service; every 500 hours_{58-57}....193
Maintenance service; every 1000 hours_{58-25}....195
Maintenance service; every 1000 hours_{58-00}....197
Maintenance service; every 2000 hours_{49-56}....199
Maintenance service; every 2000 hours_{49-29}....202
Maintenance service; every 4000 hours_{48-57}....205
Maintenance service; every 4000 hours_{48-32}....208
Maintenance service; every 4500 hours....211
Maintenance service; every 6000 hours_{54-40}....212
Maintenance service; every 6000 hours_{54-15}....213
Maintenance service; every 8000 hours....214
Maintenance service; every 12000 hours....215
Test-run and check....216
MATRIS; reading; export reading....219
VCADS Pro; logged errors; read off....222
The machine; check for external damages; cracks and wear damages....225
Washer fluid level; check....228
Engine; oil level; check....229
Coolant level; check_{51-27}....231
Coolant level; check_{51-00}....233
Hydraulic oil level; check_{50-28}....235
Hydraulic oil level; check_{50-01}....237
Fuel filter; change....239
Water separator; check_drain....241
Extra water separator (optional equipment); check_drain....243
Water separator filter element; change....245
Extra water separator (optional equipment); filter element; change....247
Fuel tank sediment; drain....250
Fuel tank air ventilation filter; change....252
Hydraulic oil servo filter; change....254
Engine air cleaner primary filter; cleaning_{47-06}....256
Engine air cleaner primary filter; cleaning_{46-35}....258
Engine air cleaner primary filter; replacing_{46-00}....260
Engine air cleaner primary filter; replacing_{45-29}....262
Engine air cleaner secondary filter; replacing_{44-55}....264
Engine air cleaner secondary filter; replacing_{44-23}....267
Battery condition; check_{23-47}....270
Battery condition; check_{23-16}....274
Belts and belt tension; check; replace when needed._{22-39}....278
Belts and belt tension; check; replace when needed._{22-10}....280
Radiator; cleaning....282
Hydraulic oil cooler outside; cleaning....284
Hydraulic oil drain filter; change....287
Hydraulic oil suction strainer; clean....289
Valves; adjusting_{20-09}....291
Valves; adjusting_{19-35}....298
Coolant anti-freeze resistance; checking_....304
Coolant; change....308
Diesel particulate filter; replacing_....311
Air dryer cartridge; change....315
Air pump oil level; check....318
Air pump oil; change....320
Spark plug cable; replacing_....323
Spark plug; replacing_....325
EGR venturi tube; checking_....328
Air conditioner main filter; clean....331
Air conditioner main filter; change....335
Cab prefilter; cleaning....339
Cab prefilter; replacing....341
Lubrication; see lubrication chart....343
Swing gearbox oil level; check....345
Swing motor gearbox; changing oil....347
Swing ring gear bearing; lubricate....350
Swing bath grease; check....351
Cab; door; covers; hinges; joints and locks; lubricate....352
Track shoe bolts; check....354
Track tension_condition; check....357
Track gearbox oil level; check....359
Track motor gearbox; changing oil ....361
Loose and loss of bolts; check....363
Oil-bath air cleaner's reservoir (optional equipment); oil; check....366
Oil-bath air cleaner's reservoir (optional equipment); clean; and oil; change....368
Oil-bath air cleaner's reservoir (optional equipment); filter insert; clean....371
X1 return filter (optional equipment); change_{06-45}....374
X1 return filter (optional equipment); change_{06-16}....377
Service history (included in the respective Operator's manual); fill in...379
Engine oil and filter; changing....382
CareTrack backup battery; replacing....385
Hydraulic oil; changing....390
Hydraulic oil return filter; replacing....394
Hydraulic oil tank breather filter; replacing....398
Starting engine with booster cables_....400
19 - GENERAL....404
Safety concerns everybody!....405
CE-marking; EMC-directive....410
Safety when handling the machine....414
Safety rules when servicing....421
Move and operate machine safely....426
Welding and grinding work....430
Fire prevention measures....434
Checklist after a fire or heat exposure....441
Safety when handling oils and fuel....446
Safety when using lifting equipment....451
Safety when working with hydraulic systems....456
Safety when working with air conditioning refrigerant....461
Starting with booster batteries....467
Safety when working with batteries....472
Environmental handling for the future....478
Environmentally safe handling....483
Environmentally hazardous fluids....488
Health hazards with paint; plastics and rubber....493
Working in environmentally contaminated areas....499
Decontamination....504
Waste handling....509
Cautions during operation....514
002 - ENGINE WITH MOUNTING AND EQUIPMENT....521
20 - GENERAL....522
Engine; description_{50-12}....523
Engine; description_{49-46}....528
VCADS Pro; Operations_{49-13}....533
VCADS Pro; Operations_{48-47}....535
Component locations_{48-15}....538
Component locations_{47-47}....541
Engine; identification....544
E-ECU MID 128 pre-programmed; replacing_{46-55}....546
E-ECU MID 128 pre-programmed; replacing_{46-24}....550
E-ECU MID 128 non-programmed; replacing_{35-50}....554
E-ECU MID 128 non-programmed; replacing_{35-19}....558
21 - ENGINE....562
Engine; specifications_{32-54}....564
Engine; specifications_{32-28}....565
Engine rotation speed sensor (crankshaft); replacing....566
Engine rotation speed sensor (camshaft); replacing ....569
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope....573
Engine; removing_{30-37}....579
Engine; removing_{29-59}....591
VCADS Pro; MID 128; programming E-ECU_{29-16}....603
VCADS Pro; MID 128; programming E-ECU_{28-51}....605
Engine; installing_{28-18}....607
Engine; installing_{27-49}....617
Valve cover; tightening torques....628
Cylinder head; tightening torques....630
Cylinder head; description....633
Crankcase ventilation; description_{24-52}....636
Crankcase ventilation; description_{24-23}....641
Crankcase ventilation separator; replacing....644
Valve mechanism; tightening torques....647
Valve mechanism; specifications_{22-51}....650
Valve system; specifications_{22-24}....654
Rocker arms; replacing....657
Rocker arm shaft; tightening torques....660
Valves; adjusting_{21-09}....662
Valves; adjusting_{20-36}....669
Valve cover; removing....675
Valve cover; installing....679
Engine transmission; tightening torque....684
Engine transmission; specification....690
Camshaft; replacing....693
Timing gear plate; replacing_{17-31}....704
Timing gear plate; replacing_{33-49}....737
Crank mechanism; description....773
Flywheel; tightening torques....777
Crankshaft front oil seal; replacing....780
Crankshaft rear oil seal; replacing....792
Oil level sensor; replacing_{18-38}....798
Oil level sensor; replacing_{18-10}....801
Oil sump; tightening torque....804
Engine mounting; tightening torque_{15-14}....806
Engine mounting; tightening torque_{14-48}....808
22 - LUBRICATING SYSTEM....810
Lubrication system; description_{10-28}....811
Lubrication system; description_{09-50}....817
Lubrication system; description_{09-20}....824
Lubrication system; specifications....831
Lubrication oil consumption; checking....833
Lubrication system; component locations_{08-06}....838
Lubrication system; component locations_{07-41}....840
Lubrication oil pressure; checking with pressure gauge....842
Oil cooler; tightening torques....845
23 - FUEL SYSTEM....847
Fuel system; description....848
Fuel system; specifications....854
Fuel system; tightening torques....855
Air in fuel system; checking....862
Carbon dioxide in fuel system; checking....865
Fuel system; component locations_{03-03}....871
Fuel system; component locations_{02-36}....873
Fuel feed pump; description....875
Feed pump pressure; checking....877
Feed pump; replacing....879
Fuel pump; inspecting....881
Fuel system; bleeding_{19-11}....886
Fuel system; bleeding_{18-44}....888
Feed pump bearing housing; replacing....890
Fuel tank; specifications....899
Fuel filler pump; specifications....900
Fuel tank; description....902
Fuel filling pump; removing....903
Fuel filling pump; installing....905
Unit injectors; description....907
Unit injector pretension; adjusting....910
Injectors; checking....912
Yoke; injector; checking....924
Injectors; replacing_{12-39}....929
Injectors; replacing_{12-02}....938
Overflow valve; replacing....948
Injector sleeves; replacing_{10-51}....950
Injector sleeves; replacing_{10-00}....959
25 - INLET & EXHAUST SYSTEM....966
Inlet and exhaust system; description_{07-06}....968
Inlet and exhaust system; description_{06-32}....972
Inlet and exhaust system; component locations_{05-57}....977
Inlet and exhaust system; component locations_{05-32}....979
Inlet and exhaust system; tightening torques_{04-59}....981
Inlet and exhaust system; tightening torques_{04-31}....983
Exhaust manifold; tightening torques_{02-58}....985
Exhaust manifold; tightening torques_{02-33}....987
Exhaust pipe flexible tube; replacing....989
Exhaust aftertreatment system; description....992
Exhaust aftertreatment system; component locations....1000
Regeneration process; description....1002
Exhaust aftertreatment system; specifications....1005
Perform a service regeneration....1008
Diesel particulate filter; replacing....1011
Exhaust aftertreatment system; tightening torques....1015
ACM (Aftertreatment control module) non-programmed; replacing....1019
ACM (Aftertreatment control module) pre-programmed; replacing....1021
Atomization unit; replacing....1023