Volvo EW180D Wheeled Excavator Workshop Service Repair Manual PDF - MVLVCONEW180D.zip
A full workshop service repair guide, featuring electrical wiring schematics, for the Volvo EW180D Excavator — providing every technical detail needed to service, troubleshoot, fix, and overhaul the machine the way trained technicians do.
This workshop service and repair manual for Volvo Construction wheeled excavators, model EW180D, covers:
* 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.
PRODUCT DETAILS:
Total Pages: 3,316 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo EW180D Excavators Service Repair Manual.pdf
TABLE OF CONTENTSS
0 - Foreword................2
0 - GENERAL................3
000 - DESCRIPTION; COMPLETE MACHINE................4
Description; complete machine................5
Component locations ................6
Product plates................10
003 - SPECIFICATIONS................11
Tightening torques................12
Conversion tables................18
Machine weights................26
Capacities................27
Specifications; weight................28
005 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION................29
Lifting instructions................30
007 - STANDARD TIME................33
Operation numbers for additional work................34
008 - TOOL................36
E-tool; 3500 Support plate for travel gearbox and motor................37
E-tool; 3502 Plate for turning crankshaft................39
Infrared Thermometer................41
E-3509................43
E-3508................45
009 - MISCELLANEOUS................47
Service positions................48
Welding on the machine................51
Hydraulic cylinders; dieseling................52
Control units; changing................54
1 - STANDARD PARTS; SERVICE................55
16 - LUBRICANT; FUEL; OTHER FLUID................56
Coolant with freezing and corrosion protection................57
Recommended lubricants_{05-27-25}................59
Recommended lubricants_{05-27-01}................63
Coolant................66
Alternative fuels................71
17 - SERVICE................74
Bearings................78
Elimination of trapped hydraulic pressure................79
Replacement parts................81
Service................82
Service methods................83
Pressure testing................84
Hoses and tubes................85
Cleaning prior to repair................86
Tech Tool; operations ................87
Arrival Inspection; according to Inspection Programme................88
Delivery Inspection; according to Inspection Programme................93
Maintenance of Stored Machines; according to Inspection Programme................95
Periodic maintenance................97
Service positions ................98
Maintenance service; daily................101
Maintenance service; every 50 hours................102
Maintenance service; every 250 hours................103
Maintenance service; first 500 hours................104
Maintenance service; every 500 hours................105
Maintenance service; every 1000 hours................107
Maintenance service; every 2000 hours................109
Maintenance service; every 3000 hours_{05-16-36}................111
Maintenance service; every 3000 hours_{05-16-15}................113
Maintenance service; every 4000 hours................115
Maintenance service; every 4500 hours................117
Maintenance service; every 6000 hours_{05-15-01}................118
Boom suspension accumulator; checking and adjusting................119
Tyres; wear and air pressure; checking................123
Checking for cracks and leaks................125
Check engine oil level................126
Test-run and check................127
Lubrication................128
Grease points on dipper arm; lubrication................129
Grease points on booms; lubrication................132
Grease points on undercarriage; lubrication................134
Grease points on superstructure; lubrication................138
Hydraulic system; checking oil level................140
Water separator; drain................142
Coolant level; check................143
Axles; checking oil level................145
Travel gearbox oil level; checking................148
Fuel tank water and sediment; drain................150
Battery condition; check................152
Door hinges; lubricate with grease................155
Cab; prefilter; clean................157
Axles; changing oil................159
Engine; oil and filter; change.................163
Fuel filters; primary and secondary filter; replace................167
Radiator; cleaning................169
Cab; main filter; clean................172
Belts and belt tension; check; replace when needed.................175
Trailer hitch; checking................178
Swing ring gear; grease check................182
Swing gearbox oil level; checking................184
Swing gearbox oil; changing................186
Service journal (included in Operator's manual); fill in................188
Wheel nuts; check torque................189
Brake system; checking function................190
Engine; air cleaner; main filter; replacing.................191
Air conditioning unit; maintenance................194
MATRIS; reading; export reading................195
VCADS Pro; logged errors; read off................197
Travel gearbox; changing oil................199
Brake discs; checking wear................201
Engine; air cleaner; secondary filter; replacing.................204
Cab; prefilter; replace................206
Cab main filter; replacing................208
Fuel tank breather filter; replacing................212
Hydraulic oil return filter; changing_{04-52-31}................214
Hydraulic oil return filter; changing_{04-52-07}................216
Hydraulic tank breather filter; changing................218
Hydraulic oil servo filter; change_{04-51-02}................220
Hydraulic oil servo filter; change_{04-50-34}................224
Hydraulic oil drain filter; change................227
Coolant's freezing point; check................229
Valves; adjusting ................231
Hydraulic system; changing oil................239
Turbocharger inclusive inlet and exhaust systems; leakage; check................243
Coolant; change................247
DPF (Diesel particulate filter); checking and cleaning ................251
Spark plug; replacing ................257
Hydraulic oil suction strainer; cleaning................259
CareTrack backup battery; replacing................262
Measuring condition................265
Cylinder speed................266
Creeping of hydraulic cylinder................269
Swing speed................273
Measuring of swing bearing clearance................274
Coasting left and right swing................275
Travel Speed................277
Emergency operation; description................278
Towing................281
Secondary lowering of digging equipment................284
Starting engine with booster cables................286
19 - GENERAL................288
Safety concerns everybody!................289
Service positions................291
CE marking and declaration of conformity................294
Safety when handling the machine................296
Safety rules when servicing................300
Checklist after a fire or heat exposure................302
Fire prevention measures................303
Health hazards with paint; plastics and rubber................306
Some simple rules regarding tyre handling................308
Safety when using lifting equipment................310
Safety when handling oils and fuel................311
Safety when working with batteries................312
Starting with booster batteries................314
Safety when working with air conditioning refrigerant................315
Safety when working with hydraulic systems................317
Environmental handling for the future................319
Environmentally safe handling................320
Environmentally hazardous fluids................322
Working in environmentally contaminated areas................323
Decontamination................324
Waste handling................325
2 - ENGINE WITH MOUNTING AND EQUIPMENT................326
20 - GENERAL................327
Engine; description................328
Tech Tool; operations................332
Engine; identification................334
Engine; volume................335
Component locations................336
Engine; weights ................339
Electric components location_{04-23-36}................340
Electric components location_{04-23-12}................347
E-ECU MID 128 pre-programmed; replacing................354
E-ECU MID 128 non-programmed; replacing................357
21 - ENGINE................360
Engine; specifications................361
Cylinder compression; PC test................362
Engine characteristic curve................363
Basic check; Engine................365
Troubleshooting................366
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope................368
Engine; removing................374
Engine; installing................384
Engine; weights................395
Engine; tightening torques................396
Crankcase ventilation; description................398
Valve system specifications................399
Valves; adjusting................400
Valve cover; removing................408
Valve cover; installing................413
Crankshaft; description................418
Vibration damper; description................419
Connecting rod; description................421
Oil sump; replacing................423
Oil level sensor; replacing................430
Engine mount front; replacing................434
Engine mounting rear; changing................439
Engine mounting; tightening torque................442
22 - LUBRICATING SYSTEM................445
Lubricating system; description................446
Lubrication system; specifications................450
Lubrication system; tightening torques................452
Lubrication system; component locations................454
Lubrication oil pressure; checking with pressure gauge................456
Oil cooler; replacing................460
Oil cooler; description................464
23 - FUEL SYSTEM................465
Fuel system; description................467
Fuel system; specifications................473
Fuel system; tightening torques................475
Fuel pressure; specifications................481
Instructions for working with electronic fuel injection................483
Fuel pressure; checking................484
Fuel system; component location................487
Fuel feed pump; description................489
Fuel filter; description................490
Feed pump pressure; checking................491
Fuel filter; checking................496
Fuel system; bleeding................497
Feed pump; replacing................499
Fuel filters; replacing................505
Fuel filter extra; replacing................507
Fuel tank; specification................509
Fuel filler pump; specifications................510
Fuel tank; description................511
Fuel tank; replacing................513
Air cleaner; specification ................520
Fuel filler pump; description................521
Fuel filling pump; removing................523
Fuel filling pump; installing................526
Fuel return pressure; checking................528
Injectors; specifications................530
Injectors; replacing................531
High pressure fuel pump; checking................540
Injector sleeves; replacing................545
Fuel rail; replacing................554
Fuel rail pressure; checking................562
Fuel rail pressure sensor; replacing................567
High pressure fuel pump; replacing................569
Fuel control valve (FCV); checking................574
Fuel control valve (FCV); replacing................579
Pressure relief valve (PRV); inspecting................582
Pressure relief valve (PRV); replacing................587
25 - INLET & EXHAUST SYSTEM................590
Inlet and exhaust system; description................592
Inlet and exhaust system; component location................596
Inlet and exhaust system; tightening torques................598
Exhaust pipe flexible tube; replacing................600
Exhaust Aftertreatment System; description_{03-42-38}................603
Exhaust Aftertreatment System; description_{03-42-06}................614
Exhaust Aftertreatment System; component location................625
Regeneration process; description................627
Exhaust aftertreatment system; specifications................632
DPF regeneration control................635
Semi-auto DPF regeneration................636
Perform a service regeneration................637
DPF (Diesel particulate filter); checking and cleaning................639
Exhaust aftertreatment system; tightening torques................645
DPF (Diesel particulate filter) inlet temperature sensor; replacing................647
Spark plug control unit; replacing................650
Glow plug; replacing................652
Fuel metering unit A; replacing................654
Fuel metering unit B; replacing................658
Air pump safety valve; replacing................664
DPF (Diesel particulate filter) outlet temperature sensor; replacing................666
ACM (Aftertreatment control module) non-programmed; replacing................669
ACM (Aftertreatment control module) pre-programmed; replacing................671
Spark plug; inspecting................673
Spark plug cable; replacing................675
Air pump; replacing................677
Burner function; checking................680
Burner; replacing................685
Spark plug; replacing................692
NOx sensor; replacing................694
DOC (Diesel oxidation catalyst); replacing................698
Turbocharger; description................701
Turbocharger; replacing................703
Air cleaner; description................708
Air cleaner; specification................709
Preheating coil; replacing................710
Charge air cooler; replacing................712
26 - COOLING SYSTEM................715
Cooling system; description................716
Cooling system; specifications................719
Carbon dioxide in coolant system; checking................720
Cooling system; tightening torques................726
Cooling system; component location................727
Cooling system pressure; checking................730
Coolant anti-freeze resistance; checking................732
Radiator; description................734
Radiator; replacing................736
Radiator hoses all; replacing................740
Expansion tank; replacing................743
Radiator; removing................746
Radiator; installing................753