Volvo EC45 Compact Excavator Workshop Service Repair Manual PDF Download - MVLVCONEC45.zip

A full workshop manual covering the Volvo EC45 Compact Excavator, packed with the shop-level detail needed to service, troubleshoot, fix, and rebuild the machine the way trained technicians do.

This Volvo Construction Equipment EC45 Compact Excavator service and repair guide 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 EC45 Compact Excavators Service Repair Manual.pdf

TABLE OF CONTENTS

0 - Foreword.....2

0 - GENERAL.....3

00 - DESCRIPTION; COMPLETE MACHINE.....4

Position of components.....5

Warning and information decals.....6

Caution sign - Operation and maintenance.....7

Warning sign - Open engine hood only with engine stopped.....8

Foreword.....9

Warning sign - Safety distance from the work area.....10

Warning sign - Safety distance from the movement area.....11

Caution sign - Track tension.....12

Caution sign - Diesel engine starting procedure.....13

Caution sign - Lifting the machine.....14

Caution sign - Lashing.....15

Caution sign - Emergency exit.....16

Machine identification.....17

03 - SPECIFICATIONS.....19

Tightening torques.....20

Main dimensions EC 45.....31

Load capacity tables EC 45-22.....33

Fuel; lubricant and filling capacities-56.....34

Load capacity tables EC 45.....35

Reach of the working attachment EC 45.....36

Reach EC 45.....37

Strength class 8.8 Metric coarse and fine threads.....39

Strength class 10.9 Metric coarse and fine threads.....40

UNC-threads; coarse pitch.....41

Plugs with tapered thread.....42

Tightening torques; engine-55.....43

Mechanical transmission - track gearbox.....44

Hydraulic motor 1 - travel system.....45

Fuels; lubricants and filling capacities (litres).....46

ENGINE.....47

Electrical system.....49

Power transmission.....50

Hydraulic system EC 45.....51

Slewing ring; tightening torques-27.....52

07 - STANDARD TIME.....53

Operation numbers for additional work.....54

1 - STANDARD PARTS; SERVICE.....56

16 - LUBRICANT; FUEL; OTHER FLUID.....57

Hydraulic oil.....58

Recommended lubricants.....63

Alternative fuels.....64

17 - SERVICE.....67

Service and maintenance.....68

Repairing hydraulic system.....70

Electric welding.....71

Cleanliness; braking and hydraulic system.....72

Maintenance instructions.....73

Engine air filter unit.....77

Change engine oil; replace filter.....79

Recharging of batteries.....81

Hydraulic system; replacement of hydraulic filter element.....82

Changing the hydraulic oil-.....84

Travel gear; oil change.....87

Inspection.....88

Cylinder speed.....89

Swing speed.....93

Slewing overtravel.....94

Measuring the play of the slewing bearing.....96

Travel Speed.....99

Jump starting.....101

19 - GENERAL.....103

Safety concerns everybody!.....104

General precautions.....106

Preparations for work.....109

Safety measures during operation.....112

Move and operate machine safely.....117

2 - ENGINE WITH MOUNTING AND EQUIPMENT.....119

20 - GENERAL.....120

Description-00.....121

Precautions.....123

Troubleshooting chart.....124

21 - ENGINE.....130

Specification; engine.....131

Specification; weight.....132

Specification; filling capacities.....133

Valve timing.....134

COOLING SYSTEM.....135

Tightening torques; engine.....136

Engine trouble shooting.....137

Compression pressure inspection.....139

Valves; adjusting.....141

22 - LUBRICATING SYSTEM.....143

Lubrication system; specification.....144

Lubricating system; description.....145

Removing the oil filter.....147

Installing the oil filter.....148

Removing the oil pressure switch.....149

Installing the oil pressure switch.....151

23 - FUEL SYSTEM.....152

Description.....153

Disassembling the fuel pump.....154

Installing the fuel pump.....155

Changing the fuel filter-24.....156

Bleeding the fuel system.....158

Disassembling the fuel injection line.....159

Assembling the fuel injection line.....160

Idle speed; inspection and adjustment.....161

25 - INLET & EXHAUST SYSTEM.....163

Schematic.....164

26 - COOLING SYSTEM.....165

Removing the coolant pump.....166

Removing the thermostat housing.....169

Tensioning the V-belt.....173

Changing the V-belt.....174

3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....175

30 - GENERAL.....176

Electrical system; description.....177

Electrical system; technical data.....178

Basic objects of examination.....179

Diagnostics.....180

Electric system; trouble shooting.....182

Precautions when handling plug connectors.....183

31 - BATTERY.....185

Battery; location and removal.....186

Battery; description.....188

Battery; specification.....189

32 - ALTERNATOR; CHARGE REGULATOR.....190

Tests before disassembly.....191

Removing the generator.....193

Installing the generator.....194

Disassemble the generator.....196

Assemble the generator.....202

Checking the voltage regulation.....204

Checking the performance characteristics.....205

33 - STARTING SYSTEM.....207

Starter motor; disassembly and assembly.....208

35 - LIGHTING.....210

Boom_cabin_weather roof.....211

Working headlights and main headlights; description.....214

Working headlights and main headlights; specification.....215

37 - CABLE; FUSE; RELAY.....216

Colour codes.....217

Designations of electrical components.....218

Wiring diagram; schematic drawing (part 1).....225

Wiring diagram; schematic drawing (part 2).....228

Wiring engine; schematic drawing.....231

Complete wiring diagram (part 1).....234

Complete wiring diagram (part 2).....236

Fuses for machine equipment.....239

Fuses for cabin equipment.....240

Relay.....241

38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....242

Electrical components (hydraulic system side part 1).....243

Electrical components (hydraulic system side part 2).....244

Electronic multi-function switch PUMA (ECU1).....245

error codes.....247

4 - POWER TRANSMISSION.....248

40 - GENERAL.....249

Fuel; lubricant and filling capacities.....250

Working principle of the travel system.....251

Technical data.....254

44 - HYDROSTATIC DRIVE.....256

Design of travel motor.....257

Design of axial piston motor.....259

Brake valve (counter balance valve).....261

Removing the travel motor.....264

Assembling the travel motor.....267

Travel motor; exploded view.....270

Travel gear; dismantling.....272

Travel gear; mounting.....281

Hydraulic motor 001; travel gear.....292

Disassembling the hydraulic motor.....295

Assembling the hydraulic motor.....308

Removing the gear motor.....321

Assembling the gear motor.....323

Hydraulic motor – slewing of superstructure.....325

Removing the oil distributor seals.....327

Assembling the oil distributor seals.....329

Removing the cylinder block.....330

Assembling the cylinder block.....332

Disassembling pistons and guide sleeves.....333

Assembling pistons and guide sleeves.....335

Removing the radial seals.....336

Assembling the radial seals.....337

Disassembling the roller bearings.....339

Assembling the roller bearings.....340

Swivel joint.....343

49 - MISCELLANEOUS.....345

Applying the brake.....346

Releasing the slewing brake.....347

Assembling the brake discs.....348

Removing the brake discs.....350

Miscellaneous.....351

5 - BRAKE.....352

53 - TRACK BRAKE.....353

Brake; description.....354

6 - STEERING.....355

60 - GENERAL.....356

Steering system; description.....357

7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....358

71 - FRAME.....359

Slewing ring; tightening torques.....360

General description.....361

Removing the superstructure.....363

Assembling the superstructure.....365

77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....366

Drive gear; tightening torque.....367

Track supporting idler; tightening torque.....368

Track roller; tightening torque.....369

Track pad; tightening torque.....370

Removing the guide sprocket .....371

Assembling the guide sprocket-.....373

Sprocket; measurement of wear-.....375

Sprocket; measurement of wear.....376

Removing the guide sprocket.....377

Assembling the guide sprocket.....378

Adjusting the Track Tension.....379

Removing the crawler tracks.....381

Assembling the crawler track.....383

Removing the rubber track.....385

Assembling the rubber track.....387

Removing the top roller.....388

Assembling the top roller.....389

Removing the track roller.....390

Assembling the track roller.....392

8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....393

80 - GENERAL.....394

Cabin; specification.....395

Cabin; tightening torques.....396

Removing the cabin.....397

Assembling the cabin.....400

83 - DOORS; HATCH; COVER PLATE; (all).....403

Cabin door; description.....404

Windscreen.....406

9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....408

90 - GENERAL.....409

Hydraulic circuit; dipper arm - Image.....410

Hydraulic circuit; dozer blade - Image.....411

Servo hydraulics - Image.....412

Hydraulic system; auxiliary pressure block - Image.....413

Hydraulic circuit; slewing gear_offset - Image.....414

Hydraulic diagram EC 45; complete - Image.....415

Hydraulic system; function diagram - Image.....416

Hydraulic components; cleanliness during handling.....417

Hydraulic system; function diagram.....418

Hydraulic diagram EC 045; complete.....420

Hydraulic circuit; slewing gear_offset.....422

Hydraulic circuit; travel system.....424

Hydraulic circuit; boom.....427

Hydraulic system; auxiliary pressure block.....429

Servo hydraulics.....431

Hydraulic circuit for bucket.....433

Hydraulic circuit; dozer blade.....435

Hydraulic circuit; dipper arm.....437

Hydraulic system; capacities.....439

Hydraulic system; description.....440

Hydraulic oil; description.....442

Hydraulic oil; storage and handling.....443

Hydraulic components; storing and transporting.....444

91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....445

Solenoid valve for hydraulic working unit - Image.....447

Balancing valve (offset cylinder) Test and adjustment procedure - Image.....448

Balancing valve (offset cylinder) - Image.....449

Hydraulic oil tank; filling capacity.....450

Checking the hydraulic oil level.....451

Changing the hydraulic oil.....452

Oil cooling system.....455

Removing the oil cooler.....456

Changing the hydraulic oil filter.....459

Test and adjustment values EC 045.....461

Way valve; control valve.....463

Control valve.....465

Removing the valve block.....467

Installing the valve block.....468

Dismantling the valve block.....470

Assembling the valve block.....471

Pressure relief valves.....473

Checking and adjusting the pilot pressure.....474

Stand-by pressure.....477

Checking and adjusting the FR pressure control valve.....478

Checking and adjusting the LS pressure relief valve.....480

Tests and adjustments of the power control.....483

Checking and adjusting the dipper arm cylinder (volumetric capacity).....486

Checking and adjusting the breaker (volumetric capacity).....488

Hydraulic lock; hose rupture valve.....490

Hose rupture valve on boom cylinder-056.....492

Hose rupture valve on boom cylinder Test and adjustment procedure.....494

Hose rupture valve on boom cylinder; leak test.....496

Hose rupture valve on dipper.....497

Hose rupture valve on dipper arm cylinder; leakage test.....499

Balancing valve (offset cylinder).....500

Balancing valve (offset cylinder) Test and adjustment procedure.....502

Valve block for slewing gear.....504

Control valve block for slewing gear; test and adjustment.....507

Solenoid valve for hydraulic working unit.....509