Volvo EW180E Excavator Workshop Service & Repair Manual PDF with Wiring Diagrams - MVLVCONEW180E.zip
This is a full service and repair guide, complete with electrical wiring diagrams, for the Volvo Construction EW180E Excavator line. It contains every technical detail needed to service, troubleshoot, fix, and rebuild these machines just as a professional technician would.
The Volvo EW180E Excavator workshop service and repair manual covers the following:
* 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 EW180E Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,431 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword................2
0 - GENERAL................3
00 - DESCRIPTION; COMPLETE MACHINE................4
Complete machine; descriptions................5
Product identification plates................7
Machine view................8
03 - SPECIFICATIONS................10
Measurement conversion tables................11
Tightening torques................15
Machine weights................21
Specifications; weight................22
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION................23
Lifting instructions................24
Measurements before transporting machine................26
Tying down machine................27
07 - STANDARD TIME................29
Operation numbers for additional work................30
08 - TOOL................32
E-tool; 3500 Support plate for travel gearbox and motor................33
E-tool; 3502 Plate for turning crankshaft................35
Infrared Thermometer................37
88830268 User Instruction................39
88830540 User Instruction................42
E-3509................45
E-3508................47
09 - MISCELLANEOUS................49
Service positions................50
Welding on the machine................51
Hydraulic cylinders; dieseling................52
1 - STANDARD PARTS; SERVICE................54
16 - LUBRICANT; FUEL; OTHER FLUID................55
AdBlue®_DEF................56
Fuel................62
Coolant with freezing and corrosion protection................63
Recommended lubricants................65
Coolant................68
Alternative fuels................73
Fuel; lubricant and filling capacities_{31-23}................76
Fuel; lubricant and filling capacities_{31-04}................78
Air cleaner; description................80
17 - SERVICE................82
Bearings................86
Elimination of trapped hydraulic pressure................87
Replacement parts................90
Service................91
Service methods................92
Pressure testing................93
Hoses and tubes................94
Cleaning prior to repair................95
Tech Tool; operations................96
Arrival Inspection; according to Inspection Programme................97
Delivery Inspection; according to Inspection Programme................102
Maintenance of Stored Machines; according to Inspection Programme................104
Maintenance service; first 500 hours................106
Maintenance service; every 10 hours................107
Maintenance service; every 50 hours................108
Maintenance service; every 100 hours................109
Maintenance service; every 250 hours................110
Maintenance service; every 500 hours_{23-49}................111
Maintenance service; every 500 hours_{23-30}................113
Maintenance service; every 1000 hours_{23-02}................115
Maintenance service; every 1000 hours_{22-43}................117
Maintenance service; every 2000 hours_{22-10}................119
Maintenance service; every 2000 hours_{21-51}................122
Maintenance service; every 4000 hours_{21-22}................125
Maintenance service; every 4000 hours_{21-03}................128
Maintenance service; every 5000 hours................131
Maintenance service; every 6000 hours_{20-17}................132
Maintenance service; every 6000 hours_{19-58}................133
Maintenance service; every 8000 hours................134
Service position ................135
Lubrication; every 50 hours................138
Lubrication; every 100 hours................143
Lubrication; every 500 hours................147
Test running and checking................148
Leakage; checking................150
Engine belt tension; checking................151
Valves; adjusting ................153
Engine oil level; checking................161
Engine oil and filter; changing................162
Water separator; checking................165
Fuel filters; replacing................166
Fuel tank breather filter; replacing................168
Fuel tank sediment; draining................170
Diesel particulate filter; regenerating................172
Diesel particulate filter; checking and cleaning................174
AdBlue®_DEF pump unit filter; replacing................182
AdBlue®_DEF tank breather filter; replacing................186
Engine air cleaner primary filter; replacing................189
Engine air cleaner secondary filter; replacing................191
Coolant level; checking................193
Coolant; changing................195
Coolant freezing point; checking................199
Radiator; cleaning................202
MATRIS and Tech Tool; reading................204
Software update; checking................206
Battery; checking................210
CareTrack backup battery; replacing................212
Travel gearbox oil level; checking................215
Travel gearbox oil; changing................217
Swing ring gear lubrication; checking................219
Swing gearbox oil level; checking................221
Swing gearbox oil; changing................223
Drive axles and hubs oil level; checking................225
Drive axles and hubs oil; changing................228
Brake disc wear; measuring................232
Brake pressure and function; checking................235
Tyre wear and air pressure; checking................239
Wheel nuts torque; checking................241
Cab prefilter; cleaning................242
Cab prefilter; replacing................244
Cab main filter; cleaning................246
Cab main filter; replacing................250
Air conditioner compressor belt; checking................254
Hydraulic oil level; checking................256
Hydraulic oil; changing................258
Hydraulic oil drain filter; replacing................263
Hydraulic oil servo filter; replacing................265
In-line hydraulic oil filter; cleaning................268
Hydraulic oil return filter; replacing................271
Hydraulic oil tank breather filter; replacing................273
Boom suspension accumulator; checking................275
Trailer hitch; checking_{54-49}................280
Trailer hitch; checking_{54-28}................285
Universal quick coupler; checking................290
Measuring condition................292
Cylinder speed................293
Creeping of hydraulic cylinder................296
Swing speed................299
Measuring of swing bearing clearance................301
Coasting left and right swing................302
Travel Speed................304
Towing................305
Secondary lowering of digging equipment................308
Starting engine with booster cables................310
19 - GENERAL................312
Safety concerns everybody!................313
CE-marking; EMC-directive................315
Safety when handling the machine_{46-19}................317
Safety when handling the machine_{45-59}................320
Safety rules when servicing................324
Service position................327
Checklist after a fire or heat exposure................330
Fire prevention measures................331
Health hazards with paint; plastics and rubber................334
Some simple rules regarding tyre handling................336
Safety when using lifting equipment................338
Safety when handling oils and fuel................339
Safety when working with batteries................340
Starting with booster batteries................342
Safety when working with air conditioning refrigerant................343
Safety when working with hydraulic systems................345
Environmental handling for the future................347
Environmentally safe handling................348
Environmentally hazardous fluids................350
Working in environmentally contaminated areas................351
Decontamination................352
Waste handling................353
2 - ENGINE WITH MOUNTING AND EQUIPMENT................354
20 - GENERAL................355
Engine; description_{36-49}................356
Engine; description_{36-28}................364
Component locations................371
Tech Tool; operations_{35-31}................373
Tech Tool; operations_{35-12}................376
Engine control module (ECM); replacing pre-programmed................378
Engine control module (ECM); replacing non-programmed................381
Engine; reference values................384
21 - ENGINE................387
Engine; specifications................388
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope................389
Engine; removing................395
Engine; installing................405
Engine; replacing_{030-50}................415
Engine; replacing_{030-32}................419
Engine; tightening torques................422
Cylinder compression; testing................429
Crankcase ventilation; description................432
Valve system; specifications................436
Valves; adjusting................437
Valve cover; removing................445
Valve cover; installing................449
Oil level sensor; replacing................453
Engine mount front; replacing................455
Engine mounting rear; changing................460
Engine mounting; tightening torque................463
22 - LUBRICATING SYSTEM................465
Lubrication system; description................466
Lubrication system; specifications................471
Lubrication oil consumption; checking................473
Lubrication system; component locations................477
Lubrication system; tightening torques................479
Lubrication oil pressure; checking with pressure gauge................482
23 - FUEL SYSTEM................484
Fuel system; description................485
Fuel system; specifications................492
Fuel system; tightening torques................494
Carbon dioxide in fuel system; checking................500
Fuel system; component location................506
Feed pump pressure; checking................508
Fuel system; bleeding................510
Fuel tank; specification................512
Fuel filler pump; specifications................513
Fuel tank; description................514
Fuel tank; replacing................515
Fuel filling pump; removing................520
Fuel filling pump; installing................523
Injectors; replacing................525
Injector sleeves; replacing................530
Fuel rail; replacing................539
Fuel rail pressure sensor; replacing................542
High pressure fuel pump; replacing................544
High pressure fuel pipes; replacing................547
Fuel control valve (FCV); replacing................549
Pressure relief valve (PRV); replacing................554
25 - INLET & EXHAUST SYSTEM................558
Inlet and exhaust system; description................560
Inlet and exhaust system; specification................566
Inlet and exhaust system; component location................568
Inlet and exhaust system; tightening torques................570
Exhaust pipe flexible tube; replacing................576
Exhaust Aftertreatment System; description................578
Exhaust Aftertreatment System; component location_{005-36}................592
Exhaust Aftertreatment System; component location_{005-16}................594
Regeneration process; description................596
AdBlue®_DEF dosing injector; replacing................603
AdBlue®_DEF mixing tube; replacing................606
AdBlue®_DEF tank; replacing_{003-27}................609
AdBlue®_DEF tank; replacing_{003-05}................618
AdBlue®_DEF; draining................627
Coolant valve; replacing_{002-15}................630
Coolant valve; replacing_{001-55}................633
SCR (Selective catalytic reduction) muffler; replacing................636
AdBlue®_DEF quality; checking................639
SCR (Selective catalytic reduction) dosing system; checking................642
AdBlue®_DEF pump unit diagnostics; description................645
Exhaust aftertreatment system muffler unit; removing................649
Exhaust aftertreatment system muffler unit; installing................653
DPF (Diesel particulate filter); checking and cleaning................656
ACM (Aftertreatment control module) non-programmed; replacing................658
ACM (Aftertreatment control module) pre-programmed; replacing................660
Inlet throttle; replacing................662
DOC (Diesel oxidation catalyst); replacing................664
AdBlue®_DEF pump unit; replacing................668
AdBlue®_DEF tank armature; replacing_{057-09}................673
AdBlue®_DEF tank armature; replacing_{056-50}................678
AdBlue®_DEF tank armature; cleaning................684
AdBlue®_DEF tank armature suction filter; replacing................687
AdBlue®_DEF hoses; replacing................689
Crystallization of AdBlue®_DEF; checking................693
AdBlue®_DEF pump unit; flushing................698
AdBlue®_DEF pump unit; inlet nipple; replacing................702
Regeneration log; checking................706
AdBlue®_DEF tank; cleaning................718
Turbocharger; replacing................722
Wastegate; checking................726
Preheating coil; replacing................728
26 - COOLING SYSTEM................732
Cooling system; description................733
Cooling system; specifications................737
Carbon dioxide in coolant system; checking................739
Cooling system; component location................745
Cooling system; tightening torques................748
Cooling system pressure; checking................751
Radiator; description................753
Expansion tank; replacing................755
Radiator; removing................758
Radiator; installing................764
Radiator; disassembling................771
Radiator; assembling................775
Coolant pump; replacing................780
Thermostat; replacing................787
Cooling fan; description................790
Cooling fan control................791
Cooling fan rpm; specifications................794
Fan belt and_or alternator belt; replacing................795
AC compressor belt; replacing................798
Cooling fan clutch; description................800
Cooling fan clutch; replacing................802
27 - ENGINE CONTROL................808
Engine speed control; description_{09-34-48}................809
Engine speed control; description_{09-34-21}................813
Engine speed control; description_{09-33-56}................816
Engine control; specifications_{09-33-19}................819