Volvo EC230C Excavator Workshop Repair Service Manual PDF Download - MVOLCOEC230C.zip
Full service and repair documentation, complete with electrical wiring schematics, for the EC230C Volvo Excavator — everything needed to service, troubleshoot, fix, and overhaul the machine to professional-technician standards.
The workshop service and repair guide for EC230C Volvo 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.
EC230C Volvo Excavators Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,693 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
Description; complete machine................5
Component locations................6
Product plates................8
03 - SPECIFICATIONS................9
Tightening torques................13
Conversion tables................19
Engine; specifications ................27
Engine; weights ................28
Valve system specifications ................29
Flywheel; weight ................31
Lubrication system; specifications-................33
Fuel pressure; specifications-................34
Fuel tank; specification-................36
Injectors; specifications-................37
Cooling system; specifications-................38
Coolant pump; thermostat; specifications-................39
Engine speed control switch; specifications-................41
Electrical system; specifications-................42
Engine control unit E-ECU; specifications-................44
Electronic climate control unit ECC; specification-................46
Wireless control unit W-ECU; specification_{11-42-34}................48
Wireless control unit W-ECU; specification_{11-42-11}................50
Wireless control unit W-ECU; specification_{11-41-49}................51
Keypad; specification-................53
Alternator; specifications-................56
Starter motor; specifications-................58
Electric horn; specifications-................59
Rotating beacon; specifications-................61
Travel alarm; specifications-................62
Wiper controller; specifications-................64
Windscreen flusher pump; specifications-................66
Start switch; specifications-................68
Control lockout lever switch; specifications-................70
Emergency engine speed control switch; specifications-................72
Auto_Manual pump control switch; specifications-................73
Relay; specifications-................74
Circuit breaker; specification-................76
Audio remote controller; specifications_{11-35-10}................78
Audio remote controller; specifications_{11-34-48}................81
Machine weights................83
Capacities................84
Specifications; weight................85
Engine; oil and filter; change.-................86
Radio with tape or CD player; specifications-................89
DC–DC converter; specifications-................92
Travel motor; specifications-................93
Propeller shaft; specifications-................95
Front axle; specification-................96
Rear axle; specification-................97
Slew ring gear; specifications-................98
Steering axle; specifications-................99
Counterweight; specifications-................100
Engine; volume-................101
Air cleaner; specification-................102
Air cleaner; specification ................103
Fuel filler pump; specifications-................104
Engine control; specifications ................105
Instrument control unit I-ECU; specifications ................106
Vehicle control unit V-ECU; specifications ................108
Battery; specifications ................113
Preheating; specifications ................114
Lighting; specifications ................115
Lower wiper motor; specifications ................116
Battery disconnect switch; specifications ................117
Multi-function lever switch; specifications ................118
Control levers; specifications ................119
Manual travel control switch; specifications ................126
Control lockout solenoid valve; specifications ................127
Stabiliser solenoid valve; specifications ................128
Electric center passage; specification ................129
Power outlet; specifications ................130
Flasher relay; specifications ................131
Hydraulic oil filter pressure switch; specifications ................132
Auto idle pressure switch; specifications-................133
Slew position sensor; specfications-................134
Rear view camera; specifications................135
Slew motor; specifications................136
Travel gearbox; specifications-................137
Wheels; specifications ................138
Cab; specifications................139
Cab; weight-................142
Air conditioning unit; specifications ................144
Diesel coolant heater (5kw); specifications ................145
Automatic lubrication system; specifications ................147
Brake pump; specifications ................149
Steering pump; specifications ................150
Control valve (steering unit); specification ................151
Hydraulic pressure; specifications ................152
X1; Specifications................154
Cruise control; specifications................158
Hydraulic tank; specifications ................159
Working pump; specifications ................160
Servo pump; specifications ................161
Digging equipment bearings; specifications ................162
Cylinder data ................164
Hydraulic oil cooling system; specifications ................165
Lifting instructions................167
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION................169
Lifting instructions................170
07 - STANDARD TIME................172
Operation numbers for additional work................173
08 - TOOL................175
E-tool; 3500 Support plate for travel gearbox and motor................176
E-tool; 3501 Puller for gear wheel fan pump................178
E-tool; 3502 Plate for turning crankshaft................179
E-tool; 3506 Flange................181
E-tool; 3507 Plug................182
Infrared Thermometer................183
09 - MISCELLANEOUS................185
Service positions-................186
Welding on the machine................189
Hydraulic cylinders; dieseling................192
Control units; changing................194
1 - STANDARD PARTS; SERVICE................196
16 - LUBRICANT; FUEL; OTHER FLUID................197
Coolant with freezing and corrosion protection................198
Recommended lubricants................199
Coolant................202
Alternative fuels................207
17 - SERVICE................210
Bearings................213
Elimination of trapped hydraulic pressure................217
Replacement parts................219
Service................223
Service methods................224
Pressure testing................228
Hoses and tubes................232
Cleaning prior to repair ................236
Arrival Inspection; according to Inspection Programme................237
Delivery Inspection; according to Inspection Programme................242
Cleaning prior to repair................244
Maintenance of Stored Machines; according to Inspection Programme................245
Warranty inspection 100 hours................247
Warranty inspection 1000 hours................248
Periodic maintenance................249
Maintenance service; daily................251
Maintenance service; every 50 hours................252
Maintenance service; every 250 hours................253
Maintenance service; first 500 hours................254
Maintenance service; every 500 hours................255
Maintenance service; every 1000 hours................256
Maintenance service; every 4000 hours................257
Maintenance service; every 6000 hours................258
Tyres; wear and air pressure; checking................259
Checking for cracks and leaks................261
Check engine oil level................262
Test-run and check................263
Grease points on dipper arm; lubrication................264
Grease points on booms; lubrication................267
Grease points on undercarriage; lubrication................269
Grease points on superstructure; lubrication................271
Hydraulic system; checking oil level................272
Water separator; drain................274
Coolant level; check................276
Axles; checking oil level................277
Axle hubs; checking oil level................279
Travel gearbox oil level; checking................281
Fuel tank water and sediment; drain................283
Battery condition; check................285
Door hinges; lubricate with grease................288
Cab; prefilter; clean................290
Axles; changing oil................292
Hub reduction gear; changing oil................294
Engine; oil and filter; change.................296
Fuel filters; primary and secondary filter; replace_{09-37-37}................299
Fuel filters; primary and secondary filter; replace_{09-36-56}................301
Radiator and coolers; cleaning................303
Condenser; clean (with compressed air) (optional equipment)................306
Cab; main filter; clean................308
Belts and belt tension; check; replace when needed.................310
Service journal (included in Operator's manual); fill in................313
Wheel nuts; check torque................314
Brake system; checking function................315
Air cleaner primary filter; change................316
Air conditioning unit; maintenance-................319
MATRIS; reading; export reading................320
VCADS Pro; logged errors; read off................322
Swing bath grease; check................324
Travel gearbox; changing oil................327
Brake discs; checking wear................329
Air cleaner secondary filter; change................332
Cab; prefilter; replace................334
Cab main filter; replacing................336
Fuel tank breather filter; replacing................338
Hydraulic oil return filter; changing_{08-05-58}................340
Hydraulic oil return filter; changing_{08-05-03}................342
Hydraulic tank breather filter; changing................344
Hydraulic oil servo filter; change_{09-08-24}................346
Hydraulic oil servo filter; change_{09-06-30}................350
Coolant's freezing point; check................352
Valve clearance and IEGR; check................354
Hydraulic system; changing oil................355
Hydraulic oil suction strainer; change................359
Turbocharger inclusive inlet and exhaust systems; leakage; check................362
Coolant; change................364
CareTrack backup battery; replacing................368
Creeping of hydraulic cylinder ................371
Emergency operation; description................375
Towing................378
Secondary lowering of digging equipment................380
Emergency operation slew function; description................382
Starting engine with booster cables................386
19 - GENERAL................388
Safety concerns everybody!................389
Service positions................391
CE marking and declaration of conformity................394
Safety when handling the machine................396
Safety rules when servicing................400
Checklist after a fire or heat exposure ................402
Fire prevention measures................403
Health hazards with paint; plastics and rubber................406
Checklist after a fire or heat exposure................411
Some simple rules regarding tyre handling................415
Safety when using lifting equipment................417
Safety when handling oils and fuel................421
Safety when working with batteries................425
Starting with booster batteries................430
Safety when working with air conditioning refrigerant................434
Safety when working with hydraulic systems................439
Environmental handling for the future................441
Environmentally safe handling................445
Environmentally hazardous fluids................448
Working in environmentally contaminated areas................452
Decontamination................456
Waste handling................460
2 - ENGINE WITH MOUNTING AND EQUIPMENT................464
20 - GENERAL................465
Engine; description................466
E-ECU MID 128 pre-programmed; replacing................468
E-ECU MID 128 non-programmed; replacing................471
Engine; identification................474
Engine; volume................475
Engine; tightening torques................476
Component locations................479
Engine; weights ................481
21 - ENGINE................482
Engine; specifications................484
Cylinder compression; PC test................485
Engine characteristic curve................486
Basic check; Engine................488
Troubleshooting ................490
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope................493
Engine; removing................499
Engine; weights................509
Cylinder head; description................510
Cylinder head gasket; description................512
Cylinder; description-................514
Pistons; description................515
Piston rings; description................517
Piston cooling................519
Valve system specifications................521
Valves; description................524
Internal Exhaust Gas Recirculation (IEGR); description................526
Valves; adjusting................532
Engine timing gear; description................545
Camshaft; description................548
Timing gear case new gasket; installing................551
Flywheel; weight................558
Crankshaft; description................560
Vibration damper; description................563
Connecting rod; description................566
Crankshaft front oil seal; replacing................569
Oil sump; description................578
Oil sump; replacing................580
Oil level sensor; replacing................585
Engine mounting................589
Engine mount front; replacing................592
Engine mounting rear; changing................596
22 - LUBRICATING SYSTEM................599
Lubricating system; description................600
Lubrication system; specifications................604
Lubrication system; principle of operation................605
Oil pump; replacing................609
Lubrication oil pressure; checking with pressure gauge................621
Oil cooler; replacing................623
Oil cooler; description................626
23 - FUEL SYSTEM................627
Fuel system; description................629
Fuel pressure; specifications................631
Instructions for working with electronic fuel injection................633
Fuel pressure; checking................634