Volvo EC220D LR Excavator Service Repair Manual
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Volvo EC220D LR Excavator Service Repair Manual
Size: 486.80 MB
Format: PDF
Language: English
Machine: Excavator
Machine Model: EC220D LR
Document: Service Repair Manual, Electrical Wiring Diagram, Hydraulic Diagram
Pages: 6630 Pages
The Bookmarks of Volvo EC220D LR Excavator Service Repair Manual:
1.EC220D LR
Descriptions
Adjustable boom (1st boom), description
Adjustable boom (2nd boom), description
Adjustable boom cylinder, description
Adjustable boom valve, description
Air conditioning unit, description
Air distribution, description
Alternator, description
Alternator, test
Anti-theft system
Audio remote controller, description
Auto Manual pump control switch description
Auxiliary heater, description
Auxiliary heater, principles'
Auxiliary start
Battery charging capacity, checking
Battery, description
Boom cylinder, description
Boom float position, description
Boom, description
Bottom roller, description
Bucket cylinder, description
Cab suspension, description
Center passage, description
Check valve, description
Communication with data buses
Component designations
Component list Alternator, batteries, capacitors, electronic units, voltage outlet
Component list, Heating coils
Connectors, overview
Control lockout lever switch, description
Control pattern selector valve, description
Cooling fan clutch, description
Cooling system, component location
Cooling system, description
Crankcase ventilation, description
Cylinder, description
Cylinder, troubleshooting
Data buses, function
Dipper arm cylinder, description
Dipper arm, description
Display unit
Driver's seat, description
Electrical system, special instructions for servicing, action when working on machine
Electrical system, special instructions for servicing, electrical components, batteries
Electrical system, special instructions for servicing, electronic components
Electrical system, special instructions for servicing, general
Electrical system
Electronic climate control unit ECC, description
Electronic control system, description
Emergency operation, description
Engine characteristic curve
Engine control unit E-ECU, function description
Engine limp home switch, description
Engine oil
Engine system
Engine, description
Exhaust Aftertreatment System, component location
Exhaust Aftertreatment System, description
Exhaust gas recirculation (EGR), component location
Exhaust Gas Recirculation (EGR), description
Falling object protection structure (FOPS), description
Fan motor, description
Fan motor, troubleshooting
Fan pump, description
Fire suppression system, component description
Fuel system, component location
Fuel system, description
Fuel tank, description
Function description
Heating system, description
HVAC system
Hydraulic components, description
Hydraulic components, storage and transport
Hydraulic cylinders, dieseling
Hydraulic diagram, schematic
Hydraulic oil cooler, description
Hydraulic oil cooling system, description
Hydraulic oil, description
Hydraulic oil, storage and handling
Hydraulic pump coupling, description
Hydraulic pump, description
Hydraulic quickfit, description
Hydraulic system, cleanliness when handling hydraulic components
Hydraulic system, description
Hydraulic system, position of main components
Hydraulic system, repair of hydraulic components in workshop
Hydraulic system, work instructions
Hydraulic system
Hydraulic tank, description
Idler, description
Inlet and exhaust system, description
Instrument control unit I-ECU, function description
Instruments and controls, left instrument panel
Instruments and controls, rear instrument panel
Instruments and controls, right instrument panel
Keypad, description
Link, description
Lubricating system, description
MA9109 Quickfit solenoid valve, description
Main control valve, description 1
Main control valve, description
Main control valve, port size and tightening torque
Preheating, description
Pressure accumulator, description
Product plates
Proportional relief valve, description
Proportional solenoid valve, description
Pump, troubleshooting
Quickfit system, operation
Radiator, description
Radio with CD and MP3 player, description'
Radio, description
Radio, replacing
Regeneration process, description
Regulator, description
Regulator, disassembly and assembly
Remote control valve (Lever), description
Rotating beacon, description
Rotating beacon, replacing
Rotator (X3 Line option), description
Selection of track shoes
Service connection and programming connection
Service mode
Service positions
Service
Servo hydraulic block
Servo pump, description
Shuttle valve block, description
Single pedal stopper position
Slew motor, adjustment
Spring package, assembly dimension
Start switch, description
Starter motor, description
Starter switch, testing
Starting engine with booster cables
Starting operation
Straight travel pedal, description
Swing gearbox, description
Swing motor, description
Swing motor, principle of operation
Swing ring gear, description
Tightening torque, specifications
Top roller, description
Track chain, description
Track gearbox, description
Track guards
Track motor, adjustment
Track motor, description
Track motor, maintenance standard
Travel alarm, replacing
Troubleshooting hvac
Turbocharger, description
Vehicle control unit V-ECU, function description
Vehicle information
Welding on the machine
Wire harness layout
Wiring harnesses
X1 Line, description
Diagrams
Control system diagram
Electrical distribution box, circuit board replacing
Electrical distribution box
Electrical symbols and designations
Explanations to hydraulic diagram
Fuse, description
Hydraulic diagram, standard 1
Hydraulic diagram, standard
Hydraulic diagram, with option 4
Hydraulic diagram, with option
Hydraulic diagram, with option 1
Hydraulic diagram, with option 2
Hydraulic diagram, with option components
Instruments and controls, front instrument panel
Instruments and controls, overview
Relay, description
Wiring diagram SCH01
Wiring diagram SCH02 1
Wiring diagram SCH02
Wiring diagram SCH03 1
Wiring diagram SCH03
Wiring diagram SCH04
Wiring diagram SCH05
Wiring diagram SCH07
Wiring diagram SCH08
Wiring diagram SCH10
Wiring diagram SCH11
Wiring diagram SCH12
Wiring diagram SCH13
Wiring diagram SCH14 1
Wiring diagram SCH14
Wiring diagram SCH15
Wiring diagram SCH16
Wiring diagram SCH17.1
Wiring diagram SCH17
Wiring diagram SCH18
Wiring diagram SCH20
Wiring diagram SCH21
Wiring diagram SCH22
Wiring diagram SCH23
Wiring diagram SCH24
Wiring diagram SCH26
Wiring diagram SCH30
Wiring diagram, electrical dist
Repair
2 stage port relief valve, adjustment
3 way selector valve, description
Accumulator, replacing
ACM (After treatment control module), replacing, non-Programd
ACM (After treatment control module), replacing, pre-Programd
Adjustable boom valve, disassembly
Air cleaner, cleaning filter element 1
Air cleaner, cleaning filter element
Air cleaner, primary filter replacing
Air cleaner, secondary filter replacing
Air conditioner compressor belt, check
Air conditioner main filter, change
Air conditioner main filter, clean
Air conditioning unit, maintenance
Air mix door actuator, replacing
Air pump, replacing
Alternator, replacing incl function check
Antenna, replacing
Arm parallel conflux check valve, disassembly and assembly
Arm parallel conflux valve, disassembly and assembly
Arm regenerating valve, disassembly
Backrest, replacing
Batteries, replacing
Battery condition, check
Battery disconnector, replacing
Battery, charging
Boom and arm holding valve (Boom-1, Arm-1), disassembly
Boom back pressure check valve, disassembly
Boom cylinder, installation
Boom cylinder, removal
Boom cylinder, replacing
Boom, installation
Boom, removal
Boom, replacing
Bottom roller, measurement of wear
Bottom roller, replacing one
Bottom roller, replacing seal
Breather, replacing
Bucket assembly, installation
Bucket assembly, removal
Bucket assembly, replacing
Bucket cylinder bushing lever-link, replacing
Bucket cylinder bushing on dipper arm, changing
Bucket cylinder, installation
Bucket cylinder, removal
Bucket cylinder, replacing
Bucket flow control valve, disassembly
Bucket regenerating valve, disassembly
Burner, replacing
Cab filter, replacing
Cab, installing
Cab, prefilter, clean
Cab, prefilter, replace
Cab, removing 1
Cab, removing
Cab; door, covers, hinges, joints and locks, lubricate
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, check
CareTrack antenna, replacing
CareTrack battery, replacing
CareTrack W-ECU, description
Center bypass valve, disassembly and assembly
Center passage, assembly
Center passage, disassembly
Center passage, maintenance standard
Center passage, replacing seal kit
Center passage, replacing
Coasting left and right swing
Component locations engone
Compressor, replacing incl draining and filling
Compressor, replacing magnetic clutch (compressor removed)
Condenser, replacing incl draining and filling
Connecting rod yoke, installation
Connecting rod yoke, removal
Connecting rod yoke, replacing
Control lockout lever switch, replacing
Control types for X1 and X3 operation
Control valve, replacing
Coolant level, check
Coolant, changing 1
Coolant, changing
Coolant, checking anti-freeze resistance 1
Coolant, checking anti-freeze resistance
Cooler and Heater assembly, replacing
Counterweight, description
Counterweight, replacing
Creeping of hydraulic cylinder
Cylinder speed
Cylinder, disassembly and assembly
Diesel particulate filter, checking and cleaning 1
Diesel particulate filter, checking and cleaning
Digging unit, maintenance
Dipper arm connecting rod, installation
Dipper arm connecting rod, removal
Dipper arm connecting rod, replacing
Dipper arm cylinder bushing on boom, replacing
Dipper arm cylinder bushing on dipper arm, replacing
Dipper arm cylinder, installation
Dipper arm cylinder, removal
Dipper arm cylinder, replacing
Dipper arm, installation
Dipper arm, removal
Dipper arm, replacing
Door window, replacing
Door, replacing
Earth lead to battery, replacing
ECC, MID 146, changing non-Programd ECU
ECC, MID 146, changing pre-Programd ECU
Electric pedal control on X1 (on-off), replacing
Electric pedal control on X1 (proportional), replacing
Engine hood, replacing
Engine oil and filter, changing
Engine oil pressure sensor, replacing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor, replacing
Engine speed control switch, replacing
Engine temperature sensor, replacing
Engine wire harness, replacing
Engine, installing
Engine, oil level, check
Engine, removing
Evaporator, replacing incl draining and filling
Exhaust pipe, flexible tube, replacing
Expansion tank, replacing
Expansion valve, replacing incl draining and filling
Fan belt and belt tension, check
Fan belt and or alternator belt, replacing
Fan belt and or alternator-, compressor belt, replacing all belts
Fan motor, assembly
Fan motor, disassembly
Fan motor, replacing
Fan motor, tools
Fan pump, assembly
Fan pump, disassembly
Fan pump, parts inspection
Feed pump, checking feed pressure
Flow control valve, disassembly and assembly
Frame and track unit, description
Front idler, replacing one
Fuel filling pump, installing
Fuel filling pump, removing
Fuel filter, change
Fuel level sender, replacing
Fuel system, bleeding
Fuel tank air ventilation filter, change
Fuel tank sediment, drain
Full track guard, replacing
Function description
General, precautions
General, tools
Hammer and shear pedal valve (RCV), replacing
Hammer return filter, description
Heater core, replacing
High pressure fuel system, pressure relief
Horn, replacing
Hour meter, replacing
Hydraulic oil drain filter, change
Hydraulic oil level, check
Hydraulic oil return filter, replacing
Hydraulic oil servo filter, change
Hydraulic oil suction strainer, clean
Hydraulic oil tank breather filter, replacing
Hydraulic oil tank, replacing
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic oil temperature sensor, replacing
Hydraulic oil, changing
Hydraulic pump (removed), changing shaft seal
Hydraulic pump, replacing
Idler, assembly
Idler, disassembly
Idler, measurement of wear
I-ECU, MID 140, changing non-Programd ECU
I-ECU, MID 140, changing pre-Programd ECU
Ignition switch, replacing
Inlet and exhaust system, component location
Instrument panel, replacing (left)
Instrument panel, replacing (right)
Intake actuator, replacing
Intercooler, replacing
Line rupture valve (arm), assembly
Line rupture valve (arm), disassembly
Line rupture valve (boom), assembly
Line rupture valve (boom), disassembly
Line rupture valve pressure, checking and adjusting
Load check valve single, disassembly and assembly
Longitudinal adjustment cable, replacing
Longitudinal suspension cable, replacing
Loose and loss of bolts, check
Lower boom cylinder bushing, replacing
Lubrication oil pressure, checking with pressure gauge
Lubrication system, component locations
Lubrication, see lubrication chart
Machine view
Main pressure relief valve, replacing
Main relief valve, adjustment
Main relief valve, disassembly and assembly
Main spool, disassembly and assembly
Maintenance service, every 50 hours
Maintenance service, every 250 hours
Maintenance service, every 500 hours
Maintenance service, every 1000 hours
Maintenance service, every 2000 hours
Maintenance service, every 3000 hours
Maintenance service, every 4000 hours
Maintenance service, every 4500 hours
Maintenance service, every 6000 hours
Maintenance service, first 500 hours
MATRIS, reading, export reading
Measuring condition
Measuring of swing bearing clearance
Mode (foot) actuator, replacing
NOx sensor, replacing
Oil cooler line bypass valve (check valve), replacing
Oil cooler, replacing
Oil level gauge, replacing
Oil level sensor, changing
Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change
Oil-bath air cleaner's reservoir (optional equipment), filter insert, clean
Oil-bath air cleaner's reservoir (optional equipment), oil, check
Pipe and hose (pump - valve), replacing
Port relief valve pressure, checking and adjusting
Port relief valve, disassembly and assembly
Preheating coil, replacing
Pre-heating relay, replacing
Proportional solenoid valve (power shift), replacing
Proportional solenoid valve, description
Proportional solenoid valve, measuring and adjustment
Pump gearbox coupling assembly, replacing
Pump regulator, replacing
Pump suction hose and pipe, replacing
Pump, assembly
Pump, disassembly
Pump, installation
Pump, maintenance standard
Pump, tools
Quickfit, installation
Quickfit, removal
Quickfit, replacing
Radiator hoses all, replacing
Radiator outside hydraulic oil cooler outside, cleaning
Radiator, replacing
Rear window, replacing
Rear-view mirror, changing
Receiver, replacing incl draining and filling
Recoil spring cylinder seal kit, replacing
Remote control valve (Lever), assembly
Remote control valve (Lever), disassembly
Remote control valve (Lever), maintenance standard
Remote control valve (lever), replacing
Remote control valve (Lever), troubleshooting
Remote control valve (pedal), assembly
Remote control valve (pedal), description
Remote control valve (pedal), disassembly
Remote control valve (pedal), maintenance standard
Remote control valve (pedal), replacing
Remote control valve (pedal), troubleshooting
Ring gear grease pipe, replacing
Rotating beacon, replacing
Rotator valve, adjustment
Rupture valve, replacing (boom cylinder)
Rupture valve, replacing (dipper arm cylinder)
Seat cushion, replacing
Seat heater, checking
Seat support, replacing
Seat, replacing
Service history (included in the respective Operator's manual), fill in.
Servo hydraulic pressure, adjustment
Servo pump, parts inspection
Servo pump, replacing
Side window, replacing
Solenoid valve (1) for hammer and shear selection
Solenoid valve, description 1
Solenoid valve, description
Solenoid valve, disassembly and assembly
Solenoid valve, inspection
Solenoid valve, replacing
Spark plug, checking
Spark plug, replacing 1
Spark plug, replacing
Speaker, replacing
Spring package, assembly
Spring package, disassembly
Sprocket, measurement of wear
Sprocket, replacing one
Starter motor, replacing
Starter motor, tests
Starter relay, replacing
Stop valve
Straight traveling performance
Superstructure, installing
Superstructure, removing
Swing bath grease, check
Swing gearbox oil level, check
Swing gearbox removed, replacing seal
Swing gearbox removed, replacing shaft
Swing gearbox, assembly
Swing gearbox, disassembly
Swing gearbox, maintenance standard
Swing gearbox, replacing
Swing motor gearbox, changing oil
Swing motor relief valve, replacing
Swing motor removed, replacing seal
Swing motor, assembly
Swing motor, disassembly
Swing motor, maintenance standard
Swing motor, replacing brake piston seal
Swing motor, replacing plate (brake)
Swing motor, replacing
Swing ring gear bearing, lubricate
Swing ring gear cover, installation
Swing ring gear cover, removal
Swing ring gear inner seal, replacing
Swing ring gear outer seal, replacing
Swing ring gear outer seal, replacing1
Swing ring gear, replacing
Swing speed
Swing unit, replacing
Test-run and check
Thermostat, checking
Thermostat, replacing
Tool box assembly, replacing
Tools & equipment
Top roller, measurement of wear
Top roller, replacing one
Track chain assembly, installing
Track chain assembly, removing
Track chain, measurement of wear
Track gearbox (removed), replacing floating seal
Track gearbox oil level, check
Track gearbox, assembly
Track gearbox, disassembly
Track gearbox, maintenance standard
Track gearbox, replacing cover
Track guard, replacing one
Track link, dimension
Track links, replacing
Track motor gearbox, changing oil
Track motor relief valve, replacing 1
Track motor relief valve, replacing
Track motor, assembly 1
Track motor, assembly
Track motor, disassembly 1
Track motor, disassembly
Track motor, replacing
Track recoil spring (tensioner) assembly, replacing
Track running speed
Track shoe bolts, check
Track shoe, replacing one
Track tensio condition, check
Track unit, replacing
Track, adjusting track sag
Travel alarm, replacing
Travel Speed
Turbocharger, replacing
Undercarriage, description
Upper boom cylinder bushing, replacing
Valves, adjusting 1
Valves, adjusting
VCADS Pro, connecting problems
VCADS Pro, logged errors, read off
V-ECU, MID 187, changing non-Programd ECU
V-ECU, MID 187, changing pre-Programd ECU
Vent actuator, replacing
Voltage converter, replacing
Washer fluid level, check
Water separator filter element, change
Water separator, check drain
W-ECU, MID142, changing non-Programd ECU
W-ECU, MID142, changing pre-Programd ECU 1
W-ECU, MID142, changing pre-Programd ECU
Windows, general
Windscreen flusher pump, replacing
Windscreen wiper front, replacing motor
Windscreen wiper, replacing controller
Windscreen wiper, replacing switch
Windscreen, replacing
Work lighting, replacing one head lamp assy
X1 Pre-set relief valve, adjusting
X1 return filter (optional equipment), change
Safety
CE-marking, EMC-directive
Checklist after a fire or heat exposure
Decontamination
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Fire prevention measures
Health hazards with paint, plastics and rubber
Safety concerns everybody!
Safety rules when servicing
Safety when handling oils and fuel
Safety when handling the machine
Safety when handling the waste handler
Safety when using lifting equipment
Safety when working with air conditioning refrigerant
Safety when working with batteries
Safety when working with hydraulic systems
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
Service Bulletins
Air conditioning compressor improvement
Arm conflux hose improvement
Attachment shims for clearance adjustment of pin joint
Auto belt tensioner (D5E, D7E)
Auxiliary heater
Battery improvement
Battery maintenance guideline for long term stock machines
Biodegradable hydraulic oil
Blower motor
Bottom roller improvement
Bucket cylinder protection improvement
Cab door latch
Cab door latch1
Cab door
Cabin light operation problem
Cable harness connector, engine
Camshaft, hardening process update
CareTrack Telematics system
CareTrack, new software version 2008w6
CD & MP3 player
Check method on engine oil consumption
Cigar lighter and ashtray change
Coolant pump improvement
Crankshaft and camshaft gear manufacturing improvements
D4 – D7 Alternator improvement
D6-D7 Exhaust gas leakage into the cooling system
D6E and D7E, high pressure pipe leakage
DEF AdBlue AUS32 sampling, method
Diesel fuels - quality and function
Dipstick level gauge improvement for swing gearbox
ECU, functional check
Electric connector
Electric horn improvement
Electric horn
Electrical distribution box
Engine limp home switch wire harness
Engine oil leakage
Engine Oil Level
Engine speed control switch improvement
Engine starting in the manual mode
Expansion tank
Fuel cap improvement
Fuel Level
Fuel pump (Tier 3) manufacturing process improvement1
Fuel pump (Tier 3) manufacturing process improvement2
Fuel sampling, method
Fuel tank crack
Heat-resistant kit for RCV leakage
Hose leakage
Hour counter improvement
Hydraulic hose assembly leakage handling
Hydraulic oil
Hydraulic system flushing method
Hydraulic tank air breather
Idler wheel and bushing improvement
I-ECU, clock and rear view camera
Improved Volvo quick-fit block
Improvement of grading performance
Improvement of return check valve
Injector wire harness for D4E-D6E-D7E
Injector yoke bolt
Injector yoke retention bolt loose
Instrument ECU change
Instrument ECU Improvement
Internal modem change
Leakage at engine oil pump gasket
Line rupture valve hose, improvement
Lubrication point change on swing bearing
Machine model
Main Control Valve, logic valve
Modification of CareTrack wire harness
Muffler bracket improvement
New engine oil level sensor
New fan bracket with profile washer
New oil change interval for Volvo bio hydraulic oil
New product1
New product2
New product3
New product4
New slew ring gear seal
New software for anti-theft and cold starting improvement
New software for low engine oil level warning
New software release1
New software release2
New software1
New software2
New software3
New TechTool VCADS Pro interface
New turbo charger for D6E D7E
Oil analyses
Oil sampling, method
Oil sampling, sampling points
Operating hour parameter
Pipe leakage
Plastic shims for Boom Arm pin joints
Plates
Poor grading with RCV
Portable refillable O-ring kits
Quick fit cylinder hose
Receiver drier improvement
Recoil spring grease valve
Recoil spring package rod
Recommendations for Oil Sampling Intervals
Reporting of product misuse & near-miss report
Reports
Reversible fan, modes and setting
Rotating beacon lamp, tightening torque
Routines for reporting cracks on Boom and Arm
Sprocket improvement
Swing ring gear seal improvement
Swing ring gear seal1
Swing ring gear seal2
Thermostat failure (D4, D5, D6 & D7)
Tool box change
Tool box improvement
Travel gearbox floating seal improvement
Travel motor
Travel motor1
Turbocharger
Volvo Product incident accident report & Interview Form
Washer pump improvement
Washer pump improvement1
Waste handler strobe light
Water separator drain valve
Windshield, water and dust entering
X1 stop valve
Special Tools, Misc
01 Time Guide Current generation
11 Time Guide Previous generation
21 Time Guide Old generation
35 GRD G700B LabourTimeGuide
40 RM Compaction Time guide old version
41 RM Compaction ABG Time Guide
42 RM Paving Systems ABG Time Guide
Special tool catalog
Special Tools Recommendations
Time Guide Current generation
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