Volvo EC650 Excavator Repair Service Manual

Description

Table of Content EC650 Service Information

• GENERAL
  • SPECIFICATIONS
    • General
  • STANDARD TIME
    • General
  • TOOL
    • General
      • E-tool, Net 00002
        Disassembly tool
      • E-tool, NET 00005 Guide pin for travel
        motor
      • E-tool, NET 00011 Track andslew
        brake puller
  • MISCELLANEOUS
    • Service instruction; safety instruction
      • Hydraulic cylinders,
        dieseling
      • Shrink
        joint, installation
      • Welding on the
        machine

• STANDARD PARTS, SERVICE
  • LUBRICANT; FUEL; OTHER FLUID
    • General
      • Hydraulic oil,
        cleaning
      • Hydraulic
        oil, specifications
      • Oil and lubricant
        types
  • SERVICE
    • Maintenance
    • Emergency measures
      • Jump
        starting of machine, connection of cables
    • Miscellaneous
      • Vacuum suction, hydraulic systems
      • Hydraulic system, repair of hydraulic components
        in workshop
      • Hydraulic system, storage and transport
        of hydraulic components
      • Hydraulic system,
        cleanliness when handling hydraulic components

• ENGINE WITH MOUNTING AND EQUIPMENT
  • ENGINE
    • General, common info about 211 – 218
      • Crank mechanism, connecting rod,crankshaft
        damper, Specifications, TD122
      • Description,
        TD122
      • Specifications,
        TD122
      • Timing gear, camshaft, Description,
        TD122
      • Valve
        mechanism, Description, TD122
    • Engine mounting
      • Engine
        mounting, removal
  • LUBRICATING SYSTEM
    • General, common info about 221 – 224
      • Specifications,
        TD122
    • Oil pump; line
      • Description,
        TD122
    • Oil filter; filter housing
      • Specifications,
        TD122
  • FUEL SYSTEM
    • General (common info about 233 – 238)
      • Fuel lift pump and cleaner, Description,
        TD122
      • Fuel system,
        description
      • Fuel
        system, bleeding
      • Injection pump, regulator and pump
        coupling,Description, TD122
      • Injector and delivery pipe, Description,
        TD122
      • Intake and exhaust system, Turbocharger,
        Description, TD122
    • Fuel tank; fuel filling pump
      • Fuel filling pump, connections included
        • Fuel
          filling pump, replacement
    • Injection pump; regulator; pump companion
      • Injection pump,
        removal
      • Injection
        pump, specifications
  • INLET SYSTEM; EXHAUST SYSTEM
    • Charge air cooler with connections
      • Coolant
        pump, removal
      • Description,
        TD122
  • COOLING SYSTEM
    • General, common info about 261 – 269
      • Description,
        TD122
    • Radiator, mounting and connections included
      • Radiator,
        removal
    • Fan; fan shroud; fan coupling
      • Fan drive, mechanical
        • Vee
          belts, replacement
  • ENGINE CONTROL
    • Automatic speed control
      • Automatic engine speed
        control, adjustment
      • Automatic engine
        speed control, description

• ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
  • GENERAL
    • Comprehensive info, electrical system
      • Electrical
        system, specifications
      • Electrical
        system, work instructions
      • Main electrical components,
        location
  • BATTERY; ENERGY STORAGE SYSTEM; MOUNTING PARTS
    • General, common info about 311 – 313
      • Battery,
        charging
      • Battery,
        specifications
  • ALTERNATOR; CHARGING; ELECTRIC MOTOR; ELECTRIC DRIVES
    • General, common info about 321 – 322
      • Alternator,
        checking the charging voltage
      • Alternator,
        specifications
  • STARTING SYSTEM
    • General, common info about 331 – 334
      • Starter
        circuit, description
    • Starter motor inclusive solenoid
      • Starter motor
        • Starter motor,
          description
        • Starter motor,
          specifications
        • Starter
          motor, replacement
    • Electric air pre-heater, excluding element
      • Preheating,
        description
  • LIGHTING
    • General, common info about 351 – 356
      • Lighting,
        specifications
    • Lighting, extra, including working lighting
      • Working lights,
        description
  • CABLE; FUSE; RELAY
    • General, common info about 371 – 379
      • Cable marking,
        description
      • Wiring diagram,
        description
      • Wiring
        diagram, list of components and index
    • Electrical distribution box; fuse box; junction box
      • Electrical distribution box
        • Distribution box 1
          • Distribution box
            A1, replacement
          • Distribution
            box A1, description
        • Distribution box 2
          • Distribution box A2,
            fuses and relays
          • Distribution box
            A2, replacement
          • Distribution
            box A2, description
  • INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM
    • General, common info about 383 – 387
      • Information system,
        programming of parameters
      • Information
        system, description
    • Sender, monitoring system
      • Sensors and monitors, air
        filter pressure monitor
      • Sensors and monitors, coolant
        level monitor
      • Sensors and monitors, coolant
        temperature sensor
      • Sensors and monitors, end
        position monitor
      • Sensors and monitors, engine
        oil level monitor
      • Sensors and monitors, engine
        oil pressure monitor
      • Sensors and monitors, engine
        speed (rpm) sensor
      • Sensors and monitors, fuel
        level monitor
      • Sensors and monitors, hydraulic
        oil level monitor
      • Sensors and monitors, hydraulic
        oil temperature sensor
      • Sensors and monitors, monitor
        for suction flap valve
      • Sensors and monitors, overload
        pressure monitor
      • Sensors and monitors, safety
        bar
      • Sensors and monitors,
        adjustment of enginespeed (rpm) sensor
      • Sensors and monitors,
        replacement (general)
      • Sensors
        and monitors, description
    • Warning/information unit, display unit
      • Central computer
        • Central
          unit A3, description
        • Central
          unit A3, replacement
      • Display unit
        • Display unit
          A9, description
        • Display
          unit A9, replacement

• POWER TRANSMISSION
  • GENERAL
    • General, common info about 410 – 436
      • Power transmission,
        description
  • GEARBOX,
    • Gearbox
      • Track gearbox, crawler machine
        • Track brake, replacement
          of brake discs
        • Travel
          gearbox, removal
      • Swing gearbox + swing pinion shaft
        • Slew
          gearbox, removal
        • Slew
          pinion shaft, removal
      • Pump gearbox with coupling
        • Pump
          gearbox, removal
  • HYDROSTATIC DRIVE
    • Hydraulic motor incl. operating system.
      • Hydraulic motor
        • Hydraulic
          motor, replacement of radial seal
      • Hydraulic motor 1, traveling
        • Travel motor,
          specifications
        • Travel
          motor, removal
      • Hydraulic motor, swing of superstructure
        • Slew motor,
          specifications
    • Centre passage; lines
      • Centre passage
        • Centre passage,
          description
        • Centre
          passage, removal of housing
  • MISCELLANEOUS
    • Swing system upper part
      • Swing ring
        • Slew ring, measurement
          of axial play
        • Slew
          ring, removal
      • Swing brake; swing holding brake; swing lock
        • Slew brake,
          description
      • Slew system for superstructure, measurement
        of rotational play
      • Slew system
        for superstructure, description

• FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
  • FRAME
    • Counterweight
    • Frame, excavator
      • Undercarriage (crawler machine)
        • Undercarriage,
          specifications
  • WHEELS; TRACKS; TYRE; HUB; DRUM
    • Crawler unit
      • Front idler, incl. fork
        • Idler,
          replacement
        • Idler,
          specifications
      • Sprocket
        • Drive sprocket,
          specifications
        • Drive
          sprocket, replacement
      • Steel track
        • Track chain
          • Track chain, measurement
            of wear betweenchain pin and bushing
          • Track
            chain, specification
        • Track, measurement of track
          tension
        • Track,
          opening
        • Track,
          specifications
      • Top rollers; skid rails
        • Topp rollers
          • Top roller, measurement
            of wear
          • Top
            roller, specifications
      • Bottom rollers
        • Bottom roller, measurement
          of wear
        • Bottom roller,
          replacement
        • Bottom
          roller, specifications
      • Track support, chain guide (derailing protection)
        • Derailing
          protection, replacement
      • Spring pakage; adjusting cylinder
        • Spring package
        • Adjusting cylinder
          • Tensioning
            cylinder, renovation

• MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
  • CAB, NAKED; CANOPY
    • General
      • Cab body
        • Operator’s
          cab, removal
      • Lifting device, whind shield
        • Window
          opening control, replacement of gas spring
  • DOORS; HATCH; COVER PLATE, (all)
    • Door, complete with catch, hinges (no glass)
      • Cab
        door, replacement of door catch
  • TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
    • Glass; sealing moulding
      • Windshield, without lifting device
        • Upper
          windscreen, replacement
      • Window
        pane, replacement
    • Window, openable (not windshield)
      • Sliding
        window, replacement
  • AIR CONDITIONING UNIT
    • Heating unit
      • Heating radiator
        • Heating
          coil, replacement
      • Heating control valve
        • Heat
          valve, replacement
      • Heater
        fan, replacement

• HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
  • WORKING HYDRAULICS; SERVO HYDRAULICS
    • General, common info about 911 – 917
      • End
        position dampening, setting
      • Hydraulic diagram, component
        list
      • Hydraulic system,
        work instructions
      • Hydraulic
        diagram
      • Hydraulic
        pressure, setting
      • Hydraulic
        pressure, specifications
      • Hydraulically
        driven oil cooler fan, description
    • Tank; line; oil cooling; filter; breather; filling pump
      • Tank
        • Hydraulic oil tank,
          removal
        • Hydraulic oil
          tank, description
      • Oil cooling system
        • Thermostat
          • Cooling fan thermostat,
            replacement
          • Cooling
            fan thermostat, description
        • Hydraulic oil cooler,
          removal
        • Hydraulic oil
          cooler, description
        • Oil cooling, replacement
          of shunt valve
        • Oil cooling,
          description of shunt valve
      • Tank, line, oil cooling, filter, breather, filling pump
        • Fan pump,
          specifications
    • Working hydraulics
      • Directional valve; control valve
        • Float position valve
          • Float valve,
            description
        • Directional valve,
          replacement of spring
        • Directional
          valve, description
        • Directional
          valve, secondary, adjustment
      • Pressure limiting valve (relief valves)
        • Chock valve
          • Shock valve,
            description
        • Pressure
          limiting valve, replacement
      • Hydraulic lock; line rupture valve
        • Line rupture valve, boom
          • Hose rupture valve
            for boom cylinder, replacement
          • Hose rupture
            valve for boom cylinder, description
      • Block for valve assembly
        • Valve block, slewing
          • Slew valve block,
            description
          • Slew valve block,
            removal
        • Main valve block
          • Main valve block,
            description
          • Main valve block,
            removal
      • Refilling valve (anti-caviation valve)
        • Anti cavitation
          valve, description
        • Anti cavitation
          valve, replacement
    • Pump, working hydraulics
      • Pump, slew
        • Working pump, fixed,
          installation
        • Working pumps,
          description
        • Working pumps,
          seal replacement
        • Working pumps,
          specifications
      • Pump, boom
        • Working pump, variable
          flow, installation
    • Servo hydraulic system
      • Pump
        • Servo pump,
          specifications
      • Control pressure valve, except brake valve
        • Control pressure (pedal)
          valve, adjustment
        • Control pressure valve,
          adjustment
        • Control pressure valve,
          checking
        • Control pressure
          valve, description
        • Control
          pressure valve, renovation of insert
      • Solenoid valve, on/off function
        • Solenoid valves,
          functions with and without voltage
        • Solenoid valves,
          location
    • Other hydraulic equipment
      • Hammer and shears,
        hydraulic diagram
      • Slope bucket/rotator,
        description
      • Slope
        bucket/rotator, hydraulic diagram
  • UNIT, DIGGING
    • General, common info about 971 – 975
      • Bearings, replacement
        of link bearing
      • Bearings,
        measurement of radial play
      • Bearings,
        specifications
      • Digging equipment
        sinking, measurement
      • Hydraulic cylinder,
        description
    • Boom with links
      • Boom
      • Cylinder, boom lifting
        • Boom
          cylinder, removal
    • Dipper arm with links
      • Dipper arm
      • Cylinder, dipper arm
        • Dipper
          arm cylinder, removal
      • Cylinder, bucket
        • Bucket
          cylinder, removal