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Volvo EC27C Compact Excavator Service Repair Manual Instant Download.pdf

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Service Information
Document Title: Function Group: Information Type: Date:
Engine, description 200 Service Information 2014/3/26
Profile:
CEX, EC27C [GB]
Engine, description
The engine is a vertical, water-cooled, in-line, three-cylinder, four-stroke diesel with direct injection. It is a low emission
engine that complies with American EPA Guideline Stage interim Tier IV and European Directive 97/68/EC Class IIIA with
automatic idle.
The engine serial number is stamped on the name plate, on the top of the valve cover. The engine model designation and
serial number must be indicated when ordering spare parts.
The direction of rotation viewed from the flywheel is anticlockwise. Firing order: 1-3-2 (cylinder no. 1 on flywheel side).
Figure 1
Engine, front view
1 Lifting eye 4 Alternator 7 V-belt
2 Exhaust manifold 5 Crankshaft V-pulley
3 Starter motor 6 Fan rotor
Figure 2
Engine, rear view
1 Engine name plate 6 Injection pump 11 Fuel oil inlet
2 Rocker arm cover 7 Fuel filter 12 Flywheel
3 Lifting eye 8 Oil filter 13 Intake manifold
4 Fan 9 Oil pan 14 Lifting eye
5 Oil filler port 10 Dipstick gauge
Service Information
Document Title: Function Group: Information Type: Date:
Engine, removing 210 Service Information 2014/3/26
Profile:
CEX, EC27C [GB]
Engine, removing
Op nbr 210-070
Hoist or crane
Lifting device
Catch basin
WARNING
The work involves handling heavy components - failure to stay alert may result in severe crushing injuries.
1. Place the machine in the service position 1. See .
091 Service position 1
2. Battery disconnect switch off.
Figure 1
Battery disconnection switch
3. Remove the bonnet.
Figure 2
Bonnet, remove
4. Remove right-hand side panel.
Figure 3
Right-hand side panel, remove
5. Remove rear cover.
Figure 4
Rear cover, remove
6. Remove left-hand side panel.
Figure 5
Left-hand side panel, remove
7. Remove counterweight. See .
716 Counterweight, removing
8. Remove silencer with tailpipe. See .
252 Silencer, removing
WARNING
Open the radiator cap carefully if the engine is warm. High pressure in the radiator may cause hot coolant
to jet out.
WARNING
Risk of scalding and burns. The coolant may be hot.
9. Open the radiator cap (1) slightly to relieve pressure and then remove the radiator cap.
Figure 6
Position of radiator cap
1.
2.
3.
4.
5.
Radiator cap
Upper radiator hose
Feed
Return
Engine temperature sensor
10. Provide a suitable catchment container for the coolant.
Figure 7
Position of drain plug
1. Drain plug
11. Undo and unscrew the drain plug (1). Drain all of the coolant into a catch basin.
NOTICE
Cooling system conditioners must be disposed of in accordance with environmental regulations.
NOTICE
Do the work in an environmentally safe manner.
12. Remove the expansion tank from the bracket and drain the fluid into the catch basin.
13. Screw in the drain plug and screw on the radiator cap.
14. Remove hoses (3, 4) for cab heating on the engine.
15. Remove the hose clamp on the upper radiator hose (2) and pull off the hose.
16. Remove the hose clamp on the lower radiator hose (1) and pull off the hose.
Figure 8
Radiator hose, remove
1. Lower cooler hose
17. Remove the fixing bolts (1) from the fan grille (2) and remove the fan grille.
Figure 9
Fan grille, removal
1.
2.
Retaining screw
Fan grid
18. Turn fuel cock to OFF position.
Figure 10
Fuel cock, close.
19. Disconnect the electrical connection from the air filter sensor (1) and lay the connecting cable aside.
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Volvo EC27C Compact Excavator Service Repair Manual Instant Download.pdf

  • 1. Service Information Document Title: Function Group: Information Type: Date: Engine, description 200 Service Information 2014/3/26 Profile: CEX, EC27C [GB] Engine, description The engine is a vertical, water-cooled, in-line, three-cylinder, four-stroke diesel with direct injection. It is a low emission engine that complies with American EPA Guideline Stage interim Tier IV and European Directive 97/68/EC Class IIIA with automatic idle. The engine serial number is stamped on the name plate, on the top of the valve cover. The engine model designation and serial number must be indicated when ordering spare parts. The direction of rotation viewed from the flywheel is anticlockwise. Firing order: 1-3-2 (cylinder no. 1 on flywheel side). Figure 1 Engine, front view 1 Lifting eye 4 Alternator 7 V-belt 2 Exhaust manifold 5 Crankshaft V-pulley 3 Starter motor 6 Fan rotor
  • 2. Figure 2 Engine, rear view 1 Engine name plate 6 Injection pump 11 Fuel oil inlet 2 Rocker arm cover 7 Fuel filter 12 Flywheel 3 Lifting eye 8 Oil filter 13 Intake manifold 4 Fan 9 Oil pan 14 Lifting eye 5 Oil filler port 10 Dipstick gauge
  • 3. Service Information Document Title: Function Group: Information Type: Date: Engine, removing 210 Service Information 2014/3/26 Profile: CEX, EC27C [GB] Engine, removing Op nbr 210-070 Hoist or crane Lifting device Catch basin WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Place the machine in the service position 1. See . 091 Service position 1 2. Battery disconnect switch off. Figure 1 Battery disconnection switch 3. Remove the bonnet. Figure 2 Bonnet, remove 4. Remove right-hand side panel.
  • 4. Figure 3 Right-hand side panel, remove 5. Remove rear cover. Figure 4 Rear cover, remove 6. Remove left-hand side panel. Figure 5 Left-hand side panel, remove 7. Remove counterweight. See . 716 Counterweight, removing 8. Remove silencer with tailpipe. See . 252 Silencer, removing WARNING Open the radiator cap carefully if the engine is warm. High pressure in the radiator may cause hot coolant to jet out. WARNING Risk of scalding and burns. The coolant may be hot.
  • 5. 9. Open the radiator cap (1) slightly to relieve pressure and then remove the radiator cap. Figure 6 Position of radiator cap 1. 2. 3. 4. 5. Radiator cap Upper radiator hose Feed Return Engine temperature sensor 10. Provide a suitable catchment container for the coolant. Figure 7 Position of drain plug 1. Drain plug 11. Undo and unscrew the drain plug (1). Drain all of the coolant into a catch basin. NOTICE Cooling system conditioners must be disposed of in accordance with environmental regulations. NOTICE Do the work in an environmentally safe manner. 12. Remove the expansion tank from the bracket and drain the fluid into the catch basin. 13. Screw in the drain plug and screw on the radiator cap. 14. Remove hoses (3, 4) for cab heating on the engine. 15. Remove the hose clamp on the upper radiator hose (2) and pull off the hose. 16. Remove the hose clamp on the lower radiator hose (1) and pull off the hose.
  • 6. Figure 8 Radiator hose, remove 1. Lower cooler hose 17. Remove the fixing bolts (1) from the fan grille (2) and remove the fan grille. Figure 9 Fan grille, removal 1. 2. Retaining screw Fan grid 18. Turn fuel cock to OFF position. Figure 10 Fuel cock, close. 19. Disconnect the electrical connection from the air filter sensor (1) and lay the connecting cable aside.
  • 7. Figure 11 Air filter, remove connections 1. Air cleaner sensor 20. Detach the hose clamp (2) at the intake air hose (3) and pull off the intake air hose (3). Figure 12 Air filter casing with hose connections 1. 2. 3. 4. 5. 6. Air cleaner case Hose clamp Intake air hose Hose clamp Air intake hose, engine Air cleaner sensor 21. Detach the hose clamp (4) at the engine intake air hose (5) and pull off the engine intake air hose (5). 22. Remove the air filter holder fixing bolts and remove holder together with air filter casing.
  • 8. Figure 13 Air filter holder fixing bolts 23. Remove accelerator cable on engine. Figure 14 Remove accelerator cable 24. Disconnect the plug connection (5) at the fuel feed pump. Figure 15 Fuel feed pump 1. 2. 3. 4. Output (OUT) Fuel feed pump Retaining screw Input (IN)
  • 9. 5. 6. Plug connection Plug connection, automatic idle control - LS 25. Disconnect the plug connection (6) for automatic idle control (option) at LS. 26. Disconnect the plug connection (3) for automatic idle control (option). Figure 16 Automatic idle control, remove 1. 2. 3. Holder with magnet Attaching screws Plug connection 27. Remove fixing bolts (2) at the holder, and lay aside holder and magnets (1) for automatic idle control (option). 28. Remove hose lines at the fuel filter (3). NOTICE When a hose has been disconnected, plug both the hose and the connection immediately. The hoses should be marked for correct connection. Figure 17 Fuel lines, disconnect 1. 2. 3. Fuel return Fuel supply Fuel filter 29. Loosen and unscrew the pump mounting bolts.
  • 10. Figure 18 Fixing bolts, remove 30. Pull the pump towards the back and secure against falling. 31. Disconnect the main power supply (terminal 87) from the battery to the starter. Figure 19 Main power supply to starter, disconnect 32. Remove retaining bolts (1) at engine mount. Figure 20 Retaining bolts at engine mount, remove 1. Retaining bolts 33. Disconnect the plug connections of the frame and engine shutdown cable harnesses.
  • 11. Figure 21 Plug connections, disconnect 34. Remove fixing clamps on wiring harness. WARNING Risk of personal injury. Very heavy object. 35. Attach lifting gear to engine lifting eyes. NOTE! Weight: approx. 170 kg (374.79 lb) Figure 22 Lifting gear, attach 36. Slowly lift out the engine and deposit on a suitable support.
  • 12. Service Information Document Title: Function Group: Information Type: Date: Engine, installing 210 Service Information 2014/3/26 Profile: CEX, EC27C [GB] Engine, installing Op nbr 210-072 Hoist or crane Lifting device WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Attach the engine to suitable lifting gear. NOTE! Weight: approx. 170 kg (374.79 lb) Figure 1 Engine with lifting gear 2. Slowly lower the engine into the engine bay and position on the engine mounts. NOTICE Make sure that no hoses or cables are trapped. 3. Screw in retaining bolts (1) on engine mounts and tighten with a torque wrench. See . 030 Engine, tighten torques
  • 13. Figure 2 Retaining bolts at engine mount, install 1. Retaining bolts 4. Remove the lifting gear. 5. Position the fan grille and fit the fixing bolts. Figure 3 Fan grille, installing 1. 2. Retaining screw Fan grid 6. Connect the plug connections of the frame and engine shutdown cable harnesses.
  • 14. Figure 4 Plug connections, connect 7. Install fixing clamps on wiring harness. 8. Connect the main power supply from the battery to the starter. Figure 5 Main power supply to starter, connect 9. Insert pump splined shaft into clutch carrier plate. Figure 6 Hydraulic pump, install
  • 15. 10. Screw in the fixing bolts and tighten. Figure 7 Fixing bolts, screw in 11. Install the hose lines (1, 2) at the fuel filter (3). Figure 8 Fuel lines, connect 1. 2. 3. Fuel return Fuel supply Fuel filter NOTE! Note feed and return flows! 12. Install air filter holder with air filter, and insert fixing bolts. Figure 9 Air filter holder with air filter, install 13. Connect the engine intake air hose (5) and fit hose clamp (4).
  • 16. Figure 10 Air filter casing with connections 1. 2. 3. 4. 5. 6. Air cleaner case Hose clamp Intake air hose Hose clamp Air intake hose, engine Air cleaner sensor 14. Connect the intake air hose (3) and fit hose clamp (2). 15. Connect the electrical connection for the air filter sensor (1). Figure 11 Connections, install 1. Air cleaner sensor 16. Install holder with magnet (1) for automatic idle control (option).
  • 17. Figure 12 Automatic idle control, install 1. 2. 3. Holder with magnet Attaching screws Plug connection 17. Connect the plug connection (3) for automatic idle control (option). 18. Connect the plug connection at the fuel feed pump (5). Figure 13 Plug connections, connect 1. 2. 3. 4. 5. 6. Output (OUT) Fuel feed pump Retaining screw Input (IN) Plug connection Plug connection, automatic idle control - LS 19. Connect the plug connection (6) for automatic idle control (option) at LS. 20. Install accelerator cable on engine.
  • 18. Figure 14 Accelerator cable on the engine, install 21. Connect the lower radiator hose (1) and fit hose clamp. Figure 15 Radiator hose, install 1. Lower radiator hose 22. Connect the upper radiator hose (2) and fit hose clamp. Figure 16 Hoses, install 1. 2. 3. 4. Radiator cap Upper radiator hose Feed Return
  • 19. Suggest: If the above button click is invalid. Please download this document first, and then click the above link to download the complete manual. Thank you so much for reading
  • 20. 5. Engine temperature sensor 23. Connect cab heating hoses (3, 4) and fit hose clamps. NOTE! Note feed and return flows! 24. Install the silencer with tailpipe. See 252 Silencer, installing 25. Install the counterweight. See . 716 Counterweight, fitting 26. Turn fuel cock to ON position. Figure 17 Open fuel cock. 27. Unscrew the radiator cap and top up coolant through the coolant filler nozzle. Coolant, see . 160 Lubricants, specifications NOTICE Do the work in an environmentally safe manner. 28. Fill the expansion tank with coolant up to the MAX mark. 29. Install left-hand side panel. Figure 18 Left-hand side panel, install 30. Install rear cover.