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Volvo EC25 Compact Excavator Service Repair Manual Instant Download.pdf

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Service Information
Document Title: Function Group: Information Type: Date:
Description 200 Service Information 2014/4/17
Profile:
Description
The EC25 is powered by a 3-cylinder four-stroke diesel inline engine.
Service Information
Document Title: Function Group: Information Type: Date:
Installing the
engine
200 Service Information 2014/4/17
Profile:
Installing the engine
Op nbr 2101
Lifting sling 1 m
Shackle 3/8""
Figure 1
1. Attach the lifting tackle to the engine. Weight approx. 125 kg.
2. Lift the engine into the machine.
NOTE!
Take care not to damage the hydraulic hoses.
3. Assemble the front left hand engine mounting. Cover the screws slightly with Loctite and tighten with 55 Nm.
4. Turn in the screws between engine mountings and rubber elements and tighten with 105 Nm.
5. Remove the lifting tackle to the engine.
Figure 2
1. Bracket
2. Hydraulic pump
6. Install compensation tank bracket and engine hood lock.
7. Mount the hydraulic pump and tighten the screws with 105 Nm.
8. Fasten both brackets with hydraulic hoses to the rear engine mounts.
9. Assemble fan grid and heating hose bracket to the engine mounting.
10. Install heating and coolant hoses with new hose clamps.
11. Fasten the throttle control to the injection pump.
Figure 3
1.
2.
3.
4.
Engine block fastening screws
Fastening screw
Exhaust muffler bracket
Traverse
12. Install the engine wiring loom and connect the following components:







Oil pressure switch
Injection pump
Glow plug
Temperature sensor
Generator
Starter
Ground cable
Fasten the cables with cable straps.
13. Assemble the exhaust muffler traverse.
14. Install the exhaust system, attach bracket (3) and tighten screw (2) with 85 Nm.
15. Fasten the exhaust bracket on the engine block and tighten screws (1) with 25 Nm.
Figure 4
16. Install the air filter with bracket and tighten the screws with 24 Nm.
17. Connect the electrical cables and terminals to the following components:



Socket
Fuel pump
Air filter vacuum gauge
Fasten the cables with cable straps.
18. Reconnect the fuel pipes.
19. Set the valve lever on the fuel pre-cleaner to position OPEN.
Figure 5
20. Fill in coolant. Filling capacity: approx. 6 litres.
21. Connect the ground cable to the battery.
22. Fold the lateral weight back in and fasten with
screws.
23. Assemble engine hood and floor plate.
24. Start the engine and make sure that there are no leaks.
Service Information
Document Title: Function Group: Information Type: Date:
Operator side 200 Service Information 2014/4/17
Profile:
Operator side
Figure 1
Engine, side view
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Oil filler neck
Injection pump
Water pump
Oil filler neck
Crankshaft pulley
Oil filter
Oil drain plug
Oil dipstick
Flywheel
Coolant drain plug
Intake manifold
Injection nozzle
Service Information
Document Title: Function Group: Information Type: Date:
Performance characteristics
(measuring
values for one hour
with fan)
200 Service Information 2014/4/17
Profile:
Performance characteristics (measuring values for one hour with fan)
Engine performance diagram
Figure 1
Engine power
Engine (hp/kW) S3L
With fan
S3L2
With fan
Power rpm
1500 12.0 / 8.8 14.5 / 10.7
1800 15.0 / 11.0 18.0 / 13.2
2000 17.0 / 12.5 20.0 / 14.7
2200 19.0 / 14.0 22.0 / 16.2
1 hour
(without overload) 2500 21.5 / 15.8 24.5 / 18.0
1500 11.4 / 8.4 13.8 / 10.1
Continuous
1800 14.3 / 10.5 17.1 / 12.6
2000 16.2 / 12 19.0 / 14.0
2200 18.1 / 13.3 20.9 / 15.4
2500 20.4 / 15 23.3 / 17.1
Service Information
Document Title: Function Group: Information Type: Date:
Removing the engine 200 Service Information 2014/4/17
Profile:
Removing the engine
Op nbr 2101
Lifting sling 1 m
Shackle 3/8""
Figure 1
1. Disassemble engine hood and floor plate.
2. Unscrew the bolts from the lateral weights and pull the weights out.
3. Disconnect the ground cable from the battery.
WARNING
When opening the lid of the compensation tank (radiator cap) there is a risk of scalding because of the
overpressure in the cooling system.
4. Unscrew the drain plug, open the radiator cap and drain of all coolant.
Filling quantity approx. 6 litres.
Figure 2
5. Set the valve lever on the fuel pre-cleaner to position CLOSED.
6. Disassemble the fuel pipes.
7. Disconnect all necessary electrical cables and terminals from the following components:



Socket
Fuel pump
Air filter vacuum gauge
8. Unscrew the top and bottom fastening screws from the bracket and remove the complete air filter.
Figure 3
1.
2.
3.
4.
Engine block fastening screws
Fastening screw
Exhaust muffler bracket
Traverse
9. Remove the exhaust silencer from the exhaust tube.
10. Unscrew the fastening screws from bracket and engine block and remove the exhaust system.
11. Disassemble the exhaust muffler traverse.
12. Disconnect all necessary electrical cables and terminals from the following components:







Oil pressure switch
Injection pump
Glow plug
Temperature sensor
Generator
Starter
Ground cable
Figure 4
1.
2.
Bracket
Hydraulic pump
13. Lay the engine wiring loom to the side.
14. Disconnect the throttle control from the injection pump.
15. Remove the heating hose bracket from the engine mounting.
16. Disassemble heating and coolant hoses.
17. Remove the fan grid.
18. Disassemble both brackets for hydraulic hoses from the rear engine mounts.
19. Remove the hydraulic pump from the engine.
20. Unscrew the screws between engine mounts and rubber elements.
21. Remove front left hand engine mounting, compensation tank bracket and engine hood lock.
Figure 5
Attach the lifting tackle
1.
2.
Lifting sling 1 m
Shackle 3/8""
22. Attach the lifting tackle to the engine.
23. Lift the engine out.
Weight: approx. 125 kg
Service Information
Document Title: Function Group: Information Type: Date:
Specification, engine 200 Service Information 2014/4/17
Profile:
Specification, engine
Engine
Type designation S3L -61A S3L2-61A
Firing sequence (injection sequence) 1 - 3 - 2
Compression ratio 22:1
Type of combustion chamber Swirl chamber
Number of cylinders 3
Bore x stroke, mm 78 x 78.5 78 x 92
Displacement, litres 1.125 1.318
Compression pressure 32 bar
Max. permissible pressure deviation between
cylinders
3 bar
Idle speed 900 + 100 rpm
Full speed 2400 + 20 rpm
Installed net power (ISO 9249) 17.1 kW at 2200 rpm
Maximum torque 77 kW at 1600 rpm
Cooling Centrifugal water pump with temperature control
Air filter Dry
Service Information
Document Title: Function Group: Information Type: Date:
Specification, filling
capacities
200 Service Information 2014/4/17
Profile:
Specification, filling capacities
Engine, oil change incl. filter 5.7 l
Service Information
Document Title: Function Group: Information Type: Date:
Specification, weight 200 Service Information 2014/4/17
Profile:
Specification, weight
Engine, standard 125 kg
Service Information
Document Title: Function Group: Information Type: Date:
Starter side 200 Service Information 2014/4/17
Profile:
Starter side
Figure 1
Engine, side view
1.
2.
3.
4.
5.
6.
7.
8.
Exhaust manifold
Starter
Oil sump
V-belt
Fan
Generator
Lifting eye
Thermostat
Service Information
Document Title: Function Group: Information Type: Date:
Tightening torque 200 Service Information 2014/4/17
Profile:
Tightening torque
Tightening torques engine S3L-S3L2
Tightening torques Nm
Cylinder head bolt 88 ± 5
Rocker cover bolt 11.3 ± 1.5
Rocker shaft bracket bolt 14.7 ± 5
Thermoswitch 22.6 ± 4
Crankshaft pulley nut 172 ± 25
Main bearing cap bolt 51.5 ± 2.5
Connecting rod cap nut 34.8 ± 2.5
Rear plate bolt (tractor engine) 93 ± 10
Rear plate bolt (standard) 64 ± 10
Rear plate bolt (stamping) 11.3 ± 1.5
Flywheel bolt 132 ± 5
Oil pan bolt (tractor motor) 27.5 ± 3
Oil pan drain plug 39 ± 5
Pressure relief valve 49 ± 5
Oil filter 12 ± 1
Oil pressure switch 10 ± 2
Fuel injection pipe nut 29 ± 5
Fuel leak-off pipe nut 27 ± 2.5
Delivery valve holder 49 ± 5
Fuel injection nozzle holder 54 ± 5
Retaining nut for delivery valve holder body 37 ± 2.5
Sliding sleeve shaft 35 ± 6
Special nut for torque spring set 20 ± 5
Glow plug 17.2 ± 2.5
Glow plug connection plate 1.2 ± 0.2
Stop solenoid nut 44 ± 5
Starter B terminal 10.8 ± 1
Service Information
Document Title: Function Group: Information Type: Date:
Valve timing 200 Service Information 2014/4/17
Profile:
Valve timing
Technical data, general
Valve system
Valve clearance (warm or cold engine)
Intake valve 0.25 mm
Exhaust valve 0.25 mm
Service Information
Document Title: Function Group: Information Type: Date:
Checking
the compression pressure
211 Service Information 2014/4/17
Profile:
Checking the compression pressure
Op nbr
ST332270 Adapter for pressure gauge
Figure 1
1. Set the control lever to a position in which the fuel supply is interrupted.
2. Disassemble all glow plugs and install adapter (1) ST332270 with pressure gauge (2) to one of the cylinders.
3. Crank the engine with the starter.
Compression pressure, see table [Invalid linktarget]
The measured compression pressure depends on the starter speed during the measuring process and the altitude
of the engine location.
Limit values can therefore not be specified precisely. The compression pressure measurement is only recommended
as a comparison measurement for all cylinders of an engine. If a deviation of more than 10% is found the respective
cylinders should be disassembled in order to detect the cause.
4. Insert all glow plugs and tighten with 17.2 ± 2.5 Nm.
Service Information
Document Title: Function Group: Information Type: Date:
Adjusting
the valves
214 Service Information 2014/4/17
Profile:
Adjusting the valves
Figure 1
Op nbr 21412
NOTE!
Before starting adjustment work clean the area around the rocker cover.
1. Pull off the crankcase ventilation hose.
2. Remove the rocker cover.
3. Crank the engine until the valves are overlapping.
NOTE!
Overlapping of valves means: Exhaust valve not yet closed, intake valve starts to open. Both push rods cannot be
turned.
Figure 2
4. Adjust the valve clearance on the respective cylinder with a feeler gauge ( [Invalid linktarget] )
5. Tighten the counter nut. Check the adjustment once again with a feeler gauge.
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
6. Attach the gasket to the rocker cover.
7. Fasten the rocker cover. Tighten the screws with a torque of 11.3 Nm.
8. Plug on the crankcase ventilation hose.

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Volvo EC25 Compact Excavator Service Repair Manual Instant Download.pdf

  • 1. Service Information Document Title: Function Group: Information Type: Date: Description 200 Service Information 2014/4/17 Profile: Description The EC25 is powered by a 3-cylinder four-stroke diesel inline engine.
  • 2. Service Information Document Title: Function Group: Information Type: Date: Installing the engine 200 Service Information 2014/4/17 Profile: Installing the engine Op nbr 2101 Lifting sling 1 m Shackle 3/8"" Figure 1 1. Attach the lifting tackle to the engine. Weight approx. 125 kg. 2. Lift the engine into the machine. NOTE! Take care not to damage the hydraulic hoses. 3. Assemble the front left hand engine mounting. Cover the screws slightly with Loctite and tighten with 55 Nm. 4. Turn in the screws between engine mountings and rubber elements and tighten with 105 Nm. 5. Remove the lifting tackle to the engine. Figure 2 1. Bracket
  • 3. 2. Hydraulic pump 6. Install compensation tank bracket and engine hood lock. 7. Mount the hydraulic pump and tighten the screws with 105 Nm. 8. Fasten both brackets with hydraulic hoses to the rear engine mounts. 9. Assemble fan grid and heating hose bracket to the engine mounting. 10. Install heating and coolant hoses with new hose clamps. 11. Fasten the throttle control to the injection pump. Figure 3 1. 2. 3. 4. Engine block fastening screws Fastening screw Exhaust muffler bracket Traverse 12. Install the engine wiring loom and connect the following components:        Oil pressure switch Injection pump Glow plug Temperature sensor Generator Starter Ground cable Fasten the cables with cable straps. 13. Assemble the exhaust muffler traverse. 14. Install the exhaust system, attach bracket (3) and tighten screw (2) with 85 Nm. 15. Fasten the exhaust bracket on the engine block and tighten screws (1) with 25 Nm.
  • 4. Figure 4 16. Install the air filter with bracket and tighten the screws with 24 Nm. 17. Connect the electrical cables and terminals to the following components:    Socket Fuel pump Air filter vacuum gauge Fasten the cables with cable straps. 18. Reconnect the fuel pipes. 19. Set the valve lever on the fuel pre-cleaner to position OPEN. Figure 5 20. Fill in coolant. Filling capacity: approx. 6 litres. 21. Connect the ground cable to the battery. 22. Fold the lateral weight back in and fasten with screws. 23. Assemble engine hood and floor plate. 24. Start the engine and make sure that there are no leaks.
  • 5. Service Information Document Title: Function Group: Information Type: Date: Operator side 200 Service Information 2014/4/17 Profile: Operator side Figure 1 Engine, side view 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Oil filler neck Injection pump Water pump Oil filler neck Crankshaft pulley Oil filter Oil drain plug Oil dipstick Flywheel Coolant drain plug Intake manifold Injection nozzle
  • 6. Service Information Document Title: Function Group: Information Type: Date: Performance characteristics (measuring values for one hour with fan) 200 Service Information 2014/4/17 Profile: Performance characteristics (measuring values for one hour with fan) Engine performance diagram Figure 1 Engine power Engine (hp/kW) S3L With fan S3L2 With fan Power rpm 1500 12.0 / 8.8 14.5 / 10.7 1800 15.0 / 11.0 18.0 / 13.2 2000 17.0 / 12.5 20.0 / 14.7 2200 19.0 / 14.0 22.0 / 16.2 1 hour (without overload) 2500 21.5 / 15.8 24.5 / 18.0 1500 11.4 / 8.4 13.8 / 10.1 Continuous
  • 7. 1800 14.3 / 10.5 17.1 / 12.6 2000 16.2 / 12 19.0 / 14.0 2200 18.1 / 13.3 20.9 / 15.4 2500 20.4 / 15 23.3 / 17.1
  • 8. Service Information Document Title: Function Group: Information Type: Date: Removing the engine 200 Service Information 2014/4/17 Profile: Removing the engine Op nbr 2101 Lifting sling 1 m Shackle 3/8"" Figure 1 1. Disassemble engine hood and floor plate. 2. Unscrew the bolts from the lateral weights and pull the weights out. 3. Disconnect the ground cable from the battery. WARNING When opening the lid of the compensation tank (radiator cap) there is a risk of scalding because of the overpressure in the cooling system. 4. Unscrew the drain plug, open the radiator cap and drain of all coolant. Filling quantity approx. 6 litres. Figure 2 5. Set the valve lever on the fuel pre-cleaner to position CLOSED.
  • 9. 6. Disassemble the fuel pipes. 7. Disconnect all necessary electrical cables and terminals from the following components:    Socket Fuel pump Air filter vacuum gauge 8. Unscrew the top and bottom fastening screws from the bracket and remove the complete air filter. Figure 3 1. 2. 3. 4. Engine block fastening screws Fastening screw Exhaust muffler bracket Traverse 9. Remove the exhaust silencer from the exhaust tube. 10. Unscrew the fastening screws from bracket and engine block and remove the exhaust system. 11. Disassemble the exhaust muffler traverse. 12. Disconnect all necessary electrical cables and terminals from the following components:        Oil pressure switch Injection pump Glow plug Temperature sensor Generator Starter Ground cable Figure 4 1. 2. Bracket Hydraulic pump
  • 10. 13. Lay the engine wiring loom to the side. 14. Disconnect the throttle control from the injection pump. 15. Remove the heating hose bracket from the engine mounting. 16. Disassemble heating and coolant hoses. 17. Remove the fan grid. 18. Disassemble both brackets for hydraulic hoses from the rear engine mounts. 19. Remove the hydraulic pump from the engine. 20. Unscrew the screws between engine mounts and rubber elements. 21. Remove front left hand engine mounting, compensation tank bracket and engine hood lock. Figure 5 Attach the lifting tackle 1. 2. Lifting sling 1 m Shackle 3/8"" 22. Attach the lifting tackle to the engine. 23. Lift the engine out. Weight: approx. 125 kg
  • 11. Service Information Document Title: Function Group: Information Type: Date: Specification, engine 200 Service Information 2014/4/17 Profile: Specification, engine Engine Type designation S3L -61A S3L2-61A Firing sequence (injection sequence) 1 - 3 - 2 Compression ratio 22:1 Type of combustion chamber Swirl chamber Number of cylinders 3 Bore x stroke, mm 78 x 78.5 78 x 92 Displacement, litres 1.125 1.318 Compression pressure 32 bar Max. permissible pressure deviation between cylinders 3 bar Idle speed 900 + 100 rpm Full speed 2400 + 20 rpm Installed net power (ISO 9249) 17.1 kW at 2200 rpm Maximum torque 77 kW at 1600 rpm Cooling Centrifugal water pump with temperature control Air filter Dry
  • 12. Service Information Document Title: Function Group: Information Type: Date: Specification, filling capacities 200 Service Information 2014/4/17 Profile: Specification, filling capacities Engine, oil change incl. filter 5.7 l
  • 13. Service Information Document Title: Function Group: Information Type: Date: Specification, weight 200 Service Information 2014/4/17 Profile: Specification, weight Engine, standard 125 kg
  • 14. Service Information Document Title: Function Group: Information Type: Date: Starter side 200 Service Information 2014/4/17 Profile: Starter side Figure 1 Engine, side view 1. 2. 3. 4. 5. 6. 7. 8. Exhaust manifold Starter Oil sump V-belt Fan Generator Lifting eye Thermostat
  • 15. Service Information Document Title: Function Group: Information Type: Date: Tightening torque 200 Service Information 2014/4/17 Profile: Tightening torque Tightening torques engine S3L-S3L2 Tightening torques Nm Cylinder head bolt 88 ± 5 Rocker cover bolt 11.3 ± 1.5 Rocker shaft bracket bolt 14.7 ± 5 Thermoswitch 22.6 ± 4 Crankshaft pulley nut 172 ± 25 Main bearing cap bolt 51.5 ± 2.5 Connecting rod cap nut 34.8 ± 2.5 Rear plate bolt (tractor engine) 93 ± 10 Rear plate bolt (standard) 64 ± 10 Rear plate bolt (stamping) 11.3 ± 1.5 Flywheel bolt 132 ± 5 Oil pan bolt (tractor motor) 27.5 ± 3 Oil pan drain plug 39 ± 5 Pressure relief valve 49 ± 5 Oil filter 12 ± 1 Oil pressure switch 10 ± 2 Fuel injection pipe nut 29 ± 5 Fuel leak-off pipe nut 27 ± 2.5 Delivery valve holder 49 ± 5 Fuel injection nozzle holder 54 ± 5 Retaining nut for delivery valve holder body 37 ± 2.5 Sliding sleeve shaft 35 ± 6 Special nut for torque spring set 20 ± 5 Glow plug 17.2 ± 2.5 Glow plug connection plate 1.2 ± 0.2 Stop solenoid nut 44 ± 5 Starter B terminal 10.8 ± 1
  • 16. Service Information Document Title: Function Group: Information Type: Date: Valve timing 200 Service Information 2014/4/17 Profile: Valve timing Technical data, general Valve system Valve clearance (warm or cold engine) Intake valve 0.25 mm Exhaust valve 0.25 mm
  • 17. Service Information Document Title: Function Group: Information Type: Date: Checking the compression pressure 211 Service Information 2014/4/17 Profile: Checking the compression pressure Op nbr ST332270 Adapter for pressure gauge Figure 1 1. Set the control lever to a position in which the fuel supply is interrupted. 2. Disassemble all glow plugs and install adapter (1) ST332270 with pressure gauge (2) to one of the cylinders. 3. Crank the engine with the starter. Compression pressure, see table [Invalid linktarget] The measured compression pressure depends on the starter speed during the measuring process and the altitude of the engine location. Limit values can therefore not be specified precisely. The compression pressure measurement is only recommended as a comparison measurement for all cylinders of an engine. If a deviation of more than 10% is found the respective cylinders should be disassembled in order to detect the cause. 4. Insert all glow plugs and tighten with 17.2 ± 2.5 Nm.
  • 18. Service Information Document Title: Function Group: Information Type: Date: Adjusting the valves 214 Service Information 2014/4/17 Profile: Adjusting the valves Figure 1 Op nbr 21412 NOTE! Before starting adjustment work clean the area around the rocker cover. 1. Pull off the crankcase ventilation hose. 2. Remove the rocker cover. 3. Crank the engine until the valves are overlapping. NOTE! Overlapping of valves means: Exhaust valve not yet closed, intake valve starts to open. Both push rods cannot be turned. Figure 2 4. Adjust the valve clearance on the respective cylinder with a feeler gauge ( [Invalid linktarget] ) 5. Tighten the counter nut. Check the adjustment once again with a feeler gauge.
  • 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. 6. Attach the gasket to the rocker cover. 7. Fasten the rocker cover. Tighten the screws with a torque of 11.3 Nm. 8. Plug on the crankcase ventilation hose.