Volvo EC25 Compact Excavator Repair Manual

Table of Content EC25 Service Information

GENERAL
DESCRIPTION, COMPLETE MACHINE
General
Position of components
TABLES, FOR DESIGNING
Load capacity tables
Warning sign – Open engine hood only with engine stopped
Warning sign – Safety distance from the movement area
Warning sign – Safety distance from the work area
Fuels Lubricants and filling capacities (litres)
Strength class 8.8 Metric coarse and fine threads
Strength class 10.9 Metric coarse and fine threads
UNC-threads, coarse pitch
Volvo standard tightening torques
STANDARD PARTS, SERVICE
LUBRICANT; FUEL; OTHER FLUID
Recommended lubricants
SERVICE
Maintenance
Condition test
Creeping of hydraulic cylinders
Measuring conditions
Measuring the play of the slewing bearing
Performance when travelling straight on
Track travel speed
Maintenance instructions
Emergency measures
Jump starting
Starting the engine with jump wires
ENGINE WITH MOUNTING AND EQUIPMENT
General, engine installation and its function
Installing the engine
Performance characteristics (measuring valuesł forł oneł hour with fan)
ENGINE
Cylinder head
Checking the compression pressure
Valve mechanism
Adjusting the valves
LUBRICATING SYSTEM
General, common info about 221 – 224
Lubrication system, description
Lubrication system, specification
Oil filter; filter housing
Removing and installing the pressure relief valve
Removing the oil filter
FUEL SYSTEM
General (common info about 233 – 238)
Bleeding the fuel system
Checking and adjusting the injection nozzles
Schematic, fuel system
Fuel pump; filter; strainer
Fuel feed pump
Adjusting the fuel injection timing
Filter; strainer
Changing the fuel filter
COOLING SYSTEM
General, common info about 261 – 269
Coolant pump; thermostat
Coolant pump
Removing and installing the coolant pump
Thermostat
Removing and installing the thermostat housing
ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Comprehensive info, electrical system
Electrical system, description
Electrical system, trouble shooting
Precautions when handling plug connectors
BATTERY; ENERGY STORAGE SYSTEM; MOUNTING PARTS
General, common info about 311 – 313
ALTERNATOR; CHARGING; ELECTRIC MOTOR; ELECTRIC DRIVES
General, common info about 321 – 322
Checking the performance characteristics
Tests before disassembly
Alternator inclusive drive
Dismantling and assembling the generator
Removing and installing the generator
Charging; converter
Checking the voltage regulation
STARTING SYSTEM
General, common info about 331 – 334
Starter motor inclusive solenoid
Starter motor
Assembling the starter
Dismantling the starter
Removing and installing the starter
Starter relay
Installation of the solenoid
Key-operated engine shut down system with EDD-solenoid
Electric air pre-heater, excluding element
Characteristics of the glow plug system
Installing the glow plug
LIGHTING
Lighting, extra, including working lighting
Working lighting
Working headlights and main headlights, specification
Working headlights and main headlights, description
POWER TRANSMISSION
General, common info about 410 – 436
General notes to be observed when working on power transmission assemblies
GEARBOX,
Gearbox
Track gearbox, crawler machine
Removing and installing the travel gear
HYDROSTATIC DRIVE
Hydraulic motor incl. operating system.
Hydraulic motor 1, traveling
Brake valve (counter balance valve)
Design of travel motor
Miscellaneous
The loaded motor does not run with normal speed
Centre passage; lines
Centre passage
MISCELLANEOUS
Swing system upper part
Swing brake; swing holding brake; swing lock
Applying the brake
BRAKE
Comprehensive info about brakes
STEERING
Comprehensive info, steering
Steering system, description
FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
Comprehensive info about frame and track unit/wheels
Frame and crawler unit
FRAME
Frame, excavator
Revolving frame
Removing and installing the superstructure
WHEELS; TRACKS; TYRE; HUB; DRUM
Crawler unit
Front idler, incl. fork
Removing and installing the guide sprocket
Sprocket
Removing and installing the track drive
Steel track
Adjusting the track sagging
Removing and installing the rubber track
Removing and installing the track
Top rollers; skid rails
Removing and installing the track supporting idler
Bottom rollers
Removing and installing the track roller
MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Comprehensive info, machinery house and cab
Removing and installing the cabin
HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
Adjusting the pressure and checking for leaks
General notes to be observe when working on the hydraulic system
Test and adjustment mark for EC 25
WORKING HYDRAULICS; SERVO HYDRAULICS
General, common info about 911 – 917
Tank; line; oil cooling; filter; breather; filling pump
Tank
Changing the hydraulic oil
Checking the hydraulic oil level
Oil cooling system
Cleaning the oil cooler
Filters
Changing the hydraulic oil filter
Working hydraulics
Directional valve; control valve
Assignment of elements
Hydraulic circuit for slewing gear and offset
Hydraulic circuit of travel motors
Return flow, hydraulic accessories circuit
Pressure limiting valve (relief valves)
Checking and adjusting the pressure relief valves
Pressure relief valve P1 Test and adjustment procedure
Pressure relief valve P2 Test and adjustment procedure
Pressure relief valve P3
Hydraulic lock; line rupture valve
Hose rupture valve on boom cylinder, leak test
Hose rupture valve on boom cylinder
Hose rupture valve on boom cylinder Test and adjustment procedure
Hose rupture valve on dipper, leak test
Hose rupture valve on dipper
Secondary valves Test and adjustment procedure
Electric valve, in working hydraulics
Balancing valve (offset cylinder)
Solenoid valve for hydraulic working unit
Block for valve assembly
Control valve block for slewing gear Test and adjustment
Dismantling the valve block
Removing the valve block
Tests and adjustments of the power control
Valve block for slewing gear
Servo hydraulic system
Solenoid valve, on/off function
Hydraulic safety solenoid valve
Checking and adjusting the pressure reducer
Pressure regulator (hydraulic control elements)