Volvo EC25 Compact Excavators Parts Manual
Volvo EC25 Compact Excavators Parts Manual.pdf
Volvo EC25 Compact Excavators Service Repair Manual (incomplete bonus material).pdf
PRODUCT DETAILS:
Pages: 792
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
Volvo EC25 Compact Excavators Parts Manual........1
0 - Foreword........2
0 - GENERAL........3
03 - SPECIFICATIONS........4
Product identification plate........5
2 - ENGINE WITH MOUNTING AND EQUIPMENT........6
21 - ENGINE........7
Engine S3L2-63ES........8
Engine S3L2-W263ES........10
Repair kits for engine........12
Cylinder head........13
Cylinder block........15
Flywheel housing........17
Pistons........19
Rocker arm shaft........21
Timing gear casing........23
Timing gears........25
Camshaft........27
Connecting rods........29
Lubrication oil sump........31
Engine mounts........33
22 - LUBRICATING SYSTEM........35
Lubricating oil pump........36
Oil filter........38
23 - FUEL SYSTEM........40
Fuel pump-........41
Fuel pump........42
Fuel filter........43
Sediment bowl-[3422]........44
Sediment bowl........46
Gas-oil tank-[3345]........47
Gas-oil tank........48
Fuel circuit-[3309]........49
Fuel circuit-[3248]........51
Fuel circuit injection pump........53
Fuel circuit........55
Injection pump........57
Injector........59
Engine injection pump control S3L2-63ES........61
Engine injection pump control S3L2-W263ES........63
25 - INLET & EXHAUST SYSTEM........65
Exhaust manifold........66
Intake manifold........68
Muffler-[3011]........70
Muffler........72
Muffler with catalytic exhaust........74
Intake _ air filter........75
Air filter........77
Preheating coil........79
Pre-cleaner........81
26 - COOLING SYSTEM........82
Radiator ( water )........83
Expansion tank........84
Cooling circuit........85
Radiator installation-[2720]........86
Radiator installation........88
Water pump........90
Thermostat........92
27 - ENGINE CONTROL........94
Engine stop electromagnet........95
Engine acceleration control........96
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS........98
31 - BATTERY........99
Battery........100
32 - ALTERNATOR; CHARGE REGULATOR........101
Alternator installation........102
Alternator 12V - 50A........104
33 - STARTING SYSTEM........105
Starter motor installation........106
Starter motor 12V - 2KW........108
Starting and preheating switch-[2328]........109
Starting and preheating switch........110
Coded keypad ( anti-start )........111
35 - LIGHTING........112
Front headlight on canopy-[2227]........113
Front headlight on canopy........114
Front headlight on cab-[2150]........115
Front headlight on cab........117
Rear headlight-[2115]........119
Rear headlight........120
Work light on boom........121
36 - OTHER ELECTRICAL EQUIPMENT........123
Horn........124
Flashing light........125
Cleaning system-[1941]........126
Cleaning system........128
Oil pressure switch........130
Clogging indicator........132
Thermal switch........134
Operator's station instrument panel ( right )-[1817]........135
Operator's station instrument panel ( left )-[1757]........137
Inspection light socket........139
Control panel........140
37 - CABLE; FUSE; RELAY........141
Electrical system (front) _ without Puma-[1655]........142
Electrical system (front) _ without Puma........143
Electrical system _ Canopy-[1619]........145
Electrical system _ Canopy........146
Electrical system _ cab-[1543]........147
Electrical system _ cab........148
Electrical system (rear) _ without Puma-[1507]........150
Electrical system (rear) _ without Puma........151
Cables; battery........152
Electrical equipment _ without Puma........154
Battery cut-out........156
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM........157
Transmitter........158
39 - MISCELLANEOUS........160
Radio kit-[1309]........161
Radio kit........162
4 - POWER TRANSMISSION........164
41 - CLUTCH; TORQUE CONVERTER........165
Engine coupling _ hydraulic pump-[1212]........166
Engine coupling _ hydraulic pump-[0758]........167
Engine coupling _ hydraulic pump-[0738]........168
Engine coupling _ hydraulic pump........169
44 - HYDROSTATIC DRIVE........170
Hydraulic travelling motor........171
Travelling gear motor assy _ without brake........173
Control valve........175
Balancing valve ( travelling )........177
Slewing gear motor installation-[0549]........178
Slewing gear motor installation........179
Slewing gear motor-[0513]........180
Slewing gear motor........182
Swivel joint equipment-[0436]........184
Swivel joint equipment........185
Swivel joint S_N15618........187
Swivel joint S_N15611-S_N15617........189
49 - MISCELLANEOUS........191
Slewing ring........192
Lubrication ( slewing ring )........193
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT........194
71 - FRAME........195
Counterweight........196
Lower frame........198
Platform........200
77 - WHEELS; TRACKS; TYRE; HUB; DRUM........202
Track tensioning ( steel tracks )........203
Track tensioning ( rubber tracks )........205
Sprocket........207
Steel tracks........208
Rubber tracks........209
Upper roller ( steel and rubber tracks )........211
Lower roller ( steel tracks )........212
Lower roller ( rubber tracks )........213
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE........214
81 - CAB; NAKED; CANOPY........215
Equipped cabin........216
Cab sliding window ( front )-[5849]........217
Cab sliding window ( front )........219
Canopy........221
Wind protector........223
82 - ENGINE HOOD; MUDGUARD; FOOT STEP........224
Engine coverage........225
Lock ( engine coverage )........227
83 - DOORS; HATCH; COVER PLATE; (all)........229
Cab door-[5650]........230
Cab door........232
Cabin floor ( standard and canopy )........234
Right coverage........235
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING........237
Cab glass-[5532]........238
Cab glass........239
Cab windshield-[5456]........240
Cab windshield........242
Cab sliding window ( right )-[5420]........244
Cab sliding window ( right )........246
85 - CAB INTERIOR; UPHOLSTERY........248
Cab accessories-[5334]........249
Cab accessories........251
Suspended seat........253
Operator's station plating........255
87 - AIR CONDITIONING UNIT........257
Cab heating installation-[5216]........258
Cab heating installation........260
88 - INTERIOR EQUIPMENT........262
Operator's station instrument panel ( right )........263
Operator's station instrument panel ( left )-[5114]........265
Operator's station instrument panel ( left )........267
Cab console-[5038]........269
Cab console........271
Safety belt STD........273
Safety belt 2 ........275
Safety belt 3 ........276
89 - MISCELLANEOUS........277
Toolbox........278
Glue Kit for cab-[4850]........279
Glue Kit for cab........281
Tools........282
Transfer........284
Transfer cab STD ; USA........285
Transfer canopy STD ; USA........287
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS........289
91 - WORKING HYDRAULIC; SERVO HYDRAULICS........290
Seals suitcase for union ; elbow ; fitting .........293
Hydraulic tank-[4636]........296
Hydraulic tank........298
Attachments supply and return circuit-[4559]........300
Attachments supply and return circuit........302
Hydr. circuit. ( Oil cooler )-[4523]........304
Hydr. circuit. ( Oil cooler )-[4503]........306
Hydr. circuit. ( Oil cooler )........308
Oil cooler-[4427]........310
Oil cooler........311
Hydraulic oil filter........313
Lubrication oil filler and breather........314
Control valve 9 spools........315
Control valve 8 spools........318
Handling operations Ce _ without Puma-[4249]........321
Handling operations Ce _ without Puma........323
Hydraulic circuit ( safety valve _ dipper arm )........325
Slewing-offset selector switch-[4158]........326
Slewing-offset selector switch........328
Slewing-offset selector switch ( for valve )-[4122]........330
Slewing-offset selector switch ( for valve )........331
Balancing valve ( slewing )-[4046]........333
Balancing valve ( slewing )-[4026]........335
Balancing valve ( slewing )-[4006]........337
Balancing valve ( slewing )........338
Balancing valve ( offset cylinder )........339
Safety valve ( boom cylinder )-[3915]........341
Safety valve ( boom cylinder )........343
Safety valve ( dipper arm cylinder )........345
Control levers steel pedal........347
Control levers plastic pedal........349
Control lever dozer blade........351
Control lock ( safety system )........353
Hydraulic pump-[3722]........354
Hydraulic pump-[3702]........356
Hydraulic pump-[3641]........358
Hydraulic pump........360
Pump........362
Accumulator _ electrovalve-[3550]........363
Accumulator _ electrovalve........365
Electrovalve........367
Accumulator........369
Hydr. circuit ( control's attachment ) STD-[3444]........370
Hydr. circuit ( control's attachment ) STD........372
Hydr. circuit ( control's attachment ) USA-[3408]........374
Hydr. circuit ( control's attachment ) USA........376
Control lever dipper arm _ slewing ( left )-[3333]........378
Control lever dipper arm _ slewing ( left )........379
Control lever boom _ bucket ( right )-[3257]........380
Control lever boom _ bucket ( right )........381
Control selector switch installation USA........382
Std or Iso equipment control selector switch (us) USA........383
Hydr. circuit. ( travelling )-[3151]........385
Hydr. circuit. ( travelling )........387
Hydraulic circuit ( lower frame )........389
Hydr. circuit. ( dozer blade )-[3100]........391
Hydr. circuit. ( dozer blade )........392
Hydr. circuit. ( boom slewing _ offset )-[3024]........393
Hydr. circuit. ( boom slewing _ offset )........395
Hydraulic circuit ( platform )-[2948]........397
Hydraulic circuit ( platform )........399
Hydr. circuit.( boom _ dipper arm _ bucket )........401
Hydraulic circuit ( balancing valve _ offset cylinder )-[2857]........403
Hydraulic circuit ( balancing valve _ offset cylinder )........404
Hydraulic circuit ( accessories )........405
Kit coupler ( accessories )........407
Hydraulic circuit ( double-acting )........409
Kit coupler ( double acting )........410
Hydr. circuit. ( attachment ) ( grab jaw )........412
Kit coupler ( grab jaw )........414
92 - MECHANICAL EQUIPMENT_ATTACHMENT........416
Tool holder _ mechanical control........417
Tool holder _ hydraulic control........419
Lever........421
Hydraulic circuit ( snap-action attachment )-[2552]........422
Hydraulic circuit ( snap-action attachment )........424
Hyd. circuit (quickfit_double-acting)-[2517]........426
Hyd. circuit (quickfit_double-acting)........428
Electrovalve (quickfit )........430
Bucket........431
Buckets for Quickfit........433
Grading bucket........435
Grading bucket for Quickfit........437
Hammer 11839397 HB150LN-[2324]........439
Hammer 11839397 HB150LN-[2304]........440
Hammer 11839397 HB150LN........441
Bulk bag........443
Dozer blade........444
Dozer blade cylinder S_N15541-S_N15702;S_N15704-S_N15714;S_N15717;S_N15718........446
Dozer blade cylinder S_N15539;S_N15540;S_N15703;S_N15715;S_N15716........448
97 - UNIT; DIGGING........450
Pivot pin........451
Boom offset cylinder S_N15541-S_N15702;S_N15704-S_N15714;S_N15717;S_N15718........453
Boom offset cylinder S_N15539;S_N15540;S_N15703;S_N15715;S_N15716........455
Lubrication ( boom offset cylinder )........457
Boom........458
Boom cylinder S_N15541-S_N15702;S_N15704-S_N15714;S_N15717;S_N15718........460
Boom cylinder S_N15539;S_N15540;S_N15703;S_N15715;S_N15716........462
Cylinder rod protection-[1928]........464
Dipper arm........465
Dipper arm cylinder S_N15541-S_N15702;S_N15704-S_N15714;S_N15717;S_N15718........467
Dipper arm cylinder S_N15539;S_N15540;S_N15703;S_N15715;S_N15716........469
Bucket cylinder S_N15541-S_N15702;S_N15704-S_N15714;S_N15717;S_N15718........471
Bucket cylinder S_N15539;S_N15540;S_N15703;S_N15715;S_N15716........473
Cylinder rod protection........475
Volvo EC25 Compact Excavators Service Repair Manual (incomplete bonus material)........476
0 - Foreword........477
0 - GENERAL........478
00 - DESCRIPTION; COMPLETE MACHINE........479
Main dimensions........480
Position of components........482
03 - SPECIFICATIONS........483
Chapter 2 Engine........484
Chapter 3 Electrical system........486
Chapter 4 Power transmission........488
Chapter 9 Hydraulic system........489
Engine........490
Fuels Lubricants and filling capacities (litres)........491
Hydraulic motor 1 - travel system........492
Mechanical transmission - track gearbox........493
Plugs with tapered thread........494
Strength class 8.8 Metric coarse and fine threads........495
Strength class 10.9 Metric coarse and fine threads........496
UNC-threads; coarse pitch........497
Volvo standard tightening torques........498
1 - STANDARD PARTS; SERVICE........499
16 - LUBRICANT; FUEL; OTHER FLUID........500
Recommended lubricants........501
17 - SERVICE........503
Maintenance instructions........504
Creeping of hydraulic cylinders........509
Cylinder speed........510
Measuring conditions........513
Measuring the play of the slewing bearing........514
Performance when travelling straight on........517
Slewing overtravel........519
Slewing speed........521
Track travel speed........522
Travel speed........523
Starting the engine with jump wires........525
2 - ENGINE WITH MOUNTING AND EQUIPMENT........527
20 - GENERAL........528
Description........529
Installing the engine........530
Operator side........533
Performance characteristics (measuring values for one hour with fan)........534
Removing the engine........536
Specification; engine........539
Specification; filling capacities........540
Specification; weight........541
Starter side........542
Tightening torque........543
Valve timing........544
21 - ENGINE........545
Checking the compression pressure........546
Adjusting the valves........547
22 - LUBRICATING SYSTEM........549
Lubrication system; description........550
Lubrication system; specification........551
Installing the oil filter........552
Removing and installing the oil pressure switch........553
Removing and installing the pressure relief valve........555
Removing the oil filter........557
23 - FUEL SYSTEM........558
Bleeding the fuel system........559
Checking the openings for clogging........561
Checking and adjusting the injection nozzles........562
Idle speed; inspection and adjustment........565
Schematic; fuel system........568
Adjusting the fuel injection timing........569
Changing the fuel filter........574
26 - COOLING SYSTEM........576
Fault remedy........577
Technical data........578
Removing and installing the coolant pump........579
Removing and installing the thermostat........582
Removing and installing the thermostat housing........584
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS........587
30 - GENERAL........588
Diagnostics........589
Electrical system; description........591
Electrical system; trouble shooting........594
General test items........595
Precautions when handling plug connectors........596
31 - BATTERY........598
Battery; description........599
Battery; specification........600
32 - ALTERNATOR; CHARGE REGULATOR........601
Checking the performance characteristics........602
Tests before disassembly........603
Dismantling and assembling the generator........605
Removing and installing the generator........612
Checking the voltage regulation........614
33 - STARTING SYSTEM........615
Starting process........616
Testing method........618
Assembling the starter........619
Dismantling the starter........622
General-........630
Removing and installing the starter........634
Ignition switch........636
Ignition switch; specification........638
Installation of the solenoid........639
Key-operated engine shut down system with EDD-solenoid........641
Characteristics of the glow plug system........642
Checking the glow plug........644
Installing the glow plug........645
35 - LIGHTING........646
Working headlights and main headlights; specification........647
Working headlights and main headlights; description........648
4 - POWER TRANSMISSION........649
40 - GENERAL........650
Control valve........651
General notes to be observed when working on power transmission assemblies........652
Working principle of the travel system........654
43 - GEARBOX........656
Removing and installing the travel gear........657
44 - HYDROSTATIC DRIVE........661
Brake valve (counter balance valve)........662
Design of travel motor........665
High speed solenoid valve........666
External oil losses........668
Loud motor noises........669
The loaded motor does not run with normal speed........670
The motor does not turn........671
The motor rotates irregularly........672
Design........673
Function........674
49 - MISCELLANEOUS........675
Applying the brake........676
Releasing the slewing brake........677
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT........678
70 - GENERAL........679
Frame and crawler unit........680
71 - FRAME........681
Removing and installing the superstructure........682
77 - WHEELS; TRACKS; TYRE; HUB; DRUM........684
Removing and installing the guide sprocket........685
Removing and installing the track drive........687
Track drive; wear measurement........689
Adjusting the track sagging........690
Removing and installing the rubber track........693
Removing and installing the track........695
Removing and installing the track supporting idler........699
Removing and installing the track roller........701
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE........704
80 - GENERAL........705
Cabin; specification........706
Removing and installing the cabin........707
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS........709
90 - GENERAL........710
Adjusting the pressure and checking for leaks........711
General notes to be observe when working on the hydraulic system........712
Test and adjustment mark for EC 025........714
91 - WORKING HYDRAULIC; SERVO HYDRAULICS........716
Solenoid valve for hydraulic working unit - Image........718
Hydraulic circuit........719
Hydraulic diagram........720
Changing the hydraulic oil........723
Checking the hydraulic oil level........725
Cleaning the oil cooler........727
Changing the hydraulic oil filter........728
Assignment of elements........730
By-pass valve........731
Hydraulic circuit for boom........733
Hydraulic circuit for bucket........734
Hydraulic circuit for dozer blade........736
Hydraulic circuit for slewing gear and offset........738
Hydraulic circuit for swing arm........740
Hydraulic circuit of travel motors........742
Return flow; hydraulic accessories circuit........744
Checking and adjusting the pressure relief valves........747
Pressure relief valve P001........748
Pressure relief valve P002........750
Pressure relief valve P003........752
Hose rupture valve on boom cylinder; leak test........754
Hose rupture valve on boom cylinder........755
Hose rupture valve on boom cylinder Test and adjustment procedure........757
Hose rupture valve on dipper; leak test........760
Hose rupture valve on dipper........761
Secondary valves........763
Balancing valve (offset cylinder)........765
Solenoid valve for hydraulic working unit........767
Assembling the valve block-039........770
Assembling the valve block........771
Control valve block for slewing gear Test and adjustment........772
Dismantling the valve block........774
Installing the valve block........775
Removing the valve block........776
Tests and adjustments of the power control........777
Valve block for slewing gear........781
Auxiliary pressure block........783
Checking and adjusting the pressure reducer........785
General........787
Pressure regulator (hydraulic control elements)........789
Hydraulic safety solenoid valve........791
Volvo EC25 Compact Excavators Parts Manual
