Volvo EC45 Compact Excavator Service Repair Manual Instant Download

1
Service Information
Document Title Description Function Group 200 Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB
Description Engine, description and external
views The EC45 is powered by a 4-cylinder
four-stroke diesel in line engine with water
cooling.

• Figure 1 Engine, left side
• Fan
• V-belt
• Thermostat
• Alternator
• Engine hanger
• Exhaust manifold
• Starter
• Flywheel
• Oil pan
• Crankshaft pulley

2

• Figure 2
• Engine, right side
• Fuel injection nozzle
• Fuel return
• Intake manifold
• Oil filler
• Oil filter
• Fuel inlet
• Injection pump
• Water pump
• Governor
• Oil drain plug
• Oil filter
• Disptick

3
Service Information
Document Title Precautions Function Group 200 Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB

• Precautions
• Make preparation as follows before starting
  engine inspection and service.
• Fix the engine on a horizontal base.
• Remove the coolant hoses, fuel oil pipes, wire
  harness, control wires etc. connecting the driven
  machine and engine, and drain coolant,
  lubricating oil and fuel.
• Remove soil, oil, dust, etc. from the engine by
  washing with solvent, air, steam, etc. Carefully
  operate so as not to let any foreign matter enter
  the engine.
• Any part which is found defective as a result of
  inspection or any part whose measured value does
  not satisfy the standard or limit shall be
  replaced.
• Any part predicted to dissatisfy the standard or
  limit before the next service as estimated from
  the state of use should be replaced even when the
  measured value then satisfies the standard or
  limit.

4
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Service Information
Document Title Troubleshooting chart Function Group 200 Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB
Troubleshooting chart The following table
summarizes the general trouble symptoms and their
causes. If any trouble symptom occurs, take
corrective action before it develops into a
serious problem so as not to shorten the engine
service life. Engine troubleshooting chart
Trouble symptoms Causes Corrective actions
Engine does not start Improper clearance of inlet/exhaust valve Adjust the valve clearance
Engine does not start Seizure of inlet/exhaust valve Correct or replace
Engine does not start Seized or broken piston ring Replace the piston ring
Engine does not start Worn piston ring, piston or cylinder Perform honing and use oversize parts
Engine does not start Seized crankpin metal or bearing Repair or replace
Engine does not start Foreign matter trapped in combustion chamber Disassemble and repair
Engine does not start Improper open/close timing of intake/exhaust valves Adjust the valve clearance
Engine does not start Improper properties of lubricating oil Use proper lubricating oil
Engine does not start Water entrance in fuel system Perform draining from the fuel filter
Engine does not start Clogged fuel filter Clean or replace
Engine does not start Air entrance in fuel system Perform air bleeding
Engine does not start Clogged or cracked fuel pipe Clean or replace
Engine does not start Insufficient fuel supply to fuel injection pump Check the fuel tank cock, fuel tank, fuel pipe and fuel feed pump
Engine does not start Priming failure (foreign matter trapped in the valve inside the priming pump) Disassemble and clean
Engine does not start Starting motor defect Repair or replace
Engine does not start Alternator defect Repair or replace
Engine does not start Open circuit in wiring harness Repair
Engine does not start Battery voltage drop Inspect and charge the battery
Engine starts, but stops soon. Exhaust smoke none. Improper clearance of inlet/exhaust valve Adjust the valve clearance
Engine starts, but stops soon. Exhaust smoke none. Seized crankpin metal or bearing Repair or replace
Engine starts, but stops soon. Exhaust smoke none. Improper arrangement of piston rings joint Correct the ring joint positions
Engine starts, but stops soon. Exhaust smoke none. Defective governor Make adjustment
Engine starts, but stops soon. Exhaust smoke none. Improper properties of lubricating oil Use proper lubricating oil
Engine starts, but stops soon. Exhaust smoke none. Insufficient lubricating oil level Add proper lubricating oil
Engine starts, but stops soon. Exhaust smoke none. Clogged fuel filter Clean or replace
Engine starts, but stops soon. Exhaust smoke none. Air entrance in fuel system Perform air bleeding
Engine starts, but stops soon. Exhaust smoke none. Clogged or cracked fuel pipe Clean or replace
Engine starts, but stops soon. Exhaust smoke none. Insufficient fuel supply to fuel injection pump Check the fuel tank cock, fuel tank, fuel pipe and fuel feed pump
Engine starts, but stops soon. Exhaust smoke excessive. Seizure of inlet/exhaust valve Correct or replace
Engine starts, but stops soon. Exhaust smoke excessive. Seized or broken piston ring Replace the piston ring
Engine starts, but stops soon. Exhaust smoke excessive. Worn piston ring, piston or cylinder Perform honing and use oversize parts
Engine starts, but stops soon. Exhaust smoke excessive. Water entrance in fuel system Perform draining from the fuel filter
6
Insufficient engine output. Exhaust color ordinary Clogged air filter Clean
Insufficient engine output. Exhaust color ordinary Improper clearance of inlet/exhaust valve Adjust the valve clearance
Insufficient engine output. Exhaust color ordinary Compression leakage from valve seat Lap the valve seat
Insufficient engine output. Exhaust color ordinary Seizure of inlet/exhaust valve Correct or replace
Insufficient engine output. Exhaust color ordinary Blowout from cylinder head gasket Replace the gasket
Insufficient engine output. Exhaust color ordinary Worn crankpin and journal bearing Measure and replace
Insufficient engine output. Exhaust color ordinary Improper properties of lubricating oil Use proper lubricating oil
Insufficient engine output. Exhaust color ordinary Improper properties of fuel oil Use proper fuel oil
Insufficient engine output. Exhaust color ordinary Clogged fuel filter Clean or replace
Insufficient engine output. Exhaust color ordinary Air entrance in fuel system Perform air bleeding
Insufficient engine output. Exhaust color ordinary Clogged or cracked fuel pipe Clean or replace
Insufficient engine output. Exhaust color ordinary Insufficient fuel supply to fuel injection pump Check the fuel tank cock, fuel tank, fuel pipe and fuel feed pump
Insufficient engine output. Exhaust color ordinary Clogged strainer at fuel feed pump inlet Clean the strainer
Insufficient engine output. (Exhaust color white) Seized or broken piston ring Replace the piston ring
Insufficient engine output. (Exhaust color white) Worn piston ring, piston or cylinder Perform honing and use oversize parts
Insufficient engine output. (Exhaust color white) Improper arrangement of piston rings joint Correct the ring joint positions
Insufficient engine output. (Exhaust color white) Reverse assembly of piston ring Reassemble correctly
Insufficient engine output. (Exhaust color white) Worn inlet/exhaust valve guide Measure and replace
Insufficient engine output. (Exhaust color white) Improper open/close timing of intake/exhaust valves Adjust the valve clearance
Insufficient engine output. (Exhaust color white) Timing of fuel injection pump too late Check and adjust
Insufficient engine output. (Exhaust color white) Improper properties of fuel oil Use proper fuel oil
Insufficient engine output. (Exhaust color white) Water entrance in fuel system Perform draining from the fuel filter
Insufficient engine output. (Exhaust color white) Uneven injection volume of fuel injection pump Check and adjust
Insufficient engine output. (Exhaust color white) Poor spray pattern from fuel injection nozzle Check and adjust
Insufficient engine output. (Exhaust color black) Compression leakage from valve seat Lap the valve seat
Insufficient engine output. (Exhaust color black) Seizure of inlet/exhaust valve Correct or replace
Insufficient engine output. (Exhaust color black) Improper open/close timing of intake/exhaust valves Adjust the valve clearance
Insufficient engine output. (Exhaust color black) Insufficient cooling effect of radiator, Defective thermostat (kept opened) or slipping fan belt Repair or replace thermostat and fan belt
Insufficient engine output. (Exhaust color black) Insufficient coolant level Check leakage from cooling system
Insufficient engine output. (Exhaust color black) Slackened fan belt Adjust the belt tension
Insufficient engine output. (Exhaust color black) Defective thermostat Check or replace
Insufficient engine output. (Exhaust color black) Timing of fuel injection pump too late Check and adjust
Insufficient engine output. (Exhaust color black) Improper properties of fuel oil Use proper fuel oil
Insufficient engine output. (Exhaust color black) Uneven injection volume of fuel injection pump Check and adjust
Insufficient engine output. (Exhaust color black) Poor spray pattern from fuel injection nozzle Check and adjust
Insufficient engine output. (Exhaust color black) Clogged air filter Clean
Insufficient engine output. (Exhaust color black) Engine used at high temperature or at high altitude Study output drop and load matching
Insufficient engine output. (Exhaust color black) Clogged exhaust pipe Clean
Poor exhaust color white (During work) Seized or broken piston ring Replace the piston ring
Poor exhaust color white (During work) Worn piston ring, piston or cylinder Perform honing and use oversize parts
Poor exhaust color white (During work) Reverse assembly of piston ring Reassemble correctly
Poor exhaust color white (During work) Improper open/close timing of intake/exhaust valves Adjust the valve clearance
Poor exhaust color white (During work) Excessive cooling effect of radiator, Repair or replace
7
Defective thermostat (kept closed)
Defective thermostat
Check or replace
Timing of fuel injection pump too early
Check and adjust
Timing of fuel injection pump too late
Check and adjust
Improper properties of fuel oil
Use proper fuel oil
Water entrance in fuel system
Perform draining from the fuel filter
Uneven injection volume of fuel injection pump
Check and adjust
Poor spray pattern from fuel injection nozzle
Check and adjust
Poor exhaust color black (During work)
Compression leakage from valve seat
Lap the valve seat
Seizure of inlet/exhaust valve Correct or replace
Improper open/close timing of intake/exhaust
Adjust the valve clearance
valves Timing of fuel injection pump too
early Check and adjust Timing of fuel injection
pump too late Check and adjust Improper
properties of fuel oil Use proper fuel oil Uneven
injection volume of fuel injection pump Check
and adjust Excessive fuel injection volume Check
and adjust Poor spray pattern from fuel injection
nozzle Check and adjust Clogged air
filter Clean Engine used at high temperature or
at high Study output drop and load matching
altitude Clogged exhaust pipe Clean High knocking
sound during Timing of fuel injection pump too
early Check and adjust compression Abnormal
engine sound Improper clearance of
inlet/exhaust valve Adjust the valve clearance
Compression leakage from valve seat Lap the valve
seat Seizure of inlet/exhaust valve Correct or
replace Seized or broken piston ring Replace the
piston ring Seized crankpin metal or
bearing Repair or replace Worn crankpin and
journal bearing Measure and replace Loosened
connecting rod screw Tighten to specified torque
Foreign matter trapped in combustion
chamber Disassemble and repair Excessive gear
backlash Adjust gear and repair Improper
open/close timing of intake/exhaust Adjust the
valve clearance valves
Improper properties of fuel oil Use proper fuel
oil Water entrance in fuel system Perform
draining from the fuel filter
Uneven combustion sound
Uneven injection volume of fuel injection pump
Check and adjust Poor spray pattern from fuel
injection nozzle Check and adjust Clogged air
filter Clean Clogged exhaust pipe Clean Seized or
broken piston ring Replace the piston ring Seized
crankpin metal or bearing Repair or replace Worn
crankpin and journal bearing Measure and
replace Defective governor Make adjustment Water
entrance in fuel system Perform draining from the
fuel filter Uneven injection volume of fuel
injection pump Check and adjust Poor spray
pattern from fuel injection nozzle Check and
adjust Seizure of inlet/exhaust valve Correct or
replace
Hunting during idling
Hunting during work
8
Large engine vibration Seized crankpin metal or bearing Repair or replace
Large engine vibration Worn crankpin and journal bearing Measure and replace
Large engine vibration Defective governor Make adjustment
Large engine vibration Water entrance in fuel system Perform draining from the fuel filter
Large engine vibration Uneven injection volume of fuel injection pump Check and adjust
Large engine vibration Poor spray pattern from fuel injection nozzle Check and adjust
Large engine vibration Seizure of inlet/exhaust valve Correct or replace
Large engine vibration Seized or broken piston ring Replace the piston ring
Large engine vibration Seized crankpin metal or bearing Repair or replace
Large engine vibration Worn crankpin and journal bearing Measure and replace
Large engine vibration Loosened connecting rod screw Tighten to specified torque
Large engine vibration Defective governor Make adjustment
Large engine vibration Timing of fuel injection pump too early Check and adjust
Large engine vibration Uneven injection volume of fuel injection pump Check and adjust
Large engine vibration Poor spray pattern from fuel injection nozzle Check and adjust
Difficulty in returning to low speed Defective governor Make adjustment
Excessive fuel consumption Compression leakage from valve seat Lap the valve seat
Excessive fuel consumption Excessive cooling effect of radiator, Defective thermostat (kept closed) Repair or replace
Excessive fuel consumption Timing of fuel injection pump too late Check and adjust
Excessive fuel consumption Excessive fuel injection volume Check and adjust
Excessive fuel consumption Poor spray pattern from fuel injection nozzle Check and adjust
Excessive fuel consumption Engine used at high temperature or at high altitude Study output drop and load matching
Excessive lubricating oil consumption Seized or broken piston ring Replace the piston ring
Excessive lubricating oil consumption Worn piston ring, piston or cylinder Perform honing and use oversize parts
Excessive lubricating oil consumption Improper arrangement of piston rings joint Correct the ring joint positions
Excessive lubricating oil consumption Reverse assembly of piston ring Reassemble correctly
Excessive lubricating oil consumption Foreign matter trapped in combustion chamber Disassemble and repair
Excessive lubricating oil consumption Worn inlet/exhaust valve guide Measure and replace
Excessive lubricating oil consumption Improper properties of lubricating oil Use proper lubricating oil
Excessive lubricating oil consumption Leakage from lubricating oil piping system Repair
Excessive lubricating oil consumption Excessive fuel injection volume Check and adjust
Lubricating oil diluted by fuel Seizure of inlet/exhaust valve Correct or replace
Lubricating oil diluted by fuel Seized or broken piston ring Replace the piston ring
Lubricating oil diluted by fuel Worn piston ring, piston or cylinder Perform honing and use oversize parts
Lubricating oil mixed with water Blowout from cylinder head gasket Replace the gasket
Lubricating oil mixed with water Cracked water jacket Repair or replace
Low lubricating oil pressure Worn crankpin and journal bearing Measure and replace
Low lubricating oil pressure Loosened connecting rod screw Tighten to specified torque
Low lubricating oil pressure Cracked water jacket Repair or replace
Low lubricating oil pressure Improper properties of lubricating oil Use proper lubricating oil
Low lubricating oil pressure Leakage from lubricating oil piping system Repair
Low lubricating oil pressure Insufficient delivery capacity of trochoid pump Check and repair
Low lubricating oil pressure Clogged lubricating oil filter Clean or replace
Low lubricating oil pressure Defective pressure regulating valve Check, adjust or replace
Low lubricating oil pressure Insufficient lubricating oil level Add proper lubricating oil
Excessive blow-by gas Compression leakage from valve seat Lap the valve seat
9
Overheating of coolant Seizure of inlet/exhaust valve Correct or replace
Overheating of coolant Seized or broken piston ring Replace the piston ring
Overheating of coolant Worn piston ring, piston or cylinder Perform honing and use oversize parts
Overheating of coolant Seized crankpin metal or bearing Repair or replace
Overheating of coolant Improper arrangement of piston rings joint Correct the ring joint positions
Overheating of coolant Reverse assembly of piston ring Reassemble correctly
Overheating of coolant Foreign matter trapped in combustion chamber Disassemble and repair
Overheating of coolant Worn inlet/exhaust valve guide Measure and replace
Overheating of coolant Improper properties of lubricating oil Use proper lubricating oil
Overheating of coolant Clogged lubricating oil filter Clean or replace
Overheating of coolant Excessive fuel injection volume Check and adjust
Overheating of coolant Blowout from cylinder head gasket Replace the gasket
Overheating of coolant Seized or broken piston ring Replace the piston ring
Overheating of coolant Insufficient cooling effect of radiator, Defective thermostat (kept opened) or slipping fan belt Repair or replace thermostat and fan belt
Overheating of coolant Insufficient coolant level Check leakage from cooling system
Overheating of coolant Cracked water jacket Repair or replace
Overheating of coolant Slackened fan belt Adjust the belt tension
Overheating of coolant Defective thermostat Check or replace
Overheating of coolant Excessive fuel injection volume Check and adjust
Overheating of coolant Engine used at high temperature or at high altitude Study output drop and load matching
Low coolant temperature Excessive cooling effect of radiator, Defective thermostat (kept closed) Repair or replace
Low coolant temperature Defective thermostat Check or replace
Air inlet pressure drop Improper clearance of inlet/exhaust valve Adjust the valve clearance
Air inlet pressure drop Compression leakage from valve seat Lap the valve seat
Air inlet pressure drop Seizure of inlet/exhaust valve Correct or replace
Air inlet pressure drop Clogged air filter Clean
Air inlet pressure drop Engine used at high temperature or at high altitude Study output drop and load matching
Air inlet pressure rise Excessive fuel injection volume Check and adjust
Exhaust temperature rise Improper clearance of inlet/exhaust valve Adjust the valve clearance
Exhaust temperature rise Compression leakage from valve seat Lap the valve seat
Exhaust temperature rise Seized or broken piston ring Replace the piston ring
Exhaust temperature rise Insufficient cooling effect of radiator, Defective thermostat (kept opened) or slipping fan belt Repair or replace thermostat and fan belt
Exhaust temperature rise Insufficient coolant level Check leakage from cooling system
Exhaust temperature rise Slackened fan belt Adjust the belt tension
Exhaust temperature rise Timing of fuel injection pump too late Check and adjust
Exhaust temperature rise Uneven injection volume of fuel injection pump Check and adjust
Exhaust temperature rise Excessive fuel injection volume Check and adjust
Exhaust temperature rise Clogged exhaust pipe Clean
10
Service Information
Document Title Engine trouble shooting Function Group 210 Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB
Engine trouble shooting Engine faults must be
detected and rectified as quickly as possible in
order to avoid more expensive repairs. The
following table summarizes the most important
faults and their rectification.
Problem/fault Possible cause of fault Fault remedy
Engine does not start Starter switch defective Tighten connections. Replace the switch.
Engine does not start Starter power too low If the starter is OK, check condition of battery and electric connections.
Engine does not start Air in fuel system Bleed the system.
Engine does not start Air filter dirty Replace the air filter.
Engine does not start Wrong oil viscosity Check viscosity and fill in correct oil.
Engine does not start Engine too cold Check the function of the preheater plug.
Engine does not start Injection valves defective Check and adjust the injection valves Replace defective valves.
Engine does not start Incorrect injection timing Adjust the injection timing. Check the valve clearance.
Engine does not start Compression pressure too low Check condition of cylinder head gasket, valves and piston rings.
Engine shuts down automatically Fuel tank empty Fill in fuel.
Engine shuts down automatically Air in fuel system Bleed the fuel system.
Engine shuts down automatically Fuel filter dirty Clean or replace the fuel filter.
Engine shuts down automatically Fuel pump defective Check connection of fuel pump or replace fuel pump.
Engine shuts down automatically Exhaust system clogged Clear or replace the exhaust system.
Erratic running of engine Fuel pump defective Replace the pump.
Erratic running of engine Fuel filter dirty Clean or replace the fuel filter. Bleed the fuel system.
Erratic running of engine Air filter dirty Clean the air filter. Check the intake air.
Erratic running of engine Injection valves defective Check and adjust the injection valves Replace defective valves.
Engine overheating Cooling system elements defective Check elements (water pump, radiator, thermostat, cylinder head gasket, coolant hoses).
Engine overheating Fan not running Check presence, tension and cleanliness of V-belt.
Engine overheating Lubrication system elements defective Check elements (oil filter, oil pump, suction filter) and replace defective parts.
Engine overheating Incorrect injection timing Adjust the injection timing. Check the valve clearance.
Engine overheating Oil level too low Fill in oil. Check whether the oil in the engine meets the operating conditions.
Engine overheating Governor incorrectly adjusted Adjust the governor.
Engine overheating Coolant level not correct Correct the coolant level. Check whether the coolant meets the operating conditions.
Engine develops black smoke Air cleaner soiled Clean or replace the air filter.
Engine develops black smoke Poor fuel quality Check quality of fuel and suitability for climatic
11
conditions.
Irregular idle speed Valve clearance and injection timing not correct Adjust valve clearance and injection timing.
Irregular idle speed Compression pressure not O.K. Check condition of cylinder head gasket, valves and piston rings.
Irregular idle speed Injection pressure not O.K. Check and adjust the injection valves
Irregular idle speed Injection pump defective Check injection pump, replace if necessary.
Irregular idle speed Engine control cable incorrectly adjusted Adjust the control cable.
Irregular idle speed Poor engine oil quality Fill in oil as required for the operating conditions.
Irregular idle speed Poor fuel quality Check quality of fuel and suitability for climatic conditions.
Irregular idle speed Valve clearance and injection timing not correct Adjust valve clearance and injection timing.
Irregular idle speed Opening pressure of injection valves not correct Check opening pressure and injection valves.
Irregular idle speed Compression pressure not O.K. Check condition of cylinder head gasket, valves and piston rings.
Irregular idle speed Injection pump defective Check injection pump, replace if necessary.
Unusual engine noise Poor fuel quality Check quality of fuel and suitability for climatic conditions.
Unusual engine noise Air cleaner soiled Clean or replace the air filter.
Unusual engine noise Incorrect injection timing Adjust the injection timing.
Unusual engine noise Engine shut-down solenoid not O.K. Check the engine shut-down solenoid.
Unusual engine noise Injection pressure not O.K. Adjust the injection valves.
Unusual engine noise Compression pressure not O.K. Check condition of cylinder head gasket, valves and piston rings.
Unusual engine noise Injection pump defective Replace the injection pump.
Oil pressure too low Oil level and oil quality not correct Check oil level and oil quality and fill in specified oil.
Oil pressure too low Oil pressure switch defective Check and replace the oil pressure switch.
Battery charge condition too low Fan V-belt too loose Tighten the V-belt or replace, if defective.
Battery charge condition too low Generator defective Check and replace the generator.
Battery charge condition too low Battery defective Replace the battery.
Battery charge condition too low Wiring not O.K. Check correct connection of cables.
Battery charge condition too low Regulator defective Check regulator, replace if necessary.
Engine cannot be shut down Starter switch defective Tighten connections. Replace the switch.
Engine cannot be shut down Engine shut-down solenoid not O.K. Check engine shut-down solenoid, replace if necessary.
12
Service Information
Document Title Compression pressure inspection Function Group Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB

• Compression pressure inspection
• Compression pressure drop is one of major causes
  of increasing blow-by gas (lubricating oil
  contamination or increased lubricating oil
  consumption as a resultant phenomenon) or
  starting failure. The compression pressure is
  affected by the following factors
• Degree of clearance between piston and cylinder
• Degree of clearance at intake/exhaust valve seat
• Gas leak from nozzle gasket or cylinder head
  gasket
• In other words, the pressure drops due to
  increased parts wear and reduced durability
  resulting from long use of the engine. A pressure
  drop may also be caused by scratched cylinder or
  piston by dust entrance from the dirty air
  cleaner element or worn or broken piston ring.
  Measure the compression pressure to diagnose
  presence of any abnormality in the engine.
• Compression pressure measurement method

• Figure 1
• Measurement, compression pressure
• Compression gauge
• After warming up the engine, remove the fuel
  injection nozzle from the cylinder to be
  measured.
• Crank the engine before installing the
  compression gauge adapter.
• Perform cranking with the stop handle at the stop
  position (no injection state).
• Install the compression gauge and compression
  gauge adapter at the cylinder to be measured.
• NOTE!
• Do not forget to install a gasket at the tip end
  of the adapter.
• Crank the engine by the starting motor until the
  compression gage reading is stabilized.
• Standard compression pressure
• Standard 30 kgf/cm2 (427 psi)
• Limit 26 kgf/cm2 (370 psi)

13
Service Information
Document Title Valves, adjusting Function Group Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB
Valves, adjusting Adjusting the valves
Figure 1 Op nbr 21412

• NOTE!
• Clean the area around the rocker cover before
  starting adjustment work.
• Pull off the hose for crankcase ventilation.
• Remove the cylinder head cover.
• Crank the engine until the valves are
  overlapping.
• NOTE!
• Overlapping of valves means Exhaust valve not
  yet closed, intake valve starts to open. In this
  situation the push rods cannot be turned.

14

• Figure 2
• Adjust the valve clearance on the respective
  cylinder using a feeler gauge.
• Tighten the counter nut. Check the adjustment
  again with the feeler gauge.
• Attach the gasket to the rocker cover.
• Install the rocker cover. Tighten the screws with
  a torque of 11.3 Nm.
• Push on the crankcase ventilation hose.
• Intake 0.25 mm (0.01 in)
• Exhaust 0.25 mm (0.01 in)
• Valve clearance values

15
Service Information
Document Title Lubricating system, description Function Group 220 Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB

• Lubricating system, description
• The oil pump delivers pressurized engine oil to
  lubricate the contact faces of moving parts, such
  as crankshaft, camshaft, intake/exhaust valves,
  rockers and engine timing gears.
• Schematic flow of lubrication oil

• Figure 1
• Drain plug
• Oil screen
• Dipstick
• Oil pump
• Check valve
• Oil filter
• Oil pressure switch

16

1. Rocker shaft
2. Rocker arm
3. Oil filler cap
4. Camshaft
5. Oil pan

17
Service Information
Document Title Removing the oil filter Function Group 222 Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB
Removing the oil filter Op nbr 22202 Filter
wrench

• Figure 1 Remove oil filter
• Oil filter
• Pressure switch
• Oil pump
• Place a bowl under the oil filter to catch
  running out oil.
• Unscrew the oil filter from the engine block
  using the filter wrench.

18
Service Information
Document Title Installing the oil filter Function Group 222 Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB
Installing the oil filter Op nbr 22202

• Figure 1
• Slightly oil the seal on the new oil filter with
  engine oil.
• Screw on the new filter cartridge by hand. When
  the seal touches the contact face turn further
  for another 1/2 of a turn.
• Fill in 0.5 litres of oil.
• Start the engine and check for leaks in the
  vicinity of the filter.
• Shut the engine down. Check the oil level, fill
  up oil if necessary.

19
Service Information
Document Title Removing the oil pressure switch Function Group 222 Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB
Removing the oil pressure switch Oil pressure
switch Op nbr 22205 Socket wrench for oil
pressure switch 1. Unscrew oil pressure switch
using a socket wrench for oil pressure switch.

• Figure 1
• remove oil pressure switch
• Oil filter
• Pressure switch
• Oil pump
• Oil pressure test Op nbr Ohmmeter
• 1. Check the current flow between terminal and
  housing with an ohmmeter, as shown in the
  illustration. If this current flow is not assured
  replace the pressure switch.

20
Figure 2 Oil pressure test 2. Insert a small
diameter rod into the oil bore of the pressure
switch and push slightly in to check, whether
current flow is applied (see illustration). If
this is the case, replace the pressure switch.
Figure 3 Oil pressure test 3. Blow with
compressed air of 0.5 bar into the oil bore
(arrow) to check whether current flow is present.
If this is the case, replace the pressure switch.
Check the switch also for air leaks. An air leak
may be caused by a broken orifice. In this case
the oil pressure switch must also be replaced.
21
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Service Information
Document Title Installing the oil pressure switch Function Group 222 Information Type Service Information Date 2014/4/16
Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB Profile CEX, EC45 GB
Installing the oil pressure switch Op nbr
22205 Socket wrench for oil pressure switch 1.
Cover the thread on the oil pressure switch with
sealing compound. Turn in the oil pressure switch
and tighten with the socket wrench to 10 2 Nm.
23
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com