Volvo EC15C Compact Excavator Service Repair Manual Instant Download

1
Service Information
Document Title Engine, description Function Group 200 Information Type Service Information Date 2014/3/20
Profile CEX, EC15C GB Profile CEX, EC15C GB Profile CEX, EC15C GB Profile CEX, EC15C GB
Engine, description The engine is a vertical,
water-cooled, in-line, three-cylinder,
four-stroke diesel with eddy chamber injection.
It is a low emission engine to American EPA
Guideline Tier IV. 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. Ignition
sequence 1-3-2 (cylinder no. 1 on flywheel side).
Figure 1 Engine and Components
1 Alternator 7 Valve cover / cylinder head cover
2 Fan rotor 8 Starter motor
3 Lifting eye 9 Exhaust manifold
4 Engine identification plate 10 Muffler
5 Lifting eye 11 Radiator
6 Flywheel
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Figure 2 Engine and Components 1 Main fuel filter
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Injection pump
3
2 Air intake hose 10 Dipstick gauge
3 Throttle cable 11 Engine oil filter
4 Air cleaner assembly 12 Gear oil outlet
5 Fuel delivery valves 13 Oil pan
6 Coolant expansion tank 14 Injection pump shutdown solenoid
Fuel water separator Oil filler pipe 15 Electric fuel feed pump
4
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Service Information
Document Title Troubleshooting chart Function Group 200 Information Type Service Information Date 2014/3/20
Profile CEX, EC15C GB Profile CEX, EC15C GB Profile CEX, EC15C GB Profile CEX, EC15C 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
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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
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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, removing Function Group 210 Information Type Service Information Date 2014/3/20
Profile CEX, EC15C GB Profile CEX, EC15C GB Profile CEX, EC15C GB Profile CEX, EC15C GB
Engine, removing Op nbr 210-070 Lifting device
Seat belt, 2m Seat belt, 0.5m 2 Shackle
WARNING

• The work involves handling heavy components -
  failure to stay alert may result in severe
  crushing injuries.
• Place the machine in the service position 1, see
  191 Service position 1
• Set the battery disconnect switch to the Off
  position.

Figure 1 Battery disconnection switch 3. Turn
fuel cock to position C.
Figure 2 Main fuel filter
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4. Turn fuel cock to position C.
Figure 3 Water separator 5. Remove upper
left-hand side panel.

• Figure 4
• Left-hand side panels, remove
• Attaching screws
• Attaching screws
• 6. Remove lower left-hand side panel.

WARNING
If the battery's plus terminal is short-circuited
to the minus terminal or to the chassis, there is
a risk of explosion or fire. Therefore, always
protect the battery terminals. 7. Disconnect
ground terminal (1) at battery.
12

• Figure 5
• Battery, disconnect terminals
• Ground terminal (- pole)
• Positive terminal ( pole)
• Remove pole cover at the positive terminal (2) of
  the battery and disconnect terminal.
• Remove battery holder.

• Figure 6
• Battery holder, remove
• Carefully lift battery out of superstructure.
• Remove ground cable (1).

Figure 7 Remove battery bracket
13

• Ground cable
• Attaching screws
• Hose clamp
• Remove hose clamp (3), fixing bolts (2) and
  bracket.
• Remove hose clamp at underside of battery
  disconnection switch.

Figure 8 Hose clamp, remove 14. Remove fixing
bolts (1) for upper rear panel and remove upper
rear panel including engine hood.
Figure 9 Remove rear panel 1. Attaching
screws 15. Remove closing panel (1).
Figure 10 Closing panel, remove 1. Closing panel
14
16. Remove cover plate (1)

• Figure 11
• Cover plate, remove
• Cover plate
• Drain plug, fuel tank
• 17. Remove drain plug (2) and drain fuel tank
  into a suitable catchment container.

NOTICE

• Do the work in an environmentally safe manner.
• Drain hydraulic tank, see 173 Hydraulic system,
  changing oil.
• Remove nuts (1) from rear cab fixing bolts.

• Figure 12
• Cab mounting
• Nuts, cab fixing bolts
• Connecting bolt cab - cab platform

WARNING
The parts are heavy. Take appropriate safety
precautions. 20. Using suitable lifting gear,
raise cab at rear eyelets by approx. 3 cm (1.18
in) and secure.
15

• Figure 13
• Cab with lifting tool NOTE!
• Weight approx. 260 kg (573.2 lbs)
• Remove radiator, see 261 Radiator, removal.
• Remove alternator, see 321 Alternator, removing.
• Detach air intake hose (1) at engine.

Figure 14 Engine with ancillaries 1. Air intake
hose 24. Remove hose clamp (2) from throttle
cable.
16

• Figure 15
• Hose clamp, remove
• Mounting screw
• Hose clamp, throttle cable
• 25. Detach hose for hydraulic tank ventilation at
  tank.

Figure 16 Hose line, remove 26. Remove hose
clamp (2) and connecting hose (3) with grommet
(4).

• Figure 17
• Hydraulic tank ventilation, remove
• Hose clamp
• Screw
• Jumper hose
• Grommet
• Withdraw connecting cable at air filter casing
  sensor.
• Remove air filter casing with bracket (1).

17
Figure 18 Air filter 1. Carrier 29. Detach
cable at fixing and at lever.
Figure 19 Cable, remove 30. Remove hose (4) at
inlet to hydraulic oil filter.

• Figure 20 Return filter
• Mounting screw
• Hydraulic oil filter inc. filter holder
• Hose clamp
• Hose assembly

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1. Remove fixing bolts (1) and remove hydraulic oil
   filter.
2. Remove fixing bolt (1) for main fuel filter.

• Figure 21
• Main fuel filter, remove
• Main fuel filter
• Leak-oil filter
• Remove fixing bolts and remove leakage oil filter
  (2).
• Remove hydraulic hose at leakage oil filter.

NOTICE
When a hose has been disconnected, plug both the
hose and the connection immediately. The hoses
should be marked for correct connection. 35.
Guide leakage oil lines through the opening in
the hydraulic oil tank bracket.

• Figure 22
• Opening, hydraulic oil tank bracket
• Hose clamp, return line
• Opening, hydraulic oil tank bracket
• 36. Release hose clamp (2) and remove suction
  hose (3) from hydraulic pump.

NOTICE
Collect draining oil.
19

• Figure 23
• Hydraulic pump, remove
• Attaching screws
• Hose clamp
• Suction line
• Remove hydraulic pump
• Release pipe bracket (1) and connecting clamp (2)
  and remove exhaust tailpipe (3).

• Figure 24
• Exhaust tailpipe, remove
• Pipe bracket
• Clamp
• Exhaust tailpipe
• 39. Release fixing bolts on bracket (1).

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Figure 25 Bracket, remove 1. Bracket 40. Remove
upper fixing bolt (2) for left transport bracket
(1) on engine, release lower fixing bolt (3) and
swivel the bracket forwards.

• Figure 26
• Transport bracket, swivel
• Transport bracket
• Upper fixing bolt
• Lower fixing bolt
• Remove hydraulic oil tank bracket together with
  hydraulic oil tank.
• Swivel the transport bracket into the original
  position and install bolts (2, 3).
• Remove bolts (1) for engine mount

Figure 27 Engine mount 1. Screw 44. Remove hose
clamp (1) on engine mount.
21
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Figure 28 Hose clamp, remove 1. Clamp, coolant
hoses 45. Remove engine mount rear/right
Figure 29 Engine mount, remove 46. Remove
heating hoses on engine.
Figure 30 Remove coolant hoses
NOTICE

• Do the work in an environmentally safe manner.
• Detach hose lines from fuel tank and withdraw.
• Remove connecting cable from fill level sender
  (SE 2303) and fuel pump (MO 2303).

23
https//www.ebooklibonline.com Hello dear
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