SD 110 Step 1 Training Engine

Road machine

Eng ngin ine e Ide dent ntif ific ica ati tion on - 010102

Engine identification plate Also on engine cover

Volvo Construction Equipment Global Global CST- Training Training 168 2012-12-20

D5 engine training Road machine

Eng ngin ine e Ide dent ntif ific ica ati tion on pl pla ate - 010103

Engine Type plate: • • Engine spec No • Engin ngine e seri serial al numb numbe er (8 (8 dig digits) its) • • Inje Inject ctio ion n timi timing ng and and typ type e of cam cam shaf shaftt • Injection pump code • Piston class Volvo Construction Equipment Global Global CST- Training Training 169 2012-12-20


Engine view from right

1. 2. . 4. 5. 6. 7. 8. 9. 10.

Crank case breather Lubricating oil filling Lubricating oil stick Lube oil cooler Lube oil re lacement filter Lubricating oil drain plug Exchangeable fuel filter N/A V-belts Generator

Volvo Construction Equipment Global CST- Training 170 2012-12-20

Paver D5 engine

Engine view from left

. 2. 3. . 5. 6.

om us on a r n e Coolant out let Coolant inlet Exhaust outlet Starter


Paver D5 engine

Engine Ignition order - 010104 rec on o ro a on: oun er c oc w se As seen from the fly wheel

En ine I nition order : 1 – 3 – 4 - 2 Volvo Construction Equipment Global CST- Training 172 2012-12-20


Cylinder head valves - 010202

Valves:


•

The valve springs of D5D / D7D have no s ecial direction of installation and are replaceable

•

D5D / D7D valve guide are seal with ‘O” rings


Crank mechanism - 010301

•



Crank mechanism

Crank mechanism - 010302



Crank mechanism - 010303 Connecting rod:


•

The connecting rod is made of forged steel and the bearing cap (1) is guided us ng wo gu e p n

•

Locating lug (2) are provided in

•

Connecting rod and bearing are marked 4

•

Marking (5) on the piston is to face the fly wheel


Piston - 010304

Max injection pressure 1500 bar

•

The pistons are made of special aluminum alloy. The piston is slightly off – Centre (A) in relation to the piston guide pin

•

The piston must be installed with fly wheel symbol on the piston top facing the fly wheel There are three piston rings. The top ring has a ring carrier made of cast iron

• •

o e nozz e Volvo Construction Equipment Global CST- Training 177 2012-12-20


Selecting gasket - 010305

1, 2 & 3

Piston crown clearance: • To obtain the power, fuel consumption and exhaust gas emission specified for engine the piston height above the block face has to me measured and correct thickness for the cylinder head gasket has to be determined • The piston height is measured using a dial gauge (1) fixture (2) and spacer (3) • The procedure is described in service manual Volvo Construction Equipment Global CST- Training 178 2012-12-20


Engine Timing gear - 010401

1. 2.

Governor ear Transfer gear

3.

Cam shaft gear

4. Crank shaft gear



Lubricating oil diagram 1. Lubricating oil sump . 3. Pressure limiting valve TCD2013 4. Lube oil cooler 6. 7. 8. 9. 10. 11. 12. 13. 14. .

Bypass valve Bypass valve Pressure control valve Lubricating oil filter Main lube oil channel Piston cooling nozzle Rocker arm Internally switched exhaust gas return Turbo charger


Paver D5 engine

Lubrication system - 020103 Lubrication system D5D 7.

Lube oil filter with integrated by pass valve 2.5 bar

8.

By pass valve oil cooler located in oil cooler housing 4.0 bar

9.

Oil pressure valve located in oil cooler housing 10 bar .



Oil pump - 020202 . 2. Pressure chamber to crank housing


3.

Inner Rotor

4.

Outer Rotor

5.

Driven from crank shaft

6.

Safety valve


Piston Cooling Nozzle - 020301

•

The piston cooling nozzle made of plastic are fitted in the main bearing pedestals



Fuel system - 030101

• • •

Change unit injector pump for cylinder number 3 on D5D with injection timer Read off EP code for cylinder No 3 on the engine identification plate under column EP (1) Read sequence Line 1 = cylinder 1 Line 2 = cylinder 2 and so on……




. 2.

Delivery pipe

3.

Engine block

4.

Shim

5.

Roller tappet

.

am s a

7.

Fuel rack

8.

Fuel duct

. Volvo Construction Equipment Global CST- Training 185 2012-12-20


Mechanical single injection pump system


Paver D5 engine




Fuel sch s che ema mati tic c

1. 2. . 4. 5. 6. 7. 8. 9. 10. 10.

Fuel tank Fuel pre-filter Exchangeable fu fuel filter Fuel su supply liline to to the FCU Contr ontrol ol block lock fuel fuel contr ontrol ol unit unit High pressure pump Rail (N (Not applicable) Injector Fuel Fuel ret retur urn n to fue fuell tank tank


Paver D5 engine

Fuel sch s che ema mati tic c


Paver D5 engine

Fue uell bl bloc ock k di dia agr gra am 1.

Diesel Tank

2.

Water separator

Fuel filter

6.

U. I High pressure pump

Volvo Construction Equipment

7.

9.

Excess leak return

Global Global CST- Training Training 190 2012-12-20

Feed pump

5. Fuel Fuel supp supply ly to fuel fuel cont contro roll uni unitt / Cont Contro roll blo block ck

4.

8.

3.


Injector

Diesel Tank

Coolant diagram (example) 1. . 3. 4. 5. 6. 7. 8. 9. 10. 11. . 13. 14.

Cooler Coolant pump Coolant partial flow to the lubricating oil cooler Lube oil cooler Coolant supply for engine cooling Cylinder pipe head cooling Connection possibility for cab heating Heat exchanger Return line Coolant return to thermostat oo ant out et Compensation line Venting pipe


Paver D5 engine

Schematic outlet controlled cooling system

Expansion Tank

Thermostat Water inlet

Engine oil cooler


Radiator Paver D5 engine

Coolant block diagram (example) 1.

Oil cooler inlet

2.

Water pump

3.

Engine cooler

4. Engine block / Head / Engine cylinder Head

5.

7.

Thermostat cooler out let

6.

By pass thru special lines

Oil cooler outlet



Working description The coolant pump (“water pump”) draws in the coolant via hose lines directly , thereafter enters the engine, flows along the cylinder, upwards into the cylinder head and to the thermostat at the coolant outlet. From there, the coolant is directed via s ecial lines to the cooler inlet. When the engine is still cold the coolant is short circuited through the engine until thermostat response temperature has been reached (starting opening) according to the volume of hot coolant flowing off, the water pump draws in cold coolant from the cooler


Paver D5 engine

Coolant thermostat Checking the thermostat when removed 1.

Measure dimension “a” on thermostat “ ” . “b” end of lift at approx. 95 +5 (T2)

Lift movement with indicated temp T2, Min. 8 mm



Fuel system cylinder No positions 030113



Internal exhaust gas recirculation . Inlet valve opens briefly during the outlet cycle suction system. This partial volume is sucked back in the next suction cycle


Paver D5 engine

Charging

Compressor Turbine

From filter

Turbo charger with charge air cooling Advanta es: ¾

Volumetric efficiency of engine increases ¾ Increase Horse Power ¾ Emission improved ¾ Compact in size

To CAC


Paver D5 engine

Charging piping connection Air filter

Compressor

CAC

Engine Inlet manifold

Engine exhaust Volvo Construction Equipment Global CST- Training 199 2012-12-20

Paver D5 engine

Fuel shut off solenoid

Resistance 4.9 ohms

1. Fuel shut off solenoid operates when ere s gn on supp y – pos on 2. Fuel shut off solenoid + excess fuel solenoid in 3rd start position



Excess fuel solenoid

1.

Excess fuel solenoid

2.

Sensor Not applicable

1. Fuel shut off solenoid operates when ere s gn on supp y – pos on 2. Fuel shut off solenoid + excess fuel solenoid in 3rd start position


Electrical Harness Installation –SD110

Engine oil pressure switch



Engine water temperature switch



Engine glow plug

¾ ¾


Time - 8 seconds Temperature 950 0 c


Diesel tank fuel sender

¾


Fuel sender


Mechanical governor

Governor adjustment screws

J

G


E

Full load

“G”

Torque maximum

“E”

NA based fuel charge

“J”

Excess fuel start solenoid

Paver D5 engine

Engine V- belt

V – belt AVX 11 (Width 11 mm) Belt tensioning – Automatic tensioning Spring – loaded clamping roller



Removing the Starter motor



Installing the Starter motor



EK code - 030114



A measurement - 030115



Dimensions, definitions - 030116



Theoretical shim thickness - 030118



Actual shim thickness - 030119



Reinstallation - 030120



Special tools - 030121



Unit pump installation - 030122



Unit pump installation - 030123



Assembly injection pump



Unit injection pump system



Explanation Lo & EP- code for D5D engines



EP-Code on identification plate



Determination compensation shim



From value T to S



F I P installation, step 1



F I P installation, step 2



Example – Lubricating oil consumption (at least 100 operating hours) engine in high load operation Op. h

Fuel Lts

Lube oil

Date

Driver

9

423

2

15.2 12

Paul

12

551

2

16.2.12 . .

11

600

2

18.2.12

13

620

2

19.2.12

Shashi

. . 10

450

2

21.2.12

11

597

2

22.2.12

12

580

2

23.2.12

13

620

2

24.2.12


Ballal

Ramalu


Example

SD 110 Step 1 Training Engine

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