Sd 110 Step 1 Training Engine

D5 Engine Training Road machine

Engine g Identification - 010102

Engine identification plate Also on engine cover Engine serial number Volvo Construction Equipment Global CST- Training 168 2012-12-20

D5 engine training Road machine

Engine g Identification plate p - 010103

Engine Type plate: • Engine model • Engine spec No • Engine serial number (8 digits) • Rated engine speed • Injection timing and type of cam shaft • Injection pump code • Piston class Volvo Construction Equipment Global CST- Training 169 2012-12-20

D5 engine training Road machine

Engine g view from right g

1. 2. 3 3. 4. 5. 6. 7. 8. 9. 10.

Crank case breather Lubricating oil filling Injection pump Lubricating oil stick Lube oil cooler Lube oil replacement p 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 g view from left

1. 1 2. 3. 4 4. 5. 6.

Combustion C b ti air i iinlet l t Coolant out let Coolant inlet Connection charge air cooler Exhaust outlet Starter

Volvo Construction Equipment Global CST- Training 171 2012-12-20

Paver D5 engine

Engine g Ignition g order - 010104 Direction Di ti off rotation: t ti C Counter t clockwise l k i As seen from the fly wheel

Engine g Ignition g order : 1 – 3 – 4 - 2 Volvo Construction Equipment Global CST- Training 172 2012-12-20

D5 engine training Road machine

Cylinder y head valves - 010202

Valves:

Volvo Construction Equipment Global CST- Training 173 2012-12-20

•

There are some difference in valve guide

•

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

•

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

D5 engine training Road machine

Crank mechanism - 010301

•

Volvo Construction Equipment Global CST- Training 174 2012-12-20

D5 engine training Road machine

Crank mechanism

Crank mechanism - 010302

D5D & D7D: Wet liner replaceable

Volvo Construction Equipment Global CST- Training 175 2012-12-20

D5 engine training Road machine

Crank mechanism - 010303 Connecting rod:

Volvo Construction Equipment Global CST- Training 176 2012-12-20

•

The connecting rod is made of forged steel and the bearing cap (1) is guided using two guide pin (3)

•

Locating lug (2) are provided in bearing shells

•

Connecting rod and bearing are marked a ed ((4))

•

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

D5 engine training Road machine

Piston - 010304

Max injection pressure 1500 bar

•

The p pistons are made of special p aluminum alloy. y The p piston is slightly g y 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

•

6h hole l nozzle l Volvo Construction Equipment Global CST- Training 177 2012-12-20

D5 engine training Road machine

Selecting g gasket g - 010305

Gasket holes 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

D5 engine training Road machine

Engine g Timing g gear g - 010401

1. Governor gear g 2. Transfer gear 3.

Cam shaft gear

4. Crank shaft gear

Volvo Construction Equipment Global CST- Training 179 2012-12-20

D5 engine training Road machine

Lubricating g oil diagram g 1. 2 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15 15.

Lubricating oil sump Lubricating oil pump Pressure limiting valve TCD2013 Lube oil cooler Check valve TCD 2012 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 Air compressor

Volvo Construction Equipment Global CST- Training 180 2012-12-20

Paver D5 engine

Lubrication system y - 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 9.

Oil pressure valve l llocated d iin oilil cooler l housing 10 bar

10 Lube oil pump 90 l/min at 2500 rpm 10.

Volvo Construction Equipment Global CST- Training 181 2012-12-20

D5 engine training Road machine

Oil p pump p - 020202 1 Suction 1. 2. Pressure chamber to crank housing 3. Inner Rotor

Volvo Construction Equipment Global CST- Training 182 2012-12-20

4.

Outer Rotor

5.

Driven from crank shaft

6.

Safety valve

D5 engine training Road machine

Piston Cooling g Nozzle - 020301

•

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

Volvo Construction Equipment Global CST- Training 183 2012-12-20

D5 engine training Road machine

Fuel system y - 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 Li 2 = cylinder Line li d 2 and d so on……

Volvo Construction Equipment Global CST- Training 184 2012-12-20

D5 engine training Road machine

Fuel system y - 030104

1 Injection pump 1. 2. Delivery pipe 3. Engine block 4. Shim 5. Roller tappet 6 Cam 6. C shaft h ft 7. Fuel rack 8. Fuel duct 9 Injector 9.

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

D5 engine training Road machine

Mechanical single g injection j pump p p system y

Volvo Construction Equipment Global CST- Training 186 2012-12-20

Paver D5 engine

Fuel system y - 030105

Volvo Construction Equipment Global CST- Training 187 2012-12-20

D5 engine training Road machine

Fuel schematic

1. 2. 3 3. 4. 5. 6. 7. 8. 9. 10.

Fuel tank Fuel pre-filter Fuel pump Exchangeable fuel filter Fuel supply line to the FCU Control block fuel control unit High pressure pump Rail (Not applicable) Injector Fuel return to fuel tank

Volvo Construction Equipment Global CST- Training 188 2012-12-20

Paver D5 engine

Fuel schematic

Volvo Construction Equipment Global CST- Training 189 2012-12-20

Paver D5 engine

Fuel block diagram g 1. Diesel Tank

4. Fuel filter

2. Water separator

5. Fuel supply to fuel control unit / Control block

6. U. I High pressure pump

Global CST- Training 190 2012-12-20

7. Injector

9. Diesel Tank

8. Excess 8 cess leak ea return eu Volvo Construction Equipment

3. Feed pump

D5 engine training Road machine

Coolant diagram g (example) ( p ) 1. 2 2. 3. 4. 5. 5 6. 7. 8. 9. 10. 11. 12 12. 13. 14.

Cooler Cooler inlet 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 C l t outt let Coolant l t Compensation line Venting pipe

Volvo Construction Equipment Global CST- Training 191 2012-12-20

Paver D5 engine

Schematic outlet controlled cooling g system y

Expansion Tank Water out let Thermostat Water inlet

Water Pump Engine oil cooler Volvo Construction Equipment Global CST- Training 192 2012-12-20

Radiator Paver D5 engine

Coolant block diagram g (example) ( p ) 1. Oil cooler inlet

2. Water pump

3. Engine cooler

4. Engine block / Head / Engine cylinder Head

5. Thermostat cooler out let

6. By pass thru special lines

7. Oil cooler outlet Volvo Construction Equipment Global CST- Training 193 2012-12-20

D5 engine training Road machine

Working g description p The coolant pump (“water pump”) draws in the coolant via hose lines directly from the cooler and delivers it first via the engine-integrated engine integrated lube oil cooler cooler, 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 special p 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

Volvo Construction Equipment Global CST- Training 194 2012-12-20

Paver D5 engine

Coolant thermostat Checking the thermostat when removed 1. Measure dimension “a” on thermostat Note: “a” a starts of lift at approx approx. 83+2 (T1) “b” end of lift at approx. 95+5 (T2) Lift movement with indicated temp T2, Min. 8 mm

Volvo Construction Equipment Global CST- Training 195 2012-12-20

D5 engine training Road machine

Fuel system y cylinder y No p positions 030113

Volvo Construction Equipment Global CST- Training 196 2012-12-20

D5 engine training Road machine

Internal exhaust g gas recirculation 1 Additional cam for exhaust gas recirculation 1. Inlet valve opens briefly during the outlet cycle and emits an exhaust gas partial flow to the suction system. This p partial volume is sucked back in the next suction cycle

Volvo Construction Equipment Global CST- Training 197 2012-12-20

Paver D5 engine

Charging g g

C Compressor Turbine

From filter

Turbo charger with charge air cooling Advantages: g ¾ Volumetric efficiency of engine increases ¾ Increase Horse Power ¾ Emission improved ¾ Compact in size

To CAC

Volvo Construction Equipment Global CST- Training 198 2012-12-20

Paver D5 engine

Charging g g piping p p g 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 th there iis iignition iti supply l – 2nd position iti 2. Fuel shut off solenoid + excess fuel solenoid in 3rd start position

Volvo Construction Equipment Global CST- Training 200 2012-12-20

D5 engine training Road machine

Excess fuel solenoid 1. Excess fuel solenoid 2. Sensor Not applicable

1. Fuel shut off solenoid operates when th there iis iignition iti supply l – 2nd position iti 2. Fuel shut off solenoid + excess fuel solenoid in 3rd start position

Volvo Construction Equipment Global CST- Training 201 2012-12-20

Electrical Harness Installation –SD110

Engine g oil pressure p switch

¾ Engine oil pressure switch

Volvo Construction Equipment Global CST- Training 202 2012-12-20

D5 engine training Road machine

Engine g water temperature p switch

¾ Engine Water temperature switch

Volvo Construction Equipment Global CST- Training 203 2012-12-20

D5 engine training Road machine

Engine g glow g plug p g

¾ Engine Glow plug ¾ Time - 8 seconds ¾ Temperature 950 0 c

Volvo Construction Equipment Global CST- Training 204 2012-12-20

D5 engine training Road machine

Diesel tank fuel sender

¾ Fuel sender

Volvo Construction Equipment Global CST- Training 205 2012-12-20

D5 engine training Road machine

Mechanical governor g

Governor adjustment screws

J

G

Volvo Construction Equipment Global CST- Training 206 2012-12-20

E

Full load

“G”

Torque maximum

“E”

NA based fuel charge

“J”

Excess fuel start solenoid

Paver D5 engine

Engine g V- belt Procedure Change Engine V belt V – belt AVX 11 (Width 11 mm) Belt tensioning – Automatic tensioning Spring – loaded clamping roller

Volvo Construction Equipment Global CST- Training 207 2012-12-20

D5 engine training Road machine

Removing g the Starter motor

Volvo Construction Equipment Global CST- Training 208 2012-12-20

D5 engine training Road machine

Installing g the Starter motor

Volvo Construction Equipment Global CST- Training 209 2012-12-20

D5 engine training Road machine

EK code - 030114

Volvo Construction Equipment Global CST- Training 210 2012-12-20

D5 engine training Road machine

A measurement - 030115

Volvo Construction Equipment Global CST- Training 211 2012-12-20

D5 engine training Road machine

Dimensions, definitions - 030116

Volvo Construction Equipment Global CST- Training 212 2012-12-20

D5 engine training Road machine

Theoretical shim thickness - 030118

Volvo Construction Equipment Global CST- Training 213 2012-12-20

D5 engine training Road machine

Actual shim thickness - 030119

Volvo Construction Equipment Global CST- Training 214 2012-12-20

D5 engine training Road machine

Reinstallation - 030120

Volvo Construction Equipment Global CST- Training 215 2012-12-20

D5 engine training Road machine

Special p tools - 030121

Volvo Construction Equipment Global CST- Training 216 2012-12-20

D5 engine training Road machine

Unit p pump p installation - 030122

Volvo Construction Equipment Global CST- Training 217 2012-12-20

D5 engine training Road machine

Unit p pump p installation - 030123

Volvo Construction Equipment Global CST- Training 218 2012-12-20

D5 engine training Road machine

Assembly y injection j p pump p

Volvo Construction Equipment Global CST- Training 219 2012-12-20

D5 engine training Road machine

Unit injection j pump p p system y

Volvo Construction Equipment Global CST- Training 220 2012-12-20

D5 engine training Road machine

Explanation p Lo & EP- code for D5D engines g

Volvo Construction Equipment Global CST- Training 221 2012-12-20

D5 engine training Road machine

EP-Code on identification plate p

Volvo Construction Equipment Global CST- Training 222 2012-12-20

D5 engine training Road machine

Determination compensation p shim

Volvo Construction Equipment Global CST- Training 223 2012-12-20

D5 engine training Road machine

From value TS to SS

Volvo Construction Equipment Global CST- Training 224 2012-12-20

D5 engine training Road machine

F I P installation, step p1

Volvo Construction Equipment Global CST- Training 225 2012-12-20

D5 engine training Road machine

F I P installation, step p2

Volvo Construction Equipment Global CST- Training 226 2012-12-20

D5 engine training Road machine

Example p – Lubricating g oil consumption p (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

13

523

2

17.2.12

11

600

2

18.2.12

13

620

2

19.2.12

14

590

2

20 2 12 20.2.12

10

450

2

21.2.12

11

597

2

22.2.12

12

580

2

23.2.12

13

620

2

24.2.12

118

5554

20

Volvo Construction Equipment Global CST- Training 227 2012-12-20

Shashi

Ballal

Ramalu

D5 engine training Road machine

Example

Example p – Lubricating g oil consumption p (at least 100 operating hours) engine in high load operation Calculation example: 9 Fuel consumption = 5554 l 9 Lubricating oil consumption = 20 l ¾ Calculation: 5554 l = 100% 20 l

100 %

5554 L

= x

Volvo Construction Equipment Global CST- Training 228 2012-12-20

X=

20 L

D5 engine training Road machine

= 0.36 %