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Volvo EC650 Excavator Service Repair Manual Instant Download.pdf

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Volvo EC650 Excavator Service Repair Manual Instant Download.pdf

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Service Information
Document Title: Function Group: Information Type: Date:
Description,
TD122
210 Service Information 2014/11/26
Profile:
Description, TD122
GENERAL
The TD 122 is a six-cylinder, direct-injected, four-stroke, turbocharged diesel engine. Certain engine versions also have an
intercooler.
Lubrication is provided by a force feed lubrication system. An oil pump supplies all lubrications points with oil.
The turbocharger supplies the engine with air under pressure, which produces an excess of air. The quantity of fuel injected
can thereby be increased, raising the engine output. The turbocharger is lubricated and cooled by the engine’s lubrication
system. It is driven by the engine’s exhaust gases and thus utilizes energy that would otherwise be wasted.
The engine’s type and serial number is stamped on the right and left-hand sides of the cylinder block.
Service Information
Document Title: Function Group: Information Type: Date:
Description, TD122 210 Service Information 2014/11/26
Profile:
Description, TD122
The engine has six separate cylinder heads that are interchangeable. They are made of cast iron and each secured with eight
bolts (9/16"-12, UNC).
The cylinder head valve seats and valve guides of both intake and exhaust valves can be replaced.
The intake and exhaust manifolds are connected to opposite sides of the cylinder head. Valves are mounted in the
cylinder head and have double valve springs.
Service Information
Document Title: Function Group: Information Type: Date:
Description, TD122 210 Service Information 2014/11/26
Profile:
Description, TD122
Cylinder liners
Figure 1
Cylinder liners
Cylinder liners are replaceable and of the wet type.
Cylinder liners have a flame ridge that sits in a groove in the cylinder head. Four O-rings are used as outer seals for each
cylinder liner.


Sealing ring 1 under the liner collar has a diameter of 2.4 mm (0.094 in).
The lower liner seal consists of three sealing rings. The lowest sealing ring 3 is made of fluor rubber, see the
"General" section.
Service Information
Document Title: Function Group: Information Type: Date:
Engine specifications,
engine speed
210 Service Information 2014/11/26
Profile:
Engine specifications, engine speed
Working speed1) 30 rps (1 800 rpm)
High idling speed2) (control engine speed) 33.9 rps (2 035 ±40 rpm)
Idling speed
(control engine speed)
10.3 rps (620 ± 40 rpm)
1) Maximum rpm with no load on engine.
2) Nominal rpm at max. specified power.
Service Information
Document Title: Function Group: Information Type: Date:
General specifications 210 Service Information 2014/11/26
Profile:
General specifications
Make Volvo
Model TD 122 KIE
Gross power at 1 800 rpm (according to SAE J1349) 284 kW (386 hp)
Net power at 1 800 rpm (according to ISO 9249/DIN 6271) 273 kW (371 hp)
Number of cylinders 6
Cylinder displacement 11.98 l (3.2 US gal)
Cylinder bore 130.17 mm (5.125 in)
Stroke 150 mm (5.9 in)
Valve clearance, inlet 0.40 mm (0.016 in)
Valve clearance, outlet 0.70 mm (0.028 in)
Service Information
Document Title: Function Group: Information Type: Date:
General specifications 210 Service Information 2014/11/26
Profile:
General specifications
Wear tolerances
Cylinder head
Height, min. 124.65 mm (4.907 in)
Cylinder block (Fig.)
Height, upper block face - crankshaft centre (A) min. 463.8 mm (18.26 in)
Height, lower block face - crankshaft centre (B) 120 mm (4.724 in)
Cylinder liners
Cylinder liners (pistons and piston rings) should be replaced after 0.40-0.45 mm
of wear, or if oil consumption is abnormally high.
Crankshaft
Max. permitted out-of-round of main and crankshaft journals 0.08 mm (0.003 in)
Max. permitted taper of main and crankshaft journals 0.05 mm (0.002 in)
Max. axial play of crankshaft 0.40 mm (0.016 in)
Max. radial play of crankshaft 0.20 mm (0.008 in)
Connecting rods
Straightness, max. deviation along 100 mm length 0.05 mm (0.002 in)
Distortion, max. deviation along 100 mm length 0.1 mm (0.004 in)
Valves
Valve spindle, max. permitted wear 0.07 mm (0.003 in)
Max. permitted clearance between valve spindle and valve guide
Intake
Exhaust
0.3 mm (0.012 in)
0.2 mm (0.008 in)
Edge of valve head shall be min.
Intake
Exhaust
1.9 mm (0.075 in)
1.4 mm (0.055 in)
Valve seat can be ground until distance from valve head
(new valve) to cylinder head face is max:
Intake (if values are exceeded, replace the valve seats)
Exhaust
1.5 mm (0.059 in)
1.5 mm (0.059 in)
Camshaft
Max. permitted out-of-round (with new bearing) 0.05 mm (0.002 in)
Bearing, max. permitted wear 0.05 mm (0.002 in)
Lifting height, min.
Intake
Exhaust
8.4 mm (0.331 in)
9.0 mm (0.354 in)
Tappets, max. permitted radial play 0.08 mm (0.003 in)
Turbocharger
Compressor shaft
max. axial play
max. radial play
0.08 mm (0.003 in)
0.17 mm (0.007 in)
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  • 1. Service Information Document Title: Function Group: Information Type: Date: Description, TD122 210 Service Information 2014/11/26 Profile: Description, TD122 GENERAL The TD 122 is a six-cylinder, direct-injected, four-stroke, turbocharged diesel engine. Certain engine versions also have an intercooler. Lubrication is provided by a force feed lubrication system. An oil pump supplies all lubrications points with oil. The turbocharger supplies the engine with air under pressure, which produces an excess of air. The quantity of fuel injected can thereby be increased, raising the engine output. The turbocharger is lubricated and cooled by the engine’s lubrication system. It is driven by the engine’s exhaust gases and thus utilizes energy that would otherwise be wasted. The engine’s type and serial number is stamped on the right and left-hand sides of the cylinder block.
  • 2. Service Information Document Title: Function Group: Information Type: Date: Description, TD122 210 Service Information 2014/11/26 Profile: Description, TD122 The engine has six separate cylinder heads that are interchangeable. They are made of cast iron and each secured with eight bolts (9/16"-12, UNC). The cylinder head valve seats and valve guides of both intake and exhaust valves can be replaced. The intake and exhaust manifolds are connected to opposite sides of the cylinder head. Valves are mounted in the cylinder head and have double valve springs.
  • 3. Service Information Document Title: Function Group: Information Type: Date: Description, TD122 210 Service Information 2014/11/26 Profile: Description, TD122 Cylinder liners Figure 1 Cylinder liners Cylinder liners are replaceable and of the wet type. Cylinder liners have a flame ridge that sits in a groove in the cylinder head. Four O-rings are used as outer seals for each cylinder liner.   Sealing ring 1 under the liner collar has a diameter of 2.4 mm (0.094 in). The lower liner seal consists of three sealing rings. The lowest sealing ring 3 is made of fluor rubber, see the "General" section.
  • 4. Service Information Document Title: Function Group: Information Type: Date: Engine specifications, engine speed 210 Service Information 2014/11/26 Profile: Engine specifications, engine speed Working speed1) 30 rps (1 800 rpm) High idling speed2) (control engine speed) 33.9 rps (2 035 ±40 rpm) Idling speed (control engine speed) 10.3 rps (620 ± 40 rpm) 1) Maximum rpm with no load on engine. 2) Nominal rpm at max. specified power.
  • 5. Service Information Document Title: Function Group: Information Type: Date: General specifications 210 Service Information 2014/11/26 Profile: General specifications Make Volvo Model TD 122 KIE Gross power at 1 800 rpm (according to SAE J1349) 284 kW (386 hp) Net power at 1 800 rpm (according to ISO 9249/DIN 6271) 273 kW (371 hp) Number of cylinders 6 Cylinder displacement 11.98 l (3.2 US gal) Cylinder bore 130.17 mm (5.125 in) Stroke 150 mm (5.9 in) Valve clearance, inlet 0.40 mm (0.016 in) Valve clearance, outlet 0.70 mm (0.028 in)
  • 6. Service Information Document Title: Function Group: Information Type: Date: General specifications 210 Service Information 2014/11/26 Profile: General specifications Wear tolerances Cylinder head Height, min. 124.65 mm (4.907 in) Cylinder block (Fig.) Height, upper block face - crankshaft centre (A) min. 463.8 mm (18.26 in) Height, lower block face - crankshaft centre (B) 120 mm (4.724 in) Cylinder liners Cylinder liners (pistons and piston rings) should be replaced after 0.40-0.45 mm of wear, or if oil consumption is abnormally high. Crankshaft Max. permitted out-of-round of main and crankshaft journals 0.08 mm (0.003 in) Max. permitted taper of main and crankshaft journals 0.05 mm (0.002 in) Max. axial play of crankshaft 0.40 mm (0.016 in) Max. radial play of crankshaft 0.20 mm (0.008 in) Connecting rods Straightness, max. deviation along 100 mm length 0.05 mm (0.002 in) Distortion, max. deviation along 100 mm length 0.1 mm (0.004 in) Valves Valve spindle, max. permitted wear 0.07 mm (0.003 in) Max. permitted clearance between valve spindle and valve guide Intake Exhaust 0.3 mm (0.012 in) 0.2 mm (0.008 in) Edge of valve head shall be min. Intake Exhaust 1.9 mm (0.075 in) 1.4 mm (0.055 in) Valve seat can be ground until distance from valve head (new valve) to cylinder head face is max: Intake (if values are exceeded, replace the valve seats) Exhaust 1.5 mm (0.059 in) 1.5 mm (0.059 in) Camshaft Max. permitted out-of-round (with new bearing) 0.05 mm (0.002 in) Bearing, max. permitted wear 0.05 mm (0.002 in) Lifting height, min. Intake Exhaust 8.4 mm (0.331 in) 9.0 mm (0.354 in) Tappets, max. permitted radial play 0.08 mm (0.003 in) Turbocharger Compressor shaft max. axial play max. radial play 0.08 mm (0.003 in) 0.17 mm (0.007 in)
  • 7. Service Information Document Title: Function Group: Information Type: Date: Short block 210 Service Information 2014/11/26 Profile: Short block Cylinder block The cylinder block is made of cast iron and has wet, replaceable cylinder liners. The crankshaft is seated in bearings in the block for which there are prepared bearing shells. The camshaft bearing bushings must however be bored once pressed into the block. Figure 1 Seal, cylinder block - cylinder head 1. 2. 3. 4. 5. 6. Cylinder head Shallow groove (in cylinder head) Gasket Cylinder liner flame ridge Cylinder block Stepped edge Seal The seal between the cylinder heads, block and liners comprises a solid steel gasket and a so-called flame ridge on each liner and a corresponding groove in the cylinder heads. The liners have a so-called stepped edge on the sealing surface between the liners and the gasket. This edge is raised between 0.47 and 0.52 mm (0.019 and 0.020 in) above the block face. There are also two shallow grooves in each cylinder head. Grooves Cylinder head faces have two wide concentric grooves directly above the cylinder liner collar (see fig.). These grooves reduce the size of the sealing surface producing sufficient pressure at moderate tightening torques, thus eliminating the risk deforming the liner shelf in the cylinder block. Cylinder heads also have a groove for cylinder liner flame ridges.   The shallow grooves in the cylinder head deform the gasket and secure it in place. The flame ridge of the cylinder liner protects the gasket from combustion pressure and heat.
  • 8. Service Information Document Title: Function Group: Information Type: Date: Specifications, TD122 210 Service Information 2014/11/26 Profile: Specifications, TD122 General Cylinder liners Type Wet, replaceable Height, total 313.5 mm (12.342 in) Height of stepped edge above block face 0.47-0.52 mm (0.019 and 0.021 in) Piston Height, above block face max. 0.55 mm (0.022 in) Number of ring grooves 3 Front marking Arrow pointing forward Piston rings Compression rings Number 2 Piston ring play in groove upper compression ring lower compression ring 0.12 mm (0.005 in) 0.09 mm (0.004 in) Piston ring opening 1st ring 2nd ring 0.5 mm (0.020 in) 0.4 mm (0.016 in) Oil ring Number 1 Piston ring play in groove 0.05 mm (0.002 in) Piston ring opening 0.05 mm (0.002 in) Gudgeon pins Play, gudgeon pin - connecting rod bushing 0.023 mm (0.001 in) Gudgeon pins, std 54.998-55.004 mm (2.165-2.166 in) Gudgeon pin hole diameter in piston 55.003-55.010 mm (2.165-2.166 in)
  • 9. Service Information Document Title: Function Group: Information Type: Date: Complete engine, installation 210 Service Information 2014/11/26 Profile: Complete engine, installation Op nbr 210-02 14 360 000 Vacuum pump Lifting chains, min. 2000 kg (4400 lbs) Locking compound Replace all cable ties that have been removed from hoses and electrical cables. 1. Transfer the fan 1, alternator 2 and servo pump 3. Transfer the engine mountings 4 and 8 (3 mountings per side). Apply locking compound to the bolts. Tightening torque: 90 (Nm) (66.38 lbf ft) Transfer the exhaust pipe 5, bracket 6 and hydraulic cylinder 7. Figure 1 Transfer of engine components 1 Fan 5 Exhaust pipe 2 Alternator 6 Bracket 3 Servo pump 7 Hydraulic cylinder 4 Engine mounting 8 Engine mounting 2. Transfer the starter motor 1, hose 2 and electrical cables. Transfer the fan pump 3 and compressor mounting 4.
  • 10. Figure 2 Engine 1. 2. 3. 4. Starter motor Hose Fan pump Mounting 3. Loop a sling 2 round the three upper pumps. Remove the bolts 1 between the pump gearbox and engine and lift off the gearbox. Figure 3 Engine 1. 2. Bolts Sling 4. Transfer the clutch half 1 and fit the pump gear. Figure 4 Engine 1. Clutch half
  • 11. 5. Attach lifting chains to the lifting eyes 1 and lift in the engine. Figure 5 Engine 1. Lifting eyes 6. Apply locking compound to the centre bolts 1 (6) and tighten them. Tightening torque: 540 Nm (398 lbft ft) NOTE! New bolts are recommended. Figure 6 Engine compartment 1. Centre bolts 7. Fit the electrical cables to the engine as previously noted. 8. Turn on the battery disconnector. 9. Start the vacuum pump. 10. Connect the hydraulic hoses to the fan pump 1 and the coolant hose 3 to the top side of the engine. Fit the compressor 2to its mounting.
  • 12. Figure 7 Engine compartment 1. 2. 3. Fan pump Compressor Coolant hose 11. Connect the hydraulic hoses 1 to the servo pump and the fuel hoses 3 to the injection pump. Fit the throttle cable 2 to the bracket and the stop cable4 to the injection pump. Connect the hose 5 to the hydraulic pump and all coolant hoses between the radiator and engine. Figure 8 Engine 1 Hydraulic hoses 4 Stop cable 2 Throttle cable 5 Hose 3 Fuel hoses 12. Connect all suction pipes 1, delivery pipes 2 and the marked drain hoses 3 to the pumps. Figure 9 Pumps
  • 13. 1. 2. 3. Suction pipe Delivery pipe Drain hoses 13. Disconnect the vacuum pump, see [Invalid linktarget] . 14. Open the suction flap valve. Figure 10 Rear section 1. Slings 15. Attach two slings 1 to the short sides of the rear section and lift it in. 16. Fit the bolts to the short sides of the rear section. 17. Fit the fasteners 2 to both sides of the radiator. Fit the hatch 1. Figure 11 Radiator 1. 2. Hatch Fastener 18. Fit the dipstick 1 and hose 2.
  • 14. Figure 12 Engine compartment 1. 2. Dipstick Hose 19. Fit the cables 1 and filter 2. Figure 13 Engine compartment 1. 2. Cables Filter 20. Fit the frame sections 1, 3 and 5 to the rear section, and refit the expansion tank 2 and partitions 4. Figure 14 Engine compartment 1 Frame 4 Partitions 2 Expansion tank 5 Frame 3 Frame
  • 15. 21. Fill the system with coolant through the expansion tank. 22. Bleed the fuel system, see [Invalid linktarget]. 23. Start the engine. 24. Check for leaks and repair if needed. 25. Check the coolant level and top up, if needed. 26. Fit all hatches. 27. Fit the counterweight as described in [Invalid linktarget] .
  • 16. Service Information Document Title: Function Group: Information Type: Date: Complete engine, removal 210 Service Information 2014/11/26 Profile: Complete engine, removal Op nbr 210-01 14 360 000 Vacuum pump Lifting chains, min. 2000 kg (4400 lbs) WARNING Before starting any work, allow the engine to cool down in order to avoid burn injuries. Plug hoses and connections when undone. 1. Remove the counterweight according to [Invalid linktarget] . 2. Remove the hatches under the engine, the air filter hood and the cover plate from the rear section. 3. Remove the hatches from the oil cooler, from the main valve block and from behind the hydraulic oil tank. 4. Release the gas springs from the frame member and remove the engine access door. 5. Fit a suitable hose 1 to the drain nipple. Undo the drain nipple and empty the coolant into clean receptacles (approx. 70 litres (18.48 US gal)). Figure 1 Underside of radiator 1. Hose 6. Release the frame sections 1, 3 and 5 from the rear section and remove the expansion tank 2 and partitions 4.
  • 17. Figure 2 Engine compartment 1 Frame 4 Partitions 2 Expansion tank 5 Frame 3 Frame 7. Undo the choke cables 1 and the filter 2. Figure 3 Engine compartment 1. 2. Cables Filter 8. Undo the dipstick 1 and the hose 2. Figure 4 Engine compartment 1. 2. Dipstick Hose
  • 18. 9. Remove the hatch 1. Remove the fasteners 2 on both sides and release the radiator from the rear section. Figure 5 Radiator 1. 2. Hatch Fastener 10. Connect the vacuum pump, see [Invalid linktarget]. 11. Close the suction flap valve. Figure 6 Rear section 1. Slings 12. Remove the bolts from the short sides of the rear section. 13. Attach two slings 1 to the short sides and lift off the rear section. 14. Undo all suction pipes 1 and delivery pipes 2from the pumps. Mark and undo all drain hoses 3 from the pumps.
  • 19. Figure 7 Pumps 1. 2. 3. Suction pipe Delivery pipe Drain hoses 15. Undo the hydraulic hoses 1 from the servo pump and the fuel hoses 3 from the injection pump. Undo the throttle cable 2 from the bracket (make note of the attachment position), the stop cable4 from the injection pump, the hose 5 from the hydraulic cylinder and all coolant hoses between the radiator and the engine. Figure 8 Engine 1 Hydraulic hoses 4 Stop cable 2 Throttle cable 5 Hose 3 Fuel hoses 16. Unplug the hydraulic hoses from the fan pump 1 and the coolant hoses 3 from the top side of the engine. Undo the compressor 2 from the mounting. NOTE! Do not disconnect any hoses from the compressor. Figure 9 Engine compartment 1. 2. 3. Fan pump Compressor Coolant hose 17. Check that all hoses are correctly plug and then switch off the vacuum pump. 18. Turn off the battery disconnector.
  • 20. Suggest: If the above button click is invalid. Please download this document first, and then click the above link to download the complete manual. Thank you so much for reading
  • 21. 19. Make a note of the position of all electrical cables on the engine and release them. Figure 10 Engine compartment 1. Centre bolts 20. Remove the centre bolts 1 (6). Figure 11 Engine 1. Lifting eyes 21. Connect lifting chains to the lifting eyes 1 and lift out the engine. 22. Place the engine on stable supports.