This is a very practical manual

1. Service Information
Document Title: Function Group: Information Type: Date:
Description D5D 200 Service Information 2014/7/4 0
Profile:
EXC, EW140B [GB]
Description D5D
The D5D engine is a straight, four cylinder, direct-injection, four-stroke, diesel engine, with electronically controlled fuel
injection EMR (Engine Management System).
The engine meets the emission requirements according to EURO2.
The engine number is stamped on the name plate and on the right side of the cylinder block.
Model and serial number must always be indicated when ordering spare parts.

2. Service Information
Document Title: Function Group: Information Type: Date:
Precaution for replacing
the engine
210 Service Information 2014/7/4 0
Profile:
EXC, EW140B [GB]
Precaution for replacing the engine
The E-ECU contains an engine specific data set, and this is fixedly assigned to each engine. So in case of the engine
replacement, the new E-ECU should be ordered together with the new engine, and should be programmed with the correct
data set.

3. Service Information
Document Title: Function Group: Information Type: Date:
Engine, removing 210 Service Information 2014/7/4 0
Profile:
EXC, EW140B [GB]
Engine, removing
Op nbr 210-01
14360000 Vacuum pump
Lifting links, min. 1000 kg
WARNING
Risk of burns - stop the diesel engine and allow it to cool down before starting any work.
Plug and mark all hoses and connections when disconnecting.
1. To facilitate the work, remove the counterweight, see .
716 Counterweight, removing
2. Remove the covers under the engine.
Remove the covers over the engine.
3.
Figure 1
Frame
1.
2.
Cover
Frame
Detach the outer frame and lift away the frame together with the cover.

4. 4.
Figure 2
Engine/hydraulic compartment
1. Intermediate wall
Remove the intermediate wall.
5.
Figure 3
Engine/hydraulic compartment
1. Frame
Remove the remaining framework.
6.
Figure 4
Draining coolant
1. Drain valve
Drain the coolant into a clean vessel by connecting the drain hose to the drain valve on the radiator.

5. 7. Connect the vacuum pump, see .
900 Vacuum pump, connection
8.
Figure 5
Working pump
1.
2.
3.
4.
5.
Connector
LS-hose
Leak-off oil hoses
Pressure hoses
Suction line
Disconnect the suction line at the connection on the working pump.
Disconnect leak-off oil hoses, pressure hoses and the LS-hose from the working pump.
Detach the connector from the working pump.
NOTE!
Mark and plug and the suction line and other hoses with metal plugs to maintain pressure, as the vacuum pump
will be disconnected further on in the instructions.
9.
Figure 6
Working pump
1.
2.
Hydraulic hoses
Attachment

6. Detach the hoses from the attachment.
10.
Figure 7
Servo/steering pump
1.
2.
3.
4.
5.
Suction line
Tank line
Servo pressure hose
Hose to fan motor, hydraulic oil cooler
Hose to brake valve
Disconnect the suction line at the joint between pipe and hose and disconnect the other hoses from the servo/
steering pump.
NOTE!
Mark and plug and the hoses with metal plugs to maintain pressure, as the vacuum pump will be disconnected
further on in the instructions.
11. Turn off the vacuum pump and turn off the battery disconnect switch.
12.
Figure 8
Exhaust pipe
1. Joint between turbocharger and exhaust pipe
Detach the turbocharger from the exhaust pipe.

7. 13.
Figure 9
Underside of silencer bracket
1. Attaching bolts
Secure the silencer and bracket with a strap.
Remove the attaching bolts for the silencer bracket and remove the silencer and bracket.
14.
Figure 10
Heat radiation shield over starter motor
1. Heat radiation shield
Remove the heat radiation shield over the starter motor.
15.

8. Figure 11
Engine
1 Ground cable 6 Lower cooling hose
2 Starter motor cable
harness
7 Hose
3 Preheating cable harness 8 AC compressor
4 Upper intercooler hose 9 Induction hoses to
turbocharger
5 Upper cooling hose
Disconnect the ground cable from the engine.
Detach the starter motor cable harness from the engine.
Detach the preheating cable harness from the engine.
Disconnect the upper intercooler hose and the upper and lower cooling hoses from the engine.
Disconnect the hose from the engine.
Disconnect the induction hoses from the turbocharger.
Detach the AC compressor from the bracket.
NOTE!
Do not disconnect the hoses from the AC compressor.
16.
Figure 12
Engine
1 EMR cable harness 4 Fuel hose, return
2 Alternator cable harness 5 Fuel hose, pump
3 Cooling hoses 6 Lower intercooler hose
Detach the EMR and alternator cable harnesses from the engine.
Disconnect the cooling hoses from the engine.
Disconnect the return fuel hose and the fuel hose to the fuel pump from the engine.
Detach the lower intercooler hose from the engine.

9. 17.
Figure 13
Cooling fan
1.
2.
3.
Cooling fan
Attaching bolts
Belt pulley
Remove the attaching bolts between fan and belt pulley. Move the cooling fan forward toward the radiator.
18.
Figure 14
Lifting links on engine
1.
2.
Lifting links
Lifting lugs
Connect the lifting links to the two lifting lugs on the engine and to a lifting device.
19. Remove the bolted joints for the engine mountings.
20. Carefully lift the engine out of the machine.
21. Place the engine on stable supports.

10. Service Information
Document Title: Function Group: Information Type: Date:
Engine, installing 210 Service Information 2014/7/4 0
Profile:
EXC, EW140B [GB]
Engine, installing
Op nbr 210-02
14360000 Vacuum pump
Lifting links, min. 1000 kg
1. Connect lifting links to the lifting lugs on the engine and carefully lift the engine into the machine.
2. Install the bolted joint for the engine mountings.
Tightening torque:687 ±68 Nm.
3.
Figure 1
Cooling fan
1.
2.
3.
Cooling fan
Attaching bolts
Belt pulley
Install the cooling fan. Apply locking fluid and install the attaching bolts between fan and belt pulley.

11. 4.
Figure 2
Engine
1 EMR cable harness 4 Fuel hose, return
2 Alternator cable harness 5 Fuel hose, pump
3 Cooling hoses 6 Lower intercooler hose
Connect the fuel hose to the fuel pump.
Connect the return fuel hose, the cooling hoses and the EMR cable harness to the engine.
Connect the alternator cable harness to the alternator.
5.
Figure 3
Engine
1 Ground cable 6 Lower cooling hose
2 Starter motor cable
harness
7 Hose
3 Preheating cable harness 8 AC compressor
4 Upper intercooler hose 9 Induction hoses to
turbocharger
5 Upper cooling hose
Install the AC compressor on the bracket.
Connect the induction hoses to the turbocharger.
Connect the hose, the upper intercooler hose and the upper and lower cooling hoses to the engine.
Connect the ground cable, the starter motor and preheating cable harnesses.

12. 6.
Figure 4
Heat radiation shield over starter motor
1. Heat radiation shield
Install the heat radiation shield over the starter motor.
7.
Figure 5
Underside of silencer bracket
1. Attaching bolts
Install the silencer together with bracket and install the attaching bolts for the silencer bracket.
8.
Figure 6
Exhaust pipe
1. Joint between turbocharger and exhaust pipe

13. Install the exhaust pipe on the turbocharger.
9. Switch on the battery disconnect switch and connect the vacuum pump, see .
900 Vacuum pump, connection
10.
Figure 7
Servo/steering pump
1.
2.
3.
4.
5.
Suction line
Tank line
Servo pressure hose
Hose to fan motor, hydraulic oil cooler
Hose to brake valve
Connect the suction line and the other hoses to the servo/steering pump.
11.
Figure 8
Working pump
1.
2.
Hydraulic hoses
Attachment
Install the hoses in the attachment.

14. 12.
Figure 9
Working pump
1.
2.
3.
4.
5.
Connector
LS-hose
Leak-off oil hoses
Pressure hoses
Suction line
Connect the suction line, connector, LS-hose and pressure hoses to the working pump.
Fill the pump with hydraulic oil through the connection for the leak-off oil hoses.
Connect the leak-off oil hoses.
13. Disconnect the vacuum pump, see .
900 Vacuum pump, disconnection
14.
Figure 10
Engine/hydraulic compartment
1. Frame
Install frame 1.

15. 15.
Figure 11
Engine/hydraulic compartment
1. Intermediate wall
Install intermediate wall 1.
16.
Figure 12
Frame
1.
2.
Cover
Frame
Install the outer frame together with the cover.
17. Install the counterweight, see .
716 Counterweight, removing

16. 18.
Figure 13
Expansion tank
1.
2.
Cap
Sight glass
Remove the cap and fill coolant in the expansion tank until the level is in the middle of the sight glass.
Install the cap.
19.
Figure 14
Radiator
1. Filling point
Fill the radiator until the level stands right up in the filler neck.
20. Check the oil level in the engine.
Top up if required
21. Bundle hoses and cable harnesses to avoid damage by chafing.
22. Start the diesel engine, place the digging equipment in position A, see .
091 Service positions
Check that there are no leaks.
23. Install the cover over and under the diesel engine.
24. Stop the diesel engine and check the hydraulic oil level, top up if needed.
Check the coolant level, top up if required.

17. Service Information
Document Title: Function Group: Information Type: Date:
Cylinder head, description 211 Service Information 2014/7/4 0
Profile:
EXC, EW140B [GB]
Cylinder head, description
The cylinder head is made of cast iron and is common for all cylinders. The induction air enters vertically (A) and the
exhausts leave horizontally (B). Inlets and exhaust outlets are located on the same side of the cylinder block. On order for the
engine to fulfill governing emission standards, there are 3 cylinder head gaskets of different thicknesses between the
cylinder head and the piston.
Figure 1

18. Service Information
Document Title: Function Group: Information Type: Date:
Pistons, description 213 Service Information 2014/7/4 0
Profile:
EXC, EW140B [GB]
Pistons, description
The pistons are made of special alloy aluminium. The piston's combustion compartment has a somewhat off-center
(eccentric) position in relation to the piston pin.
The pistons are provided with 3 piston rings. The first ring has a ring carrier made of cast iron.
The piston is cooled with oil sprayed up on the inside of the piston top.
The piston cooling nozzles are made of plastic and are mounted in the cylinder head by the main bearing positions.
The first piston ring has an asymmetric cross-section area (A). The cross-section area for piston ring number two
(compression ring) is tapered. When installing the piston rings, the marking TOP by the opening in the rings must face up.
The third ring is an oil ring with bevelled edge.
Figure 1

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20. Service Information
Document Title: Function Group: Information Type: Date:
Valves, description 214 Service Information 2014/7/4 0
Profile:
EXC, EW140B [GB]
Valves, description
The engines are equipped with one inlet and one exhaust valve per cylinder.
At the upper end of the valve guide, there's an O-ring seal against the valve spindle to prevent major oil consumption and to
reduce the amount of hydrocarbons in the exhausts.
The valves are rotated by the eccentric action of the rocker arms.
The new compressed tapered shape enables the valves to turn easily despite loading.
Rocker arm lubrication is part of the engine's force-feed lubrication system. The oil is supplied via the tappets and push rods.