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Volvo EC160C NL EC160CNL Excavator Service Repair Manual Instant Download.pdf

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Service Information
Document Title: Function Group: Information Type: Date:
Engine, description 200 Service Information 2015/3/13
Profile:
EXC, EC160C NL [GB]
Engine, description
D6E - tier 3 compliant
The D6E configuration is a four stroke, straight six cylinder, turbocharged, direct injected diesel engine with charge air
cooling and wet, replaceable cylinder liners.
The D6E engine uses a Common Rail Fuel System controlled by the engine electronic control (E-ECU) software.
Electronically controlled IEGR (Internal Exhaust Gas Recirculation) reduces NO formation and lowers emissions without the
need for exhaust after treatment. Volvo's latest engine management system, E-ECU is used to control all engine electronic
functions.
The cylinders are numbered consecutively beginning at the flywheel end. Engine rotational direction is counterclockwise as
seen from the flywheel end.
Figure 1
Engine, D6E
Service Information
Document Title: Function Group: Information Type: Date:
Engine, identification 200 Service Information 2015/3/13
Profile:
EXC, EC160C NL [GB]
Engine, identification
Identification plate
The engine model, serial number and performance data are stamped on an identification plate which is attached on the
cylinder head cover. The engine model designation and serial number must be indicated when ordering spare parts.
Figure 1
Engine identification, D6E
Service Information
Document Title: Function Group: Information Type: Date:
Engine, tightening torques 200 Service Information 2015/3/13
Profile:
EXC, EC160C NL [GB]
Engine, tightening torques
NOTICE
Regarding bolted joints which are not listed here, see “Volvo standard tightening torques”
Engine, tightening torque
Rocker arm bracket on cylinder head 30 Nm (22.2 lbf ft)
Cylinder head cover (M6) on cylinder head 13 Nm (9.6 lbf ft)
Exhaust return module on cylinder head Step 1: 10 Nm (7.4 lbf ft)
Step 2: 30 Nm (22.2 lbf ft)
Lock nut, valve adjusting screw 20 ±2 Nm (14.8 ±1.5 lbf ft)
Locking screw on cylinder head 34 Nm (25.2 lbf ft)
Solenoid valve on cylinder head 24 Nm (17.8 lbf ft)
Front cover on crankcase Step 1: 3 Nm (2.2 lbf ft)
Step 2: 21 Nm (15.5 lbf ft)
Drain plug on oil pan, M18 55 Nm (40.7 lbf ft)
Crankcase ventilation on cylinder head 21 Nm (15.5 lbf ft)
Return line to return stop valve 30 Nm (22.2 lbf ft)
Return stop valve to crankcase 80 Nm (59.2 lbf ft)
Impulse transmitter (crankshaft) on holder on front cover 9 Nm (6.7 lbf ft)
Impulse transmitter (camshaft) on gearcase 9 Nm (6.7 lbf ft)
Turbocharger on exhaust manifold 42 Nm (31.1 lbf ft)
Clamping shoe injector on cylinder head 16 Nm (11.8 lbf ft)
Injection lines on rail and injector, high pressure line on high-pressure
pump
25 Nm (18.5 lbf ft)
Fuel supply pump on holder 22 Nm (16.3 lbf ft)
Holder fuel supply pump on holder 30 Nm (22.2 lbf ft)
V-belt pulley on fuel supply pump 27 Nm (20.0 lbf ft)
High pressure pump on crankcase, M10 Step 1: 10 Nm (7.4 lbf ft)
Step 2: 50 Nm (37.0 lbf ft)
Fuel control valve 30 Nm (22.2 lbf ft)
Fuel pipe on high pressure pump 29 Nm (21.5 lbf ft)
Fuel pipe on control block 39 Nm (28.9 lbf ft)
Rail on cylinder head 30 Nm (22.2 lbf ft)
Pressure relief valve on rail 100 Nm (74.0 lbf ft)
Rail pressure sensor on rail 70 Nm (51.8 lbf ft)
Pipe clips, fuel line fastening 30 Nm (22.2 lbf ft)
Fuel line on control block, fuel filter console and rail 39 Nm (28.9 lbf ft)
Fuel pipe (return) on control block 49 Nm (36.3 lbf ft)
Fuel pipe (return) on cylinder head 29 Nm (21.5 lbf ft)
Fuel line on fuel filter8 39 Nm (28.9 lbf ft)
Fuel filter console/radiator tank on crankcase 30 Nm (22.2 lbf ft)
Fuel pressure sensor on fuel filter console 30 Nm (22.2 lbf ft)
Cover plate on cylinder cover, M6 30 Nm (22.2 lbf ft)
Service Information
Document Title: Function Group: Information Type: Date:
Component locations 200 Service Information 2015/3/13
Profile:
EXC, EC160C NL [GB]
Component locations
Component position, engine D6E. The following figures show the position of a number of components on engine D6E.
Figure 1
Component locations, front side
1 Engine oil filler 10 Oil dipstick
2 Transport eye 11 Power take off
3 Alternator 12 Engine oil filter
4 Fuel feed pump 13 Fuel filter
5 V-rib belt drive on crankshaft 14 Connection to E-ECU
6 V-rib belt 15 Crankcase bleeding valve
7 Automatic belt tensioner 16 High pressure fuel pump
8 Coolant pump 17 Common rail
9 Engine oil cooler 18 Injector
Figure 2
Component locations, flywheel side
19 Crankcase bleeding valve 25 Turbocharger
20 Charge air manifold 26 Coolant inlet
21 Flywheel housing 27 Air outlet (to charge air cooler)
22 Oil pan 28 Coolant outlet
23 Starter motor 29 Exhaust manifold
24 Oil return line from turbocharger 30 Cylinder rocker arm cover
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  • 1. Service Information Document Title: Function Group: Information Type: Date: Engine, description 200 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Engine, description D6E - tier 3 compliant The D6E configuration is a four stroke, straight six cylinder, turbocharged, direct injected diesel engine with charge air cooling and wet, replaceable cylinder liners. The D6E engine uses a Common Rail Fuel System controlled by the engine electronic control (E-ECU) software. Electronically controlled IEGR (Internal Exhaust Gas Recirculation) reduces NO formation and lowers emissions without the need for exhaust after treatment. Volvo's latest engine management system, E-ECU is used to control all engine electronic functions. The cylinders are numbered consecutively beginning at the flywheel end. Engine rotational direction is counterclockwise as seen from the flywheel end. Figure 1 Engine, D6E
  • 2. Service Information Document Title: Function Group: Information Type: Date: Engine, identification 200 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Engine, identification Identification plate The engine model, serial number and performance data are stamped on an identification plate which is attached on the cylinder head cover. The engine model designation and serial number must be indicated when ordering spare parts. Figure 1 Engine identification, D6E
  • 3. Service Information Document Title: Function Group: Information Type: Date: Engine, tightening torques 200 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Engine, tightening torques NOTICE Regarding bolted joints which are not listed here, see “Volvo standard tightening torques” Engine, tightening torque Rocker arm bracket on cylinder head 30 Nm (22.2 lbf ft) Cylinder head cover (M6) on cylinder head 13 Nm (9.6 lbf ft) Exhaust return module on cylinder head Step 1: 10 Nm (7.4 lbf ft) Step 2: 30 Nm (22.2 lbf ft) Lock nut, valve adjusting screw 20 ±2 Nm (14.8 ±1.5 lbf ft) Locking screw on cylinder head 34 Nm (25.2 lbf ft) Solenoid valve on cylinder head 24 Nm (17.8 lbf ft) Front cover on crankcase Step 1: 3 Nm (2.2 lbf ft) Step 2: 21 Nm (15.5 lbf ft) Drain plug on oil pan, M18 55 Nm (40.7 lbf ft) Crankcase ventilation on cylinder head 21 Nm (15.5 lbf ft) Return line to return stop valve 30 Nm (22.2 lbf ft) Return stop valve to crankcase 80 Nm (59.2 lbf ft) Impulse transmitter (crankshaft) on holder on front cover 9 Nm (6.7 lbf ft) Impulse transmitter (camshaft) on gearcase 9 Nm (6.7 lbf ft) Turbocharger on exhaust manifold 42 Nm (31.1 lbf ft) Clamping shoe injector on cylinder head 16 Nm (11.8 lbf ft) Injection lines on rail and injector, high pressure line on high-pressure pump 25 Nm (18.5 lbf ft) Fuel supply pump on holder 22 Nm (16.3 lbf ft) Holder fuel supply pump on holder 30 Nm (22.2 lbf ft) V-belt pulley on fuel supply pump 27 Nm (20.0 lbf ft) High pressure pump on crankcase, M10 Step 1: 10 Nm (7.4 lbf ft) Step 2: 50 Nm (37.0 lbf ft) Fuel control valve 30 Nm (22.2 lbf ft) Fuel pipe on high pressure pump 29 Nm (21.5 lbf ft) Fuel pipe on control block 39 Nm (28.9 lbf ft) Rail on cylinder head 30 Nm (22.2 lbf ft) Pressure relief valve on rail 100 Nm (74.0 lbf ft) Rail pressure sensor on rail 70 Nm (51.8 lbf ft) Pipe clips, fuel line fastening 30 Nm (22.2 lbf ft) Fuel line on control block, fuel filter console and rail 39 Nm (28.9 lbf ft) Fuel pipe (return) on control block 49 Nm (36.3 lbf ft) Fuel pipe (return) on cylinder head 29 Nm (21.5 lbf ft) Fuel line on fuel filter8 39 Nm (28.9 lbf ft) Fuel filter console/radiator tank on crankcase 30 Nm (22.2 lbf ft)
  • 4. Fuel pressure sensor on fuel filter console 30 Nm (22.2 lbf ft) Cover plate on cylinder cover, M6 30 Nm (22.2 lbf ft)
  • 5. Service Information Document Title: Function Group: Information Type: Date: Component locations 200 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Component locations Component position, engine D6E. The following figures show the position of a number of components on engine D6E. Figure 1 Component locations, front side 1 Engine oil filler 10 Oil dipstick 2 Transport eye 11 Power take off 3 Alternator 12 Engine oil filter 4 Fuel feed pump 13 Fuel filter 5 V-rib belt drive on crankshaft 14 Connection to E-ECU 6 V-rib belt 15 Crankcase bleeding valve 7 Automatic belt tensioner 16 High pressure fuel pump 8 Coolant pump 17 Common rail 9 Engine oil cooler 18 Injector
  • 6. Figure 2 Component locations, flywheel side 19 Crankcase bleeding valve 25 Turbocharger 20 Charge air manifold 26 Coolant inlet 21 Flywheel housing 27 Air outlet (to charge air cooler) 22 Oil pan 28 Coolant outlet 23 Starter motor 29 Exhaust manifold 24 Oil return line from turbocharger 30 Cylinder rocker arm cover
  • 7. Service Information Document Title: Function Group: Information Type: Date: Engine characteristic curve 210 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Engine characteristic curve Figure 1 Engine, characteristic curve P Output power S Engine speed T Torque be Fuel consumption
  • 8. Service Information Document Title: Function Group: Information Type: Date: Basic check, Engine 210 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Basic check, Engine NOTE! Certain tests and checks are performed with unlocked safety locking lever. Make sure that the machine cannot operate unexpectedly when the control lockout lever is unlocked. Purpose of the basic check The purpose of the basic check is to provide fast and accurate information about the general condition of the engine. The basic check should be performed and evaluated according to instructions in the PC-tool VCADS Pro. Tests included in the basic check The basic check which is divided into the following tests should be performed after reading out error codes and checking parameters. Tests: 1. 2. 3. Cylinder compression, test The purpose of the test is to show if any cylinder has a deviating compression pressure. The test replaces the old pressure check method but does not give any absolute values. Feed pressure, test The purpose of the test is to check that the feed pressure is as per specification. Sensor, test The purpose of the test is to check the function of all sensors.
  • 9. Service Information Document Title: Function Group: Information Type: Date: Troubleshooting 210 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Troubleshooting General about troubleshooting When a malfunction is suspected or has been confirmed, it is important to identify the cause as soon as possible. The starting point for all troubleshooting is that there is some type of trouble symptom or malfunction. Malfunctions can be indicated by:   generation of error codes detection of a malfunction symptom. Troubleshooting work The first step in troubleshooting is to gather information from the operator concerning the malfunction symptoms, see Electrical and information system, Collection of basic data. Then, attempt to pin-point the cause by checking in a certain order, for more information, see Electrical and information system, troubleshooting strategy. The different checking steps are:    Check error codes Check parameters Perform basic check Troubleshooting information The following is included in Electrical and information system and is used when troubleshooting: 1. 2. 3. 4. 5. 6. 7. 8. 9. Troubleshooting strategy Describes troubleshooting work, step by step. Troubleshooting, assistive devices Brief summary of the assistive devices that are available for troubleshooting. Functional checks and tests, VCADS Pro Brief description of VCADS Pro. For a detailed description, see VCADS Pro User’s Manual. Error code information Contains information regarding error code design, lists of all error codes and error code information about each error code. Components, troubleshooting and specifications Contains methods and measuring values for troubleshooting of components. Also includes wiring diagrams and certain specifications. Parameters Incorrectly set parameters may cause malfunction symptoms. The parameter list includes all limit and command values for parameters. Control units, functional description Describes the functions of the control units, inputs and outputs as well as communication between the various control units. Control units, active and passive measuring Contains measuring values for active and passive measuring of the ECUs. Software functions Describes the pre-requisite conditions for the control and monitoring functions that are performed by the software in the ECUs.
  • 10. Service Information Document Title: Function Group: Information Type: Date: Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope 210 Service Information 2015/3/13 Profile: EXC, EC160C L, EC180C L, EC160C NL [GB] Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope Op nbr 210-090 9990014 Break out harness 9990062 Cable 9998699 Adapter 88890040 Oscilloscope VCADS Pro VCADS Pro Service Tool 1. Connect 88890040 Oscilloscope to the VCADS Pro computer and perform 28420-3, Flywheel and camshaft signals, test. NOTE! Instructions for how to connect the equipment are described in the VCADS Pro operation. NOTE! To be able to start the oscilloscope operation when USB-interface is default in VCADS Pro, then 88890180 Interface must be connected to the computer. However, in this case the interface does not have to be connected to the machine. For computers with only one USB-port, the interface configuration must be changed to 9998555. However, in this cases the interface does not have to be connected to the machine. Detailed user support is available under the the menu Help in the software. NOTE! The function “Save” overwrites the original file. Therefore, choose “Save as...” to save the read-off.
  • 11. Figure 1 1. Click to start and stop the read-off Figure 2 Example of read-off of sensor signals with oscilloscope 1. 2. Signal from flywheel sensor Signal from camshaft sensor 2. Check that the signal from the camshaft sensor's signal coincides with the signal from the flywheel sensor within the marked area in the figure.   If the signal for the camshaft sensor is displaced to the left the camshaft is displaced one gear tooth in the camshaft's rotational direction. If the signal for the camshaft sensor is displaced to the right the camshaft is displaced one gear tooth opposite to the camshaft's rotational direction. For adjusting the camshaft's position, see service manual for respective engine.
  • 12. Figure 3 Relationship between camshaft signal and flywheel signal A. Area where the signal from the camshaft shall coincide with the signal from the flywheel sensor 1. 2. Flywheel sensor Camshaft sensor Figure 4 Example of incorrect signal In this case, the signal for the camshaft sensor is displaced to the left. 3. Check that the curves are not mirror-imaged (see figure). If the curves are mirror-imaged:   Check the connection to the oscilloscope. If the connection to the oscilloscope is correct, check that the connections for the crankshaft sensor are installed correctly. If needed, unplug the connector for the flywheel sensor and change place of the cable connections.
  • 13. Figure 5 Example of incorrect signal In this case, the signal for the flywheel sensor is mirror-imaged 4. Check the voltage across the camshaft sensor. To ensure reliable start and operation of the engine, the voltage across the sensors shall be according to . 3021 SE2703, description and measuring If the signal is too low:   Check that the sensor is correctly installed and adjusted. Remove the sensor and check that it is not damaged. Check the distance between the sensor and the sensor ring gear is according to . Install the sensor 386 Engine rotation speed sensor (camshaft), replacing and check the signal again. If the sensor is damaged, rotate the crankshaft and check if the camshaft gear has any damage that has caused damage to the sensor. Figure 6 A. Signal voltage camshaft sensor (V) 5. Check the voltage across the flywheel sensor. To ensure reliable start and operation of the engine, the voltage across the sensors shall be according to
  • 14. . 3021 SE2701, description and measuring If the signal is too low:   Check that the sensor is correctly installed and adjusted. Remove the sensor and check that it is not damaged. Check the distance between the sensor and the sensor ring gear/flywheel is according to . Install the sensor 386 Engine rotation speed sensor, replacing and check the signal again. If the sensor is damaged, rotate the crankshaft and check if the flywheel has any damage that has caused damage to the sensor. Figure 7 A. Signal voltage flywheel sensor (V)
  • 15. Service Information Document Title: Function Group: Information Type: Date: Cylinder head, description 211 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Cylinder head, description The cylinder head is made of grey 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. Inlet and exhaust valve size is increased to optimize the gas exchange and combustion process. Valve guides are replaceable. Coolant flow in the cylinder head is modified to accommodate an outlet controlled cooling system. 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
  • 16. Service Information Document Title: Function Group: Information Type: Date: Cylinder head gasket, description 211 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Cylinder head gasket, description The cylinder head gasket is a multi layered gasket with 1, 2 or 3 identification holes to indicate three different thicknesses available. Selection of the proper thickness of gasket is determined by the measurement of piston projection above the cylinder block sealing surface. Recalibration for the correct gasket thickness would be required if new pistons or a new cylinder block were installed. Figure 1 1. Cylinder head gasket, marking
  • 17. Service Information Document Title: Function Group: Information Type: Date: Cylinder block, description 212 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Cylinder block, description The cylinder block is cast in one piece and has wet, replaceable cylinder linings. Combustion pressure tensile breaking strength in cylinder head screws is led through stiffened sections of the cylinder block wall directly to the main bearings. The cylinder block surface should not be ground as the distance between the pistons and the valve heads may become too small. There is also a risk that injector tips will be incorrectly placed in relation to the pistons and that exhaust values will worsen.
  • 18. Service Information Document Title: Function Group: Information Type: Date: Cylinder, description 213 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Cylinder, description Figure 1 Cylinder liner 1 Cylinder liner 2 Crankcase 3 Liner projection: 0.07 - 0.12 mm D6E engine with a bore about 98 mm (3.86 in) is provided with dry, plateau-honed slip-fit cylinder liners. In case of damage, the cylinders of the D6E series are repaired by replacing the slip-fit liners.
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  • 20. Service Information Document Title: Function Group: Information Type: Date: Pistons, description 213 Service Information 2015/3/13 Profile: EXC, EC160C NL [GB] Pistons, description D6E Engine 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