Road machine
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
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
Paver D5 engine
1. 1 2. 3. 4 4. 5. 6.
Combustion C b ti air i i inlet l t Coolant out let Coolant inlet Connection charge air cooler Exhaust outlet Starter
Paver D5 engine
Valves: 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
Crank mechanism
Piston - 010304
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
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
The piston cooling nozzle made of plastic are fitted in the main bearing pedestals
D5 engine training Road machine
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
D5 engine training Road machine
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.
Paver D5 engine
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
Paver D5 engine
Fuel schematic
Paver D5 engine
4. Fuel filter
7. Injector
9. Diesel Tank
D5 engine training Road machine
Radiator
Paver D5 engine
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
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
Paver D5 engine
Charging g g
From filter
C Compressor Turbine Turbo charger with charge air cooling Advantages: g Volumetric efficiency of engine increases Increase Horse Power Emission improved Compact in size
To CAC
Paver D5 engine
Engine exhaust
Volvo Construction Equipment
Global CST- Training 199 2012-12-20
Paver D5 engine
1. Fuel shut off solenoid operates when th there i is i ignition iti supply l 2nd position iti 2. Fuel shut off solenoid + excess fuel solenoid in 3rd start position
D5 engine training Road machine
1. Fuel shut off solenoid operates when th there i is i ignition iti supply l 2nd position iti 2. Fuel shut off solenoid + excess fuel solenoid in 3rd start position
Electrical Harness Installation SD110
Fuel sender
Mechanical governor g
Governor adjustment screws Full load J Torque maximum NA based fuel charge G E G E J
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
EK code - 030114
A measurement - 030115
Reinstallation - 030120
From value TS to SS
F I P installation, step p1
F I P installation, step p2
Fuel Lts 423 551 523 600 620 590 450 597 580 620 5554
Lube oil 2 2 2 2 2 2 2 2 2 2 20
Date 15.2 12 16.2.12 17.2.12 18.2.12 19.2.12 20 2 12 20.2.12 21.2.12 22.2.12 23.2.12 24.2.12
Driver Paul
Example
Shashi
Ballal
Ramalu