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 i inlet 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 of f 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

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Global CST- Training 172 2012-12-20

D5 engine training Road machine

Cylinder y head valves - 010202

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

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Global CST- Training 173 2012-12-20

D5 engine training Road machine

Crank mechanism - 010301

D5 engine training Road machine

Crank mechanism

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Global CST- Training 174 2012-12-20

Crank mechanism - 010302

D5D & D7D: Wet liner replaceable

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Global CST- Training 175 2012-12-20

D5 engine training Road machine

Crank mechanism - 010303

Connecting rod: 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

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Global CST- Training 176 2012-12-20

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
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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
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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
Paver D5 engine

Volvo Construction Equipment

Global CST- Training 180 2012-12-20

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 l located di in oil il cooler l housing 10 bar

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

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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 4. 5. 6. Outer Rotor Driven from crank shaft Safety valve

Volvo Construction Equipment

Global CST- Training 182 2012-12-20

D5 engine training Road machine

Piston Cooling g Nozzle - 020301

The piston cooling nozzle made of plastic are fitted in the main bearing pedestals
D5 engine training Road machine

Volvo Construction Equipment

Global CST- Training 183 2012-12-20

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
D5 engine training Road machine

Volvo Construction Equipment

Global CST- Training 184 2012-12-20

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.

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Global CST- Training 185 2012-12-20

D5 engine training Road machine

Mechanical single g injection j pump p p system y

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Global CST- Training 186 2012-12-20

Paver D5 engine

Fuel system y - 030105

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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

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Global CST- Training 188 2012-12-20

Paver D5 engine

Fuel schematic

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Global CST- Training 189 2012-12-20

Paver D5 engine

Fuel block diagram g

1. Diesel Tank 2. Water separator 3. Feed pump

4. Fuel filter

5. Fuel supply to fuel control unit / Control block

6. U. I High pressure pump

7. Injector

8. Excess 8 cess leak ea return eu

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Global CST- Training 190 2012-12-20

9. Diesel Tank
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 out Coolant t let l t Compensation line Venting pipe
Paver D5 engine

Volvo Construction Equipment

Global CST- Training 191 2012-12-20

Schematic outlet controlled cooling g system y

Expansion Tank Water out let Thermostat Water inlet

Water Pump Engine oil cooler

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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

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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

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Global CST- Training 195 2012-12-20

D5 engine training Road machine

Fuel system y cylinder y No p positions 030113

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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
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

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 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

Volvo Construction Equipment

Global CST- Training 200 2012-12-20

Excess fuel solenoid

1. Excess fuel solenoid 2. Sensor Not applicable

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

Volvo Construction Equipment

Global CST- Training 201 2012-12-20

Engine g oil pressure p switch

Engine oil pressure switch

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Global CST- Training 202 2012-12-20

D5 engine training Road machine

Engine g water temperature p switch

Engine Water temperature switch

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Global CST- Training 203 2012-12-20

D5 engine training Road machine

Engine g glow g plug p g

Engine Glow plug Time - 8 seconds Temperature 950 0 c

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Global CST- Training 204 2012-12-20

D5 engine training Road machine

Diesel tank fuel sender

Fuel sender

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Global CST- Training 205 2012-12-20

D5 engine training Road machine

Mechanical governor g

Governor adjustment screws Full load J Torque maximum NA based fuel charge G E G E J

Excess fuel start solenoid

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Global CST- Training 206 2012-12-20

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

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Global CST- Training 207 2012-12-20

D5 engine training Road machine

Removing g the Starter motor

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Global CST- Training 208 2012-12-20

D5 engine training Road machine

Installing g the Starter motor

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Global CST- Training 209 2012-12-20

D5 engine training Road machine

EK code - 030114

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Global CST- Training 210 2012-12-20

D5 engine training Road machine

A measurement - 030115

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Global CST- Training 211 2012-12-20

D5 engine training Road machine

Dimensions, definitions - 030116

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Global CST- Training 212 2012-12-20

D5 engine training Road machine

Theoretical shim thickness - 030118

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Global CST- Training 213 2012-12-20

D5 engine training Road machine

Actual shim thickness - 030119

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Global CST- Training 214 2012-12-20

D5 engine training Road machine

Reinstallation - 030120

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Global CST- Training 215 2012-12-20

D5 engine training Road machine

Special p tools - 030121

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Global CST- Training 216 2012-12-20

D5 engine training Road machine

Unit p pump p installation - 030122

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Global CST- Training 217 2012-12-20

D5 engine training Road machine

Unit p pump p installation - 030123

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Global CST- Training 218 2012-12-20

D5 engine training Road machine

Assembly y injection j p pump p

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Global CST- Training 219 2012-12-20

D5 engine training Road machine

Unit injection j pump p p system y

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Global CST- Training 220 2012-12-20

D5 engine training Road machine

Explanation p Lo & EP- code for D5D engines g

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Global CST- Training 221 2012-12-20

D5 engine training Road machine

EP-Code on identification plate p

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Global CST- Training 222 2012-12-20

D5 engine training Road machine

Determination compensation p shim

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Global CST- Training 223 2012-12-20

D5 engine training Road machine

From value TS to SS

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Global CST- Training 224 2012-12-20

D5 engine training Road machine

F I P installation, step p1

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D5 engine training Road machine

F I P installation, step p2

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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 9 12 13 11 13 14 10 11 12 13 118
Global CST- Training 227 2012-12-20

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

Volvo Construction Equipment

D5 engine training Road machine

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 Calculation: 5554 l = 100% 20 l = x X= 100 % 20 L 5554 L = 0.36 %

Volvo Construction Equipment

Global CST- Training 228 2012-12-20

D5 engine training Road machine