Volvo EC135B LC EC135BLC Excavator Service Repair Manual Instant Download

1
Service Information
Document Title Engine, description Function Group 200 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB
Engine, description The engine is a 4-cylinder,
4-stroke, direct injected, turbocharged,
aftercooled with a cast iron block and cylinder
head. Gears in the engine gear case are hardened
helical type for strength and reduced noise,
arranged to provide quiet, smooth transmission
of power. The cylinder block and head are
designed with internal passages forming galleries
for both lubricating oil and coolant. The fan
belt is a poly type V-belt for improved
performance and an auto tension adjuster
maintains belt tension. Starter side view

• Figure 1
• Engine, starter side view
• Coolant inlet
• Coolant outlet
• Exhaust turbocharger
• Exhaust manifold
• Air intake manifold
• Flywheel housing
• Starter

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8. Oil pan Alternator side view

• Figure 2
• Engine, Alternator side view
• Alternator
• Engine lifting bracket
• Coolant outlet
• Coolant inlet
• Fan pulley
• Poly - V-pulley with vibration damper
• Poly - V-belt tension pulley
• Coolant pump
• Fuel pump
• Top view

3

• Figure 3
• Engine, top view
• Engine oil filter
• Fuel filter
• Fuel filter side view

4
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• Figure 4
• Engine, fuel filter side view
• Lube oil pressure port (M14 1.5)
• Fuel filter
• Engine oil filter
• Flywheel end view

6

• Figure 5
• Engine, flywheel end view
• Coolant temperature check port
• Coolant temperature sensor port

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Service Information
Document Title Engine characteristic curve Function Group 210 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB
Engine characteristic curve Engine characteristics
Item Specification
Maximum power (Net) 94 PS (69 kW) / 2100 rpm
Maximum torque (Net) 38 kgfm (274 lbfft, 372 Nm) / 1500 rpm
Minimum fuel consumption 157 g / PSh
Rated fuel consumption 163 g / PSh
Figure 1 Engine, characteristic curve
P Power
T Torque
FC Fuel consumption
S Speed
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Service Information
Document Title Cylinder head, description Function Group 211 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB
Cylinder head, description The cylinder head of
the D4D engine is made of grey cast iron and
designed as block type head. The combustion air
enters vertically and the exhaust air is
discharged laterally. Inlet and outlet are
located on one side of the cylinder head.
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Service Information
Document Title Determining cylinder head gasket Function Group 211 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB

• Determining cylinder head gasket
• The thickness of the cylinder head gasket is
  responsible for the correct piston crown
  clearance of the engine. The piston crown
  clearance (0.65 mm) essentially influences the
  combustion and thus
• Power
• Fuel consumption
• Exhaust emission
• The piston crown clearance is adjusted by
  determining the piston projection and the
  thickness of the cylinder head gasket.
• Measuring piston projection
• A dial gauge with a fixture is needed to measure
  the piston projection.
• The piston is in its TDC position above the
  cylinder block face.

Figure 1 Measurement, piston projection
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• Dial gauge
• Bridge
• Two spacer plates
• Set the dial gauge on the level of the cylinder
  block face to "zero".
• Position the dial gauge at measuring points (C),
  at the piston pin axis, on the piston and
  determine the maximum projection.
• Measuring points on the piston.
• Distance X 90 mm
• This measurement is performed on each piston. The
  maximum measured piston projection determines the
  thickness of the cylinder head gasket (see
  table). There are 3 different gasket thicknesses
  identified by bores (4)
• 1 bore 1.2 mm
• 2 bores 1.3 mm
• 3 bores 1.4 mm
• Piston projection

Piston projection Identification of cylinder head gasket
0.33 0.55 mm 1 bore
0.56 0.65 mm 2 bores
0.66 0.76 mm 3 bores
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Service Information
Document Title Fitting cylinder head Function Group 211 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB
Fitting cylinder head Op nbr 21182

1. Prior to fitting the cylinder head onto the
   crankcase, the sealing surfaces for the cylinder
   head gasket must be clean and free from oil. Pay
   attention to dowel sleeves.
2. Lightly oil the cylinder head bolts.
3. It is absolutely necessary to observe the bolt
   tightening order in the adjacent schematic.

• Figure 1
• Tightening order (exhaust manifold side)
• Tightening torque specification
• 1st step 30 Nm (22.2 lbfft, 3.1 kgfm)
• 2nd step 80 Nm (59 lbfft, 8.2 kgfm)
• 3rd step 90 turn
• Tightening order

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Service Information
Document Title Cylinder, description Function Group 213 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB
Cylinder, description
Figure 1 Cylinder liner D4D engine with a bore
about 101 mm (3.98 in) has a crankcase with
integrated cylinder liners (1), i.e. crankcase
and non- replaceable liners form one casting.
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Service Information
Document Title Pistons, description Function Group 213 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB
Pistons, description

• Figure 1 Piston
• The pistons of the D4D engine are made of a
  special aluminium alloy. The piston bowl has a
  small amount of eccentricity to the piston axis.
• The piston must be installed so that flywheel
  symbol (1) on the piston top faces the flywheel.
• The pistons are equipped with 3 piston rings. The
  1st ring has a ring carrier (2) of cast iron.
• The cross section of the 1st piston ring is
  asymmetrical. The cross section of the 2nd piston
  ring is conical (compression ring). When
  installing the piston, the TOP mark at the ring
  gap must point upwards. The 3rd ring is the
  bevelled-edge oil control ring.

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Service Information
Document Title Piston cooling Function Group 213 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB
Piston cooling
Figure 1 Piston cooling The piston is cooled by
spraying lube oil against the inside of the
piston top. The 2-hole piston cooling nozzles
made of plastic are fitted in the main bearing
pedestals.
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Service Information
Document Title Valves, description Function Group 214 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB

• Valves, description
• The engine is provided with one inlet and one
  exhaust valve per cylinder. The valve guides are
  shrunk in the cylinder head. The valve seat
  inserts are made of high-quality steel and are
  also shrunk in the cylinder head.
• The valves are turned by eccentric actuation
  through the rocker arms. The new compressed cone
  connection permits easy turning of the valve
  despite stress load.
• NOTE!
• The valve springs of the D4D have a special
  installation direction. The colored mark on the
  spring must show to the bottom.
• Rocker arm lubrication is integrated in the lube
  oil circuit. The oil is supplied via tappets and
  push rods.
• Valve seat angle

Inlet Exhaust
30 45
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Service Information
Document Title Valves, adjusting Function Group 214 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB
Valves, adjusting Op nbr 21412
The valve clearance must be checked and adjusted
at specified intervals. To do this, the engine
oil temperature must be between 20 C (68 F)
and 80 C (176 F). Valve clearance adjustment
Item mm inch
Inlet valve 0.3 0.012
Exhaust valve 0.5 0.020
Adjustment 1. Remove rocker cover.

• Figure 1
• Adjustment, valve clearance
• Turn crankshaft until both valves in cylinder 1
  overlap (exhaust valve about to close, inlet
  valve about to open).
• Adjust clearance of valves marked in black in
  figure. Mark respective rocker arm with chalk to
  show that adjustment has been done.
• Turn crankshaft one full revolution (360). Now
  adjust clearance of valves marked black in figure.

Figure 2 Adjustment, valve clearance
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Service Information
Document Title Camshaft and timing gears, description Function Group 215 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB
Camshaft and timing gears, description

• Figure 1
• Camshaft and timing gears
• Camshaft gear with marking
• PTO, e.g. hydraulic pump
• PTO, e.g. air compressor
• Crankshaft gear with markings
• Camshaft
• The camshaft is mounted on 5 bearings. The
  running surfaces of bearings and cams are
  induction-hardened.
• Each bearing runs in a bearing bushing pressed
  into the crankcase. There is one inlet, exhaust
  and injection pump cam per cylinder. The axial
  stop for the camshaft is located in the timing
  chest cover.
• Timing gears
• The timing gears are arranged on the flywheel
  end. Gears for the auxiliary drive of the air
  compressor are clearance- optimized. The drive
• Camshaft (injection pumps and valve gear)
• 1st PTO (hydraulic pumps)

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Service Information
Document Title Crankshaft, description Function Group 216 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB
Crankshaft, description

• The forged crankshaft of the D4D engine is
  provided with integrated balance weights. The
  drive gear for the timing gears and the flywheel
  flange are shrunk on.

• Figure 2
• Fillet radii on the bearing journal
• The material microstructure of the fillet radii
  on the bearing journals is strengthened by
  rolling.
• Remachining of the fillet radii is therefore not
  permissible.

• Figure 3
• Allowable repair limit
• In case of repair, there is available one
  undersize of 0.25 mm (referred to the diameter)
  for the crank pins and main bearing journals.

• Figure 4
• Allowable thrust bearing face repair limit
• The thrust bearing face can only be remachined
  once (oversize 0.4 mm, 0.2 mm each side).
• Thrust bearing clearance of the crankshaft in
  installed condition 0.1 to 0.28 mm (0.004 to
  0.011 in).

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Service Information
Document Title Connecting rod, description Function Group 216 Information Type Service Information Date 2015/3/16
Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB Profile EXC, EC135B LC GB

• Connecting rod, description
• The connecting rod of forged steel is fitted at
  the big end bearing bore with a balance weight
  (1) in order to compensate the manufacturing
  tolerances with regard to weight and position of
  the center of gravity.
• The number markings (A) on the big end eye and
  the bearing cap must be on one side and
  identical.
• Locating lugs (2) are provided in the lower and
  upper bearing shells to prevent the bearing
  shells from rotating in their seat these lugs
  engage in oblong shaped grooves in the big end
  eye and big end bearing cap.
• The piston must be so installed that the flywheel
  symbol (B) on the piston top faces the flywheel.
• When assembling connecting rod and piston, the
  centering pins (3) for locating the connecting
  rod bearing cap must be fitted on the upper face
  of the piston on the side of the flywheel symbol
  (B).

Figure 1 Connecting rod
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