Volvo EW60C Compact Wheel Excavator Service Repair Manual Instant Download

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Service Information
Document Title Engine, description Function Group 200 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Engine, description D3.4D Engine The D3.4D
configuration is a four stroke, straight four
cylinder, direct injected, water cooled diesel
engine. The engine produces powerful performance
using direct injection type combustion
chamber. The valve mechanism receives its
movement from the camshaft via rods and rocker
arms. Turning direction is counter- clockwise
seen from the flywheel. Firing order is 1-3-4-2
and the first cylinder is on the flywheel
side. The lubrication system consists of forced
lubrication with trochoid pump. The cooling of
the engine is performed by a high capacity
radiator and a hydraulic oil cooler.
Figure 1 Engine, D3.4D
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Service Information
Document Title Engine, identification Function Group 200 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C 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
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Service Information
Document Title Engine, tightening torque Function Group 200 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Engine, tightening torque Tightening torque,
unit Nm (lbf ft)
Item Nominal size Tighten torque Lubricating oil application (thread portion, and seat surface)
Cylinder head screw M 11 1.25 103.1 112.9 (76 83) Applied
Connecting rod screw M10 1.0 53.9 58.8 (40 43) Applied
Flywheel set screw M14 1.5 186.2 205.8 (137 152) Applied
Bearing cap set screw M 11 1.25 108.1 117.9 (80 87) Applied
Crankshaft pulley set screw M14 1.5 107.9 127.5 (80 94) Applied
Fuel injection nozzle set screw M 8 1.25 22.6 28.4 (17 21) Not applied
Fuel feed pump drive gear set nut M 18 1.5 113 123 (83 90) Not applied
High-pressure fuel lines screw M 12 1.5 19.6 24.5 (174 217) Not applied
Fuel return pipe joint screw M 6 1.0 7.8 9.8 (70 86) Not applied
Tightening torque for standard screws and nuts,
unit Nm (lbf ft)
Item Nominal size Tighten torque Lubricating oil application (thread portion, and seat surface)
Screw (7T) and nut M 6 1.0 9.8 11.8 (7 9) Use 80 of the value at left when the tightening part is aluminium. Use 60 of the value at left for 4T screws and lock nuts.
Screw (7T) and nut M 8 1.25 22.6 28.4 (17 21) Use 80 of the value at left when the tightening part is aluminium. Use 60 of the value at left for 4T screws and lock nuts.
Screw (7T) and nut M 10 1.5 44.1 53.9 (33 40) Use 80 of the value at left when the tightening part is aluminium. Use 60 of the value at left for 4T screws and lock nuts.
Screw (7T) and nut M 12 1.75 78.4 98 (58 72) Use 80 of the value at left when the tightening part is aluminium. Use 60 of the value at left for 4T screws and lock nuts.
Screw (7T) and nut M 14 1.5 127.5 147.1 (94 108) Use 80 of the value at left when the tightening part is aluminium. Use 60 of the value at left for 4T screws and lock nuts.
Screw (7T) and nut M 16 1.5 215.7 235.4 (157 174) Use 80 of the value at left when the tightening part is aluminium. Use 60 of the value at left for 4T screws and lock nuts.
PT plug 1/8 9.8 (7)
PT plug 1/4 19.6 (14)
PT plug 3/8 29.4 (22)
PT plug 1/2 58.5 (43)
Pipe joint screw M 8 12.7 16.7 (9 12)
Pipe joint screw M 10 19.6 25.5 (14 19)
Pipe joint screw M 12 24.5 34.3 (18 25)
Pipe joint screw M 14 39.2 49 (29 36)
Pipe joint screw M 16 49 58.8 (36 43)
NOTE! Lubricating oil is not applied to threaded
portion and seat surface.
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Service Information
Document Title Precautions Function Group 200 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Precautions Make preparation as follows before
starting engine inspection and service.
WARNING
Risk of personal injury. Very heavy object. Be
sure to fix the engine securely to prevent injury
or damage due to parts falling during the work.
WARNING

• Risk of personal injury! Wear safety glasses and
  use protective gloves.
• Always wear glasses or a protective face shield
  when using compressed air or steam to prevent any
  foreign matter from getting into the eyes.
• Fix the engine on a horizontal base.
• Remove the coolant hoses, fuel oil pipes, wire
  harness, control wires etc. connecting the driven
  machine and engine, and drain coolant,
  lubricating oil and fuel.
• Remove soil, oil, dust, etc. from the engine by
  washing with solvent, air, steam, etc. Carefully
  operate so as not to let any foreign matter enter
  the engine.
• Any part which is found defective as a result of
  inspection or any part whose measured value does
  not satisfy the standard or limit shall be
  replaced.
• Any part predicted to dissatisfy the standard or
  limit before the next service as estimated from
  the state of use should be replaced even when the
  measured value then satisfies the standard or
  limit.

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Service Information
Document Title Maintenance standards Function Group 200 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Maintenance standards Engine service standard
Inspection item Inspection item Inspection item Unit Standard Limit
Intake / Exhaust Valve Clearance Intake / Exhaust Valve Clearance Intake / Exhaust Valve Clearance mm (inch) 0.15 0.25 (0.006 0.010)
Fuel injection pressure Fuel injection pressure Fuel injection pressure MPa (kgf/cm2) (psi) (bar) 21.6 22.6 (220 230) (3129 3271) (21.6 225.6)
Compression at 250 rpm Compression at 250 rpm Compression at 250 rpm MPa (kgf/cm2) (psi) (bar) 3.43 0.09 (35 1) (498 14) (34.3 0.98) 2.74 0.09 (28 1) (398.2 14.2) (27.4 0.98)
Coolant capacity (engine only) Coolant capacity (engine only) Coolant capacity (engine only) Liters (US gal) 4.2 (1.1)
Lubricating oil capacity (oil pan) Lubricating oil capacity (oil pan) High Liters (US gal) 11.6 (3)
Lubricating oil capacity (oil pan) Lubricating oil capacity (oil pan) Low Liters (US gal) 5.2 (1.4)
Oil pressure switch operating pressure Oil pressure switch operating pressure Oil pressure switch operating pressure MPa (kgf/cm2) (psi) 0.04 0.06 (0.4 0.6)) (5.8 8.8))
Thermostat Valve opening temperature Valve opening temperature C (F) 82 (179.6)
Thermostat Full opening lift (temperature) Full opening lift (temperature) mm (inch) / C (F) 8 (0.32) or more / 95 (203)
Coolant Temperature Switch Coolant Temperature Switch Coolant Temperature Switch C (F) 107 113 (225 235)
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Service Information
Document Title Special tools Function Group 200 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Special tools Special tools Special tools
Tool name Applicable model and tool size Illustration
Valve guide tool (for extracting valve guide) Part number 14527850 Drift l1 20 mm (0.787 in) l2 75 mm (2.953 in) d1 6.5 mm (0.256 in) d2 10 mm (0.394 in)
Valve guide tool (for inserting valve guide) Part number 14527851 Drift l1 7 mm (0.276 in) l2 60 mm (2.362 in) d1 13 mm (0.512 in) d2 16 mm (0.630 in)
Connecting rod bushing replacer (for removal/installation of connecting rod bushing) Part number 14527852 Drift l1 20 mm (0.787 in) l2 100 mm (3.937 in) d1 30 mm (1.181 in) d2 33 -0.3/-0.6 mm (1.299 -0.012/-0.024 in)
Valve spring compressor (for removal/installation of valve spring) Part number 8931-00060 Press tool
Stem seal inserter (for inserting stem seal) Part number 14527853 Drift l1 11.8 mm (0.465 in) l2 65 mm (2.559 in) l3 4 mm (0.157 in) d1 15.2 mm (0.598 in) d2 21 mm (0.827 in) d3 12 mm (0.472 in)
Filter wrench (for removal/ installation of lubrication oil filter) Available on the market
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Camshaft bushing tool (for removing camshaft bushing) Part number 8931-00080 Installation tool l1 18 mm (0.709 in) l2 70 mm (2.756 in) d1 50 -0.3/-0.6 mm (1.967 -0.012/-0.024 in) d2 53-0.3/-0.6 mm (2.087 -0.012/-0.024 in)
Flexhone (for rehoning of cylinder liner) Applicable bore 89 101 mm (3.504 3.976 in)
Piston insertion tool (for inserting piston) The above piston insertion tool is applicable to 60 125 mm (2.362 4.921 in) diameter piston.
Piston ring replacer (for removal/ installation of piston ring) Available on the market
Measuring tools Measuring tools
Instrument name Application Illustration
Dial gauge Measurements of shaft bending, strain and gap of surface
Test indicator Measurements of narrow or deep portions that cannot be measured by dial gauge.
Magnetic stand For holding the dial gauge when measuring using a dial gauge, standing angles adjustable
Micrometer For measuring the outside diameter of crankshaft, pistons, piston pins, etc.
Cylinder gauge For measuring the side diameters of cylinder liners, rod metal, etc.
Callipers For measuring outside diameters, depth, thickness and width
Depth micrometer For measuring of valve sink
Square For measuring valve spring inclination and straightness of parts
Vblock For measuring shaft bend
Torque wrench For tightening nuts and screws to the specified torque
Feeler gauge For measuring gaps between ring and ring groove, and shaft joints during assembly
Cap tester For checking water leakage
Battery/coolant tester For checking concentration of antifreeze and the battery electrolyte charge status
Nozzle tester For measuring injection spray pattern of fuel injection nozzle and injection pressure
Digital thermometer For measuring temperature
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Speedometer (contact type) For measuring revolution by contacting the mortise in the revolving shaft
Speedometer (photoelectric type) For measuring revolution by sensing the reflecting mark on the outer periphery of the revolving shaft Revolving shaft Reflection mark
Circuit tester For measuring resistance voltage and continuity of electrical circuits
Compression gauge kit Part number 14546935 For measuring compression pressure
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Service Information
Document Title Component locations Function Group 200 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Component locations Component position, engine
D3.4D. The following figures show the position of
a number of components on engine D3.4D.
Figure 1 Component locations, front side
1 Water separator 8 Coolant temperature sensor 15 Engine oil cooler
2 Fuel control PWM valve (Governor) 9 Coolant pump 16 Engine oil filter
3 Fuel filter 10 Crankshaft V-pulley 17 Engine oil drain plug
4 Fuel return line 11 V-belt 18 Engine oil dipstick
5 Fuel supply line 12 Side filler port (engine oil) 19 Oil pressure switch
6 Top filler port (engine oil) 13 Fuel injection pump 20 Fuel feed pump
7 Thermostat 14 Speed sensor
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Figure 2 Component locations, flywheel side
21 Lifting bracket 26 Starter motor
22 Rocker arm cover 27 Cylinder block
23 EGR vavle 28 Exhaust manifold
24 Flywheel 29 Alternator
25 Oil pan
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Service Information
Document Title Engine characteristic curve Function Group 210 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Engine characteristic curve
Figure 1 Engine characteristic curve (Gross power)
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Service Information
Document Title Cylinder head, description Function Group 211 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Cylinder head, description The cylinder head,
which covers all cylinders, is a sixteen valve
cylinder head. The cylinder head has two inlet
valves and two exhaust valves for each cylinder.
Figure 1 Cylinder head with valve mechanism
1. Cylinder head 7. Spring guide
2. Exhaust valve 8. Guide
3. Inlet valve 9. Spring
4. Plug 10. Seal
5. Yoke 11. Guide
6. Valve collet
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Service Information
Document Title Exploded view, cylinder head Function Group 211 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Exploded view, cylinder head
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Figure 1 Exploded view, cylinder head
1 Crankcase breather cover 19 Cylinder head
2 Diaphragm spring 20 Intake valve
3 Diaphragm cup 21 Exhaust valve
4 Crankcase breather diaphragm 22 Cylinder head gasket
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5 Oil fill cap 23 Fuel injector nozzle protector
6 Valve cover nut 24 Fuel injector nozzle seat
7 Valve cover nut O-ring 25 Valve spring
8 Valve cover gasket 26 Valve bridge guide
9 Support bolt 27 Spring retainer
10 Rocker arm shaft support 28 Valve keepers
11 Wave washer 29 Valve bridge
12 Fuel injector retainer bolt 30 Valve bridge seat
13 Valve adjusting screw (primary) 31 Valve adjusting screw lock nut (secondary)
14 Valve adjusting screw lock nut (primary) 32 Valve adjusting screw (secondary)
15 Rocker arm shaft aligning stud 33 Push rod
16 Fuel injector retainer 34 Rocker arm shaft
17 Valve stem seal 35 Crankcase breather components
18 Valve guide 36 Valve cover
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Service Information
Document Title Cylinder head, disassembly/assembly Function Group 211 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Cylinder head, disassembly/assembly Op nbr 2111

• Disassemble in the order of the numbers shown in
  the illustration. (service point)
• Remove the alternator assembly. (service point 1)
• Remove the fan, pulley and Vbelt.
• Remove the thermostat case. (service point 2)
• Remove the fuel filter and fuel oil piping.
  (service point 3)
• Remove the oil level gauge assembly.
• Remove the oil filter. (service point 4)
• Remove the fuel injection pipes. (service point
  5)
• Remove the intake manifold assembly.
• Remove the exhaust manifold assembly.

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• The belt deflection shall be checked according to
  Inspection after initial 50 hours operation.
• Replace the belt with a new one if cracked, worn
  or damaged.

• Figure 2
• Adjustment, V-belt tension
• Bar
• Adjuster
• Alternator
• Carefully prevent the belt from being smeared
  with oil or grease.
• Point 2
• Reassembly
• Check the thermostat function.
• Point 3
• Reassemble
• Replace the fuel filter element with a new one.

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• Disassemble
• Loosen the cylinder head screws in two steps in
  the illustrated order.

• Figure 3
• Head screw disassembly order
• 1. Fan side
• Place the cylinder head assembly on cardboard to
  prevent any damage to the combustion face.
• Reassemble
• Replace the head gasket with a new one.

• Figure 4
• Head screw tightening order
• 1. Fan side
• Uniformly install the head screws manually after
  applying oil on the threads and seat portions.
• They shall be tightened in two steps in the
  reverse of the order for disassembly. Tightening
  torque
• First step 5 6 kgfm (36.1 43.3 lbfft)
• Second step 10.5 11.5 kgfm (75.8 83.0
  lbfft)
• Point 8
• Disassemble
• Carefully remove the fuel injection valve so as
  not to leave the tip end protector from being
  left inside the cylinder.
• Reassemble
• Replace the fuel injection valve protector with a
  new one.

Figure 5 Valve spring compressor
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• Keep each removed inlet/exhaust valve after
  attaching a tag showing the corresponding
  cylinder number.
• If cotter burr is seen at the shaft of each
  inlet/exhaust valve stem, remove it with an
  oilstone and extract the valve from the cylinder
  head.
• Reassemble
• Replace the stem seal with a new one when an
  intake/exhaust valve is disassembled.
• Carefully install each valve after oil
  application so as not to damage the stem seal.
• Different stem seals are provided for the intake
  and exhaust valves. Do not confuse them since
  those for exhaust valves are marked with yellow
  paint.
• After assembling the intake/exhaust valve, stem
  seal, valve spring, seat, and cotter, tap the
  head of the valve stem lightly for settling.
• Do not forget to install the valve cap.

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Service Information
Document Title Cylinder head, parts inspection and measurement Function Group 211 Information Type Service Information Date 2014/3/30
Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB Profile CEX, EW60C GB
Cylinder head, parts inspection and
measurement Cylinder head Clean the cylinder
head, mainly the combustion surface, valve seats
and intake/exhaust ports, remove carbon deposit
and bonding agent, and check the surface state.

• Figure 1
• Distortion at combustion surface
• Straight edge
• Feeler gauge

• Appearance check
• Check mainly discoloration and cracks. If a crack
  is suspected, perform dye check. Combustion
  surface distortion
• Apply a straightedge in two diagonal directions
  and on four sides of the cylinder head, and
  measure distortion with a feeler gage

?
Combustion surface distortion, unit mm (in)
Standard Limit
Distortion 0.05 (0.002) or less 0.15 (0.0059)

• Valve sink
• Measure with the valve inserted to the cylinder
  head.

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