Volvo EW140B Wheeled Excavator Service Repair Manual Instant Download

1
Service Information
Document Title Description D5D Function Group 200 Information Type Service Information Date 2014/7/4 0
Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB
Description D5D The D5D engine is a straight,
four cylinder, direct-injection, four-stroke,
diesel engine, with electronically controlled
fuel injection EMR (Engine Management
System). The engine meets the emission
requirements according to EURO2. The engine
number is stamped on the name plate and on the
right side of the cylinder block. Model and
serial number must always be indicated when
ordering spare parts.
2
Service Information
Document Title Precaution for replacing the engine Function Group 210 Information Type Service Information Date 2014/7/4 0
Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB
Precaution for replacing the engine The E-ECU
contains an engine specific data set, and this is
fixedly assigned to each engine. So in case of
the engine replacement, the new E-ECU should be
ordered together with the new engine, and should
be programmed with the correct data set.
3
Service Information
Document Title Engine, removing Function Group 210 Information Type Service Information Date 2014/7/4 0
Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB
Engine, removing Op nbr 210-01 14360000 Vacuum
pump Lifting links, min. 1000 kg
WARNING

• Risk of burns - stop the diesel engine and allow
  it to cool down before starting any work.
• Plug and mark all hoses and connections when
  disconnecting.
• To facilitate the work, remove the counterweight,
  see 716 Counterweight, removing.
• Remove the covers under the engine. Remove the
  covers over the engine.

• 3.
• Figure 1 Frame
• Cover
• Frame
• Detach the outer frame and lift away the frame
  together with the cover.

4
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5
4. Figure 2 Engine/hydraulic compartment 1. Interm
ediate wall Remove the intermediate wall.
5. Figure 3 Engine/hydraulic compartment 1. Frame
Remove the remaining framework.
6. Figure 4 Draining coolant 1. Drain
valve Drain the coolant into a clean vessel by
connecting the drain hose to the drain valve on
the radiator.
6
7. Connect the vacuum pump, see 900 Vacuum pump,
connection.

• 8.
• Figure 5 Working pump
• Connector
• LS-hose
• Leak-off oil hoses
• Pressure hoses
• Suction line
• Disconnect the suction line at the connection on
  the working pump.
• Disconnect leak-off oil hoses, pressure hoses and
  the LS-hose from the working pump. Detach the
  connector from the working pump.
• NOTE!
• Mark and plug and the suction line and other
  hoses with metal plugs to maintain pressure, as
  the vacuum pump will be disconnected further on
  in the instructions.

• 9.
• Figure 6 Working pump
• Hydraulic hoses
• Attachment

7
Detach the hoses from the attachment.

• 10.
• Figure 7 Servo/steering pump
• Suction line
• Tank line
• Servo pressure hose
• Hose to fan motor, hydraulic oil cooler
• Hose to brake valve
• Disconnect the suction line at the joint between
  pipe and hose and disconnect the other hoses from
  the servo/ steering pump.
• NOTE!
• Mark and plug and the hoses with metal plugs to
  maintain pressure, as the vacuum pump will be
  disconnected further on in the instructions.
• 11. Turn off the vacuum pump and turn off the
  battery disconnect switch.

12. Figure 8 Exhaust pipe 1. Joint between
turbocharger and exhaust pipe Detach the
turbocharger from the exhaust pipe.
8
13. Figure 9 Underside of silencer
bracket 1. Attaching bolts Secure the silencer
and bracket with a strap. Remove the attaching
bolts for the silencer bracket and remove the
silencer and bracket.
14. Figure 10 Heat radiation shield over starter
motor 1. Heat radiation shield Remove the heat
radiation shield over the starter motor.
15.
9
Figure 11 Engine
1 Ground cable 6 Lower cooling hose
2 Starter motor cable harness 7 Hose
3 Preheating cable harness 8 AC compressor
4 Upper intercooler hose 9 Induction hoses to turbocharger
5 Upper cooling hose
Disconnect the ground cable from the
engine. Detach the starter motor cable harness
from the engine. Detach the preheating cable
harness from the engine. Disconnect the upper
intercooler hose and the upper and lower cooling
hoses from the engine. Disconnect the hose from
the engine. Disconnect the induction hoses from
the turbocharger. Detach the AC compressor from
the bracket. NOTE! Do not disconnect the hoses
from the AC compressor.
16. Figure 12 Engine
1 EMR cable harness 4 Fuel hose, return
2 Alternator cable harness 5 Fuel hose, pump
3 Cooling hoses 6 Lower intercooler hose
Detach the EMR and alternator cable harnesses
from the engine. Disconnect the cooling hoses
from the engine. Disconnect the return fuel hose
and the fuel hose to the fuel pump from the
engine. Detach the lower intercooler hose from
the engine.
10

• 17.
• Figure 13 Cooling fan
• Cooling fan
• Attaching bolts
• Belt pulley
• Remove the attaching bolts between fan and belt
  pulley. Move the cooling fan forward toward the
  radiator.

• 18.
• Figure 14
• Lifting links on engine
• Lifting links
• Lifting lugs
• Connect the lifting links to the two lifting lugs
  on the engine and to a lifting device.
• Remove the bolted joints for the engine
  mountings.
• Carefully lift the engine out of the machine.
• Place the engine on stable supports.

11
Service Information
Document Title Engine, installing Function Group 210 Information Type Service Information Date 2014/7/4 0
Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB

• Engine, installing
• Op nbr 210-02
• 14360000 Vacuum pump Lifting links, min. 1000 kg
• Connect lifting links to the lifting lugs on the
  engine and carefully lift the engine into the
  machine.
• Install the bolted joint for the engine
  mountings. Tightening torque687 68 Nm.

• 3.
• Figure 1 Cooling fan
• Cooling fan
• Attaching bolts
• Belt pulley
• Install the cooling fan. Apply locking fluid and
  install the attaching bolts between fan and belt
  pulley.

12
4. Figure 2 Engine
1 EMR cable harness 4 Fuel hose, return
2 Alternator cable harness 5 Fuel hose, pump
3 Cooling hoses 6 Lower intercooler hose
Connect the fuel hose to the fuel pump. Connect
the return fuel hose, the cooling hoses and the
EMR cable harness to the engine. Connect the
alternator cable harness to the alternator.
5. Figure 3 Engine
1 Ground cable 6 Lower cooling hose
2 Starter motor cable harness 7 Hose
3 Preheating cable harness 8 AC compressor
4 Upper intercooler hose 9 Induction hoses to turbocharger
5 Upper cooling hose
Install the AC compressor on the bracket. Connect
the induction hoses to the turbocharger. Connect
the hose, the upper intercooler hose and the
upper and lower cooling hoses to the engine.
Connect the ground cable, the starter motor and
preheating cable harnesses.
13
6. Figure 4 Heat radiation shield over starter
motor 1. Heat radiation shield Install the heat
radiation shield over the starter motor.
7. Figure 5 Underside of silencer
bracket 1. Attaching bolts Install the silencer
together with bracket and install the attaching
bolts for the silencer bracket.
8. Figure 6 Exhaust pipe 1. Joint between
turbocharger and exhaust pipe
14
Install the exhaust pipe on the turbocharger. 9.
Switch on the battery disconnect switch and
connect the vacuum pump, see 900 Vacuum pump,
connection.

• 10.
• Figure 7 Servo/steering pump
• Suction line
• Tank line
• Servo pressure hose
• Hose to fan motor, hydraulic oil cooler
• Hose to brake valve
• Connect the suction line and the other hoses to
  the servo/steering pump.

• 11.
• Figure 8 Working pump
• Hydraulic hoses
• Attachment
• Install the hoses in the attachment.

15

• 12.
• Figure 9 Working pump
• Connector
• LS-hose
• Leak-off oil hoses
• Pressure hoses
• Suction line
• Connect the suction line, connector, LS-hose and
  pressure hoses to the working pump. Fill the pump
  with hydraulic oil through the connection for the
  leak-off oil hoses.
• Connect the leak-off oil hoses.
• 13. Disconnect the vacuum pump, see 900 Vacuum
  pump, disconnection.

14. Figure 10 Engine/hydraulic compartment 1. Fra
me Install frame 1.
16
15. Figure 11 Engine/hydraulic compartment 1. Inte
rmediate wall Install intermediate wall 1.

• 16.
• Figure 12 Frame
• Cover
• Frame
• Install the outer frame together with the cover.
• 17. Install the counterweight, see 716
  Counterweight, removing.

17

• 18.
• Figure 13 Expansion tank
• Cap
• Sight glass
• Remove the cap and fill coolant in the expansion
  tank until the level is in the middle of the
  sight glass. Install the cap.

• 19.
• Figure 14 Radiator
• 1. Filling point
• Fill the radiator until the level stands right up
  in the filler neck.
• Check the oil level in the engine. Top up if
  required
• Bundle hoses and cable harnesses to avoid damage
  by chafing.
• Start the diesel engine, place the digging
  equipment in position A, see 091 Service
  positions. Check that there are no leaks.
• Install the cover over and under the diesel
  engine.
• Stop the diesel engine and check the hydraulic
  oil level, top up if needed. Check the coolant
  level, top up if required.

18
Service Information
Document Title Cylinder head, description Function Group 211 Information Type Service Information Date 2014/7/4 0
Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB
Cylinder head, description The cylinder head is
made of 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. 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
19
Service Information
Document Title Pistons, description Function Group 213 Information Type Service Information Date 2014/7/4 0
Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB
Pistons, description
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
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Service Information
Document Title Valves, description Function Group 214 Information Type Service Information Date 2014/7/4 0
Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB Profile EXC, EW140B GB
Valves, description The engines are equipped with
one inlet and one exhaust valve per cylinder. At
the upper end of the valve guide, there's an
O-ring seal against the valve spindle to prevent
major oil consumption and to reduce the amount of
hydrocarbons in the exhausts. The valves are
rotated by the eccentric action of the rocker
arms. The new compressed tapered shape enables
the valves to turn easily despite loading. Rocker
arm lubrication is part of the engine's
force-feed lubrication system. The oil is
supplied via the tappets and push rods.
22
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
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