Volvo EW180 Wheeled Excavator Service Repair Manual Instant Download

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Service Information
Document Title Engine characteristic curve (Cummins B5.9-C) Function Group 210 Information Type Service Information Date 2014/5/31
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Engine characteristic curve (Cummins
B5.9-C) Engine characteristics
Item Specification
Rated output 145 PS/1900 rpm (143 HP/1900 rpm)
Max. torque (Net) 63 kgfm/1500 rpm (455 lbfft/1500 rpm)
Min. fuel consumption 151g / PSh
Rated fuel consumption 158g / PSh
Figure 1 Engine, characteristic curve T.
Torque F. Fuel consumption O. Output E. Engine
speed
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Service Information
Document Title Engine, description (Cummins B5.9-C) Function Group 210 Information Type Service Information Date 2014/5/31
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• Engine, description (Cummins B5.9-C)
• The engine is a 6-cylinder, 4-stroke, direct
  injected, turbocharged, aftercooled, water cooled
  assembly 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 formed as sets for lubrication
  and cooling. The water pump and oil cooler are
  integrally mounted.
• The fan belt is a poly type V-belt for improved
  performance and an auto tension adjuster
  maintains belt tension.

• Figure 1
• Engine, fuel filter side view
• High pressure fuel line
• Fuel injection pump
• Engine data plate
• Engine oil pressure sensor port (1/8" NPTF)
• Engine oil heater port (M22 1.5P)
• Engine speed sensor port (3/4"-16 UNF)
• Fuel feed pump
• Water temperature sensor port (3/4" NPTF)
• Primary fuel filter/water separator
• Secondary fuel filter
• Dipstick

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• Figure 2
• Engine, turbocharger side view
• Exhaust gas discharge port
• Valve cover
• Starter
• Engine block
• Oil pan
• Engine oil drain valve (M22 1.5P)
• Engine oil cooler
• Water temperature switch port (PT 1/2")
• Water inlet
• Thermostat
• Turbocharger
• Block heater port

Figure 3 Engine, top view 1. Fuel shut-off
solenoid
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1. Engine oil refill plug
2. Fan drive and pulley
3. Fan spacer
4. Aftercooler

• Figure 4
• Engine, front view
• Turbocharger
• Automatic belt tensioner
• Fan pulley
• Alternator
• Water pump
• Water inlet
• Vibration damper
• Fan belt
• Gear cover
• Fuel injection pump gear cover

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• Figure 5
• Engine, rear view
• Engine lifting eye
• Fuel filter head
• Flywheel
• Flywheel housing
• Engine oil filter
• Turbocharger

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Service Information
Document Title Valve clearance adjustment Function Group 214 Information Type Service Information Date 2014/5/12
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• Valve clearance adjustment
• Cummins B5.9-C
• Valves must be correctly adjusted for the engine
  to operate efficiently. Valve adjustment must be
  performed using the specified values.
• Adjust the valves at each 1000 hours or 1 year
  maintenance interval.
• All the valve adjustments must be made when the
  engine is cold and stabilized coolant temperature
  is 60C or below.
• Turn the valve adjustment screws in until
  touching the push rod sockets, and then loosen
  them one full turn. Use 1/2" drive, Part No.
  3377371 Engine Barring Tool.

• Figure 1
• Valve clearance adjustment condition
• Locate top dead center for cylinder No.1 by
  rotating the crankshaft slowly while pressing on
  the engine timing pin. When the pin engages the
  hole in the camshaft gear, cylinder No.1 is at
  top dead center on the compression stroke.

Figure 2 Valve clearance
Inlet valve 0.25 mm 0.010 in
Exhaust valve 0.51 mm 0.020 in
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• Figure 3
• Rotation, camshaft gear
• Camshaft gear
• Timing pin
• Gear housing
• Compression stroke

CAUTION
Disengage the timing pin. Engine components may
be damaged if the engine is rotated with the
timing pin engaged.
Figure 4 Removal, timing pin

• Figure 5
• Adjustment, clearance between the valve stem and
  rocker lever
• Tools 14 mm spanner, - screwdriver, feeler
  gauge.
• The clearance is correct when slight resistance
  is felt as the feeler gauge is moved between the
  valve stem and rocker lever. At that point,
  tighten the lock nut. (Tightening torque 24
  Nm)
• Adjust the valves indicated () in the table
  below.
• After tightening the lock nut, check the valve
  clearance again. If the clearance is not correct,
  readjust.

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Valves to be adjusted ()
Cylinder 1 2 3 4 5 6
Inlet (I)
Exhaust (E)
Figure 6 Valves to be adjusted
CAUTION
Be sure the timing pin is disengaged. NOTE! Mark
the crankpulley and cover. NOTE! Rotate the
crankshaft 360.

• Figure 7
• Marking, crankpulley
• Adjust the valves indicated () in the table
  below.
• After tightening the lock nut, check the valve
  clearance again. If the clearance is not
  correct, readjust.
• Valves to be adjusted ()

Cylinder 1 2 3 4 5 6
Inlet (I)
Exhaust (E)
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• Figure 8
• Valves to be adjusted
• Assemble the gaskets, valve covers, o-rings and
  special screws.

• Figure 9
• Assembly, valve covers
• Tools 16 mm spanner
• Tightening torque 24 Nm (18 lbfft)
• NOTE!
• Check valve covers and o-rings. If damaged,
  replace with a new one.
• Injection nozzles installation
• Assemble a sealing washer on each injection
  nozzle. Use only one sealing washer.

• Figure 10
• Assembly, injection nozzles
• Apply anti-seize compound to the threads of the
  injector hold-down nut and between the top of the
  nut and injector body.

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Figure 11 Apply, anti-seize compound
Figure 12 Installation, injection nozzle Tools
16 mm spanner, 24 mm Deep socket Tightening
torque 60 Nm (44 lbfft) NOTE! Install the
injection nozzle. The protrusion on the injector
body fits into a notch in the cylinder head to
position the injector. Tighten the injection
nozzle nuts.
Figure 13 Tightening, injection
nozzle NOTE! Some sockets can damage the sealing
surface of the fuel drain outlet.
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Service Information
Document Title Engine mounting Function Group 218 Information Type Service Information Date 2014/5/12
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Engine mounting
Figure 1 Engine mounting, front-fan side view
Figure 2 Engine mounting, rear-flywheel side
view A. A-details (cushion) NOTE! Check the
color markings for cushion installation. Cushion
(A-details) Front (fan side) - Yellow and white
Rear (flywheel side) - Blue and white Tightening
torque, unit kgfm (lbfft)
No. Mounting position Tightening torque
1 Engine mounting bracket (front) Apply loctite 243 M12 1.75 35L (4) M12 1.75 65L (2)
1 Engine mounting bracket (front) Apply loctite 243 11 12 (80 87)
2 Engine mounting bracket (rear) M12 1.75 50L
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Apply loctite 243 Apply loctite 243 7.2 8.4 (52 61)
3 Engine mounting cushion M22 2.5 130L
3 Engine mounting cushion 69.4 6.9 (501 50)
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Service Information
Document Title Lubricating system, description Function Group 220 Information Type Service Information Date 2014/5/31
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• Lubricating system, description
• Engine lubricating oil is supplied to the contact
  faces of rotating components such as
  turbocharger, crankshaft, camshaft, piston,
  inlet/exhaust valve, rocker arm and timing gear
  by means of forced lubrication from the oil pump.
• Lubricating oil flow diagram

• Figure 1 Lubrication oil flow
• Oil pump
• Pressure regulating valve
• Oil cooler
• Filter bypass valve
• Oil filter
• Turbocharger oil supply
• Turbocharger to oil pan
• Piston cooling nozzle
• Oil pump idler gear

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Service Information
Document Title Fuel injection system (Cummins B5.9-C) Function Group 230 Information Type Service Information Date 2014/5/31
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• Fuel injection system (Cummins B5.9-C)
• Highly pressurized fuel compressed by the fuel
  pump is direct injected through the injection
  nozzle into the combustion chamber.
• Remaining fuel after injection is returned to
  tank automatically.
• A water separator installed to protect the fuel
  system components provides a means to drain off
  the water and contaminants collected from the
  system.
• Fuel flow system diagram

• Figure 1
• Diagram, fuel system
• Fuel feed pump
• Fuel filter
• 2A. Filter bracket
• 2B. Secondary fuel filter

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• 2C. Primary fuel filter/water separator
• Bleed screw
• Low pressure supply line
• Fuel injection pump
• Fuel drain line
• High pressure fuel supply line
• Fuel injection nozzle

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Service Information
Document Title Fuel tank, description Function Group 2341 Information Type Service Information Date 2014/5/12
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Fuel tank, description
Figure 1 Structure, fuel tank
1 Tank 7 Screw
2 Cap 8 Plain washer
3 Screen filter 9 Spring washer
4 Drain cock 10 Shim
5 Plug 11 Level gauge
6 O-ring 12 Hydraulic tank
13 Tool box

• When mounting the tank, adjust the height by use
  of shim (10).
• Tightening torque
• Screw (7) 52.2 5.2 kgfm (377 38 lbfft)

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Service Information
Document Title Fuel filler pump, description Function Group 2344 Information Type Service Information Date 2014/5/12
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• Fuel filler pump, description
• The pump outlet is plumbed directly to the fuel
  tank to reduce the risk of introducing
  contamination.
• The master switch must be in the ON position to
  operate the fuel filler pump.

CAUTION
The filter at the end of fuel filler pump inlet
hose is a strainer, and will not filter
impurities from the fuel. When filling use CLEAN
fuel only!
CAUTION
Do not operate the fuel filler pump without fuel
or for extended periods of time.
CAUTION
Drain the fuel from the suction hose before
putting it in the storage compartment.
CAUTION
In case the pump has been disassembled, assemble
the pump so the that the sharp portion of the
vane faces the counterclockwise direction.
Figure 1 Structure, fuel filler pump
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Service Information
Document Title Fuel warmer, description Function Group 2349 Information Type Service Information Date 2014/5/12
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• Fuel warmer, description
• The fuel warmer function is to prevent filter and
  line blockage by melting the paraffin wax
  extracted from the diesel fuel in severe cold
  weather.
• If the fuel warmer switch on the switch board is
  ON, the warning lamp on the monitor panel is
  activated.

CAUTION

• After starting the engine, be sure to turn the
  fuel warmer switch to the OFF position.
• After removing the fuel secondary filter, install
  the fuel warmer assembly (K-1 K-7).
• Assemble the wire K-2 to the connector EN28-F in
  the engine compartment.

• Figure 1
• Structure, fuel warmer
• Filter head
• Fuel filter
• K-1. Fuel warmer K-2. Wires
• K-3. Gasket K-4. Adapter K-5. O-ring
• K-6. Insulator
• K-7. Center post
• Component location

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Figure 2 Component location, fuel warmer
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Service Information
Document Title Fuel lines, description Function Group 235 Information Type Service Information Date 2014/5/12
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Fuel lines, description The fuel level sensor is
installed in the fuel tank. When the fuel level
gauge indicates EMPTY, there is still
approximately 40 Liter remaining. Fuel flow Tank
? Water separator ? Fuel feed pump ? 1st fuel
filter ? 2nd fuel filter ? Fuel injection pump ?
Nozzle ? Tank

• Figure 1 Fuel line
• Suction hose
• Water separator
• Suction hose
• Return hose
• Clamp tightening torque 0.12 0.17 kgfm (0.87
  1.23 lbfft)

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