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Summary of Contents for D12D

Page 1: ...onic functions in the engine are controlled by Volvo s engine management system EMS2 Cylinders are numbered in sequence beginning farthest from at the flywheel Firing order 1 5 3 6 2 4 The engine s rotational direction is counter clockwise seen from the flywheel Figure 1 Cylinder orientation Engine identification Identification plate 1 Engine designation serial number part number and assembly plan...

Page 2: ...Figure 2 Engine identification D12D ...

Page 3: ...ral alarm levels for warnings Yellow warning indicates a less serious malfunction or level and red warning indicates that the engine must be turned off For detailed description see 387 Warning screens general Reduced torque The engine protection function can limit the torque to reduce damage and repair costs in case the operator does not notice that a warning has been activated Limited torque is a...

Page 4: ...hat the pressure increase value is obtained by comparing unfiltered and filtered crankcase pressure The filter is designed so that a sudden pressure increase gives a warning while a slowly increasing pressure caused by normal wear does not generate a warning Water in fuel A sensor in the fuel system s pre filter activates yellow warning when the water level becomes too high ...

Page 5: ... Identification plate 2 A decal with the software s ID number the engine s serial number and assembly plant is located on the valve cover to ensure installation of correct ECU on the engine in production On the back of the ECU there is a decal indicating its hardware number Assembly plants A Skövde Sweden E Curitiba Brazil F Flen Sweden L Lyon France Identification plate 3 The certification decal ...

Page 6: ...Figure 2 Certification decal ...

Page 7: ...ncludes required tools and times for applicable parts of the following operations 200 E ECU MID 128 changing non programmed ECU 1 Connect VCADS Pro computer and perform 17030 3 Parameter programming Use the function Save all read parameters to job card 2 Perform step 2 14 200 E ECU MID 128 changing non programmed ECU 3 Connect VCADS Pro computer and perform 17030 3 Parameter programming Program ea...

Page 8: ...ving E ECU CAUTION Always follow instructions according to Electrical system work instructions electronic components 3001 Electrical system special instructions for servicing electronic components CAUTION Always follow instructions according to Electrical system work instructions electronic components 2 Figure 1 E ECU 1 2 3 4 5 Connector EA Connector EB Screw for clamp Screw for cooler Screw for E...

Page 9: ... for the cooler are not damaged Mounting E ECU 9 Lift in the E ECU inside of the cooler 10 Install the screws 5 4 pcs that hold the E ECU against the engine block 11 Install the screws 4 6 pcs that hold the cooler against the E ECU 12 Plug in the connectors EA and EB for the E ECU 13 Install the screws 3 pcs that hold the clamps against the E ECU 14 Close the engine hood NOTE When changing pre pro...

Page 10: ... PC test 210 Service Information 2014 8 27 Profile ART A35E FS GB Cylinder compression PC test Connect the VCADS Pro computer and carry out 21006 3 Cylinder compression test 21006 3 This test indicates if there is any deviation in compression in any cylinder in relation to the other cylinders ...

Page 11: ...act puller 9998599 Cleaning tool 88820003 Setting tool 9993590 Gear wheel This operation also includes the tools and times needed for required parts of the following actions 214 Valves adjusting 233 Fuel system bleeding Dismantling 1 Place the machine in service position 2 Pump up the engine hood 3 Drain the cylinder head to avoid fuel in the engine oil Loosen and plug the hose connection in the e...

Page 12: ...since the studs bolts may come loose from the cylinder head and damage electrical cables and valve cover Figure 2 V1022264 6 Remove the unit injectors electrical connections 7 Remove the IEGR control valve s electrical connections and wipe clean around the control valve 8 Remove the valve cover s stud bolt located in front of the IEGR control valve Figure 3 Stud bolt 9 Remove the bolts for the IEG...

Page 13: ...shaft is not bent Remove the bolts and carefully lift away the rocker arm bridge with 9990185 and 88880003 NOTE For engines with VEB fixate the pistons in the rocker arms with rubber bands or similar so that the pistons do not fall out NOTE Pistons and rocker arms are classed as units Marking one two or three dots must match ...

Page 14: ...t injectors attaching yoke Remove the unit injector with 9996400 Impact puller9990262 Adapter9990006 Puller NOTE Place each injector in separate new plastic bags Mark which cylinder they were installed in It is important to not mix up the injectors since they are classed for a certain cylinder ...

Page 15: ...opper sleeves with a brush on an extension Figure 7 1 2 3 Extension Brush Protective sleeve 13 Check that all adapters have O rings and seal against the copper sleeve Install adapters 9998248 in the unit injectors place in the cylinder head ...

Page 16: ...haft to prevent warping and to make sure that the guide pins fit in the camshaft s support bearing See 214 Rocker arm shaft tightening torques 16 Install the IEGR control valve Check that the seal ring is placed correctly before the bolts for the IEGR control valve are tightened 17 Transfer the rubber bands so that they are located between the adapter and the unit injector s rocker arm This is don...

Page 17: ...ect any cylinder with lower pressure this may be due to leaking valves cracked piston rings worn cylinder liner or leaking cylinder head gasket In case of this Engine overhauling should be done Uniformity between the cylinders compression pressure is the most important and should not exceed 20 NOTE The parking brake must be applied when cranking the engine with the starter motor NOTE Do not run th...

Page 18: ...and centre the unit injectors between the valve springs Install the attaching yokes Tightening torque see 230 Tightening torque fuel system Figure 13 23 Lift the rocker arm shaft into place with 9990185 Make sure that the guide pins fit in the support bearing for the ...

Page 19: ...gs 26 Install the stud bolt in front of the IEGR valve 27 Install the electrical connections for the unit injectors and the control valve 28 Adjust the valves and the unit injectors see 214 Valves adjusting 29 Install the valve cover Tighten the bolts according to tightening diagram Tightening torque see 200 Engine tightening torques 30 Install the fuel lines connections on the cylinder head 31 Bl...

Page 20: ...ing may not take place for any reason without reprogramming Incorrect individual settings in the control unit may result in personal injury or machine damage For reprogramming and read out of software see VCADS Pro User manual 1 Place the machine in service position 2 Turn off the electric power with the battery disconnect switch NOTE If the height between the workshop floor and the overhead crane...

Page 21: ... very much for reading This is part of the demo page GET MORE Hydraulic System Setting Instructions Functional Description Electrical System And more Click Here BUY NOW Then Instant Download the Complete Manual ...

Page 22: ... aside Secure it NOTE Take care of harmful waste oils and fluids in an environment friendly way Figure 2 6 Drain the coolant see 173 Coolant change 7 Put the drain hose in a suitable container Connect the drain hose to the connection for draining the transmission Volume approx 36 litres 7 9 US gal NOTE The oil drain hose is inserted in the pipe for the ladder on the inside of the front grill Figur...

Page 23: ...Figure 4 9 Loosen and remove the belt guard Figure 5 10 Loosen the belt tensioner on the alternator and remove the belt Figure 6 ...

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