Volvo DH10A 245 Service Manual Download Page 2

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Contents

Group 20: General

Variant description DH10A ..............................

Performance ......................................................

Specifications ...................................................

Wear tolerances ................................................ 15
Tightening torques ............................................

Special tools .....................................................

Removing and installing engine .......................

Servicing the engine:
– Replacing fuel filters ...................................

– Topping-up oil .............................................

– Replacing oil filters ..................................... 33
– Replacing coolant filter ...............................

– Condition test, compression test ..................

– Charge pressure ...........................................

– Fuel feed pressure ........................................ 37
– Oil pressure ................................................. 38
– Pressure-testing cooling system .................. 38
– Valve tappets, valve timing ......................... 38
– Valve adjustment ......................................... 39

Group 21: Engine

Detailed list of contents .................................... 40
Cylinder head ................................................... 41
Cylinder liners, pistons, connecting rods .........

Cylinder block, crank mechanism ....................

Group 22: Lubricating system

Detailed list of contents .................................... 79
Oil pump ...........................................................

Oil cooler ..........................................................

Group 23: Fuel system

Detailed list of contents .................................... 88
Injection pump .................................................. 91
Injection timer .................................................. 92
Injectors ............................................................ 94

Group 25: Inlet and exhaust systems

Detailed list of contents .................................... 110
Air cleaner ........................................................ 111
Intercooler, pressure-drop indicator ................. 112
Starting pre-heater ............................................ 113
Turbocompressor .............................................. 115
Exhaust pressure governor ............................... 125

Group 26: Cooling system

Detailed list of contents .................................... 127
Main thermostat ................................................ 130
Coolant pump ................................................... 131
Intercooler ........................................................ 135
Cooling fan ....................................................... 137
High coolant temperature ................................. 141
Fan drive ........................................................... 143

Group 27: Engine controls

Detailed list of contents .................................... 145
Description EDC .............................................. 146
EDC-components in electrical

distributor unit .............................................. 148

Fault diagnosis .................................................. 150
Troubleshooting ................................................ 155

Order number: TP 16031/1

Summary of Contents for DH10A 245

Page 1: ...Service Manual Buses Section 2 20 27 Engine DH10A 245 285 345 350 360 TP 16031 1 ...

Page 2: ...ods 51 Cylinder block crank mechanism 58 Group 22 Lubricating system Detailed list of contents 79 Oil pump 83 Oil cooler 87 Group 23 Fuel system Detailed list of contents 88 Injection pump 91 Injection timer 92 Injectors 94 Group 25 Inlet and exhaust systems Detailed list of contents 110 Air cleaner 111 Intercooler pressure drop indicator 112 Starting pre heater 113 Turbocompressor 115 Exhaust pre...

Page 3: ...wer emissions and lower fuel consumption Net output has been measured in accordance with ISO 1585 and SAE J 1349 Smoke requirements met according to ECE EEC and the Swedish regulations DH10A fulfils smoke requirements as per 91 542 EEC Level B Euro 2 EC96 180 kW Low emissions for city buses Wastegate and water cooled turbo for flatter torque curve 210 kW Low emissions engine for city buses e g art...

Page 4: ...ssance Potentia Nm 1200 1000 800 Torque Vridmoment Drehmoment Couple Par motor 285 EC96 245 EC96 285 EC96 245 EC96 kW 280 260 240 220 200 180 160 140 120 1000 1200 1400 1600 1800 2000 2200 2400rpm 1000 1200 1400 1600 1800 2000 2200 2400rpm Output Effekt Leistung Puissance Potentia Nm 1600 1400 1200 Torque Vridmoment Drehmoment Couple Par motor 345 J96 350 TW95 360 EC96 345 J96 350 TW95 360 EC96 ...

Page 5: ... mm Displacement 9 6 dm3 9 6 liter DH10A DH10A 245 285 345 350 360 Compression ratio 20 1 18 1 Firing sequence 1 5 3 6 2 4 Direction of rotation B10M frontal view B10B rear view engine installed in bus Clockwise Low idle 8 8 0 8 r s 8 8 0 8 r s 530 50 r min 530 50 r min High idle 36 6 0 8 r s 36 6 0 8 r s 2200 50 r min 2200 50 r min De regulating speed begins at 34 8 r s 38 8 0 8 r s 2085 r min 23...

Page 6: ...g clearance in groove 0 05 mm Gudgeon pins Clearance gudgeon pin connecting rod bushing 0 03 mm Gudgeon pin diameter stnd 51 998 52 000 mm Gudgeon pin hole diameter in piston 52 005 52 013 mm Valve Mechanism Valves Disc diameter Inlet 50 mm Exhaust 46 mm Stem diameter Inlet min 10 91 mm Exhaust min 10 90 mm Max permitted wear 0 07 mm Valve seat angle valve edge Inlet 29 5 min 2 4 mm Exhaust 44 5 m...

Page 7: ...21 mm Max permitted clearance between valve stem and valve guide Inlet 0 15 mm Exhaust 0 25 mm Valve springs Outer valve spring Length off load 61 mm With 300 390 N 30 39 kp load 49 6 mm Inner valve spring Length off load 53 mm With 80 170 N 8 17 kp load 42 6 mm INLET EXHAUST Adjust the valves as follows When no 1 cyl piston is at T D C after compression adjust valves 1 2 4 5 8 and 9 When no 6 cyl...

Page 8: ... engine and valve clearance 0 At 10 flywheel A T D C no 1 cyl inlet valve should open 4 2 4 8 mm Max valve lift inlet 13 3 mm exhaust 14 3 mm Min valve lift inlet 13 0 mm exhaust 14 0 mm Camshaft bearings Bearing bores Front bearing 69 050 69 075 mm 2nd 66 675 66 700 mm 3rd 64 287 64 312 mm 4th 63 500 63 525 mm 5th 61 112 61 137 mm 6th 60 325 60 350 mm 7th 56 350 56 375 mm Wear max 0 050 mm Timing...

Page 9: ... 708 98 730 mm Main bearing journals out of round new max 0 006 mm wear out of round max 0 08 mm taper max 0 05 mm Width axial journal pin A standard 45 975 46 025 mm Oversizes 0 2 mm axial bearing 0 1 mm 46 175 46 225 mm 0 4 mm axial bearing 0 2 mm 46 375 46 425 mm 0 6 mm axial bearing 0 3 mm 46 575 46 625 mm Fillet radius R 3 75 4 00 mm Thrust washers axial bearing Thickness B standard 2 312 2 3...

Page 10: ...ds Length centre crankpin seat centre gudgeon pin seat 277 mm Diameter connecting rod bushing 57 300 57 346 mm connecting rod bushing internal diameter G 52 022 52 028 mm Axial clearance crankshaft connecting rod max 0 35 mm Connecting rod bearings radial clearance max 0 12 mm Max weight deviation for connecting rods within same engine 50 g Straightness max deviation on 100 mm measuring length 0 0...

Page 11: ...ting speed 300 500 kPa 3 5 bar Oil pressure idling low idle min 60 kPa 0 6 bar Oil quality Volvo Drain Specification alt API Service CD CE or CCMC D4 D5 Lube oil pump Type Gear driven Number of teeth 11 Axial play gear wheel 0 02 0 08 mm Backlash 0 15 0 35 mm Diameter bushing for pump shaft 18 050 18 068 mm bearing sleeve intermediate gear 92 084 92 106 mm bushing for intermediate gear 92 141 92 1...

Page 12: ... 8033 Governor type RE 30 Injection pump direction of rotation Clockwise Injection sequence 1 5 3 6 2 4 Injection pump basic setting on engine DH10A 345 5 5 0 5 B T D C DH10A 245 285 360 7 0 0 5 B T D C DH10A 350 9 0 0 5 B T D C Performance check Bus stationary Engine switched off Start key feed selector switch in drive position Accelerator pedal in idle position Reference voltage U ref 4 5 5 0 V ...

Page 13: ...rings 67 05 67 08 mm The injection timer alters the pump basic timing µ with engine at operating temp above 55 C see page 97 Feed pump Designation FP KG 24 P 307 Feed pressure depending on speed and load 100 400 kPa 1 4 bar Injectors DH10A 245 285 Nozzle stand KBEL 117 P 73 Nozzle Volvo P N DLLA 150 P555 425694 Number marking complete injector 555 Opening pressure 25 MPa Adjusting pressure new spr...

Page 14: ...st pressure governor Control pressure with warm up and exhaust pressure braking 750 kPa Cooling system Type Overpressure closed Pressure valve opens at approx 50 kPa 0 5 kp cm2 Coolant Anti freeze Type C Consists of Glycol with rustproofing Colour Blue green Volvo art no 1 kg 1128700 9 5 kg 1129701 7 235 kg 1129702 5 Radial clearance at compressor wheel 0 33 0 50 mm For engine DH10A 345 350 360 De...

Page 15: ...x 2 P N 966846 Fans B10B Temperature controlled cooling fan Type Bimetal plate coolant coupling Fan speed at engine speed 38 3 r s 2300 r min under 37 C min 7 r s 420 r min above 63 C min 35 7 r s 2100 r min Temperatures refer to temp round bimetal plate Drive belt driven cooling fan Fan drive reduction 1 1 22 Belt type size 4 belts included in this drive HC 12 5 x 1550 P N 9515805 Engine circuit ...

Page 16: ... consumption is abnormally high Crankshaft Max permitted out of round on main bearing and big end bearing journals 0 08 mm Max permitted taper on main bearing and big end bearing journals 0 05 mm Max crankshaft end float 0 40 mm Max radial clearance 0 14 mm Connecting rods Straightness max deviation on 100 mm length measured 0 05 mm Torsion max deviation on 100 mm length measured 0 1 mm End float ...

Page 17: ... 85 5 8 5 0 5 Nut for retainer injectors 45 5 4 5 0 5 Clamp bolt injection pump M11 90 5 9 0 0 5 M12 114 10 11 4 1 0 Laminate screw injection pump M10 62 5 6 2 0 5 Retaining bolt injection pump 40 4 4 0 0 4 Drive injeciton timer 33 4 3 3 0 4 Turbocompressor thrust bearings 4 5 0 45 Turbocompressor wheel 17 0 1 7 Turbocompressor turbine housing 13 6 1 4 Turbocompressor housing 5 7 0 6 Exhaust press...

Page 18: ...rift pressing out in gudgeon pin 2089 Puller plate cylinder liner 2269 2337 2479 2529 2654 2267 Drift pressing in bearings injection pump drive 2268 Drift pressing out in bearing coolant pump 2269 Counterhold fitting bearings coolant pump and fan motor 2337 Lever 2479 Holder dial indicator 2529 Socket pressing out in connecting rod 2654 Puller oil pump drive gear 2013 2089 2267 2268 1084 1801 1819...

Page 19: ...er 18 tonnes 2677 Drift pressing out in bushing rocker arm 2679 Puller camshaft and injection pump drive gear 2800 Test bench pressure tester gauge 2807 Centering tool coolant pump 4706 Stop tool flywheel 6049 Hose draining coolant pressure testing system 6065 Pressure gauge 2 5 bar fuel feed pressure charge pressure 6066 Connection nipple used together with 6065 6068 Drift exhaust pressure govern...

Page 20: ...ler polygon hub 6419 Extractor steel ring injectors 6441 Test cap with nipple pressure testing cooling system 6600 6603 6625 6626 6640 6643 6222 6239 6394 6395 6398 6413 6419 6441 6579 6591 6579 Lever 6591 Connection nipple checking charge pressure 6600 Hydraulic cylinder 10 tonnes 6603 Adapter used with 6600 6625 Spindle pressing on polygon hub 6626 Hollow drift fitting polygon hub 6640 Hollow dr...

Page 21: ...n checking oil pressure 6669 Drift pressing in valve guide inlet valve 6670 Filter tool 80 mm fuel filter 6671 Oil filter tool 6672 Filter tool 108 mm oil filter 6685 Clamp pressure testing cylinder head 6781 Hollow drift fitting seal thermostat housing 6796 Hollow drift pulling off polygon hub 6815 Connection washer pressure testing inter cooler 6816 Sealing washer pressure testing intercooler 66...

Page 22: ...est box for troubleshooting 6931 Adapter for Troubleshooting EDC 8009 Adapter compression test 8010 Extractor crankshaft rear seal 8011 Extractor seal injection pump drive 8012 Press tool fitting seal injection pump 8014 Hollow drift fitting seal polygon hub 8039 Drift seal coolant pump 8068 Crank tool flywheel formerly 6220 8074 Nipple pressure testing oil cooler Fit 2 bolts P N 955514 8011 8012 ...

Page 23: ...eeves injectors 8140 Extractor copper sleeves injectors 8180 Adapter checking charge pressure EDC 8190 Measuring instrument for injection timing 9314 8075 8419 Pin spanner for cleansing plugs 8449 Drift pressing in valve guides 8487 Tool for oil filter 9314 Nipple checking wastegate 9511 Expander turning cylinder liners when milling liner seat 9551 Milling tool cylinder liner seat 9696 Magnetic st...

Page 24: ...essor 8460 Speed gauge for measuring fan speed 8539 Compression guage 981 Description use 2546 Cleansing tool cleaning copper sleeve seats 951 Description use 0060 Multimeter Decapitat ed sleeve Hard annealed 40 mm Tool for flange discs pump coupling made by own workshop Special tool EDC for testing injection pump on test bench refer to Testing injection pump on page 102 998 5423 998 5468 998 6187...

Page 25: ...24 998 Description use 5654 Engine carrier trolley 8993 Lift table 8994 Engine fixture 999 9954 Component jack for radiator assembly 5654 8993 999 9954 8994 ...

Page 26: ...ope with the work in hand and are in good condition Make sure the lift fixture slots securely into the en gine lift points and that the guide edges fix against the lift forks or lift table Always switch off the main switch and disconnect the battery cables before removing electrical con nections The number and location of the drain points vary with bus type Drain points common to all types are the...

Page 27: ...y good pro tection against corossion Tightening torque for drain plugs 60 15 Nm 6 0 1 5 kpm Instructions on topping up oil refer to page 32 On buses with roof mounted air conditioning system where the coolant is above the level of the expansion tank the coolant has to be pumped up by starting the circulation pump Top up gradually via the expansion tank until the sys tem is full Check the coolant l...

Page 28: ...the power with the battery main switch Release the fan prop shaft 4 Release the steering servo pump 3 Remove the clutch servo 5 Detach disconnect necessary cables hoses and pipes Release gearbox attachments if any 8994 8993 2 Release the propeller shaft 6 Run the engine carrier trolley in underneath See support points overleaf ...

Page 29: ...re the engine to be angled slightly so that the pipes do not catch on the frame member Note in connection with lifting out engine Tightening torque for the following bolting Fan prop shaft 48 5 Nm 4 8 0 5 kpm Propeller shaft 54 Nm 5 4 kpm Engine mounts 80 Nm 8 kpm Bear in mind that rubber parts age and are affected by climatic conditions If necessary replace them Check the engine mounts and replac...

Page 30: ... hose from the turbocompressor Disconnect the exhaust at the flex hose between the tur bocompressor exhaust brake EPG and the silencer hook Remove the intercooler pipes under the engine to make room for the engine carrier trolley Disconnect the coolant pipe hose Otherwise the coolant pipes can remain in place Observe due care with regard to the fuel system delivery pipes After the engine has been ...

Page 31: ...30 Adjust in the supports on the lift unit as shown in the pictures below ...

Page 32: ...place both filters at the same time 1 Clean the outside of the filter bracket to prevent dirt getting in when fitting the new filter 2 Unscrew and discard the filters Use tool 6670 if the filters cannot be unscrewed by hand 3 Screw on the new fuel filters First by hand to when the seal makes contact with the filter bracket and then manually tighten a half turn more 4 If there is a relief valve mou...

Page 33: ...oil level must never go below the Min mark Oil quality According to VOLVO DRAIN SPECIFICATION VDS VDS2 or API CD CE OR CCMC D4 D5 Viscosity see graph below The temperatures refer to stable air temperatures Concerns semi synthetic or full synthetic engine oil NOTE Only SAE 5W 30 may be used 22 4 14 32 50 68 86 104 30 20 10 0 10 20 30 40 SAE 15W 40 SAE 10W 30 SAE 5W 30 SAE 20W 30 SAE 30 SAE 40 F C 2...

Page 34: ...al the only service measure permitted 4 Fit the oil filters according to the instructions on the filter cannister The alternative filter removal tool can be used if work ing area is confined 6672 Replacing coolant filter Special tool 999 6671 Filter removal tool 1 Remove the plate underneath the engine Remove the filter with tool 6671 2 Fit the new filter according to the instructions on the filte...

Page 35: ...mpression pressure on all cylinders indicate worn cylinder liners and or piston rings Should a particular cylinder have a lower pressure this may be due to leaking valves broken piston rings or damaged cylinder head gasket Low charge pressure and fuel system malfunc tion can cause the following symptoms low start torque and smoky exhaust gases Low oil pressure may indicate worn crankshaft bearings...

Page 36: ...ure check the pres sure drop indicator in the inlet hose from the air cleaner If its window is full red it is time to re place the air cleaner filter insert After testing fit and tighten up the screw plug for the measuring socket Make sure it is properly tightened as there is always a risk that an insufficiently tightened plug slackens during driving If the plug drops off the charge pressure will ...

Page 37: ...which corresponds to the voltage measured between the charge pressure sensor and the control unit The measuring is done as follows with the engine off and the start key feed selector switch in Drive posi tion Measuring on text box 6899 measuring points 1 4 reference voltage measuring points 3 4 charge pressure voltage Compare with the should values in the specifications for the respective engine C...

Page 38: ... 3 25 3 5 3 75 4 0 v Fuel feed pressure Special tools 999 6065 Pressure gauge 6066 Nipple 968179 Banjo screw Note Before using the banjo screw make sure it has been decapitated to a length of 26 mm otherwise it will break the end of the thread insert in the pump connec tion Before measuring the feed pressure run the engine at high idle and then drop it to low idle when reading off Read off the pre...

Page 39: ... for ageing hardness cracks separation blisters scuffing etc Replace a damaged or badly worn hose before checking for leakage If necessary top up with coolant before pressure testing Connect the pressure tester together with test cap and fit the cap temporarily in position Pressure test at 70 kPa 0 7 kp cm2 When the pressure stabilizes check all the components in the system radiator connections ho...

Page 40: ...nk the flywheel in its direction of rota tion one turn until no 6 cyl piston is at top dead centre position after the compression stroke 0 on the flywheel Adjust valves 3 6 7 10 11 12 Replace valve cover gaskets if necessary Valve clearance Inlet 0 40 mm Exhaust 0 70 mm Camshaft lift A Valve lift B Checking camshaft adjustment Valve lift must be within the stated tolerance in order to be able to c...

Page 41: ...onnecting rods Description 51 Pistons piston rings 52 Gudgeon pins connecting rods 53 Cylinder liners 54 Installing cylinder liners and pistons 55 Cylinder block crank mechanism Description 59 Cylinder liner seats machining 61 Cylinder block face milling 63 Front sealing ring crankshaft 64 Timing gears 65 Drive mechanism injection pump 69 Replacing camshaft 73 Crankshaft 75 Aligning machining 76 F...

Page 42: ... servicing easier Sealing against the cylinder block consists of a special groove in the cylinder head face a steel gasket and a stepped edge on the cylinder liner collar Sealing on the coolant side is provided by O rings The inlet duct in the cylinder head has a defined and accurately calculated shape that results in whirled air in the piston combustion chamber Far out on the inlet valve the cyli...

Page 43: ... coolant 2 Remove rocker arm cover delivery pipes injectors rocker arm bracket and push rods If necessary use extractor 6643 to remove the injec tors 6239 Some alterations have been made to the cylinder head compare with the THD 104 engine particularly with regard to optimating inlet air flow New features 1 Valve seats and valves on the inlet side have been moved down one millimetre 2 The inlet va...

Page 44: ... C 2 Connect up pressurized air to the pressure tester Open the shut off tap 3 Pull out the reducer valve tap lock ring Screw in the tap until pressure reaches 50 kPa 0 5 kp cm2 Hold this pressure for one minute Increase pressure to 150 kPa 1 5 kp cm2 Push in the lock ring to lock the tap Close the tap After 1 2 minutes check to see if the pressure has dropped or if air bubbles have formed in the ...

Page 45: ...ide inlet valve 0 15 mm exhaust valve 0 25 mm Pressing out Inlet 1084 6669 8449 Replacing 1 Press out the old valve guides with drift 1084 2 Oil the outside of the new valve guides before in stalling them 3 Installation tools automatically give correct height above spring face Inlet drift 8449 Exhaust drift 6669 4 If necessary ream the guides with a standard reamer Exhaust ...

Page 46: ... Do not grind off too much material It is essential that the con tact angle is correct and that the surface is even Valve seats are available in standard size and oversize The outer diameter on an oversize is 0 2 mm greater than that on a standard size They are used when grind ing valve seat recesses Usually valve seat damage is quite insignificant This means that normally it is not necessary to r...

Page 47: ...nder head is adjusted by grinding the valve seats Grind new valve seats so that the distance is the same as on new engines Do not grind existing valve seats so that the distance exceeds the max measurement see Specifications Otherwise the seats must be replaced Checking after machining Place the valve without springs in the cylinder head Pour water over the valve discs Press the valve against its ...

Page 48: ... threads on the adjusting screws and lock nut that the lock nut is not damaged that the contact face against the valve stems is not worn or damaged in any way Minor wear can be remedied by grinding to a smooth fin ish Rocker arm mechanism Special tools 999 2677 Drift 2267 Drift Replacing bushings 1 Press out the old bushing with drift 2677 and coun terhold 2267 2 Oil and press in the new bushing M...

Page 49: ...re width A more exact method must be used when checking cyl inder head unevenness since the tolerances are very small Machining It is most important that the contact face for the cylin der liners is even Max surface finish roughness is 0 006 mm The overall height of the cylinder head after machining must be minimum 114 65 mm There is no need to alter the depth of the groove for the cylinder head s...

Page 50: ... in the cylinder head 6647 Copper sleeve Expander Steel ring Clearance min 0 5 mm 6 Smear the copper sleeve with a soapy solution and fit the sleeve in the cylinder head Hold the stem on tool 6647 steady while tightening up the large nut Continue until the stem loosens and the expander can be drawn through the copper sleeve 5 Fit the injector steel ring on tool 6647 and a new copper sleeve Screw i...

Page 51: ... the cylinder head bolts 5 Tighten the bolts in the correct sequence see in structions below under Tightening cylinder head bolts 6 Fit and tighten up the bolts for the inlet and ex haust manifolds Use lock washers to lock the ex haust manifold bolts 7 Fit the delivery pipes and by pass fuel pipes to gether with ties washers and brackets 8 Fit the push rods rocker arm mechanism and in jectors Tigh...

Page 52: ...lass Pistons and cylinder liners are supplied as spare parts only as a single unit The engine has pistons with so called re entry type combustion chambers These pistons have a large area between the piston outer edge and the combustion chamber Difference between re entry type piston and the early prod type piston dash line Precisely at the end of the compression stroke the air will find itself in ...

Page 53: ...ar or out of round which would make it difficult to fit the rings in their original positions Heavy oil consumption could also be a reason for replacing piston rings 4 Measure the piston ring gap Checking pistons Check for cracks broken off sections between the piston ring grooves and also for groove wear Pis tons with seizure marks on the jackets must be scrapped The piston should also be renewed...

Page 54: ...r cracks Check straightness and for warp In both cases max permitted deviation is 0 01 mm on a measured length of 100 mm Use the measur ing fixture when measuring Cracked bent or warped connecting rods must be renewed In cold condition the gudgeon pin grip in the pis ton should be max 0 004 mm It is most important that the lube hole is positioned op posite the lube drilling in the connecting rod T...

Page 55: ... in Cylinder liner Checking Measure the cylinder liners with a cylinder indica tor Max wear 0 40 0 45 mm Measure cylinder liner wear with a cylinder indicator To get max accurate wear first gauge the cylinder in dicator with a gauge ring or micrometer Use the cylinder liner original diameter as reference value Note Cylinder lines and pistons are co classed This means that the pistons must be fitte...

Page 56: ...64 Piston ring compressor 8068 Crank tool 1 Fit new sealing rings in the cylinder block Note Lubricate the two bottom rings with the grease contained in the packet containing the rings Concerning order and location of the sealing rings refer to installation instructions in the packet Removing Special tools 999 2089 Puller plate 2479 Holder 6394 Spacer two 6395 Spacer two 6645 Extractor 1 If the li...

Page 57: ...down into the cyl inder block using drift 6599 and handle 2000 Apply load to the the cylinder liner with two tools 2666 The load must not be taken off the cylinder liner until the cylinder head is fitted in position 6 Place tools 6664 on top of the cylinder liner Oil the piston Fit piston and connecting rod in the cyl inder liner with the FRONT markings pointing ahead 7 Check to make sure the conn...

Page 58: ...low also the instructions on page 90 9 Fit installation ring 6664 on the piston Fit the pis ton along with the connecting rod in the cylinder 10 Fit the connecting rod cap along with bearing as per line up marks Tightening main bearing bolts The bolts are tightened in the following stages First tightening 40 Nm 4 kpm Second tightening 75 Nm 7 5 kpm Final tightening angle tightening 90 ...

Page 59: ...58 Cylinder block crank mechanism ...

Page 60: ...range in size starting at the front and gradually becoming smaller towards the rear This arrangement makes it easier to install the bearing bush ings in the cylinder block The following are the engine timing gears 1 Crankshaft gear 2 Intermediate timing gear 3 Injection pump drive gear 4 Power steering oil pump drive gear 5 Camshaft gear 6 Space normally occupied by air compressor drive gear 7 Int...

Page 61: ...gned to suit the new vibration damper The vibration damper consists of a housing containing a rectangular damper ring which is surrounded by sili cone oil that acts as a speed buffer between the damper ring and the housing Since the housing is fixed to the crankshaft the speed buffer has a dampening effect on crankshaft oscillations The vibration damper is placed on the inside of the timing gear c...

Page 62: ... liner seat 1 Remove the cylinder liner sealing rings 2 Lightly apply marking colour underneath the seal on the cylinder liner collar Fit the cylinder liner and rotate it back and forth with expander tool 9511 while pressing down at the same time 3 Pull out the cylinder liner and check the contact pattern 4 Minor defects can be rubbed off with grinding paste which is applied to the underside of th...

Page 63: ...up the liner seat with emery paper 4 Fit the used O ring at the lower cylinder liner seal to ensure accurate centering of the milling tool 5 Remove the small fillet in the bottom of the cylin der liner seat if this has not been done already 6 Use milling tool 9551 which is bolted onto the cylinder block Use suitable flat washers under the bolt heads Make sure the feed screw does not press against ...

Page 64: ...p plying pressure 11 Check the contact surface of the cylinder liner seat Note Place the shim on the cylinder liner NOT in the cylinder block An upper O ring will hold the shim in position on the underside of the cylinder liner collar Example how to calculate shim thickness and machining depth A Read off the cylinder liner height from the dial in dicator assumed to be 0 12 mm The cylinder lin er i...

Page 65: ...ller 8014 Hollow drift 1 Remove the thrust ring If necessary use puller 2679 Tightening torque for thrust ring bolts 60 6 Nm 6 9 0 6 kpm 2679 8014 2000 2337 2 Place the sealing ring on the press drift before fit ting it 3 Grease the seal lips 4 Fit the dust cover Removing Fitting ...

Page 66: ...ol 8068 Crank tool 4706 Stop 6600 Hydraulic cylinder 6222 Hydraulic pump 6796 Hollow drift 6603 Die 6413 Extension 1 Fit crank tool 8068 on the flywheel and crank until No 1 cyl pistion is at top dead centre compres sion stroke 0 on flywheel Lock the crankshaft temporarily with stop 4706 Check line up marking on gear wheels before removal Remove rocker arm cover for no 1 cylinder oil sump front dr...

Page 67: ...plate to make sure which type of timing gear was installed at the overhaul A nitro carburized gear N must not mesh with a hard tough gear HT but on the other hand a case hardened gear CH can be combined with a nitro carburized gear N Avoid combination N HT when replacing timing gears on earlier engines Nitro carburized gears are easily recognized by their flat grey to grey yellow colouring Moreove...

Page 68: ...e for all intermediate gears max 0 15 mm Check the key way in the crankshaft for damage and that it sits correctly in the crankshaft groove Checking Check the timing gears Replace worn or damaged gears Backlash must not exceed 0 17 mm Radial clearance for all intermediate gears max 0 082 mm ...

Page 69: ...osition Fit the camshaft drive gear Then the in termediate gear Ensure that the line up marks on the intermediate gear the crankshaft gear and the camshaft drive gear coincide 3 Fit the injection pump drive gear 2659 3 Fit the crankshaft hub centre bolt and washer Tighten the centre bolt to 560 30Nm 56 3 kpm If torque multiplier 9711 is used the tightening torque will be 140 Nm 14 kpm 2 Temporaril...

Page 70: ...on pump drive mechanism Replacing seal output shaft Special tools 999 6640 8011 8012 The injection pump and the pump coupling must first be removed applies only to DH10A 345 360 in order to replace the sealing ring on the injection timer drive mechanism For the DH10A 245 285 and 350 it is enough to re move the pump coupling Never try to bend or allow the fuel and delivery pipes to be deformed This...

Page 71: ... alternative method DH10A 345 360 1 Release the clamp bolt Remove the bolts and washers Take off the front discs first Remove the shaft 3 Pull out the old seal by screwing down the extrac tor At the same time hold tight the extractor with the drift 4 Oil the new seal and injection timer shaft 5 Fit the sealing ring on the shaft and tap it in until it is flush with the bearing housing Use drift 801...

Page 72: ...hown here should be made by the workshop 40 mm Ring grip 15 mm Decapitated sleeve socket 4 Fit the front discs 7 Tightening torques Nm kpm Clamp bolt 114 10 11 4 1 0 Flange bolt 62 5 6 2 0 5 NOTE Torque will be 4 greater if above work shop made tool is used Tightening torque with special tool Nm kpm Clamp bolt 110 11 0 Flange bolt 59 7 6 0 8 Check basic timing see page 97 ...

Page 73: ... front flange nearest the injection timer and remove the flange Do not crank the injection pump or engine 3 Remove the drive belts pulley vibration damper and timing gear cover 4 Remove the injection timer drive gear bolts and lift off the gear with stiff removal we recommend use of a standard puller 999 2679 together with in hex plug socket to pull off the gear 2679 952076 8 5 Disconnect the deli...

Page 74: ...e to the correct torque 114 10 Nm check the injection pump basic setting see under Basic setting injection pump EDC Replacing camshaft Special tools 999 2337 Lever 8068 Crank tool 8079 Extractor 1 Remove rocker arm mechanism for all the cylinder heads sump timing gear cover 8068 2 Crank the flywheel until no 1 cylinder is at top dead centre compression stroke 3 Line up mark camshaft gear position ...

Page 75: ...ermitted warp is 0 04 mm Otherwise con cerning measurements for the camshaft and bear ings refer to Specifications The camshaft bearings are pressed into their seats and thereafter bored Special tools are required for this The camshat bearings therefore can only be renewed where there is proper equipment for machining the bearings When pressing in the bearings check to make sure the lube holes coi...

Page 76: ...is fluorescent and is scrutinized under ultraviolet light For pow der type concentration current and magnetizing follow the instructions of the manufacturer See also below the types of cracks that can occur or there are longitudinal cracks within the areas marked here or when a crack is less than 10 mm outside the area marked here Individual cracks within 10 mm are acceptable or the crack is furth...

Page 77: ...or un evenness Machining Damaged bearing surfaces should be lapped If this is not enough replace the crankshaft or machine it A ni tro carburized crankshaft must be be ground more than to second undersize unless the nitro craburizing treat ment is repeated After treatment bearing surfaces and fillets should be lapped to a surface finish of 0 002 mm Grinding nicks or sharp edges are not permitted a...

Page 78: ... the pol ished sections 3 Quickly place the heated ring gear on the flywheel and tap it into position with a soft drift Fitting the ring gear Flywheel casing Checking The flywheel contact surface against the clutch cas ing should be square to the crankshaft within 0 15 mm Its inner edge should be concentric with the fly wheel within 0 25 mm With excessive dial indicator reading check the fly wheel...

Page 79: ...placing crankshaft rear seal Clutch removed Special tools 999 2000 Handle 6088 Drift 8010 Extractor 1 Remove the flywheel 2 Tap out the seal using extractor 8010 3 Clean the seal seat in the flyhweel casing 4 Apply gasket sealant part no 1161277 to the seal outer circumference and fit the seal 5 Fit the flywheel Tighten the flyhweel or flange disc bolts to 185 Nm 18 5 kpm 2665 2000 1819 8010 1801 ...

Page 80: ...79 Group 22 Lubricating System Contents Description 80 Oil pump Removing installing 83 Servicing 85 Oil cooler Oil cooler 87 Oil pressure piston cooling 87 ...

Page 81: ...3 To oil tank From oil cooler To oil cooler 0 1 2 3 4 5 6 7 1 Piston cooling valve The system has four control valves 1 Piston cooling valve 2 Relief valve for oil filters 3 By pass valve for oil cooler 4 Reducer valve 2 Relief valve oil filter 2 3 By pass valve 4 Reducer valve ...

Page 82: ...es horizontally the oil sump is of the dry type with separate oil tank The oil system delivery pump sucks the oil from the oil tank through a strainer It then pressurizes the oil out to the various lube points in the lubricating system Return oil is pumped back to the oil tank by two scav enging pumps General layout engine oil The oil pump is of the gear type and has three pump units The front uni...

Page 83: ...The full flow filters are coupled in parallel for best filtration 2 Oil pump drive gear Scavenging pump unit Oil delivery pump unit Intermediate gear Coolant pump flange Scavenging pump unit The oil pump is of the gear type and has three pump units The front unit functions as an oil delivery pump and the other two as scavenging pumps They all pump the oil back to the oil tank via the oil cooler Th...

Page 84: ...amaged or de formed they must be unreservedly replaced with new ones Great care should therefore always be taken when working on pistons connecting rods cylinder liners in piston cooling engines so as not to damage the nozzles Clogged piston cooling nozzles must not be cleaned and re used because of the risk of dirt particles being left in the system When servicing after piston seizure the oil coo...

Page 85: ...kpm Main bearings 340 25 34 0 2 5 Sump 18 2 1 8 0 2 Sump cover 24 2 2 4 0 2 Adjusting Secure the cap in a vice with aluminium jaws see Fig below Make sure the pump does not lie against the vice Mount a dial indicator with magnetic foot on the cap and position the probe to right angles to the pump Press the pump to the left Zero set the indicator dial Press the pump to the right Read off the dial P...

Page 86: ...mp body for scoring and wear also for leakage signs between the bracket and the pump body The contact surfaces will be black if there is leakage NOTE The bushings in the middle pump bodies are a bit narrower and must be centered otherwise they will block the oil drillings Pressing out in bushings NOTE The bushings must be pressed in from the outside as shown below 6849 6849 2654 ...

Page 87: ...ump gears Correct clearance 0 02 0 08 mm 2 There are two ways in which to fit the oil pump drive gear Heat the gear to approx 180 C and tap it into position or Place the gear under the bracket and press in the shaft In both cases place a feeler gauge 1 0 1 5 mm be tween the pump gear and the bracket ...

Page 88: ...o drill an M10x1 mm hole Then fit a suitable plug in the socket after completing the oil pressure check 2800 8074 8075 6398 6666 Oil cooler Pressure testing Special tools 999 2800 Test bench 8074 Nipple 8075 Cover washer 1 Drain the oil and coolant Remove the oil cooler from the engine Change to new O rings before mouting the press testing tools 2 Fit nipple 8074 and cover washer 8075 Connect up t...

Page 89: ...ction timer Checking 101 Testing injection pump 102 C Adjuster device 103 A Synchronizing 104 D Speed sensor 106 B Checking and setting fuel flows 106 E Checking oil pump 107 F Anti tamper sealing 108 Replacing damper valve holder injection pump 109 Note For more detailed information on the fuel system EDC refer to Service Bulletin 2 23 No 18 There is also a description of the EDC system in Servic...

Page 90: ...top device Injection pump setting values chiefly fuel flow and pre injection angle differs for the various engine types The reason for this is that these values are adapted to the properties that the engine has with regard to emis sions and power output ...

Page 91: ...are now placed under the starter motor The filter element consists of a spiral wound paper in sert with very large filtration area The layers of paper are folded so as to form pockets with openings that face upwards The fuel flows axially through the pockets and this separates dust particles water etc from the fuel The injectors atomize and distribute the fuel in the en gine combustion chamber Inj...

Page 92: ...n pump Differences The delivery valves have been replaced by damper valves in order to maintain a higher pressure at the in jectors without having to raise the injection pump pressure The delivery valve holders delivery pipe connections are now longer and have only one damper valve Fuel system venting has been modified to accomodate the above changes After normal venting at the filter bracket vent...

Page 93: ...ydraulical timer described in Service Bulletin 2 23 21 11 93 and Service Manual 2 20 27 Engine THD 101 104 The difference is that the centrifugally activated con trol valves in the rear flange have been removed and because of this the infinite timing setting has been re placed by a 2 position timer and the maximum timing angle has been reduced from 6 to 5 Delivery oil flow from the engine is regul...

Page 94: ...load there is read justment between 1080 and 1290 r min otherwise ad justment takes place DH10A 345 DH10A 360 Value a 5 5 7 Value b 10 5 12 Function The injection timer alters the a angle to suit operating conditions see diagram below When there is no cur rent in the solenoid valve the engine a angle is the same as the basic setting value a When operating conditions are such that current reaches t...

Page 95: ...eptable Injectors should be checked in an injector tester Check results against injector data in Specifica tions Concerning repairs to and maintenance of injec tors refer to the instructions of the Bosch factory Warning Utmost care must be taken when testing injectors Fuel spray from the injector MUST NOT be allowed to strike unprotected parts of the body The jet has tremendous force and skin pene...

Page 96: ...e contact area between the nozzle needle and the seat is narrow as the parts are manufactured with a small angle difference Cleaning copper sleeve before installing injectors Special tool 981 2546 Sleeve brush The copper sleeve seat must be cleaned in order to get proper sealing between the injector and copper sleeve Slide down the installation sleeve to compress the brush Press down the brush and...

Page 97: ...olts 62 5 Nm 6 2 0 5 kpm To note when installing injection pump Tightening cable connections The 7 pin connection for the governor has three guide slots The widest slot in the cable unit connection is at the bottom for correct connect up to the governor Con nect up is correct when the cable unit cap nut fits into the threads in the pump connection Guide slots Cable unit Pump section Guide slots 7 ...

Page 98: ... NOTE It is important that all cable connections and joints in the EDC system are fully plugged in and that the protection sleeves are pressed fully over insulators and sensors Check that there is engine oil in the bottom section of the injection pump There should be no oil in the gov ernor Basic timing injection pump EDC Special tools 998 7057 Timing tool 8068 Crank tool 1 Remove the inspection p...

Page 99: ...ota tion When both the tool diodes light read off the degree on the flywheel Compare this with what is given in the Diesel Test Standard or refer to Speci fications in this manual 6 If the timing has to be altered slacken the clamp bolt for the pump coupling and tap the pump flange until the timing is correct 7 Tighten clamp bolt M11 90 5 Nm M12 114 10 Nm 8 Check the timing again and adjust if nec...

Page 100: ...altered Each activation increases decreases idle speed by about 10 r min within the adjustable interval When the desired idling speed has been reached activate RESUME again for at least 4 seconds and then move the slide control to the neutral position Setting temporary The engine idle speed can be temporarily altered by activating the rocker switch SET or SET without depressing the brake pedal Ift...

Page 101: ... fuel into the fuel system until fuel free from air bubbles flows out Then close the vent screw 3 In the same way slacken each delivery pipe and use the feed pump hand primer to get fuel free from air bubbles and then tighten up the pipes while the fuel is still flowing out 4 Check for leakage and the function ...

Page 102: ...rease engine speed to 1200 r min and check the timing value on the measuring instrument The in crease engine speed to 1800 r min and check the pre timing value The pre timing value should in crease 6 1 between 1200 and 1800 r min If the pre timing does not change between 1200 1800 r min overhaul or replace the injection timer It is important that the sensor distance to the flywheel flex plate is a...

Page 103: ... checked calculated as follows 1 Connect up the voltmeter Blue contact to and red to on the voltmeter Note After the test connect up the green contact instead of the red one 2 Connect up power sources for 12 V constant volt age Read off the working voltage U ref on the volt meter Should be 4 99 5 01 V If the working voltage is not within 4 99 5 10 V and deviation is not greater than 10 voltage re ...

Page 104: ... that there must be a 0 1 0 3 mm gap between the control rod and the end pin when the control rod is in the non travel position and the adjuster device off circuit 7 Thereafter carry out tests 1 and 2 under C Adjust er device adjustment as per diesel test standards sheet Tips Carry out the tests at low pump rota tion e g 200 r min Compare the measured values with those given in the diesel test sta...

Page 105: ... under the flange bushing If the pump piston stroke is too early fit thicker shims Fit thinner ones if the stroke is delayed Lift from basic circle at start of measuring 1 Set no 1 pump piston to its bottom position Zero set the dial indicator Remove the relief valve from the injection pump Connect the test bench high pressure hose to the pump fuel inlet Plug the pump fuel outlet 2 Start high pres...

Page 106: ...elements are checked and if neces sary adjusted in accordance with engine firing se quence 1 5 3 6 2 4 The dial indicator is used only on no 1 tappet The oth er pump elements are adjusted with the help of the test bench protractor Mark the stroke position for no 1 pump element on the test bench protractor Then re move the dial indicator The pump camshaft is cranked 60 for each pump ele ment Compar...

Page 107: ...r sensor position ad justment B Check and setting fuel flows Run the injection pump up to normal operating temper ature Note With continuous driving at altitudes of 2000 4000 metres above sea level fuel flow must be reduced by 10 At 4000 metres and above 20 Note that with altered fuel flow the engine data programmed into the control unit when the engine was delivered from the factory must be accor...

Page 108: ...ion is unsatisfactory too much oil collects in governor housing or when the oil pump has been removed It should also be checked when the entire injection pump has been dismantled The oil pump is checked by measuring the vacuum created by the pump in the governor housing The function of the oil pump is to pump back oil that has leaked into the governor housing There will always be a small amount of...

Page 109: ...governor housing Remove the plug at the front of the pump where the control rod travel is measured Start the test bench and run the pump according to the diesel test standards Compare the vacuum measured with that in the standards F Anti tamper sealing Anti tamper seal the pump and the governor with the two screws on the governor cover ...

Page 110: ...mpare with a new 9 Also check the uncovered upper part of the pump looks alright Important If the washer has fallen down in all probability the in jection pump is damaged and must be repaired If the pump is damaged the delivery pipes and the injectors will also have to be replaced 10 Tighten the new valve holder in two stages with the special tool First to 50 Nm 5 kpm and then to 110 5 Nm 11 0 5 k...

Page 111: ...ssure drop indicator 112 Starting pre heater Troubleshooting 113 Replacing heating coil 114 Turbocompressor Description DH10A 345 350 360 115 Servicing DH10A 345 350 360 116 Description DH10A 245 285 119 Servicing DH10A 245 285 121 Wastegate 120 Exhaust pressure governor Description 125 Servicing 126 ...

Page 112: ...aner single filter insert type Exhaust pressure governor Turbo compressor Air cleaner Inlet pipe with intercooler To engine The filter insert should be replaced when the pressure drop indicator window shows red or if the filter has been in use for 18 months For more details look up the Service Manual Service and Maintenance The air cleaner may have one or two filter inserts The inner insert in the...

Page 113: ...set button If faulty replace the pressure drop indicator When fitting the pressure drop indicator make sure it is screwed on tight There must not be any air leakage on the clean side of the air cleaner Intercooler All the DH10A engines have the single circuit type in tercooler with a separate cooling circuit radiator and pump The intercooler lowers the temperature of the inlet air and this has a b...

Page 114: ...ght heat should be felt after about 50 seconds 2 Measure the resistance through the heater coil be tween the stud where the cable is connected and the outer retaining bolt at the other end This resist ance should be approx 0 3 ohm High resistance indicates failure Low resistance points to short circuit in which case the starting pre heater fuse has momentarily popped out when the starting pre heat...

Page 115: ... it is important to de insulate all retaining screws except the earth screw The earth screw is insulated on the inside but has good earth contact on the outside Current flows through this screw to engine earthing After installing the coil switch it on and see that it reaches operating temperature Then allow it to cool and check tighten the screws The screws must not be check tightened after instal...

Page 116: ...coolant con nections do not disconnect the wastegate and con trol rod 6 Remove the turbocompressor from the exhaust manifold The turbine wheel and compressor wheel are mounted on the same shaft When the compressor wheel rotates it sucks air in from the air cleaner the turbocompressor compresses it and presses it through the intercooler to the engine Concerning the charge pressure refer to Conditio...

Page 117: ...rbine housing Retaining rings and bushings Sealant 591247 2 Servicing turbocompressor DH10A 345 350 360 Special tools 998 7600 Adapter 999 9708 Torque wrench Always line up mark the position for the turbine hous ing 1 and compressor housing 2 before starting the disassembling Remove in the following numerical sequence Sealant 591 247 2 between turbine housing and diffusor 6 Retaining ring and end ...

Page 118: ...ner until deposits drop off Use a plastic scraper or soft brush for cleaning the alu minium parts Note A steel brush or metal scraper must never be used Steam wash can also be used providing that shafts and other bearing surfaces are adequately pro tected Checking Check all parts for wear Always replace bearings seals circlip lock washer with new ones from the re pair kit 7600 4 7 Circled digits r...

Page 119: ...s 0 37 0 56 mm Throw at shaft smallest diameter max 0 015 mm Throw turbine wheel rear max 0 16 mm 9708 7600 To note when assembling Oil the bearing bushings and piston rings with straight engine oil Make doubly sure that the piston ring seals centre correctly against the bearing bushings Tightening torque for thrust bearing three bolts is 4 5 Nm 0 45 kpm Torque wrench 999 9708 and adapter 998 7600...

Page 120: ...s the exhaust pressure directly to the exhaust pipe This offloads the exhaust turbine and the turbo speed drops The above function provides the turbocompressor with a broader working range and this results in an engine characteristic that has a wide high torque range and a limited charge pressure at full power output The turbine shaft journalling is lubricated and cooled by the engine pressure lub...

Page 121: ...ays check to make sure the pres sure gauge is correctly calibrated 1 Place a dial indicator 0 20 mm with magnetic holder on the turbocompressor so that the measur ing probe is in line with the control rod from the pressure box 6662 9314 3 With the reducer valve on 6662 carefully let in pressure to the pressure box and observe the dial indicator at the same time Read off the indicator exactly when ...

Page 122: ...eplaced use the repair kit for this see Parts Catalogue The kit contains a service tool fixture and necessary instructions for a correct mounting of the wastegate Always line up mark the position of the turbine hous ing 1 in relation to the compressor housing 2 before disassembling 1 Pressure box wastegate 2 Lock nut 3 Turbine housing 4 Bearing housing complete 5 Compressor housing 6 Lock nut whee...

Page 123: ...e from dirt Checking Check all parts for wear Bearings seals lock rings and circlips requiring replacement should be replaced with the corresponding parts from the repair kit A damaged shaft with scoring on the bearing surfaces must not be re fitted Minor scores are acceptable If damaged the turbine and compressor wheels must always be replaced Do not attempt to straighten out a deformed blade The...

Page 124: ...at the bevelled side faces the bearing bushing 8 Turn the piston ring seal on the turbine shaft so that its opening coincides with the oil drain hole 180 from the oil drain hole Fitting the piston ring seal is made easier by rotat ing the shaft while carefully pressing the turbine wheel together with the bearing housing 1 Lock nut 2 Circlip 3 O ring 4 Piston ring seal 5 Oil guide plate 6 Axial bea...

Page 125: ...rly locates in the groove Align the line up marks on the bearing housing and the turbine housing Tighten the screws 10 to 14 Nm Secure the turbine housing and check measure ra dial and axial clearance with the help of a dial indi cator Align the compressor wheel balance mark Mount the wheel and tighten the lock nut 1 to 17 Nm Note that the nut has a l h thread Align and carefully fit the compresso...

Page 126: ...ne works against a certain backpressure and this reduces hydrocarbon emissions and white smoke The EPG is controlled by pressurized air via a solenoid valve and a reducer valve The EPG also functions as an exhaust brake when the exhaust brake switch is activated Note The same control pressure is used for the EPG during warm up as for exhaust braking which is max 750 kPa Electric and compressed air...

Page 127: ...sembling 5 Fix the shutter in a vice 6 Fit on the shutter housing cover 7 Fit the bearing housing and piston rod 8 Fit the cylinder Make sure the evacuation hole faces down 9 Fit the spacer washer spring and piston 10 Fit the cover Cover O ring Piston Sealing ring Cylinder Spring Evacuation hole Bearing housing Spacer washer Bushings Scraper ring Stopp ring Piston rod Shutter housing cover Shutter...

Page 128: ... valve 131 Coolant pump Disassembling assembling 131 Intercooler Pressure testing 135 Cooling fan Description 137 Pressure testing cooling system 139 High coolant temperature Radiator sealing 141 Coolant temperature sensors 142 Fan drive Fan drive with drive belts 143 Hydraulic fan drive 144 ...

Page 129: ...pump engine circuit and intercoo ler circuit 1 13 Coolant pump intercooler circuit 2 14 Oil cooler engine 15 Engine 16 Intercooler element 2 17 Intercooler element 1 18 Thermostat intercooler circuit 1 19 Oil cooler in gearbox retarder The engine and intercooler circuits are connected up as before The cooling circuit for the hydraulic retarder and the automatic transmission are coupled in series w...

Page 130: ...he coolant goes up to the cooling system expansion tank At the same time a small amount of coolant flows from the intercooler circuit also up to the expansion tank This coolant is much cooler than the coolant that comes from the remaining part of the engine From the point of view of heating this is not a good mixture par ticularly at low ambient temperatures It is estimated that up to 5 of the hea...

Page 131: ...drift 6781 to locate the sealing ring properly in relation to the thermostat contact surface 1 Place the new sealing ring on drift 6781 2 Carefully tap in the sealing ring until the drift bot toms in the thermostat housing 6781 Main thermostat The thermostat housing contains two thermostats for maintaining temperature in the engine cooling circuit and one thermostat for the bus interior heating sy...

Page 132: ...in thermostat is closed especially at low engine speed This improves circulation in the heating system circuits The Fig shows valve opening under load 1 Remove the pump cover and flange Press out the shaft enough to loosen the impeller 6858 Coolant pump Special tools 999 2268 Drift 2269 Counterhold 6858 Drift 8039 Drift 8113 Drift 6859 Counterhold 2 Press out the shaft 6858 ...

Page 133: ... bearing cage 4 Remove the circlip Press out the outer bearing and the deflector ring 5 Press the shaft out of the bearing cage 2268 8113 6858 7 Fit the circlip Tap on the deflector ring 8 Mark the shaft 37 mm from its end Press the shaft in up to the mark ...

Page 134: ... drill ing 10 Press in the shaft bearing and bearing cage First use counterhold 2269 as a counterhold Then continue with drift 8113 using the handle as a counterhold 8039 8039 8113 6859 2269 13 Press the impeller about 10 mm down on the shaft 14 Place counterhold 6859 as a support under the im peller and press on the impeller ...

Page 135: ... Fit the O ring and the intermediate cover Press on the intermediate cover and impeller at the same time Stop pressing down when the gap between the pump housing and the cover is 0 5 1 0 mm 18 Fit the O ring and the outer cover NOTE The marks on the intermediate cover and the outer cover must coincide 0 5 1 0 mm ...

Page 136: ...re gauge 1 Connect the pressure gauge to the compressed air system Set pressure at 50 kPa 0 5 kp cm2 2 Fit the cover washer 6816 3 Connect the pressure gauge to the nipple and test the pressure It must not drop during one minute If it does replace the intercooler 6662 6815 4 Increase pressure to 150 kPa 1 5 kp cm2 Pres sure must not drop during one minute If it does replace the intercooler ...

Page 137: ...ing Tighten the screws in two stages in the sequence shown below Stage 1 Tighten the screws until the screw head makes contact with the block Stage 2 Tighten the screws to 20 2 Nm 2 0 2 kpm Check tightening screws difficult to access on the in tercooler requires a special tool with P N 1158239 ...

Page 138: ...5 is fully closed Oil can then go through a return channel from the coupling housing 9 to the space in the cover 2 In this mode the fan speed is re duced to approx 1 4 of the drive shaft 10 speed This is the lowest stage at which engagement takes place As the temperature increases the valve starts to open and the degree of engagement increases to full engage ment at approx 65 C at which the spring...

Page 139: ...ion tape A piece of this tape is stuck on a fan blade and another piece next to the fan drive shaft Start the check with a cold engine and an ambient tem perature of max 25 C Then run the engine to about 2000 r min If fan speed increases at temper atures below 25 C then there is something wrong with fan control mechanism The fan control mechanism is functioning properly if the degree of engagement...

Page 140: ...ardness cracks etc Replace damaged or worn hoses before checking for leakage If necessary top up before pressure testing Place or hang up the pressure tester gauge above the radiator to prevent coolant from getting into it Slowly raise the pressure to above 40 kPa 0 4 kp cm2 to build up the pressure in the cooling system At ap prox 50 kPa 0 5 kp cm2 the pressure cap overflow function should start ...

Page 141: ...ubber pads 6 Lower as far as possible the radiator assembly with the lift Raise the bus and pull out the radiator assembly Installing 1 Place the radiator assembly on lift 9954 Raise the bus enough to run the radiator assembly in underneath 2 Lower the bus and raise the lift far enough so that the assembly mount brackets can be bolted on Fit and tighten all the bracket bolts and lower the lift 3 C...

Page 142: ...or A radiator with loose or damaged fins should be re placed Side seals viewed from above Upper seal viewed from left side Sealing round radiator Make sure the gap between the radiator and the body is properly sealed Side seals should go all the way down to the frame flange bottom edge Defective sealing can be rectified with rubber stripping or similar Also check that the sealing ring between the ...

Page 143: ...ween pins 2 3 C Ω C Ω 60 116 6 14 2 0 1634 21 90 45 9 4 5 25 2000 22 100 34 9 3 1 Warning lamp activation is controlled by an electronic circuit in the temp gauge Thus the temp sensor does not have this function Activation temp is 102 3 C Temp sensor EDC 4 pin max test current 1 mA P N 3944 168 between pins 1 2 between pins 3 4 C Ω C Ω 60 607 5 59 0 1634 21 90 250 6 26 8 25 2000 22 120 116 6 14 0 ...

Page 144: ...t the pre tension to 15 on the scale This corresponds to correct belt tension ing Tighten up the lock bolt 2 With incorrect relationship between the belt ten sioner and pulleys adjust the belt tensioner posi tion 3 Tension the drive belts as shown in the Fig Tight en the lock bolt and check the belt tensioner posi tion again according to pos 1 Belt tensioner Fan drive with drive belts B10B Adjusti...

Page 145: ... layout hydraulic fan drive 1 Pump 2 Fan motor 3 Thermostat valve 4 Control valve 5 Modulator 6 Restrictor 7 Oil tank 8 Oil filter 9 Radiator assembly 10 Pulley 11 Max pressure valve Fan drive B10M Concerning troubleshooting servicing the hydraulic pump hydraulic motor refer to Service Manual Section 2 26 Hy draulic Fan Delivery line By pass oil line Suction line Return line ...

Page 146: ...area 147 Sensors on engine 147 EDC components in electrical distributor unit Relay box 148 Control unit 149 Fault diagnosis Activating fault diagnosis 150 Fault codes 151 Troubleshooting EDC troubleshooting with multimeter 154 Connecting up 155 Measurements table 155 Remarks 158 ...

Page 147: ...ction for low and raised idling Compared to a conventional fuel system the advant ages of the EDC is that it has greater opportunities to control fuel flow The electromagnetic governor reacts more rapidly and provides a more precise fuel control compared to a mechanical governor This chapter contains a description of the system check remedy measures when one or several fault codes have been regist...

Page 148: ...idle speed with cold engine speed limita tion during a certain period after starting Extra speed sensor 753B In addition to the charge pressure it is important that the control unit knows the engine speed otherwise it cannot determine the fuel flow The function of the EDC requires at least one speed signal For this reason the speed signals are doubled A speed signal is despatched as information to...

Page 149: ...to pin 32 in the control unit Pin 14 is earthed Relay box 3060 Fuse 45 for normal voltage feed Fuse 44 for cruise control stalk Control unit 9058 in N pos above 3 km hr Relay 3063 breaks when engine stops Control unit 9058 when p brake is applied 30 from coupling box TR2 circuit is wired to the automatic transmission and parking brake Its function is to simulate clutch pedal up It must be possible...

Page 150: ...erally pro grammed part 1 in one of the EE programs and can not be used until it has been programmed with engine data for some engine variants For each engine variant there is a so called engine data statement stored in a disk With the help of a PC the data statement can be stored in part 2 in the EE program Moreover each control unit is programmed with the bus data 3 that is the drive line reduct...

Page 151: ...ressed air cylinder emergen cy stop activates the injection pump stop lever Breaking to the solenoid valve 603 opens the valve 27 Position breaker 2007 on the clutch pedal earths when the clutch pedal is released Ap plies only to manual gearbox for automatic transmission see pin 6 relay box Fault diagnosis The EDC system monitors sensors functions and the governor adjuster device With fault the di...

Page 152: ...Check the resistance in the sensors see below fault code 5 B If there is nothing wrong with the sensors check for failure in cables to pins 31 and 32 The sensor is housed inside the injection pump gov ernor Sensor resistance between pins 3 and 4 on the governor 0 8 1 2 Ω The sensor is place on the engine Correct resistance is 1050 100 Ω between the sensor connection pins Incorrect values from spee...

Page 153: ...eck that voltage cuts out at 2008 extra brake pressure breaker Set cruise con trol to RESUME measure the voltage 24 V in TB 3 in SET in TB 2 and in SET and in TB 1 Fault inside control unit Engine can start and be driven but with reduced power and lower engine speed Fault code 20 Control problem general 21 Control problem control rod position extremely low 22 Control problem control rod position e...

Page 154: ...er push rod out to the end position Adjust the posi tion of the stop cylinder to get a clearance of 1 2 mm between the push rod and the lever Compressed air cylinder for emergency stop For safety reasons there is a compressed air cylinder for emergency engine switch off It is placed on the in jection pump Normally the engine shuts down when the feed voltage to the EDC control unit is broken by tur...

Page 155: ... With the test box and adapter it is possible to do a more realistic troubleshooting on the signals to and from the control unit in a very simple way Special tools 999 5009 Pedal support 951 0060 Multimeter 981 3190 Test box 60 pin 981 3192 Adapter 35 pin Troubleshooting requires a multimeter with a fault tolerance of max 0 4 and 2 decimal display when measuring voltage between 0 24 V Multimeter 9...

Page 156: ... Nominal value Component Remarks 1 19 Battery voltage Feed to control unit 2 20 Battery voltage Feed to control unit 1 15 Battery voltage Diagnostic lamp 32 19 19 V Speed sensor engine 5 33 19 4 6 4 9 V Reference voltage intercooler pressure 9 34 19 1 3 1 5 V Voltage from intercooler pressure sensor 9 21 19 Battery voltage Adjuster device injection pump 3 19 Battery voltage Adjuster device injecti...

Page 157: ...dal depressed 11 19 Battery voltage Retarder control activated 5 19 0 1 V Brake pedal depressed 5 19 Battery voltage Brake pedal released 5 19 0 1 V EDC control held in OFF position 5 19 Battery voltage EDC control held in SET SET RESUME or neutral position 12 19 Battery voltage EDC control held in SET position 12 19 0 1 V EDC control held in OFF SET RESUME or neutral position 18 19 Battery voltag...

Page 158: ... 3 28 35 2 6 3 05 V Control rod travel accelerator pedal in max position and engine max loaded Measured while driving 2 31 35 Speed sensor injection pump 10 Depending on engine variant see Specifications Measured with oscilloscope 6 29 18 24 ohm Control rod travel sensor injection pump 2 6 10 18 24 ohm Control rod travel sensor injection pump 2 31 35 0 9 1 1 ohm Speed sensor injection pump 10 1 21...

Page 159: ... engine in question it is necessary to correct the value with a view to the fact that the reference voltage can vary pins 17 and 35 The new value we call Unorm Unorm measured voltage value control rod X travel Also check the resistance see page 157 control rod travel sensor injection pump Ex of pulse wide modu lated signal A signal at low idle 200 Hz 10 pulse wide ratio B signal at 1650 rpm 200 Hz...

Page 160: ...ured with an oscilloscope Low idle 550 r min 270 300 Hz Ex of a square signal 6 The speed signal from the tachograph is a so called square with varying width on the pusle interval Amplitude is approx 7 V and the pulse width is 2 5 ms long varies according to setting on the dip switches on the tachograph At approx 100 km h the pulse interval ratio is 1 1 frequency 200 Hz The pulse width is constant...

Page 161: ...5 measured reference voltage Example The voltage for the turbo pressure Unorm is estimated at 3 7 V at an ambient temperature of 0 C Go in on the vertical axis in the diagram to 3 7 V Follow the horizontal axis to the right until it inter sects the vertical line for 0 C ambient temperature The corrected voltage is read off on the respective curve in the diagram In our example 3 5 V which correspon...

Page 162: ...Volvo Bus Corporation TP 16031 1 English 2500 06 97 Printed in Sweden by Novum Grafiska AB 97 24296 Göteborg Sweden ...

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