Service Information - Download Workshop Service Repair ECR5… · Service Information Date:...

Service Information

Document Title:

Engine, description

Function Group:

200

Information Type:

Service Information

Date:

2014/4/6 0

Profile:

CEX, ECR58 [GB]

Engine, description Model code

Model code

Symbol Description Remarks

D Diesel Engine

3.1,3.4 Displacement

C is the letter for Compact Equipment Blank

A is describing the performance version, A is the first version and the

letter B will then be the second version if the performance is upgraded

E is the emission letter

2 a number from 0 to 4 describing the emission level (Tier), E0 is then

nonregulated

E Excavator

C,W Crawler Type, Wheel Type

1,2,3,4 Order of Project in Korea

U,K Desiganation USA/Europe, Korea/International

The engine is a 4–cycle, 4–cylinder, direct injected, water cooled diesel engine.

The engine produces powerful performance using direct injection type combustion chamber.

Figure 1

Engine, top side view

1 Cooling fan 7 Fuel pipe 13 Engine data plate

2 Thermostat housing 8 Intake manifold 14 Rocker arm cover

3 Fuel return line Flywheel 9 Fuel supply line to

fuel injection

pump

15 Start motor

4 Hose for thermostat element 10 Fuel return line 16 Exhaust manifold

5 Oil filler port 11 Fuel filter 17 Engine data plate

6 Fuel injection pump 12 Fuel supply line to

fuel filter

Figure 2

Engine, front side view

18 Alternator

1 Engine oil filter 5 Hose for thermostat element 9 Alternator

2 Cooling water pump 6 Fuel return line 10 Fan pulley

3 Engine oil filler port 7 Thermostat housing 11 Starter motor

4 Fuel injection pump 8 Adjuster 12 Crankshaft V-pulley

Figure 3

Engine, rear side view

1. Alternator

2. Lifting bracket

3. Fuel filler

4. Engine oil filter

5. Flywheel

6. Oil drain valve (M22 x 1.5P)

Figure 4

Engine, starter motor side view

1 Thermostat housing 7 Starter motor

2 Lifting eye 8 Engine oil pan

3 Exhaust manifold 9 Crankshaft V-pully

4 Rocker arm cover 10 V-belt

5 Cylinder block 11 Alternator

6 Flywheel housing

Figure 5

Engine, fuel filter side view

1 Intake manifold 6 C. W. switch 11 Engine oil dipstick

2 Fuel supply line 7 Oil filler port 12 Injection pump lubricant pipe

3 Fuel return line 8 Fuel injection pump 13 Oil pressure switch

4 Fuel injection pipe 9 Engine oil filter 14 Fuel filter

5 Thermostat housing 10 Engine oil drain valve

Engine performance curve

Figure 6

Engine performance curve

A. Torque (kg·m)

B. Power (PS)

C. Speed (rpm)

D. Fuel consumption (g/ps·hr)

Service Information

Document Title:

Engine, tightening torque

Function Group:

200

Information Type:

Service Information

Date:

2014/4/6 0

Profile:

CEX, ECR58 [GB]

Engine, tightening torque Tightening torque, unit: Nm (lbf ft)

Item Nominal size Tighten torque Lubricating oil application (thread

portion, and seat surface)

Cylinder head screw M 11 × 1.25 103.1 ~ 112.9 (76 ~ 83) Applied

Connecting rod screw M10 × 1.0 53.9 ~ 58.8 (40 ~ 43) Applied

Flywheel set screw M14 × 1.5 186.2 ~ 205.8 (137 ~ 152) Applied

Bearing cap set screw M 11 × 1.25 108.1 ~ 117.9 (80 ~ 87) Applied

Crankshaft pulley set screw M14 × 1.5 107.9 ~ 127.5 (80 ~ 94) Applied

Fuel injection nozzle set screw M 8 × 1.25 22.6 ~ 28.4 (17 ~ 21) Not applied

Fuel feed pump drive gear set

nut

M 18 × 1.5 113 ~ 123 (83 ~ 90) Not applied

High-pressure fuel lines screw M 12 × 1.5 19.6 ~ 24.5 (174 ~ 217) Not applied

Fuel return pipe joint screw M 6 × 1.0 7.8 ~ 9.8 (70 ~ 86) Not applied

Tightening torque for standard screws and nuts, unit: Nm (lbf ft)

Item Nominal size Tighten torque Lubricating oil application (thread

portion, and seat surface)

Screw (7T) and nut M 6 × 1.0 9.8 ~ 11.8 (7 ~ 9)

Use 80% of the value at left

when the tightening part is

aluminium.

Use 60% of the value at left

for 4T screws and lock nuts.

M 8 × 1.25 22.6 ~ 28.4 (17 ~ 21)

M 10 × 1.5 44.1 ~ 53.9 (33 ~ 40)

M 12 × 1.75 78.4 ~ 98 (58 ~ 72)

M 14 × 1.5 127.5 ~ 147.1 (94 ~ 108)

M 16 × 1.5 215.7 ~ 235.4 (157 ~ 174)

PT plug 1/8 9.8 (7)

1/4 19.6 (14)

3/8 29.4 (22)

1/2 58.5 (43)

Pipe joint screw M 8 12.7 ~ 16.7 (9 ~ 12)

M 10 19.6 ~ 25.5 (14 ~ 19)

M 12 24.5 ~ 34.3 (18 ~ 25)

M 14 39.2 ~ 49 (29 ~ 36)

M 16 49 ~ 58.8 (36 ~ 43)

NOTE!

Lubricating oil is not applied to threaded portion and seat surface.

Service Information

Document Title:

Precautions

Function Group:

200

Information Type:

Service Information

Date:

2014/4/6 0

Profile:

CEX, ECR58 [GB]

Precautions Make preparation as follows before starting engine inspection and service.

WARNING Risk of personal injury. Very heavy object.

Be sure to fix the engine securely to prevent injury or damage due to parts falling during the work.

WARNING Risk of personal injury! Wear safety glasses and use protective gloves.

Always wear glasses or a protective face shield when using compressed air or steam to prevent any foreign matter

from getting into the eyes.

Fix the engine on a horizontal base.

Remove the coolant hoses, fuel oil pipes, wire harness, control wires etc. connecting the driven machine and

engine, and drain coolant, lubricating oil and fuel.

Remove soil, oil, dust, etc. from the engine by washing with solvent, air, steam, etc. Carefully operate so as not to let

any foreign matter enter the engine.

Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the

standard or limit shall be replaced.

Any part predicted to dissatisfy the standard or limit before the next service as estimated from the state of use

should be replaced even when the measured value then satisfies the standard or limit.

Service Information

Document Title:

Troubleshooting chart

Function Group:

200

Information Type:

Service Information

Date:

2014/4/6 0

Profile:

CEX, ECR58 [GB]

Troubleshooting chart The following table summarizes the general trouble symptoms and their causes. If any trouble symptom occurs, take

corrective action before it develops into a serious problem so as not to shorten the engine service life.

Engine troubleshooting chart

Trouble symptoms Causes Corrective actions

Engine does not start Improper clearance of inlet/exhaust valve Adjust the valve clearance

Seizure of inlet/exhaust valve Correct or replace

Seized or broken piston ring Replace the piston ring

Worn piston ring, piston or cylinder Perform honing and use oversize parts

Seized crankpin metal or bearing Repair or replace

Foreign matter trapped in combustion chamber Disassemble and repair

Improper open/close timing of intake/exhaust

valves

Adjust the valve clearance

Improper properties of lubricating oil Use proper lubricating oil

Water entrance in fuel system Perform draining from the fuel filter

Clogged fuel filter Clean or replace

Air entrance in fuel system Perform air bleeding

Clogged or cracked fuel pipe Clean or replace

Insufficient fuel supply to fuel injection pump Check the fuel tank cock, fuel tank, fuel

pipe and fuel feed pump

Priming failure (foreign matter trapped in the

valve inside the priming pump)

Disassemble and clean

Starting motor defect Repair or replace

Alternator defect Repair or replace

Open circuit in wiring harness Repair

Battery voltage drop Inspect and charge the battery

Engine starts, but stops

soon.

Exhaust smoke none.

Improper clearance of inlet/exhaust valve Adjust the valve clearance


Improper arrangement of piston rings joint Correct the ring joint positions

Defective governor Make adjustment


Insufficient lubricating oil level Add proper lubricating oil






Engine starts, but stops

soon.

Exhaust smoke excessive.





Insufficient engine output.

Exhaust color : ordinary

Clogged air filter Clean

Improper clearance of inlet/exhaust valve Adjust the valve clearance

Compression leakage from valve seat Lap the valve seat


Blowout from cylinder head gasket Replace the gasket

Worn crankpin and journal bearing Measure and replace


Improper properties of fuel oil Use proper fuel oil






Clogged strainer at fuel feed pump inlet Clean the strainer


(Exhaust color : white)




Reverse assembly of piston ring Reassemble correctly

Worn inlet/exhaust valve guide Measure and replace


valves


Timing of fuel injection pump too late Check and adjust



Uneven injection volume of fuel injection pump Check and adjust

Poor spray pattern from fuel injection nozzle Check and adjust


(Exhaust color : black)




valves


Insufficient cooling effect of radiator,

Defective thermostat (kept opened) or slipping

fan belt

Repair or replace thermostat and fan

belt

Insufficient coolant level Check leakage from cooling system

Slackened fan belt Adjust the belt tension

Defective thermostat Check or replace






Engine used at high temperature or at high

altitude

Study output drop and load matching

Clogged exhaust pipe Clean

Poor exhaust color : white

(During work)





valves


Excessive cooling effect of radiator, Repair or replace

Poor exhaust color : black

(During work)

Defective thermostat (kept closed)

Defective thermostat

Timing of fuel injection pump too early

Timing of fuel injection pump too late

Improper properties of fuel oil

Water entrance in fuel system

Uneven injection volume of fuel injection pump

Poor spray pattern from fuel injection nozzle

Compression leakage from valve seat

Seizure of inlet/exhaust valve


valves

Timing of fuel injection pump too early

Timing of fuel injection pump too late

Improper properties of fuel oil

Uneven injection volume of fuel injection pump

Excessive fuel injection volume

Poor spray pattern from fuel injection nozzle

Clogged air filter


altitude

Check or replace

Check and adjust

Check and adjust

Use proper fuel oil

Perform draining from the fuel filter

Check and adjust

Check and adjust

Lap the valve seat

Correct or replace


Check and adjust

Check and adjust

Use proper fuel oil

Check and adjust

Check and adjust

Check and adjust

Clean



High knocking sound during

compression

Timing of fuel injection pump too early Check and adjust

Abnormal engine sound Improper clearance of inlet/exhaust valve Adjust the valve clearance






Loosened connecting rod screw Tighten to specified torque


Excessive gear backlash Adjust gear and repair


valves


Uneven combustion sound Improper properties of fuel oil Use proper fuel oil






Hunting during idling Seized or broken piston ring Replace the piston ring







Hunting during work Seizure of inlet/exhaust valve Correct or replace

Large engine vibration













Timing of fuel injection pump too early Check and adjust



Difficulty in returning to low

speed


Excessive fuel consumption Compression leakage from valve seat Lap the valve seat

Excessive cooling effect of radiator,


Repair or replace


Excessive fuel injection volume Check and adjust



altitude


Excessive lubricating oil

consumption








Leakage from lubricating oil piping system Repair


Lubricating oil diluted by

fuel




Lubricating oil mixed with

water


Cracked water jacket Repair or replace

Low lubricating oil pressure Worn crankpin and journal bearing Measure and replace




Leakage from lubricating oil piping system Repair

Insufficient delivery capacity of trochoid pump Check and repair

Clogged lubricating oil filter Clean or replace

Defective pressure regulating valve Check, adjust or replace

Insufficient lubricating oil level Add proper lubricating oil

Excessive blow-by gas Compression leakage from valve seat Lap the valve seat

Overheating of coolant










Clogged lubricating oil filter Clean or replace






fan belt


belt







altitude


Low coolant temperature Excessive cooling effect of radiator,


Repair or replace


Air inlet pressure drop Improper clearance of inlet/exhaust valve Adjust the valve clearance





altitude


Air inlet pressure rise Excessive fuel injection volume Check and adjust

Exhaust temperature rise Improper clearance of inlet/exhaust valve Adjust the valve clearance





fan belt


belt







Service Information

Document Title:

Maintenance standards

Function Group:

200

Information Type:

Service Information

Date:

2014/4/6 0

Profile:

CEX, ECR58 [GB]

Maintenance standards Engine service standard

Inspection item Unit Standard Limit

Intake / Exhaust Valve Clearance mm (inch) 0.15 ∼ 0.25

(0.006 ∼ 0.010)

Fuel injection pressure MPa

(kgf/cm2)

(psi)

(bar)

21.6 ~ 22.6

(220 ∼ 230)

(3129 ∼ 3271)

(21.6 ~ 225.6)

Compression at 250 rpm MPa

(kgf/cm2)

(psi)

(bar)

3.43 ±0.09

(35 ±1)

(498 ±14)

(34.3 ±0.98)

2.74 ±0.09

(28 ±1)

(398.2 ±14.2)

(27.4 ±0.98)

Coolant capacity (engine only) Liters (US gal) 4.2 (1.1)

Lubricating oil capacity (oil pan) High 11.5 (3)

Low 5 (1.3)

Oil pressure switch operating pressure MPa

(kgf/cm2)

(psi)

0.04 ~ 0.06

(0.4 ~ 0.6))

(5.8 ~ 8.8))

Thermostat Valve opening temperature °C (°F) 82 (179.6)

Full opening lift (temperature) mm (inch) / °C (°F) 8 (0.32) or more / 95

(203)

Coolant Temperature Switch °C (°F) 107 ~ 113 (225 ~ 235)

Service Information

Document Title:

Special tools

Function Group:

200

Information Type:

Service Information

Date:

2014/4/6 0

Profile:

CEX, ECR58 [GB]

Special tools Special tools

Special tools

Tool name Applicable model and tool size Illustration

Valve guide tool (for extracting valve Part number: 14527850 Drift

guide) l1 : 20 mm (0.787 in)

l2 : 75 mm (2.953 in)

d1 : 6.5 mm (0.256 in)

d2 : 10 mm (0.394 in)

Valve guide tool (for inserting valve Part number: 14527851 Drift

guide) l1 : 7 mm (0.276 in)

l2 : 60 mm (2.362 in)

d1 : 13 mm (0.512 in)

d2 : 16 mm (0.630 in)

Connecting rod bushing replacer Part number: 14527852 Drift

(for removal/installation of connecting rod bushing) l1 : 20 mm (0.787 in)

l2 : 100 mm (3.937 in)

d1 : 30 mm (1.181 in)

d2 : 33 -0.3/-0.6 mm

(1.299 -0.012/-0.024 in)

Valve spring compressor (for

removal/installation of valve spring)

Part number: 8931-00060 Press tool

Stem seal inserter (for inserting stem Part number: 14527853 Drift

seal) l1 : 11.8 mm (0.465 in)

l2 : 65 mm (2.559 in)

l3 : 4 mm (0.157 in)

d1 : 15.2 mm (0.598 in)

d2 : 21 mm (0.827 in)

d3 : 12 mm (0.472 in)

Filter wrench (for removal/

installation of lubrication oil filter)

Available on the market

Camshaft bushing tool (for Part number: 8931-00080 Installation

removing camshaft bushing) tool

l1 : 18 mm (0.709 in)

l2 : 70 mm (2.756 in)

d1 : 50 -0.3/-0.6 mm (1.967

-0.012/-0.024 in)

d2 : 53-0.3/-0.6 mm (2.087

-0.012/-0.024 in)

Flex–hone (for re–honing of cylinder

liner)

Applicable bore : 89 ~ 101 mm

(3.504 ~ 3.976 in)

Piston insertion tool (for inserting

piston)

The above piston insertion tool is

applicable to 60 ~ 125 mm (2.362 ~

4.921 in) diameter piston.

Piston ring replacer (for removal/

installation of piston ring)

Available on the market

Measuring tools

Measuring tools

Instrument name Application Illustration

Dial gauge Measurements of shaft bending, strain

and gap of surface

Test indicator Measurements of narrow or deep

portions that cannot be measured by

dial gauge.

Magnetic stand For holding the dial gauge when

measuring using a dial gauge, standing

angles adjustable

Micrometer For measuring the outside diameter of

crankshaft, pistons, piston pins, etc.

Cylinder gauge For measuring the side diameters of

cylinder liners, rod metal, etc.

Callipers For measuring outside diameters, depth,

thickness and width

Depth micrometer For measuring of valve sink

Square For measuring valve spring inclination

and straightness of parts

V–block For measuring shaft bend

Torque wrench For tightening nuts and screws to the

specified torque

Feeler gauge For measuring gaps between ring and

ring groove, and shaft joints during

assembly

Cap tester For checking water leakage

Battery/coolant tester For checking concentration of antifreeze

and the battery electrolyte charge status

Nozzle tester For measuring injection spray pattern of

fuel injection nozzle and injection

pressure

Digital thermometer For measuring temperature

Speedometer (contact type) For measuring revolution by contacting

the mortise in the revolving shaft

Speedometer (photoelectric type) For measuring revolution by sensing the

reflecting mark on the outer periphery

of the revolving shaft

1 : Revolving shaft

2 : Reflection mark

Circuit tester For measuring resistance voltage and

continuity of electrical circuits

Compression gauge kit Part number: 14546935

For measuring compression pressure

Service Information

Document Title:

Periodic inspection and

maintenance procedure

Function Group:

200

Information Type:

Service Information

Date:

2014/4/6 0

Profile:

CEX, ECR58 [GB]

Periodic inspection and maintenance procedure Check before daily operation

Be sure to check the following points before starting the engine every day.

If any problem is found, do not use the machine before the engine repairs have been completed.

Oil leak from the lubrication system

Fuel leak from the fuel system

Coolant leak from the cooling system

Damaged parts

Loosened or lost screws

Fuel, radiator rubber hoses cracked, loosened clamp

Thermostat and Thermal Switch Inspection

Figure 1

Thermostat

1. Cover

2. Thermostat

3. Thermostat switch

A. To radiator

1. Thermostat

Place the thermostat in a container filled with water.

Heat it while measuring the water temperature, and see that the thermostat is actuated at the temperature of

following table.

Valve opening temperature, °C (°F) Full open lift, mm (°C, °F)

69.5 ~ 72.5 (157.1 ~ 162.5) 8 mm or more (85 °C, 185 °F)

Hello

Thank you very much

for your patience.

DOWNLOAD MANUAL

http://catexcavatorservicerepairmanual.com/volvo-ecr58-excavator-service-repair-manual/

Service Information - Download Workshop Service Repair ECR5… · Service Information Date:...

Documents

Transcript of Service Information - Download Workshop Service Repair ECR5… · Service Information Date:...