Service Information Document Title: Hydraulic dieseling
Function Group: cylinders, 091
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo If air enters the hydraulic cylinders during work on the hydraulic system, this can lead to spontaneous ignition, an effect known as dieseling. This occurs if a favourable mixture of air and hydraulic oil is compressed when the piston approaches its end position in the cylinder. A sufficiently high temperature can be reached for the mixture to spontaneously ignite.
NOTICE The dieseling effect may result in burnt piston seals and bushings. In order to prevent dieseling, the lines for the hydraulic cylinders must be bled after work is completed, as follows: 1. 2.
No load and keep the lowest engine rpm Operate the piston slowly up to the middle of cylinder in order to remove air from inner chamber of cylinder. Repeat over 5 times. After that, operate the piston up to the end of cylinder in order to remove residual air from cylinder, pipe and hose gradually. Repeat over 5 times.
NOTICE If the cylinders are pressurized either through lifting of the machine or lifting of a load in the bucket, without first performing the mentioned bleeding movements, the seals will likely be damaged. If a cylinder is to be pressure-tested after a repair, the piston rod should be run in and out a few times before increasing the pressure to testing pressure.
Service Information Document Title: Welding on the machine
Function Group: 091
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo
NOTICE During electric welding on the machine or attachments connected to the machine, components such as bearings and electric units may be damaged if the ground cable is connected incorrectly. The following actions should be taken before starting electric welding to eliminate these risks: 1. 2.
Turn off the electric power using the battery disconnect. Disconnect the batteries. NOTE! Both the plus and minus terminal.
3.
Disconnect the all electronic units. – General Purpose Machine Electronic Control Unit 1 (GPMECU1) – Human Machine Interface Control Unit (HMICU) – Engine Control Module (ECM) – Instrument Control (IC) – Climate Control Module (CCM) – Aftertreatment Control Module (ACM) – Telemetries Electronic Control Unit (WECU) – Key Pad 1 – Key Pad 2 Connect the welding unit's ground connection as close as possible to the welding point, and make sure that the current does not pass across a bearing.
4.
If welding is necessary on the boom or dipper arm, the following basic rules should be followed: 1. 2. 3. 4.
Welding beads should be laid down in the longitudinal direction. If possible, weld in the middle of the metal section and never closer than 80 mm to an edge. Do not weld near the welded connections of the cylinder mounting eyes. Minimum distance from eye's weld to weld for weld lug = 100 mm. Do not weld close to where a metal plate has been bent.
Service Information Document Title: Service positions
Function Group: 091
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo Park the machine on a horizontal and firm surface. The suitable position is indicated in the description for the various service jobs. Before beginning any work on the machine. Turn off the engine and remove the ignition key. Depressurize all pressurized lines and pressure vessels carefully so that high pressure is released without risk. Allow the machine to cool down.
Figure 1 Service position A
Figure 2 Service position B
Figure 3 Service position C
Figure 4 Service position D
Figure 5 Service position E
Figure 6 Service position F
Service Information Document Title: Product plates
Function Group: 000
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo Please refer to the figure below to locate the product plate, engine plate, cab plate and attachment plates. Always use the Product Identification Number (PIN) provided on the vehicle and/or engine plates for troubleshooting purposes and/or when ordering spare parts. 1. Product plate This plate with Product Identification Number, PIN, for the complete machine indicates the model designation, serial number and when applicable, machine weight, engine power, manufacturing year and CE approval. The plate is positioned on the right side of the upper frame. Models (General application) Volvo Crawler excavators and Wheel Excavator are available in different sizes from 5 ton to 95 ton. Some machines can be equipped with different Attachments, Demolition, High Reach Demolition, Pipe Layer, Rotating Pipelayer Kit machine and Dozer blade. EC
Excavator Crawler
EW
Excavator Wheel
ECR
Excavator Crawler Short-Swing-Radius
AG
Agricultural machines
PL
Pipe Layer
FE
Feller Bunchers
L, LC
Long Crawler
NLD
Narrow Crawler Demolition
N, NC
Narrow Crawler
HR
High Reach Demolition
NL, NLC
Narrow Long Crawler
F, FX
Forestry Application
LM, LCM
Long Crawler Marsh
LD, LCD
Long Crawler Demolition
LR
Long Reach Boom & Arm
LC4
Long Crawler 4
LHDS
Long Crawler Heavy Duty Shanghai
LS
Long Crawler Shanghai
LHDC
Long Crawler Heavy Duty Changwon
NH
Narrow Heavy Duty
LRC4
Long Reach Crawler 4 (Boom & Arm)
Supplementary PIN plate (EU countries only)
Figure 1
Example of 17 digit PIN number on PIN plate A. B. C. D.
World Manufacturing Code Machine description Check letters Serial number
The supplementary plate contains information about machine mass in kg, engine net power in Kw, manufacturing year, machine serial number and a CE-mark. Machine mass The machine mass in kg on the supplementary PIN plate is based on: cab or canopy most used track type most usual bucket (without load) full fuel tank For safety reasons, 103 % of the machine mass will be shown on the supplementary PIN plate. 2. Engine The engine type designation, part and serial numbers are stamped on the top of valve cover. 3. Attachment quick coupler This nameplate is attached on the outside of the bracket and indicates the part number and weight. 4. Bucket This nameplate is attached on the top of the bucket and indicates the bucket model order number, serial number, bucket part number, rated capacity, weight, cutting width, tooth part number, and adapter part number. 5. Cab The nameplate is attached on the inside of the cab and indicates the product number, serial number, model type, and weight.
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Service Information Document Title: Tech Tool, operations
Function Group: 170
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo The following Tech Tool operations are available for function group 1. Operations used when changing or working on components are mandatory. Operation
Application
17012-3 Error codes
(17012-3) Any error codes stored in the vehicle control units can be read out and erased using this test
17021-3 Parts programming, replace control unit
–
17030-3, Parameter programming
(17030-3) This operation is used to read and program parameter values
17034-3 Vehicle information, test
(17034-3) This operation reads ECU information from the vehicle
17055-3 Central systems, updating, replace control – unit 17056-3 software
Central
systems,
17095-3 Handle component
updating,
change – –
Service Information Document Title: Cleaning prior to repair
Function Group: 170
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo Clean the exterior of all parts before repairing. Dirt and abrasive dust reduce the efficient work life of the part and lead to costly replacement. Use cleaning fluids and solvents which are suitable for cleaning parts and do not risk the safety of the user. Certain types of fluids damage rubber parts and/or cause skin irritation. The following precautions must be observed to insure hydraulic cleanliness: 1. 2. 3. 4. 5. 6.
Flush hose and tube assemblies with a solvent compatible with hose assemblies. Blow out excess solvent with shop air. Cap hydraulic fittings and protect threads until installation. Cap hoses and tube assemblies until installation. Flush hydraulic reservoir, fuel tank and chain case housings with a suitable solvent to remove any foreign debris. Protect system components from airborne contaminants. Plug all cylinder, valve, reservoir, tank and pump openings until installation. Use clean, filtered motor oil when filling the system. See Recommended lubricants
Service Information Document Title: Service
Function Group: 170
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo For the machine to operate safely and at the lowest possible cost, it must receive thorough and complete maintenance. Intervals for maintenance and lubrication refer to normal operating and environmental conditions. Maintenance work is described in the Operator's manual and the manual "Service and maintenance" as well as the Service program. Service Programme The checking boxes in the service program show what type of service should be done for intervals from every 10 hours up to and incl. 4000 hours. The service intervals from and incl. 4500 hours only contain the additional service points that are to be done at each interval. The additional service points that are to be done at the first 500 hours are presented in the same way. Time Guide The Time Guide for service intervals for every 10 hours up to and incl. 4000 hours shows time for the total service. Intervals from and incl. 4500 hours only show time for the additional service points. Example, 4500 hour interval: Do all maintenance according to the standard interval every 500 hours and also do the extra interval 4500 hours. Follow the same example at the first 500 hours.
Service Information Document Title: Safety when servicing
Function Group: 170
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo For Safety when servicing, see the Safety Section, Section S.
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Service Information Document Title: Function Group: Cooling system, 260 component locations
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
Cooling system, component locations Showing Selected Profile Valid for serial numbers Model
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EC210D Volvo
Figure 1
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Expansion tank Charge air cooler hose Radiator assembly Hydraulic oil cooler port Thermostat housing Radiator hose Coolant drain port Stay Radiator breathing hose Radiator hose Fan
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12. 13.
Coolant pump Engine oil cooler
Description Cooling system, description
Service Information Document Title: Function Group: Cooling system, description 260
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
Cooling system, description Showing Selected Profile Valid for serial numbers Model
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EC210D Volvo The cooling unit cells and tanks are made of aluminium. The hydraulic oil cooler and the charge air cooler are installed to the radiator frame. Air is drawn into the engine compartment passing through the radiator, the oil cooler and the charge air cooler as the fan rotates.
Figure 1 Cooling unit 1
Coolant inlet
7
Hydraulic oil cooler
2
Charge air inlet
8
Radiator drain plug
3
Charge air outlet
9
Radiator
4
Coolant outlet
10
Charge air cooler
5
Hydraulic oil intlet
11
Hydraulic oil cooler drain plug
6
Hydraulic oil outlet
Service Information Document Title: Function Group: Crankcase ventilation, 212 description
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
Crankcase ventilation, description Showing Selected Profile Valid for serial numbers Model
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EC210D Volvo Since some of the combustion pressure enters the crankcase after passing by the pistons and piston rings (blow-by), the crankcase must be ventilated. The purpose of the crankcase ventilation is to balance the pressure in the crankcase in order to avoid damage to engine components and to prevent oil mist formation and oil leakage into the ambient air. The crankcase ventilation consists of a housing containing a filter, with connections to the oil sump and ventilation piping.
Figure 1 Crankcase ventilation housing Air containing oil particles comes from the crankcase via the cylinder head into the crankcase ventilator. The air (blue arrows) passes through the filter, while oil particles (red arrows) are caught and led back to the oil sump via a return pipe. Supplementary information Engine, description Lubrication system, component locations
Service Information Document Title: Engine, description
Function Group: 200
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
Engine, description Showing Selected Profile Valid for serial numbers Model
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EC210D Volvo D5E - tier 3 compliant The D5E configuration is a four stroke, straight four cylinder, turbocharged, direct injected diesel engine with charge air cooling and wet, replaceable cylinder liners. The D5E engine uses a Common Rail Fuel System controlled by the engine electronic control (E-ECU) software. IEGR (Internal Exhaust Gas Recirculation) reduces NO formation and lowers emissions without the need for exhaust after treatment. Volvo's latest engine management system, E-ECU is used to control all engine electronic functions. The cylinders are numbered consecutively beginning at the flywheel end. Engine rotational direction is counterclockwise as seen from the flywheel end.
Figure 1 Engine, D5E
Service Information Document Title: Engine, identification
Function Group: 200
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo Identification plate The engine model, serial number and performance data are stamped on an identification plate which is attached on the cylinder head cover. The engine model designation and serial number must be indicated when ordering spare parts.
Figure 1 Engine identification
Service Information Document Title: Function Group: Exhaust system, description 250
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo The exhaust system is designed so that exhaust noise is remarkably reduced when the exhaust gas is passed through the manifold and muffler.
Service Information Document Title: Function Group: Fuel control valve (FCV), 237 description
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
Fuel control valve (FCV), description Showing Selected Profile Valid for serial numbers Model
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EC210D Volvo The fuel control valve controls fuel flow to the high-pressure pumps. It delivers the fuel volume needed to reach or maintain the fuel pressure in the distribution pipe (the rail). Software Fuel control valve (PWM2303) is used as input signal for Engine protection, see Engine Protection
Figure 1
1. 2. 3. 4. 5.
Solenoid valve Fuel inlet Fuel to high-pressure pumps Return fuel to tank Overflow valve
Service Information Document Title: Fuel rail, description
Function Group: 237
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo Fuel rail The high-pressure accumulator consists of a fuel rail, also called 'rail'. It is made of forged steel. The stored volume is calibrated and works like a damper for any pressure variations that occur due to pulsating feed of the fuel pump to the highpressure pump or temporary, high fuel usage during injection through the injectors. The fuel rail is dimensioned to supply full fuel volume without any noticeable pressure-drop.The fuel rail is equipped with a pressure sensor and a relief valve. If a malfunction is detected, the E-ECU can force the pressure relief valve (PRV) to open by increasing the rail pressure. The rail pressure sensor SE2309 measures the pressure in the rail and delivers data to the E-ECU, which compares the actual pressure with a reference value, which is dependent on engine speed and injection volume. The pressure relief valve, installed on the rail, limits the system pressure to avoid damage to the circuit. The pressure relief valve is a mechanical safety device which opens at 1900 (±50) bar and protects the system against excessive pressure caused by any problems or malfunctions. If the valve is open, the rail pressure within the range 650 — 850 bar (depending on engine speed and load). The engine continues to run, but with lower performance (limp home). In normal operating conditions, the pressure relief valve (PRV) does not open.
Figure 1
1. 2. 3.
Fuel rail Relief valve (PRV) Rail pressure sensor SE2309
Software
Rail pressure (SE2309) is used as input signal for Engine protection, see Engine, description
Service Information Document Title: Function Group: Fuel system, component 230 locations
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
Fuel system, component locations Showing Selected Profile Valid for serial numbers Model
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EC210D Volvo
Figure 1
1. 2. 3. 4. 5. 6. 7. 8.
Water separator filter element Extra water separator (optional) Fuel filter Fuel tank Fuel level sensor Fuel filling pump Fuel filling pump hose Fuel feed pump
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Description Fuel system, description
Service Information Document Title: Fuel system, description
Function Group: 230
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo The D5E Tier 3 engines use a pressure accumulator system known as common-rail fuel injection. The main advantage of the common-rail system is its ability to vary injection pressure and timing over a broad scale. This is made possible by separating the functions of pressure generation and fuel injection. The fuel delivery system is made up of a low pressure and high pressure circuit. The low pressure supply circuit consists of a fuel tank, water separator, belt driven fuel transfer pump, secondary fuel filter and FCU (fuel control unit ). The high pressure circuit consists of two high pressure pumps driven by the engine camshaft, a pressure-accumulator ( fuel rail ), high pressure lines, high fuel pressure ( fuel rail pressure ) sensor and electronically controlled fuel injectors. The transfer pump in the low pressure circuit draws fuel from the tank, through a water separator filter and into the pump inlet. Fuel is then forced from the pump through the secondary filter to the FCU ( Fuel Control Unit ) at the inlet of the high pressure pumps. The FCU controls filling of the high pressure pumps so as to maintain the rail pressure set point. The continuously operating high pressure fuel pumps produce the desired injection pressure that is stored in the pressure accumulator ( fuel rail ). High pressure fuel from the pressure accumulator is available to the injectors at all times. The electronic fuel injectors control injection timing and quantity.
Figure 1 Fuel system
Service Information Document Title: Injectors, description
Function Group: 237
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
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EC210D Volvo Injection timing and the fuel amount to be injected is determined by the control unit E-ECU, which gives signals to the electro-magnetically controlled fuel valve in the injector's valve housing. The duration of the injection time determines the amount of fuel that is injected into the cylinder. The 'common rail' system enables more than one injection during the piston's working phase, thus giving flexible control of the combustion process. The injection pressure is determined by the pressure in the rail and can vary between 500 bar to 1400 bar (7252–20305 PSI). The injector nozzles have six holes and are designed to give a uniform spray pattern, despite the angled unit injector and injector nozzle.
Figure 1
Figure 2
Service Information Document Title: Function Group: Inlet and exhaust system, 250 description
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
Inlet and exhaust system, description Showing Selected Profile Valid for serial numbers Model
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EC210D Volvo The engine takes in clean air through the inlet system and the turbocharger. For information about the subsystems, see Turbocharger, description
Figure 1
Blue = Inlet air Red = Exhaust gas Black, dashed = Wiring 1. 2. 3. 4. 5. 6. 7.
Air filter Ambient air temperature and pressure sensor (FX1008) Charge air cooler Charge air cooler temperature sensor (SE2512) Pre heater (HE2501) Charge air temperature and pressure sensor (FX1007) Diesel engine
8. 9.
Turbocharger Turbocharger
The air is drawn in through the air filter and flows to the turbocharger. Then the air is cooled in the charge-air cooler. Before the air is finally drawn into the cylinders it passes the pre heater. Air filter
Figure 2 Air filter It is important that the air taken into the engine is free from pollutants. The air filter insert consists of a folded filter paper which is protected by a mesh. The air is forced to flow in the intended path through the inlet. Charge air cooler Turbocharging raises the temperature of the air entering the engine. If the air is cooled when exiting the turbocharger, its volume is reduced so that more air (oxygen) can be pressed into the cylinders. This is done with a charge air cooler. The cooled air makes it possible to feed more fuel and produce more engine power. It also creates less thermal stress on the engine. The charge air cooler is an air to air cooler and reduces the air temperature and is raising engine power output. Torque is increasing and fuel consumption drops. Pre heater
Figure 3 Pre heater The purpose of the preheating coil is to heat the air in the inlet manifold before the engine is started. This heated air helps the engine to start easier and reduces white smoke in cold starts. The starter element is electrically heated and consists of two or three heater coils through which the air flows. The pre heater gets its power from the battery and is engaged if needed by the engine electronic control unit or with a switch in the cab. The time its engaged is governed by the engine electronic control unit depending on coolant temperature and atmospheric pressure.
Inlet and Exhaust manifold Each cylinder has a separate inlet channel and a separate exhaust channel on the same side of the cylinder head. The inlet manifold is mounted from above, supplying air and recirculated exhaust gas vertically into each cylinder. The exhaust manifold is mounted below the inlet manifold, receiving exhaust gas horizontally. The exhaust manifold covers the cylinders exhaust ports. The turbocharger and the EGR control valve connects to the exhaust manifold. Summary The inlet and exhaust system contains several subsystem. The inlet air is used in the normal engine operation as well as for the exhaust gas recirculation system. The inlet air is filtered in the air filter and then flows to the turbo. For cooling the air from the turbo charger the air has to pass the charge air cooler and then into the cylinders. The exhaust gas drives the turbocharger. Parameters There are no parameters for this function. Complementary Information Inlet and exhaust system, component locations Function check 28407-3 Sensor values, monitoring Diagnostics Component/Display message
Control unit
Message ID
Charge air temperature and pressure MID128 FX1007 MID128
PID102
Ambient air temperature and pressure MID128 FX1008 MID128
PID107
Pre heater HE2501
MID128
PID45
MID128
SID70
MID128
PID52
Charge air cooler temperature SE2512
PID105 PID108
Service Information Document Title: Inlet system, description
Function Group: 250
Information Type: Service Information
Date: 10/10/2024
Profile: EC210D Volvo
Inlet system, description Showing Selected Profile Valid for serial numbers Model
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EC210D Volvo The air required for combustion is filtered by the air cleaner filter, and then supplied to the engine combustion chamber through the turbocharger. For operator convenience the clogging of the inlet system is sensed and activates a warning lamp on the dash board.
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