Service Information Document Title: Hydraulic dieseling
Function Group: cylinders, 091
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D 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: Machine view
Function Group: 000
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo
Figure 1 Machine view 1
Dipper arm cylinder
14
Track motor and gearbox
2
Boom
15
Hydraulic tank
3
Boom cylinder
16
Fuel tank
4
Operator cab
17
Upper roller
5
Charged air cooler , hydraulic oil cooler and radiator
18
Turning joint
6
Swing motor and gearbox
19
Bottom roller
7
Air cleaner
20
Idler
8
Main control valve
21
Bucket
9
Engine
22
Link
10
Rear hood
23
Bucket cylinder
11
Diesel Particulate Filter (DPF)
24
Dipper arm
12
Counterweight
25
Swing ring gear
13
Main pump
Service Information Document Title: Product plates
Function Group: 000
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D 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. 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. Engine The engine type designation, part and serial numbers are stamped on the top of valve cover. Attachment quick coupler This nameplate is attached on the outside of the bracket and indicates the part number and weight. 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. Cab The nameplate is attached on the inside of the cab and indicates the product number, serial number, model type, and weight.
Service Information Document Title: Service positions
Function Group: 091
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D 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
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Figure 3 Service position C
Figure 4 Service position D
Figure 5 Service position E
Figure 6 Service position F
Service Information Document Title: Welding on the machine
Function Group: 091
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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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 disconnector. Disconnect the batteries. NOTE! Both the plus and minus terminal.
3.
Disconnect the following electronic units: – Vehicle electronic control unit (V-ECU) – Engine electronic control unit (E-ECU) – Instrument electronic control unit (I-ECU) – Electronic climate control unit (ECC) – Wiper control unit (CU3601) 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: Bearings
Function Group: 170
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo Removal Bearings should never be removed unless absolutely necessary. Always use the recommended puller to reduce the risk of bearing or related component damage. When bearings or bushing are removed, check that the bearings is free from discoloration, nicks, scuffing and signs of overheating. If in doubt, replace the bearing or bushing. Cleaning Bearings acceptable for service should be cleaned in a suitable solvent and immersed in a clean lubricating oil until needed. Installation Be sure bearings are installed with care during servicing, maintenance and repair. All bearings on this machine are installed as a press fit. When possible, always install the bearing into the rotating part first. Use the proper tools or a press when installing a bearing or bushing. In the absence of the proper tools or a press, cool the bearings and/or heat casing to assist in the installation.
Service Information Document Title: Cleaning prior to repair
Function Group: 170
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D 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: Hoses and tubes
Function Group: 170
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo Inspection If the hose end connections are damaged, always replace hoses and tubes. Damaged, dented, crushed or leaking hose fittings restrict oil flow and the operation of the parts being served. Be sure hoses are in good condition. If in doubt, replace them. Replace hoses if the following occur: chafed outer cover concealed corrosion of wire reinforcement ballooning (replace immediately!) kinked, crushed, stretched or deformed. Installation When installing a new hose, loosely connect each end and take the designed position before tightening the connection. Hoses must be tightened using two wrenches. One is used to tighten the swivel nut, the other to ensure the hose flexible part is not twisted. Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing. If a hose is replaced on a moving part, be sure it does not foul by moving the part through its complete range of travel. Be sure any hose which has been installed is not kinked, twisted or exposed to any sharp edges. Free moving, unsupported hoses must never touch each other or related work surfaces. This causes chafing, reducing hose life.
Service Information Document Title: Pressure testing
Function Group: 170
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo 1. 2. 3.
Prior to pressure testing, be sure all hoses are in good condition and all fittings are tight. Use a pressure gauge with a range that is high enough to measure the specified pressure. Comply with the correct procedure to prevent damage to the system or the equipment and to eliminate the possibility of injury.
Service Information Document Title: Replacement parts
Function Group: 170
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo For reference when ordering replacement parts or making service inquires, record the model and serial numbers of your machine. They are stamped on the serial number plate positioned under the boom on the superstructure frame.
Service Information Document Title: Safety when servicing
Function Group: 170
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo For Safety when servicing, see the Safety Section, Section S.
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Service Information Document Title: Service methods
Function Group: 170
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo Appropriate service methods and proper repair procedures are essential for safe, reliable operation of the machines and safety of the individual doing the work. This Service Manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following them will assure reliability. There are many variations in procedures, techniques, tools and parts for servicing machines, as well as work skills. This manual cannot possibly anticipate all such variations and provide advice or cautions for each one. Accordingly, anyone who intends to depart from the instructions in this manual must first consider personal safety and then machine integrity. NOTE! Volvo CE recommends the use of environmentally sound waste storage and disposal practises. Never drain fluids on the ground or into a sewer or catch basin. Use suitable collection containers, then store and/or dispose of waste products in an approved and safe manner. Check and obey all federal, state and/or local regulations regarding waste storage, disposal and recycling.
Service Information Document Title: Service
Function Group: 170
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D 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: VCADS Pro, Operations
Function Group: 170
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo The following VCADS Pro operations are available for function group 1. Operations used when changing or working on components are mandatory. Tests Operation
Application
17012-3 Error codes
Used when there is a suspicion of fault and/or at abnormal values/ readings.
17034-3 Vehicle information, test
Read out vehicle information
Programming Operation
Application
17030-3, Parameter programming
When changing parameters.
17055-3 Central systems, updating, replace When replacing ECU by conversion kit. control unit 17056-3 Central systems, updating, change When replacing software by conversion kit. software 17095-3 Handle component
When replacing the complete engine. This operation is to update machine data in Volvo’s central systems.
Service Information Document Title: Basic check, Engine
Function Group: 210
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo NOTE! Certain tests and checks are performed with unlocked safety locking lever. Make sure that the machine cannot operate unexpectedly when the control lockout lever is unlocked. Purpose of the basic check The purpose of the basic check is to provide fast and accurate information about the general condition of the engine. The basic check should be performed and evaluated according to instructions in the PC-tool VCADS Pro. Tests included in the basic check The basic check which is divided into the following tests should be performed after reading out error codes and checking parameters. Tests: 1.
2. 3.
Cylinder compression, test The purpose of the test is to show if any cylinder has a deviating compression pressure. The test replaces the old pressure check method but does not give any absolute values. Feed pressure, test The purpose of the test is to check that the feed pressure is as per specification. Sensor, test The purpose of the test is to check the function of all sensors.
Service Information Document Title: Camshaft, description
Function Group: 215
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo The camshaft is carried in seven bearings. The axial stop for the camshaft is located in the timing gear casing's cover. On the camshaft gear there are seven teeth pressed in for the cylinder position sensor. Each bearing runs in a bearing bushing which is pressed into the cylinder block. There is an inlet cam and an exhaust cam for each cylinder. There are also two cams (1) with three cam lobes for the injection pumps.
Figure 1
Service Information Document Title: Charge air description
Function Group: cooler, 258
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo The function of the intercooler is to lower the temperature of the air before it is pressed into the engine's cylinders. Turbocharging of the engine, which means that the turbocharger presses air into the cylinders, increases the air temperature. When the air is cooled after the turbo, the air volume decreases and more air (oxygen) can be pressed into the cylinders. This cooling is called charge-air cooling (intercooling) and makes it possible to inject more fuel into the cylinders, which results in a significant power increase. The intercooler lowers the air temperature by approx. 100 °C (212 °F) and this increases engine power by approx. 10%. The engine torque is also increased and fuel consumption is reduced. A turbocharged diesel engine with charge-air cooling(intercooling) has the highest efficiency of all combustion engines.
Service Information Document Title: Connecting rod, description
Function Group: 216
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo The connecting rod, made of forged steel, is provided with a balancing weight (A) at the crankshaft bearing (big-end) to compensate for manufacturing tolerances with regards to weight and the position of the centre of gravity. The number markings at the crankshaft (big-end) bearing end and on the crankshaft bearing cap must face in the same direction and must have the same number. Guide lugs in the upper and lower bearing shells prevent rotation in the bearing position. The piston must be fitted so that the flywheel symbol on the piston top faces the flywheel.
Figure 1
Service Information Document Title: Cooling fan control
Function Group: 263
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo Hydraulic oil cooling system The function controls cooling fan speed according to the input from the hydraulic oil temperature sensor. Input signals Pin No.
ECU
Description
VA40
V-ECU
Hydraulic oil temperature sensor, SE9105
Pin No.
ECU
Description
VA9
V-ECU
Hydraulic oil fan motor proportional valve
Output signals
Function description If the hydraulic oil temperature is below 60 °C, the output current will be the maximum current. The maximum current will cause low oil flow via the proportional valve to the cooling motor in port and reduce cooling fan rpm to half speed.
Figure 1 Fan speed control curve
A. B. C. D.
Maximum current Full speed Half of full speed Minimum current
a. b.
Expected rotating speed of cooling fan Current for hydraulic oil fan motor proportional valve
If the hydraulic oil temperature is higher than 90 °C, the output current will be the minimum current. The minimum current will cause full oil flow via the proportional valve to the cooling motor in port and increase cooling fan rpm to maximum speed. See also, Hydraulic oil cooling system, description.
Service Information Document Title: Function Group: Cooling system, component 260 location
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo
Figure 1
1. 2. 3. 4. 5. 6. 7. 8. 9.
Expansion tank Charge air cooler hose Fan guard Radiator assembly Hydraulic oil port Radiator drain valve Thermostat Radiator hose Stay bar
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10. 11. 12. 13. 14.
Radiator breathing hose Radiator hose Cooling fan Coolant pump Engine oil cooler
Description Cooling system, description
Service Information Document Title: Cooling system, description
Function Group: 260
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D 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.
Service Information Document Title: Crankcase description
Function Group: ventilation, 212
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D 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: Crankshaft, description
Function Group: 216
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo The forged crankshaft is provided with integrated balancing weights. The gear that drives the engine's timing gear and the flange for the flywheel are shrink-mounted on the crankshaft.
Figure 1
Service Information Document Title: Cylinder block, description
Function Group: 212
Information Type: Service Information
Date: 8/4/2020
Profile: EC170D Volvo
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EC170D Volvo The cylinder block is cast in one piece and has wet, replaceable cylinder linings. Combustion pressure tensile breaking strength in cylinder head screws is led through stiffened sections of the cylinder block wall directly to the main bearings. The cylinder block surface should not be ground as the distance between the pistons and the valve heads may become too small. There is also a risk that injector tips will be incorrectly placed in relation to the pistons and that exhaust values will worsen.
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