Engine With Mounting and Equipment

Service Information
Document Title: Function Group: Information Type: Date:

Engine, description 200 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Engine, description
D6D Engine
The engine is a 6-cylinder, 4-stroke, direct injected, turbocharged, aftercooled with a cast iron block and cylinder head.
Gears in the engine gear case are hardened helical type for strength and reduced noise, arranged to provide quiet, smooth
transmission of power.
The cylinder block and head are designed with internal passages forming galleries for both lubricating oil and coolant.
The fan belt is a poly type V-belt for improved performance and an auto tension adjuster maintains belt tension.
Figure 1
Engine, start motor side view
1 Fuel suction port 11 Blow-by gas pipe 21 Coolant pump

2 Engine oil filter 12 Air inlet (from air cleaner) 22 Belt tensioner
3 Old, Fuel filter (0.5 liters) 13 Turbocharger 23 Air outlet (to charge air cooler)
4 Unit injection pump 14 Exhaust gas outlet 24 Fan drive pulley
5 Emission label 15 Exhaust manifold 25 Air conditioner compressor pulley
6 Engine name plate 16 Intake manifold 26 Pulley with vibration damper
7 Power take off device (option) 17 Air inlet (from charge air cooler) 27 Flywheel
8 Fan drive 18 Lifting eye (front) 28 Lifting eye (rear)
9 Coolant make up port 19 Alternator 29 Crankcase breather
10 Coolant outlet (to radiator) 20 Fuel feed pump 30 Coolant temperature sensor port
Figure 2
New, Fuel filter
1 Fuel filter (1.0 liters)

2 Bracket
Serial number
Europe North America China
Old, Fuel filter Fuel filter (0.5 liters) and bracket ~ 14467 ~ 14317 ~ 30840
New, Fuel filter Fuel filter (1.0 liters) and bracket 14468 ~ 14318 ~ 30841 ~
Figure 3
Engine, air heater side view
1 Coolant inlet (from radiator) 14 Engine speed sensor 27 Belt tensioner

2 Coolant outlet (to radiator) 15 Fuel pressure holding valve 28 Engine oil level gauge
3 Coolant make up port 16 Solenoid valve 29 Engine oil pressure sensor
4 Air inlet (from air cleaner) 17 Crankcase breather 30 Fuel suction port
5 Turbocharger 18 Blowby gas pipe 31 Coolant filter return port
6 Intake manifold 19 Valve cover 32 -
7 Exhaust manifold 20 Engine oil cooler 33 Coolant supply to cab heater
8 Starter 21 Fuel filter 34 Coolant heater port
9 Poly-vee belt 22 Engine oil filter 35 Air heater relay
10 Lube oil pipe (supply) 23 Air inlet (from charge air cooler) 36 Oil drain hose
11 Lube oil pipe (return) 24 Alternator 37 Fuel feed pump
12 Engine oil pan 25 Fuel feed pump 38 E-ECU
13 Power take off device 26 Coolant pump
D6E Engine
The D6E configuration is a four stroke, straight six cylinder, turbocharged, direct injected diesel engine with charge air
cooling and wet, replaceable cylinder liners.
The D6E engine uses a Common Rail Fuel System controlled by the engine electronic control (E-ECU) software.
Electronically controlled 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 4
Engine, D6E
Service Information

Engine, identification 200 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Engine, identification
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, D6E
Service Information

Engine, tightening torques 200 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Engine, tightening torques

NOTICE
Regarding bolted joints which are not listed here, see “Volvo standard tightening torques”
Engine, tightening torque

Rocker arm bracket on cylinder head 30 Nm (22.2 lbf ft)
Cylinder head cover (M6) on cylinder head 13 Nm (9.6 lbf ft)
Exhaust return module on cylinder head Step 1: 10 Nm (7.4 lbf ft)
Step 2: 30 Nm (22.2 lbf ft)
Lock nut, valve adjusting screw 20 ±2 Nm (14.8 ±1.5 lbf ft)
Locking screw on cylinder head 34 Nm (25.2 lbf ft)
Solenoid valve on cylinder head 24 Nm (17.8 lbf ft)
Front cover on crankcase Step 1: 3 Nm (2.2 lbf ft)
Drain plug on oil pan, M18 55 Nm (40.7 lbf ft)
Crankcase ventilation on cylinder head 21 Nm (15.5 lbf ft)
Return line to return stop valve 30 Nm (22.2 lbf ft)
Return stop valve to crankcase 80 Nm (59.2 lbf ft)
Impulse transmitter (crankshaft) on holder on front cover 9 Nm (6.7 lbf ft)
Impulse transmitter (camshaft) on gearcase 9 Nm (6.7 lbf ft)
Turbocharger on exhaust manifold 42 Nm (31.1 lbf ft)
Clamping shoe injector on cylinder head 16 Nm (11.8 lbf ft)
Injection lines on rail and injector, high pressure line on high-pressure 25 Nm (18.5 lbf ft)
pump
Fuel supply pump on holder 22 Nm (16.3 lbf ft)
Holder fuel supply pump on holder 30 Nm (22.2 lbf ft)
V-belt pulley on fuel supply pump 27 Nm (20.0 lbf ft)
High pressure pump on crankcase, M10 Step 1: 10 Nm (7.4 lbf ft)
Fuel control valve 30 Nm (22.2 lbf ft)
Fuel pipe on high pressure pump 29 Nm (21.5 lbf ft)
Fuel pipe on control block 39 Nm (28.9 lbf ft)
Rail on cylinder head 30 Nm (22.2 lbf ft)
Pressure relief valve on rail 100 Nm (74.0 lbf ft)
Rail pressure sensor on rail 70 Nm (51.8 lbf ft)
Pipe clips, fuel line fastening 30 Nm (22.2 lbf ft)
Fuel line on control block, fuel filter console and rail 39 Nm (28.9 lbf ft)
Fuel pipe (return) on control block 49 Nm (36.3 lbf ft)
Fuel pipe (return) on cylinder head 29 Nm (21.5 lbf ft)
Fuel line on fuel filter8 39 Nm (28.9 lbf ft)
Fuel filter console/radiator tank on crankcase 30 Nm (22.2 lbf ft)
Fuel pressure sensor on fuel filter console 30 Nm (22.2 lbf ft)
Cover plate on cylinder cover, M6 30 Nm (22.2 lbf ft)
Service Information

Component locations 200 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Component locations
D6E Engine
Component position, engine D6E. The following figures show the position of a number of components on engine D6E.
Figure 1
Component locations, front side
1 Engine oil filler 11 Oil dipstick

2 Air inlet 12 Power take off
3 Transport eye 13 Engine oil filter
4 Alternator 14 Connection to E-ECU
5 Fuel feed pump 15 Fuel filter
6 V-rib belt drive on crankshaft 16 Crankcase bleeding valve
7 V-rib belt 17 High pressure fuel pump
8 Automatic belt tensioner 18 Common rail
9 Coolant pump 19 Injector
10 Engine oil cooler
Figure 2
Component locations, flywheel side
21 Crankcase bleeding valve 28 Turbocharger

22 Charge air manifold 29 Coolant inlet
23 Flywheel housing 30 Air outlet (to charge air cooler)
24 Drain plug 31 Coolant outlet
25 Oil pan 32 Air inlet (from charge air cooler)
26 Starter motor 33 Exhaust manifold
27 Oil return line from turbocharger 34 Cylinder rocker arm cover
Service Information

Engine characteristic curve 210 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Engine characteristic curve

D6D Engine
Figure 1
Engine, characteristic curve
P Output power
S Engine speed
T Torque
F Fuel consumption
D6E Engine
Figure 2
Engine, characteristic curve
P Output power
S Engine speed
T Torque
be Fuel consumption
Service Information

Basic check, Engine 210 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Basic check, Engine

NOTE!
Certain tests and checks are performed with unlocked safety locking lever. Make sure that the machine cannot operate
unexpectedly when the safety locking 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. 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.
2. Cylinder balancing, test
The purpose of the test is to show if there is any deviation in the fuel injection to a cylinder.
3. Feed pressure, test
The purpose of the test is to check that the feed pressure is as per specification.
4. Sensor, test
The purpose of the test is to check the function of all sensors.
Service Information

Troubleshooting 210 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Troubleshooting
General about troubleshooting
When a malfunction is suspected or has been confirmed, it is important to identify the cause as soon as possible.
The starting point for all troubleshooting is that there is some type of trouble symptom or malfunction.
Malfunctions can be indicated by:
 generation of error codes

 detection of a malfunction symptom.
Troubleshooting work
The first step in troubleshooting is to gather information from the operator concerning the malfunction symptoms, see
Electrical and information system, Collection of basic data. Then, attempt to pin-point the cause by checking in a certain
order, for more information, see Electrical and information system, troubleshooting strategy.
The different checking steps are:
 Check error codes

 Check parameters
 Perform basic check
Troubleshooting information
The following is included in Electrical and information system and is used when troubleshooting:
1. Troubleshooting strategy
Describes troubleshooting work, step by step.
2. Troubleshooting, assistive devices
Brief summary of the assistive devices that are available for troubleshooting.
3. Functional checks and tests, VCADS Pro
Brief description of VCADS Pro. For a detailed description, see VCADS Pro User’s Manual.
4. Error code information
Contains information regarding error code design, lists of all error codes and error code information about each
error code.
5. Components, troubleshooting and specifications
Contains methods and measuring values for troubleshooting of components. Also includes wiring diagrams and
certain specifications.
6. Parameters
Incorrectly set parameters may cause malfunction symptoms. The parameter list includes all limit and command
values for parameters.
7. Control units, functional description
Describes the functions of the control units, inputs and outputs as well as communication between the various
control units.
8. Control units, active and passive measuring
Contains measuring values for active and passive measuring of the ECUs.
9. Software functions
Describes the pre-requisite conditions for the control and monitoring functions that are performed by the software
in the ECUs.
Service Information

Cylinder head, description 211 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Go back to Index Page
Cylinder head, description

D6D Engine
The cylinder head of the D6D engine is made of grey cast iron and designed as block type head.The combustion air enters
vertically and the exhaust air is discharged laterally.Inlet and outlet are located on one side of the cylinder head.
Service Information

Cylinder head, description 211 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Cylinder head, description

D6E Engine
The cylinder head is made of grey cast iron and is common for all cylinders. The induction air enters vertically (A) and the
exhausts leave horizontally (B). Inlets and exhaust outlets are located on the same side of the cylinder block. Inlet and
exhaust valve size is increased to optimize the gas exchange and combustion process. Valve guides are replaceable. Coolant
flow in the cylinder head is modified to accommodate an outlet controlled cooling system.
On order for the engine to fulfill governing emission standards, there are 3 cylinder head gaskets of different thicknesses
between the cylinder head and the piston.
Figure 1
Service Information

Determining cylinder head 211 Service Information 2014/6/11
gasket
Profile:
EXC, EC210B LC [GB]
Determining cylinder head gasket

 The thickness of the cylinder head gasket is responsible for the correct piston crown clearance of the engine. The
piston crown clearance (0.65 mm) essentially influences the combustion and thus:
 Power
 Fuel consumption
 Exhaust emission
 The piston crown clearance is adjusted by determining the piston projection and the thickness of the cylinder head
gasket.
Measuring piston projection
 A dial gauge with a fixture is needed to measure the piston projection.

 The piston is in its TDC position above the cylinder block face.
Figure 1
Measurement, piston projection
1. Dial gauge
2. Bridge
3. Two spacer plates
A. Set the dial gauge on the level of the cylinder block face to "zero".
B. Position the dial gauge at measuring points (C), at the piston pin axis, on the piston and determine the
maximum projection.
C. Measuring points on the piston.
Distance X = 90 mm
This measurement is performed on each piston. The maximum measured piston projection determines the thickness of the
cylinder head gasket (see table). There are 3 different gasket thicknesses identified by bores (4):
 1 bore = 1.2 mm
 2 bores = 1.3 mm
 3 bores = 1.4 mm
Piston projection
Piston projection Identification of cylinder head gasket

0.33 ∼ 0.55 mm 1 bore
0.56 ~ 0.65 mm 2 bores
0.66 ~ 0.76 mm 3 bores
Service Information

Fitting cylinder head 211 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fitting cylinder head

Op nbr 21182
1. Prior to fitting the cylinder head onto the crankcase, the sealing surfaces for the cylinder head gasket must be clean
and free from oil. Pay attention to dowel sleeves.
2. Lightly oil the cylinder head bolts.
3. It is absolutely necessary to observe the bolt tightening order in the adjacent schematic.
Figure 1
Tightening order (exhaust manifold side)
Tightening torque specification:
 1st step: 30 N·m (22.2 lbf·ft, 3.1 kgf·m)

 2nd step: 80 N·m (59 lbf·ft, 8.2 kgf·m)
 3rd step: 90° turn
Tightening order
Service Information

Cylinder, description 213 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Cylinder, description
Figure 1
Cylinder liner
1 Cylinder liner
2 Crankcase
3 Liner projection: 0.07 - 0.12 mm
D6D/D6E engine with a bore about 98 mm (3.86 in) is provided with dry, plateau-honed slip-fit cylinder liners. In case of
damage, the cylinders of the D6D/D6E series are repaired by replacing the slip-fit liners.
Service Information

Pistons, description 213 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Pistons, description
D6D Engine
Figure 1
Piston
 The pistons of the D6D engine are made of a special aluminium alloy. The piston bowl has a small amount of
eccentricity to the piston axis.
 The piston must be installed so that flywheel symbol (1) on the piston top faces the flywheel.
 The pistons are equipped with 3 piston rings. The 1st ring has a ring carrier (2) of cast iron.
 The cross section of the 1st piston ring is asymmetrical. The cross section of the 2nd piston ring is conical
(compression ring). When installing the piston, the TOP mark at the ring gap must point upwards. The 3rd ring is
the bevelled-edge oil control ring.
Service Information

Pistons, description 213 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Pistons, description
D6E Engine
The pistons are made of special alloy aluminium. The piston's combustion compartment has a somewhat off-center
(eccentric) position in relation to the piston pin.
The pistons are provided with 3 piston rings. The first ring has a ring carrier made of cast iron.
The piston is cooled with oil sprayed up on the inside of the piston top.
The piston cooling nozzles are made of plastic and are mounted in the cylinder head by the main bearing positions.
The first piston ring has an asymmetric cross-section area (A). The cross-section area for piston ring number two
(compression ring) is tapered. When installing the piston rings, the marking TOP by the opening in the rings must face up.
The third ring is an oil ring with bevelled edge.
Figure 1
Service Information

Piston rings, description 213 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Piston rings, description

Each piston is equipped with two compression rings and one oil ring. The uppermost compression ring is of the "Keystone"
type (dual trapezoid-formed cross section). Compressions rings should be placed with the text facing upwards.
The oil ring is equipped with two scraping edges, which are pressed against the cylinder wall using the spring tension in the
ring and an expander spring placed on the inside of the ring. The oil ring can be placed on either side but should be placed
with expander spring and oil ring openings 180° from one another.
Figure 1
Service Information

Piston cooling 213 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Piston cooling
Figure 1
Piston cooling
The piston is cooled by spraying lube oil against the inside of the piston top.
The 2-hole piston cooling nozzles made of plastic are fitted in the main bearing pedestals.
Service Information

Valves, description 214 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Valves, description
D6D Engine
 The engine is provided with one inlet and one exhaust valve per cylinder. The valve guides are shrunk in the
cylinder head. The valve seat inserts are made of high-quality steel and are also shrunk in the cylinder head.
 The valves are turned by eccentric actuation through the rocker arms. The new compressed cone connection
permits easy turning of the valve despite stress load.
 Rocker arm lubrication is integrated in the lube oil circuit. The oil is supplied via tappets and push rods.
NOTE!
The valve springs of the D6D have a special installation direction. The colored mark on the spring must show to the
bottom.
Valve seat angle
Inlet Exhaust
30° 45°
Service Information

Valves, description 214 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Valves, description
D6E Engine
The engines are equipped with one inlet and one exhaust valve per cylinder.
At the upper end of the valve guide, there is an O-ring seal (A) against the valve spindle to prevent major oil consumption
and to reduce the amount of hydrocarbons in the exhausts.
The valves are rotated by the eccentric action of the rocker arms.
The new compressed tapered shape enables the valves to turn easily despite loading.
Rocker arm lubrication is part of the engine force-feed lubrication system. The oil is supplied via the tappets and push rods.
If the valve guides are replaced, they are obtained in another version (B) to facilitate installation.
Figure 1 shows a valve guide installed in production and figure 2 shows a replacement guide.
Figure 1
Service Information

Internal Exhaust Gas 214 Service Information 2014/6/11
Recirculation (IEGR),
description
Profile:
EXC, EC210B LC [GB]
Internal Exhaust Gas Recirculation (IEGR), description

Tier 3 Engine
A system for IEGR (Internal Exhaust Gas Recirculation) is used as part of V-ACT (Volvo Advanced Combustion Technology).
On D6E and D7E this takes place by an IEGR-opening piston, controlled by the lubrication oil's system pressure, acting on
the exhaust rocker arm which enables a second opening of the exhaust valves. When activated, the secondary piston will
give a limited valve opening of the exhaust valves during the induction phase, which leads exhausts back into the cylinder.
Included components
IEGR-unit
The hydraulic mechanism is housed in two interconnected IEGR-units, located on the rocker arm holders. Lubrication oil is
routed from the cylinder head via the solenoid valve to the high-pressure channel in the IEGR-unit through a channel in one
of the rocker arm holders.
Figure 1
1. IEGR-unit
Solenoid valve
The solenoid valve is located in the cylinder head on the flywheel side and is activated by the EECU via the control system
EMS 2. When IEGR is not activated, the solenoid valve is closed and no oil flow is allowed into the IEGR-unit. At activation of
IEGR, the solenoid valve opens the channel from the engine's lubrication system to the IEGR-unit.
Figure 2
1. Solenoid valve
Control valve
The control valve is located in the IEGR-unit between the high-pressure circuit and low-pressure circuit. When the low-
pressure circuit is supplied from the lubrication oil system, the control valve is lifted and closes the high-pressure circuit. The
ball in the control valve enables filling of the high-pressure circuit when IEGR is activated.
The lubrication oil is drained through the control valve.
Figure 3
1. Control valve
Main piston
The main piston is acted on by the adjusting screw on the inlet valve's rocker arm, and affects the oil pressure in the IEGR-
unit's high-pressure channel. At the end of the IEGR-phase, a pressure of 100 bar is generated in the high-pressure circuit.
Figure 4
1. Main piston
Servo piston
The servo piston is activated by the hydraulic pressure from the main piston via a channel in the IEGR-unit when the IEGR-
function is active/on (solenoid valve in open position). Then the servo piston opens the exhaust valves via the rocker arm an
extra time during the induction stroke.
Figure 5
1. Servo piston
Function
IEGR is activated by the system being supplied with full lubrication oil system pressure via the solenoid valve. The solenoid
valve is activated by the E-ECU.
The control valve closes the high-pressure circuit and the ball inside the valve enables filling of the system.
With the same movement as the inlet valve's rocker arm opens the valve, the main piston is forced upward. The pressure in
the IEGR-unit's high-pressure channel (up to 100 bar) overcomes the spring force in the servo piston. the servo piston forces
down the rocker arm, which results in the exhaust valve being open for a short time at the end of the induction stroke.
Exhausts from the exhaust manifold are sucked into the cylinder by vacuum from the other cylinders.
The breather hole between the low-pressure channel and the high-pressure channel in the IEGR-unit enables longer exhaust
recirculation at high engine speed.
Figure 6
IEGR-system (inactive)
1. Servo piston
2. Control valve
3. Solenoid valve
4. 2–5 Bar lubrication oil pressure
5. Breather hole
6. Oil channel, low-pressure
7. Oil channel, high-pressure
8. Main piston
9. Induction rocker arm
10. Exhaust rocker arm
Figure 7
IEGR-system activated
1. Servo piston
2. Control valve
3. Solenoid valve
4. 2–5 Bar lubrication oil pressure
5. Breather hole
6. Oil channel, low-pressure
7. Oil channel, high-pressure
8. Main piston
9. Induction rocker arm
10. Exhaust rocker arm
Checking and adjusting

Checking and adjusting of the IEGR-opening piston's clearance against the exhaust rocker arm should be done in
connection with checking and adjusting valves according to 214 Valves, adjusting.
Software
The function monitors the EGR valve for return of combustion gases and informs the operator if the function is not ensured
or if there is a system malfunction.
The function is also used as input signal for Engine protection.
Service Information

Valves, adjusting 214 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Valves, adjusting
The valve clearance must be checked and adjusted at specified intervals. To do this, the engine oil temperature must be
between 20 °C (68 °F) and 80 °C (176 °F).
Valve clearance adjustment
Item mm inch
Inlet valve 0.3 0.012
Exhaust valve 0.5 0.020
Adjustment
Figure 1
Valve clearance, adjustment
1. Remove rocker cover.

2. Turn crankshaft until both valves in cylinder 1 overlap (Exhaust valve about to close, inlet valve about to open).
3. Adjust clearance of valves marked in black in figure. Mark respective rocker arm with chalk to show that adjustment
has been done.
Figure 2
Lock nut, tightening
4. Tighten down the lock nut to 20 N·m (15 lbf·ft) check the adjustment again with a feeler gauge.
Figure 3
Valve clearance, adjustment
5. Turn crankshaft one full revolution (360°). Now adjust clearance of valves marked black in figure.
6. Install the valve cover together with a new gasket and tighten down the screws.
 Tightening torque: 9 N·m (6.6 lbf·ft)

Service Information

Valves, adjusting 214 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Valves, adjusting
Op nbr 214-012
9998681 Rotation tool

885812 Timing tool
WARNING
Risk of burns - stop the diesel engine and allow it to cool down before starting any work.
1. Place the machine in service position B. See 091 Service positions
2. Open the engine hood.
3. Remove turbocharger inlet tube (1).
Figure 1
4. Remove crankcase ventilation duct (1).

Figure 2
5. Remove cable bracket (1).
Figure 3
6. Remove rocker arm cover (1).
Figure 4
7. Open the side door on the right side of the machine.
8. Remove the camshaft gear cover (1) and install turning gear (2).
NOTE!
The teeth of the turning gear must mesh fully with the teeth of the camshaft gear.
Figure 5
1. Camshaft gear cover
2. Turning gear
9. Remove the IEGR unit. (if installed)

Install M 8 x 75 mm – 10.9 screws in the holes for the IEGR unit on the rocker arm holders.
Figure 6
10. Setting engine to valve overlap

Turn crankshaft using the turning gear until the valve overlap of cylinder 1 is reached.
Figure 7
Overlapping means that the exhaust valve is about to open and the inlet valve is about to close. It should not be
possible to rotate any push rods by hand for the cylinder in question in this position.
Figure 8
Overlapping
Figure 9
1, 3, 5, 7, 9 and 11 are exhaust valves

2, 4, 6, 8, 10 are 12 inlet valves
11. Adjust the valve clearance for each cylinder according to the black markings in the figure. Procedure for adjusting:
Figure 10
Figure 11
1. 885812 Timing tool

2. Adjusting screw
1. Loosen the adjusting screw's lock bolt on the rocker arm.

2. Install the protractor on the adjusting screw.
3. Turn the adjusting screw until zero clearance is obtained between rocker arm and valve. Reset the
protractor to zero.
4. Turn the adjusting screw counterclockwise 75° for inlet valve and 120° for exhaust valve.
5. Hold the adjusting screw and tighten the lock nut at the same time. Tightening torque: see
200 Engine, tightening torques
12. Rotate the crankshaft another full turn until the valves for cylinder 6 overlap. Adjust the valve clearance for each
cylinder according to the black markings in the figure.
NOTE!
When all valves are adjusted, do not rotate the engine. Continue directly with installing and adjusting the IEGR unit.
Figure 12
Installing and adjusting IEGR unit (If installed)
13. Change the O-rings on the pipe between the two IEGR sections. Lubricate the O-rings.
14. Remove the replacement bolts from the IEGR unit's installation holes.
15. Install the IEGR unit.
16. With overlapping valves for cylinder 6, adjust IEGR-opening piston for cylinder 1, 3 and 5. Procedure for adjusting
IEGR-opening piston:
Figure 13
1. 885812 Timing tool

2. Adjusting screw
1. Loosen the adjusting screw's lock bolt on the IEGR unit.

2. Install the protractor on the adjusting screw.
3. Turn the adjusting screw until zero clearance is obtained between the IEGR-opening piston and exhaust
rocker arm. Reset the protractor to zero.
4. Turn the adjusting screw counterclockwise 144°.
5. Hold the adjusting screw and tighten the lock nut at the same time. Tightening torque: see
200 Engine, tightening torques
17. Rotate the crankshaft another full turn until the valves for cylinder 1 overlap. Adjust IEGR-opening piston for
cylinder 2, 4 and 6.
18. Install the new gasket on the valve cover.

NOTE!
Make sure that the tab (1) on the gasket is positioned correctly.
Figure 14
Assembly
19. For assembly, reverse disassembly procedure.

NOTE!
Do not reuse the O-rings and gasket.
20. After the completion of the work, start the engine and check for leaks and operating condition.
Service Information

Engine timing gear, 215 Service Information 2014/6/11
description
Profile:
EXC, EC210B LC [GB]
Engine timing gear, description

On the engines, the timing gears are located at the flywheel end for the camshaft and power take-off.
Stamped markings on the crankshaft and camshaft gears are used to facilitate correct setting.
Figure 1
Service Information

Camshaft, description 215 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Camshaft, description
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

Crankshaft, description 216 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Crankshaft, description
 The forged crankshaft of the D6D engine is provided with integrated balance weights. The drive gear for the timing
gears and the flywheel flange are shrunk on.
Figure 2
Fillet radii on the bearing journal
 The material microstructure of the fillet radii on the bearing journals is strengthened by rolling.
 Remachining of the fillet radii is therefore not permissible.
Figure 3
Allowable repair limit
 In case of repair, there is available one undersize of 0.25 mm (referred to the diameter) for the crank pins and main
bearing journals.
Figure 4
Allowable thrust bearing face repair limit
 The thrust bearing face can only be remachined once (oversize: 0.4 mm, 0.2 mm each side).
Thrust bearing clearance of the crankshaft in installed condition: 0.1 to 0.28 mm (0.004 to 0.011 in).
Service Information

Crankshaft, description 216 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Crankshaft, description
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

Vibration damper, 216 Service Information 2014/6/11
description
Profile:
EXC, EC210B LC [GB]
Vibration damper, description

The engines are standard-equipped with a vibration damper.
The vibration damper is hydraulic and has a steel ring damper body. The damper's steel ring is not mechanically connected
to the damper's housing and thus rotates freely. The space between the steel ring and the housing is filled with viscous oil.
When the shaft rotates, the force pulses are transmitted from the pistons and converted to vibrations (oscillations) in the
crankshaft. The viscous oil achieves an equalization of the crankshaft's pulsing rotation. The uniform rotation of the steel ring
contributes to damping the vibrations.
Figure 1
Principle illustration
Service Information

Connecting rod, 216 Service Information 2014/6/11
description
Profile:
EXC, EC210B LC [GB]
Connecting rod, description

 The connecting rod of forged steel is fitted at the big end bearing bore with a balance weight (1) in order to
compensate the manufacturing tolerances with regard to weight and position of the center of gravity.
 The number markings (A) on the big end eye and the bearing cap must be on one side and identical.
 Locating lugs (2) are provided in the lower and upper bearing shells to prevent the bearing shells from rotating in
their seat; these lugs engage in oblong shaped grooves in the big end eye and big end bearing cap.
 The piston must be so installed that the flywheel symbol (B) on the piston top faces the flywheel.
 When assembling connecting rod and piston, the centering pins (3) for locating the connecting rod bearing cap
must be fitted on the upper face of the piston on the side of the flywheel symbol (B).
Figure 1
Connecting rod
Service Information

Connecting rod, 216 Service Information 2014/6/11
description
Profile:
EXC, EC210B LC [GB]
Connecting rod, description

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

Oil sump, description 217 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Oil sump, description

Oil pan, description
The oil pan has a central sump configuration with quick drain valve and oil level sensor.
A gasket and a sealant are used to provide the crankcase to oil pan seal.
Service Information

Engine mounting 218 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Engine mounting
Figure 1
Engine mounting
Fan side : yellow and white

Flywheel side : blue and white
Tightening torque, unit: kgf·m (lbf·ft)
No. Mounting position Tightening torque

1 Screw (fan and flywheel side) 70 ±7 (505 ±51)
2 Cushion -
3 Washer -
4 Nut -
5 Plate -
6 Engine mounting bracket (fan side) -
7 Frame (fan side) -
8 Screw 26 ±0.5 (188 ±14)
9 Screw 11.5 ±0.5 (83 ±4)
10 Engine mounting bracket (flywheel side) -
11 Frame (flywheel side) -
12 Screw 11.5 ±0.5 (83 ±4)
Service Information

Engine mounting 218 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Engine mounting
Figure 1
Engine mounting
Fan side : yellow and white

Flywheel side : blue and white
Tightening torque, unit: kgf·m (lbf·ft)
No. Mounting position Tightening torque

1 Screw (fan and flywheel side) 70 ±7 (505 ±51)
2 Cushion -
3 Washer -
4 Nut -
5 Plate -
6 Engine mounting bracket (fan side) -
7 Frame (fan side) -
8 Screw 26 ±0.5 (188 ±14)
9 Screw 11.5 ±0.5 (83 ±4)
10 Engine mounting bracket (flywheel side) -
11 Frame (flywheel side) -
12 Screw 11.5 ±0.5 (83 ±4)
Service Information

Lubrication system, 220 Service Information 2014/6/11
description
Profile:
EXC, EC210B LC [GB]
Lubrication system, description

The lubrication oil pump is a rotor pump mounted behind the engine's vibration damper and is driven by the engine's
crankshaft.
The lubrication oil is delivered by the oil pump through the oil cooler to the oil filter. The oil cooler is mounted on the oil
filter housing, which is located on the engine block's right side.
From the filter, the oil flows into the main distribution channel that supplies oil to the engine's crankshaft, camshaft, and
rocker arms via tappets and push rods, as well as the turbocharger.
The engine is also equipped with piston cooling nozzles that spray oil on the pistons' undersides to maintain an stable
operating temperature.
Figure 1
Principle illustration
1. Tappet
2. Push rod. Oil supply to rocker arm bridge
3. Rocker arm
4. Return channel
5. Piston cooling nozzle
6. Oil pressure sensor
7. Oil filter housing with oil cooler
8. Lubrication oil pump
9. Overflow valve
10. Pressure control valve
11. Full-flow filter
Service Information

description
Profile:
EXC, EC210B LC [GB]
Lubrication system, description

Engine lubricating oil is supplied to the contact faces of rotating components such as turbocharger, crankshaft, camshaft,
piston, inlet/exhaust valve, rocker arm and timing gear by means of forced lubrication from the oil pump.
Lubrication oil flow diagram
Figure 1
Lubrication oil flow
1 Oil pan 9 Camshaft bearing

2 Intake pipe 10 line to injection nozzle
3 Lube oil pump 11 Injection nozzle for piston cooling
4 Lube oil cooler 12 Tappet with rocker arm pulse lubrication
4-1 Reverse lock valve 13 Stop rod, oil supply for rocker arm lubrication
4-2 Bypass valve 14 Rocker arm
4-3 Control valve 15 Return line to oil pan
4-4 Bypass valve 16 Oil line to exhaust turbocharger
5 Exchangeable lube oil filter 17 Exhaust turbocharger
6 Main oil pipe 18 Return line from hydraulic pump
6a Engine brake lubrication 19 Hydraulic pump
7 Crankshaft bearing 20 Oil line to hydraulic pump
8 Con rod spring 21 Return line from cylinder head
22 Exhaust turbocharger return to crankcase
Service Information

principle of operation
Profile:
EXC, EC210B LC [GB]
Lubrication system, principle of operation

Lube oil ducts
The engine is provided with forced-fed circulation lubrication with lube oil cooler and lube oil filter arranged in full flow. The
lube oil is supplied by the lube oil pump through the oil cooler to the oil filter. Both components are mounted to the lube oil
cooler housing which is flanged to the crankcase. Downstream of the filter the lube oil flows into the main oil gallery and
secondary oil gallery. From here the oil is ducted to the lubricating points.
The main oil gallery supplies:
– Crankshaft
– Camshaft
– Valve tappets
– Roller tappets
The secondary oil gallery supplies:
– Exhaust turbocharger
Lubrication of the rockers is effected via the tappets and the push rods.
Lube oil pump
The lube oil rotary pump is installed in the front cover. The inner rotor (1) is seated on the crankshaft and is driven by same.
Its driver contour (4) has no 120° partition, i.e. the rotor can only be slid onto the crankshaft in a specific position.
This is attributable to deviating rotor widths.
Figure 1
Lube oil pump, sectional view
1 Inner rotor 3 Suction chamber

2 Delivery chamber towards crankcase 4 Driver contour
Unit Specification
Rotor width mm (in) 12.3 (0.48)
Volume flow l/min 65 at 2500 rpm
Minimum oil pressure at 120 °C (248 °F) oil temperature, measured at oil filter bracket.
The lubrication oil pump is designed as a rotor pump and is mounted in the front cover. The inner rotor (1) is located on the
crankshaft (4), by which it is driven.
Its flange profile has an irregular shape, that is, it can only be fitted on the crankshaft in a certain position.
Figure 2
1. Rotor
2. Pressure chamber
3. Suction chamber
4. Crankshaft
Service Information

Lubrication oil pressure, 221 Service Information 2014/6/11
checking with pressure
gauge
Profile:
EXC, EC210B LC [GB]
Lubrication oil pressure, checking with pressure gauge

Op nbr 221-022
11666037 Hose
11666017 Pressure gauge
936444 Testing nipple
1. Place the machine in service position B, see 091 Service positions.
WARNING
Risk of burns! Use protective work gloves.
2. Turn the battery disconnect switch to off position.
4.  Remove the oil pressure switch on the oil filter head and install a measuring nipple.
Figure 1
1. 13933251 Measuring nipple M14x1.5

2. 11666017 Pressure gauge
3. 11666037 Hose
 Connect the hose and pressure gauge.

 Start the engine and warm up to operating temperature. At high idle, the oil pressure should be according
to 030 Lubrication system, specifications
NOTE!
Use the new cooper washer when installing.
Service Information

Oil cooler, replacing 223 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Oil cooler, replacing

Op nbr 223-006
1. Place the machine in service position, see 091 Service positions.
3. Drain the coolant from the engine, see 261 Coolant, changing.
4. Remove mounting screws (1), (2) on the clamps.

NOTE!
Approach from the front side when removing screw (1).
Figure 1
5. Remove mounting screws on clamps (1) and disconnect hose (2)..
Figure 2
6. Remove all screws for the oil cooler.

NOTE!
Tightening torque: 22 ±2 Nm (2.2 ±0.2 kgfm) (16.3 ±1.5 lbf ft)
Figure 3
7. Remove the oil cooler from the engine block.
Figure 4
8. Clean all sealing surfaces.
9. Fit a new oil cooler on the engine block, use new seal gaskets.
Figure 5
10. For assembling, reverse disassembly procedure.
11. Fill coolant in the cooling system.
12. Start, run the engine until warm, check for leaks.
If needed, adjust the coolant level in the cooling system.
Service Information

Fuel system, description 230 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fuel system, description

General
The engine has an injection system where the fuel is injected into the combustion chambers via separate injection pumps
one for each cylinder.
The fuel is delivered from the tank via the primary filter by the fuel feed pump via the secondary filter to the supply channel
for the unit pumps.
From the unit pumps, the fuel is delivered through the pressure (delivery) pipes to the injectors.
Return fuel from the unit pumps passes via a channel in the cylinder block to the overflow valve, which is placed in the outlet
from the cylinder head fuel channel.
The overflow valve controls the feed pressure in the fuel system.
The high feed pressure ensures filling of the unit pumps.
The fuel pump has a very high flow and excess fuel helps to cool the unit pumps.
After the overflow valve, the fuel passes via a cooler to the tank.
Figure 1
Service Information

Fuel system, description 230 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fuel system, description

The 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 filter, 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

Instructions for working 230 Service Information 2014/6/11
with electronic fuel
injection
Profile:
EXC, EC210B LC [GB]
Instructions for working with electronic fuel injection

 Never disconnect any cables from the control unit or from the sensors, when the engine is running. The ignition key
must be in position 0 and the engine stopped.
 Never disconnect a battery cable while the engine is running.
 Before carrying out welding work, the control unit connectors must be disconnected from the control unit.
NOTE!
The main current supply must be switched off when the connectors are disconnected.
 Only batteries must be used as staring aid. Starting aid units may supply overvoltage and damage the electronics.
 During rapid charging of the batteries, the battery cables must be disconnected. (This does not apply during normal
trickle charging.)
 If a connector has been disconnected, make sure it is correctly reconnected, and that it is completely free from oil
or other contamination, which may cause a poor contact.
Service Information

Fuel feed pump, 233 Service Information 2014/6/11
description
Profile:
EXC, EC210B LC [GB]
Fuel feed pump, description

The fuel feed pump is designed as a rotor pump and is driven by a Vee-belt.
The non-return valve (2) prevents the fuel from draining back to the tank. This facilitates re-starting the engine.
If the fuel lines have been run dry of fuel, the fuel system should be filled and bled with the hand pump located on the
primary filter housing. The non-return valve (2) opens and allows fuel to circulate in the entire circuit. In this way, the unit
pumps are supplied with fuel free from air.
Figure 1
Service Information

Feed pump, checking feed 233 Service Information 2014/6/11
pressure
Profile:
EXC, EC210B LC [GB]
Feed pump, checking feed pressure

Op nbr 233-004
9993720 Nipple
11666052 Pressure gauge
14290262 Adapter
14290266 Hose
1. Remove the banjo bolt assembled to the fuel filter and install adapter (1), nipple (2), hose (3) and pressure gauge
(4) to the fuel pressure side connection.
Figure 1
1. 14290262 Adapter
2. 9993720 Nipple
3. 14290266 Hose
4. 11666052 Pressure gauge
2. Bleed the fuel system according to 233 Fuel system, bleeding.
3. Read the fuel feed pressure and check that it is according to .030 Fuel feed pump, specifications
If the measured pressure is too low:
Connect the gauge to the fuel supply connection (5). Bleed the fuel system according to .233 Fuel system, bleeding
Read off the fuel feed pressure. If the pressure is according to 030 Fuel feed pump, specifications, the fuel filter may
be clogged. Change filter and check the fuel feed pressure again on the outgoing fuel pressure line according to
step 1-2.
If the pressure still is too low, it may be due to a defective overflow valve, fuel pump or fuel supply. Check the fuel
feed pump and that the fuel supply line is not clogged or has an air leak.
4. Remove adapter (1), nipple (2), hose (3) and pressure gauge (4), and install the banjo bolt at the fuel filter.
5. Bleed the fuel system according to 233 Fuel system, bleeding.

Service Information

Fuel pump, inspection 233 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fuel pump, inspection

Op nbr 233-010
NOTE! Take care of fuel spills by using collection containers.
1. Place the machine in the service position B. See 091 Service positions
3. Turn belt tensioner (2) clockwise using a socket handle (1/2”), and remove alternator belt (1) from alternator (3) and
the tensioner pulley.
Figure 1
1. Alternator belt
2. Belt tensioner (socket handle installation position)
3. Alternator
NOTE!
The belt adjuster tension is very strong. Therefore pay attention to prevent injury after removing belt.
4. Remove hose (1), pipe (2), screws (4) and fuel feed pump (3).
NOTE!
Cover the ends of the hoses to prevent contamination from entering the fuel system.
NOTE!
Pay attention not to drop any fuel on the belt when removing the fuel feed pump.
Figure 2
1. Hose
2. Pipe
3. Fuel feed pump
4. Mounting screw
5. Dismantle the feed pump and check the feed pump drive for damage. If damaged, change the feed pump.
Figure 3
6. If undamaged, clean all parts very thoroughly and assemble the pump.
7. Install the feed pump.
8. Install the alternator belt.
9. Install the fuel hose and pipe on the feed pump.

NOTE!
Copper washers disassembled should be replaced with new ones.
10. Perform the air bleeding operation. See 233 Fuel system, bleeding
11. Start the engine and check for leaks.
12. Following any action, check the feed pressure.
13. Close the engine hood.

Service Information

Fuel filter, checking 233 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fuel filter, checking

Op nbr 233-020
1. Check that the fuel is not contaminated in the bowl under the primary filter. Perform this check to ensure that the
primary filter is not clogged.
In case of impurities, the filter is probably clogged. Replace the primary filter and clean the water collection bowl.
In winter, check if the water in the water collection bowl has frozen. Any ice will cause a clog.
In case of suspected impurities in the tank, clean the tank.
Draining water collection bowl
2. Open valve (1) on the water collection bowl and collect waste fuel in a suitable container.
Figure 1
Service Information

Fuel system, bleeding 233 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fuel system, bleeding

Op nbr 233-001
2. Turn off the main electric power with the battery disconnect switch.
3.
Figure 1
1. Priming pump on filter head
Turn the priming pump counterclockwise to unlock the plunger. Pump approximately 200 to 300 strokes until a
heavy resistance can be felt. Push the plunger down and turn clockwise to lock into position.
NOTE!
Air bleeding may not be performed using the starter motor.
4. Turn on the electric power, start the engine and let it idle at low idle speed for a few minutes. If the engine is
difficult to start, bleed again with the priming pump.
NOTE!
The priming pump must not be used when the engine is running.
Service Information

Feed pump, replacing 233 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Feed pump, replacing

Op nbr 233-002
WARNING
1. Open the engine hood and the radiator hood.
2. Remove the charge air cooler hose.
Figure 1
3. Remove screws (1) and the fan guard.
Figure 2
4. Turn belt tensioner (3) clockwise using a socket handle (1/2”) and then remove belt (4) from the alternator pulley.
Figure 3
1. Alternator
2. Socket handle
3. Belt tensioner
4. Belt
5. Fuel feed pump
NOTE!
5. Remove pipe (1), screws (3) and fuel feed pump (2).
Figure 4
1. Fuel inlet/outlet pipe

2. Fuel feed pump
3. Mounting screws
NOTE!
Cover the ends of the hoses to prevent impurities from entering the fuel system.
NOTE!
Pay attention not to drop any fuel onto the belt when removing the fuel feed pump.
6. Install a new feed pump.
7. Install the fuel hose and pipe on the feed pump.

NOTE!
Copper washers disassembled should be replaced with new ones.
8. Install the charge air cooler hose and fan guard.

9. Perform the air bleeding operation. See 233 Fuel system, bleeding.
10. Start the engine and check for leaks.
11. Close the engine hood and the radiator hood.

Service Information

Fuel filters, replacing 233 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fuel filters, replacing

Op nbr 233-014
9996671 Oil filter wrench
A reduction in engine power can be caused by a clogged fuel filter. If the filter becomes clogged quickly, check fuel for
contamination and clean fuel tank if necessary.
2. Loosen the fuel filter with a filter wrench (Tool part no.: 9996671), and remove.
Figure 1
Removal, filter
3. Clean the sealing surface of the filter head.
4. Lightly oil the rubber seal of the new filter, or moisten with diesel fuel.
5. Screw on the filter by hand until the seal makes contact, then tighten another half turn.
Service Information

Fuel filter extra, replacing 233 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fuel filter extra, replacing

Op nbr 233-015
11666167 Disassembly tool

9996671 Oil filter wrench
A reduction in engine power can be caused by a clogged fuel filter. If the filter becomes clogged quickly, check fuel for
contamination and clean fuel tank if necessary.
2. Turn priming pump (B) counterclockwise to unlock the plunger.

Turn shut off valve (A) clockwise 90°.
Figure 1
A. Shut off valve

B. Priming pump
3. Disconnect wire harness connector (1).
Figure 2
Disconnect, wire harness connector
4. Loosen drain valve (2) to drain the sediment from water separator bowl (3).
5. Loosen the fuel separator bowl with a filter wrench (Tool part no.: 11666167), and remove.
6. Loosen the fuel separator filter with a filter wrench, and remove.
7. Clean the sealing surface of the filter head.
8. Lightly oil the rubber seal of the new filter, or moisten with diesel fuel.
9. Screw on the filter by hand until the seal makes contact, then tighten another half turn. (Tool part no.: 9996671)
10. Screw on the filter bowl by hand until the seal makes contact, then tighten another half turn. (Tool part no.:
11666167)
Service Information

Fuel tank, description 234 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fuel tank, description
Figure 1
Structure, fuel tank
Model Machine serial no.

Type A EC210B ~ 14275
Type B 14276 ~
1 Fuel tank 8 Shims

2 Screen filter 9 Plain washer
3 Fuel tank cap 10 Spring washer
4 Drain cock valve 11 Fuel level indicator
5 Handle 12 Hydraulic oil tank
6 Outlet port 13 Tool box
7 Screw 14 Fuel tank air breather
NOTE!
Apply loctite No. 277 on screws (7).
NOTE!
When mounting the tank, adjust the height by shim (8).
NOTE!
When mounting to the frame, adjust the gap "A" : 10mm.
Tightening torque
 Level gauge (11) : 1.5 ±0.2 kgf·m (10.8 ±1.4 lbf·ft)

 Screw (7) : 52.2 ±5.2 kgf·m (377 ± 38 lbf·ft)
 Drain cock valve (4) : 1.6 ~ 1.9 kgf·m (11.6 ~ 13.7 lbf·ft)
 Drain valve clamp (4) : 0.6 kgf·m (4.3 lbf·ft)
 Flange screw (14), (2 EA) : 6.5 ±0.7 kgf·m (46 ±5 lbf·ft)
Service Information

Fuel filler pump, 234 Service Information 2014/6/11
description
Profile:
EXC, EC210B LC [GB]
Fuel filler pump, description

 The pump outlet is plumbed directly to the fuel tank to reduce the risk of introducing contamination.
 The master switch must be in the ON position to operate the fuel filler pump.
NOTE!
The filter at the end of fuel filler pump inlet hose is a strainer, and will not filter impurities from the fuel. When filling use
CLEAN fuel only!
NOTE!
Do not operate the fuel filler pump without fuel or for extended periods of time.
NOTE!
Drain the fuel from the suction hose before putting it in the storage compartment.
NOTE!
In case the pump has been disassembled, assemble the pump so the that the sharp portion of the vane faces the
counterclockwise direction.
Figure 1
Structure, fuel filler pump
Figure 2
Fuel filler pump (50 liter/minute + auto shut-off)
A. Auto shut-off controller

Service Information

Fuel filling pump, 234 Service Information 2014/6/11
removing
Profile:
EXC, EC210B LC [GB]
Fuel filling pump, removing

Op nbr 234-041
1. Place the machine in the service position F. See 091 Service positions
2. Remove the fuel tank under cover. (Tool: Socket 18 mm x 6 EA)
3. Disconnect hose (C) installed between the fuel tank and fuel feed pump (A). (Prepare a container for collecting fuel.)
4. Disconnect hose (B) from pump suction port on fuel feed pump.
5. Disconnect the wire harness connector to the fuel feed pump.
6. Remove fuel feed pump fixing screw (D). (Tool: Socket 16 mm x 2 EA)
7. Remove fuel feed pump (A) from machine.
Figure 1
Fuel filling pump
A. Fuel filling pump

B. Hose
C. Hose
D. Screw
Service Information

Fuel filling pump, installing 234 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fuel filling pump, installing

Op nbr 234-042
1. Place the machine in the service position F. See 091 Service positions
2. Install a new fuel feed pump (A) with fixing screw (D). (Tool: Socket 16 mm x 2 EA)
3. Connect the wire harness connector to fuel feed pump (A).
4. Assemble hose (B) to pump suction port on fuel feed pump (A).
5. Assemble hose (C) connecting between the fuel tank and fuel feed pump (A). (Install a new O-ring when assembling
hose to the fuel feed pump.)
6. Install the fuel tank under cover. (Tool: Socket 18 mm x 6 EA)
7. Check fuel filler pump (A).
Figure 1
Fuel filling pump
A. Fuel filling pump

B. Hose
C. Hose
D. Screw
Service Information

Injectors, description 237 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Injectors, description
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

Fuel control valve (FCV), 237 Service Information 2014/6/11
description
Profile:
EXC, EC210B LC [GB]
Fuel control valve (FCV), description

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 301 Engine Protection
Figure 1
1. Solenoid valve
2. Fuel inlet
3. Fuel to high-pressure pumps
4. Return fuel to tank
5. Overflow valve
Service Information

Injector, replacing one 237 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Injector, replacing one

Op nbr 237-004
1. Place the machine in service position B, see 091 Service positions
NOTICE
Observe the greatest possible cleanliness!
3. Remove cable bracket (1) from the valve cover.
Figure 1
4. Disconnect electric connections (1, 2) for the injectors.
Figure 2
5. Remove fuel delivery pipe (1) between the rail and injector.
Figure 3
6. Remove injector attaching yoke (2) and carefully remove injector (1) .
Figure 4
1. Injector
2. Attaching yoke
NOTE!
Make sure that the copper washer on the injector lower part also comes out.
7. Install new O-ring on the injector. Lube the O-ring sparingly with oil.
8. Install the new copper washer on the injector. Install the injector and attaching yoke. Tightening torque, see
030 Fuel system, tightening torques
9. Connect the cable harness to the injector. Tightening torque, see 030 Fuel system, tightening torques.
10. Install a new fuel delivery pipe between the rail and injector. Tightening torque, see
030 Fuel system, tightening torques.
NOTE!
Use correct torques and angles when pipe get changed.
11. Bleed the fuel system, according to 233 Fuel system, bleeding.
NOTE!
It is not allowed to loose a injector pipe for bleeding the system.
12. Start the engine, and check for leaks.

Service Information

Fuel rail pressure, checking 237 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Fuel rail pressure, checking

Op nbr 237-037
Testing conditions
1. Batteries are in good conditions and fully charged.

2. There is no fault code displayed on the VCADS Pro.
Pressure checking procedures
2. Turn off the electric power with the battery disconnect switch.
3. Connect the VCAD Pro computer to the machine through the service socket (1).
Start the VCADS Pro engine test, 23017-3 fuel supply pressure check.
Figure 1
VCADS Pro, connection
1. Service socket
NOTE!
This test is used only if there are the engine starting problems.
Engine starting condition
4. Remove the injector cover (1) from the engine, disconnect all cables (2) for the injectors.
NOTE!
Isolate the disconnected cables.
Figure 2
Injector cables, disconnection
1. Injector cover
2. Injector cables
5. Crank the engine with the starter motor for 15 to 20 seconds, check if the fuel rail pressure values are according to
the specifications. See 030 Fuel pressure, specifications.
NOTE!
Engine crank speed: 150 ±30 rpm
In case the engine crank speed is not normal

Check the battery, cables, starter motor and engine load.
In case the fuel feed pressure is not normal
Check the fuel filter and the fuel feed pump.
In case the rail pressure is not normal
Check the fuel control unit, the high pressure pump and the rail pressure relief valve.
NOTE!
If there are very abnormal results, check the fuel rail pressure sensor and the E-ECU.
6. Stop the engine.
7. Save the job card, and connect the injector cables.
Engine running, without load condition
8. Start the VCADS Pro engine test, 23017-3 fuel supply pressure check.
9. Start the engine.
10. Put the control lockout lever in the unlocked (up) position.
Check if the fuel rail pressure values are according to the specifications when there is a load below 28%. See
030 Fuel pressure, specifications.
NOTE!
Check the engine load at I-ECU service mode.
NOTE!
Check the pressure values at the different positions of the engine speed control switch, see
In case the charge air pressure is too low

Check the air intake system.
In case the engine load is too high
Check the hydraulic system load and the engine conditions.
In case the fuel feed pressure is too low
In case the rail pressure is too low
In case the rail pressure is too high
Check the Injectors.
NOTE!
11. Stop the engine.
12. Save the job card.
Engine running, with load condition
13. Start the VCADS Pro engine test, 23017-3 fuel supply pressure check.
14. Start the engine.
15. Check if the fuel rail pressure values are according to the specifications when there is a load above 60%. See
NOTE!
Check the engine load at I-ECU service mode.
NOTE!
Engine speed: 1900 rpm
NOTE!
Create the hydraulic load by moving the dipper arm and the bucket to their full stroke.
In case the charge air pressure is too low

Check the air intake system.
In case the engine load is too high
Check the hydraulic system load and the engine conditions.
In case the fuel feed pressure is too low
In case the rail pressure is too low
In case the rail pressure is too high
Check the hydraulic system load.
NOTE!
16. Stop the engine.
17. Save the job card, and disconnect the VCADS Pro cable.
18. Restore the machine to operating condition.

Service Information

Fuel control valve (FCV), 237 Service Information 2014/6/11
replacing
Profile:
EXC, EC210B LC [GB]
Fuel control valve (FCV), replacing

Op nbr 237-033
WARNING
High pressure. Wait 30 seconds after switching off the engine before working on the fuel system.
NOTICE
Maintain greatest possible cleanliness when working on the fuel system.
2. Turn the battery disconnect switch to off position.
4. Disconnect connectors (1) and (2).
Figure 1
Fuel control valve, connectors
1. Connector for fuel pressure sensor

2. Connector for fuel control valve
5. Remove fuel feed pipe (1) from fuel rail (2).

Figure 2
Fuel feed pipe, removal
1. Fuel feed pipe

2. Fuel rail
6. Loosen banjo bolt (1) and remove the fuel control inlet block.
Figure 3
Fuel control inlet block, removal
7. Remove fuel feed pipe (1), banjo bolt (2) for the fuel return line and two mounting screws (4) for flow control valve
(3).
Figure 4
1. Fuel feed pipe

2. Banjo bolt for fuel return line
3. Fuel control valve
4. Screw
Installing
8. Install the new fuel control valve.
Figure 5
Fuel Control Valve (FCV)
9. Install fuel feed pipe (1), banjo bolt (2) for the fuel return line and two mounting screws (4) for flow control valve
(3).
Figure 6
1. Fuel feed pipe

2. Banjo bolt for fuel return line
3. Fuel control valve
4. Screw
NOTE!
Use new copper washers when installing.
10. Install the fuel control inlet block.

Figure 7
Fuel control inlet block
1. Banjo bolt
NOTE!
Use new copper washers when installing.
11. Install fuel feed pipe (1) to fuel rail (2).
Figure 8
Fuel feed pipe, installation
12. Plug in the connector for fuel control valve (2) and fuel pressure sensor (1).
Figure 9
Fuel control valve, connectors
13. After completion of the work, start the engine and check for leaks.
Service Information

Inlet system, description 250 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Inlet system, description

SN: 10001 ~ 35000
 The air required for combustion is filtered by the precleaner, 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.
Figure 1
Inlet system
Tightening torque Tightening torque

1 Hose - 7 Clamp 0.6 ~ 0.8 kgf·m (4.33 ∼ 5.78 lbf·ft)
2 Pipe - 8 pre cleaner assembly
3 Clamp 0.6 ~ 0.8 kgf·m (4.33 ∼ 5.78 lbf·ft) 9 Clamp 0.5 ~ 0.6 kgf·m (3.61 ∼ 4.33 lbf·ft)
4 Sensor - 10 Turbocharger assembly
5 Hose - 11 Clamp 1.4 ± 0.14 kgf·m (10.11 ±1.01 lbf·ft)
6 Air cleaner assembly 12 Charge air cooler
SN: 35001 ~ 110000
 The air required for combustion is filtered by the pre-cleaner, 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.
Figure 2
Inlet system
1. Air cleaner
2. Pre-cleaner
3. Sensor
4. Hose
5. Turbocharger
Service Information

Exhaust system, description 250 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Exhaust system, description

D6D Engine
1. The exhaust system is designed so that exhaust noise is remarkably reduced when the exhaust gas is passed
through the manifold and muffler.
Figure 1
Installation, muffler
1. Turbocharger
2. Pipe
3. Muffler U bolts
4. Exhaust manifold
5. Turbocharger side
6. Muffler side
7. Clamp
8. Screw
Sealing clamp installation
1. Assemble the turbocharger side tube into the muffler side tube about 25 mm (1 in) as the figure.
2. Insert the gasket supplied with the clamp into the clamp.
3. Tightening two screws by turns.
NOTE!
Tightening torque : 6.9 ~ 10.4 kgf·m (49.8 ~ 75.1 lbf·ft)
D6E Engine
The exhaust system is designed so that exhaust noise is remarkably reduced when the exhaust gas is passed through the
manifold and muffler.
Figure 2
1. Turbocharger
2. Exhaust manifold
3. Muffler
Service Information

Turbocharger, description 255 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Turbocharger, description
The turbocharger is driven by the exhaust gasses as they pass through the turbine housing.
The exhaust gas flow causes the turbine rotor in the turbine housing to rotate. The compressor rotor is positioned on the
same shaft as the turbine rotor. The compressor rotor is positioned in a housing which is connected between the air cleaner
and the engine induction manifold.
When the compressor rotor rotates, air is drawn from the air cleaner. The air is compressed and forced into the engine
cylinders, after it first has been cooled down while passing through the intercooler.
The turbochargers on some engines are equipped with a wastegate valve. The waste-gate valve, which is controlled by the
charge-air pressure, allows a small amount of the exhaust gasses to by-pass the turbine rotor at high engine speeds (high
charge-air pressure). This design makes the turbocharger efficient at low engine speeds.
Figure 1
Turbocharger, principle diagram
A. Supply of lubricating oil

B. Exhaust gases from engine into turbocharger
C. Exhaust gases out from turbocharger
D. Air via air filter
E. Air to inlet manifold
Service Information

Preheating coil, replacing 256 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Preheating coil, replacing

Op nbr 256-006
WARNING
2. Remove charge air cooler outlet pipe (1) and hose (2).
Figure 1
3. Remove wire harness (3) and preheating coil mounting screw (1).
NOTE!
Check the preheating coil gaskets (each side) and replace them if necessary.
Figure 2
Removal, wire harness connector
1. Screw
2. Preheating coil
3. Wire harness
4. Install a new preheating coil and the wire harness.
5. Install the charge air cooler outlet pipe and hose.

Service Information

Charge air cooler, 258 Service Information 2014/6/11
description
Profile:
EXC, EC210B LC [GB]
Charge air cooler, description

SN: 10001 ~ 35000
Figure 1
Charge air cooler
1 Clamp tightening torque : 1.4 ±0.4 kgf·m (10.1 ±2.9lbf·ft) 6 Pipe (to intake manifold))
2 Hose 7 Charge air cooler
3 O-ring 8 Radiator
4 Turbocharger 9 Condenser and receiver dryer
5 Pipe (to Charge air cooler)
SN: 35001 ~ 110000

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.
Figure 2
Charge air cooler
1. Charge air cooler

2. Charge air cooler inlet hose
3. Charge air cooler outlet hose
Service Information

Charge air cooler 258 Service Information 2014/6/11
connection (hose, tube),
replacing
Profile:
EXC, EC210B LC [GB]
Charge air cooler connection (hose, tube), replacing

Op nbr 258-022
WARNING
2. Remove intercooler inlet/outlet hose (1, 2).
Figure 1
Removal, intercooler inlet/outlet hose
1. Intercooler inlet hose

2. Intercooler outlet hose
3. Install new intercooler inlet/outlet hoses.

Service Information

Cooling system, description 260 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Cooling system, description

SN: 10001 ~ 35000
The hydraulic oil cooler of a steel frame with cells and tanks made of aluminium. The cells contain turbolators, which create
turbulence in the oil so it makes maximum contact with the cell walls.
 Air is drawn into the engine compartment passing through the radiator, the oil cooler and the charge air cooler as
the fan rotates.
The hydraulic oil cooler and the charge air cooler are installed to the radiator frame.
See 9112 Return and pump line
Service Information

Cooling system, description 260 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Cooling system, description

SN: 35001 ~ 110000
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 outlet 11 Hydraulic oil cooler drain plug
6 Hydraulic oil inlet
Service Information

Cooling system, operation 260 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Cooling system, operation

The cooling circuits of the D6D engine are closed circuits (forced circulation cooling), continuous-flow cooling is not
permitted.
Figure 1
Cooling system (1)
1 Cooling fan 5 Thermostat 9 Coolant inlet pipe

2 Radiator 6 Fan belt 10 Water pump
3 Air vent hose 7 Cylinder cooling chamber 11 Make up hose
4 Coolant outlet hose 8 Engine filter and oil cooler 12 Coolant filter (option)
NOTE!
Tightening torque (clamps) : 0.5 ~ 0.6 kgf·m ( 3.6 ~ 4.3 lbf·ft)
Coolant
 Liquid-cooled engines are to be filled with a treated coolant as otherwise serious engine damage can occur as a
result of freezing, cavitation and corrosion.
 The water used must meet the following requirements:
Water quality Minimum Maximum

ph value at 20 °C 6.5 8.5
Chloride ion content (mg/dm3) - 100
Sulfate ion content (mg/dm3) - 100
Total hardness (°dGH) 3 12
 The coolant is prepared by adding a cooling system conditioner to the cooling water. A cooling system conditioner
which is free from nitrite, a mine and phosphate is available in 5-liter containers from your Volvo Construction
Equipment dealer through the spare parts service. The suitability of other cooling system conditioners should be
expressly confirmed by Volvo Construction Equipment Service.
 The concentration of the cooling system conditioner must not fall below or exceed the following values:
Cooling system conditioner Protection against freezing down to °C (°F)

max. 45% -35 (-31)
max. 40% -28 (-18.4)
min. 35% -22 (-7.6)
 The concentration of the coolant is checked with commercially available testers.
NOTICE
Cooling system conditioners must be disposed of in accordance with environmental regulations.
Draining cooling system
Figure 2
Draining cooling system
Draining
For draining the cooling system remove screw at the left side of the crankcase and catch coolant in a suitable container and
dispose of according to regulations.
Thereafter tighten screw again.
Service Information

Coolant, checking anti- 261 Service Information 2014/6/11
freeze resistance
Profile:
EXC, EC210B LC [GB]
Coolant, checking anti-freeze resistance

Op nbr 261-002
88890105 Refractometer
WARNING
Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant
may rush out and cause severe burns.
1. Check the freezing protection with 88890105 Refractometer.

Open the cover on the refractometer and place a few drops of the coolant on the glass surface. Close the cover and
read off the value against strong light source.
Read off the value on the ethylene scale. The coolant should be taken from the filling point on the expansion tank.
Figure 1
2. The machine is delivered with a coolant mixture for optimal cooling and corrosion characteristics.
That is why the same coolant mixture shall be filled, regardless of ambient temperature conditions. See 160 Coolant
and 160 Coolant with freezing and corrosion protection.
Figure 2
NOTE!
Volvo Construction Equipment concentrated coolant with anti-freeze must not be mixed with other brands
of anti-freeze or additives as this type of mixture could have negative effects.
Service Information

Coolant, changing 261 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Coolant, changing
Op nbr 261-004
WARNING
WARNING
Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling
system.
Draining coolant
2. Open the engine hood and slowly remove cap (1) from the expansion tank.
Figure 1
3. Open the left side door of the machine.

Open coolant drain valve (1) and drain the coolant into a suitable container.
NOTE!
Prepare a suitable container.
Figure 2
NOTE!
The cooling system is not protected from freezing after draining. There may still be pockets of coolant in the
system.
NOTE!
Handle and take care of waste oil/fluids in an environmentally safe manner.
NOTE!
The Volvo Construction Equipment Group’s concentrated coolant with anti-freeze must not be mixed with
other brands of anti-freeze or additives as this type of mixture could have negative effects.
NOTE!
Anti-freeze must always be used, see Section 1, Coolant with freezing and corrosion protection, Section S.
Refilling coolant into drained cooling system
4. Refill coolant through the expansion tank.

NOTE!
Cooling system refill volume is approximately 32 litres (8.45 US gal).
NOTE!
Fill coolant to 2/3 of the expansion tank volume.
5. Start and run the engine to operating temperature and top up with coolant so that the cooling system is
completely filled with coolant and is free of air.
6. Check the coolant level after the engine has been run to operating temperature and then cooled down.
NOTE!
Never fill or top up the cooling system with cold coolant when the engine is warm. This can cause cracking of the
engine block and the cylinder head.
Service Information

Thermostat, replacing 262 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Thermostat, replacing
Op nbr 262-098
WARNING
Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant
may rush out and cause severe burns.
2. Drain the coolant. See 261 Coolant, changing
4. Remove screws (2) and remove thermostat housing (1) with radiator outlet hose (3).
Figure 1
5. Remove thermostat (1) from the engine cylinder head.
Figure 2
6. Install a new thermostat with a new gasket (2).
Figure 3
1. Thermostat
2. Rubber gasket
7. For assembling, reverse the disassembly procedure.
8. After the work is completed, start the engine and check for leaks.
Service Information

Thermostat, check 262 Service Information 2014/6/11
Profile:
EXC, EC210B LC [GB]
Thermostat, check
1. Place the thermostat in a container filled with water.
Figure 1
Thermostat inspection
1. Thermometer
2. Thermostat
2. Heat it while measuring the water temperature, and see that the thermostat is actuated at the temperature of
following table.
Concerning the operating temperature, see 262 Coolant pump, thermostat, specifications.
NOTE!
Valve opening temperature is scribed on the flange.
Figure 2
Thermostat inspection
1. Thermometer
2. Thermostat
3. Tester probes
3. Place the thermostat in a container filled with antifreeze or oil.
Heat it while measuring the fluid temperature.
NOTE!
The switch is normal if the multi-meter shows continuity when the fluid temperature is 107 ~ 113 °C (225 ~ 235 °F).
Service Information

Fan belt and/or alternator 263 Service Information 2014/6/11
belt, replacing
Profile:
EXC, EC210B LC [GB]
Fan belt and/or alternator belt, replacing

Op nbr 263-012
WARNING
1. Open the engine hood and the radiator hood.
Figure 1
3. Remove screws (1) and the fan guard.
Figure 2
4. Loosen the two mounting screws 1 rotation.

Figure 3
5. Remove compressor belt (1) using belt adjusting nuts (3).
Figure 4
1. Belt
2. Air conditioner compressor
3. Belt adjusting nut (2 EA)
NOTE!
6. Turn belt tensioner (3) clockwise using a socket handle (1/2”), remove belt (4) and then install a new belt.
Figure 5
1. Alternator
2. Socket handle
3. Belt tensioner
4. Belt
5. Fuel feed pump
NOTE!
7. Install the air conditioner compressor belt and then adjust belt tension. Tighten the compressor mounting screws.
8. Install the fan guard and the charge air cooler hose.

Service Information

Fan belt and/or alternator-, 263 Service Information 2014/6/11
compressor belt, replacing
all belts
Profile:
EXC, EC210B LC [GB]
Fan belt and/or alternator-, compressor belt, replacing all belts

Op nbr 263-022
WARNING
1. Open the engine hood and radiator hood.
Figure 1
Removal, charge air cooler pipe
3. Remove screws (1) and fan guard.
Figure 2
4. Loosen the two mounting screws 1 rotation.

Figure 3
5. Remove compressor belt (1) using belt adjusting nuts (3).
Figure 4
1. Belt
2. Air conditioner compressor
3. Belt adjusting nut (2 EA)
NOTE!
6. Turn belt tensioner (3) clockwise using a socket handle (1/2”), remove belt (4) and then install a new belt.
Figure 5
1. Alternator
2. Socket handle
3. Belt tensioner
4. Belt
5. Fuel feed pump
NOTE!
7. Install a new air conditioner belt and then adjust belt tension.
Tighten the compressor mounting screws.
8. Install the fan guard and the charge air cooler hose.

Service Information

Engine block heater, Service Information 2014/6/11
description
Profile:
EXC, EC210B LC [GB]
Engine block heater, description

 Coolant heater (engine block) are practical engine starting aids for severe cold weather.
 The heater is designed for external power supply.(AC 120V, 240V)
Figure 1
Components location
1 Heater mounting location 5 Mounting surface

2 Coolant heater (1250 W, 120 V) 6 Flip cover
3 Clamp 7 Plug housing
4 Power cord 8 Extension cord
Service Information

Engine speed control 275 Service Information 2014/6/11
switch, description
Profile:
EXC, EC210B LC [GB]
Engine speed control switch, description
Figure 1
Engine speed control switch
 The operator can easily control the work mode, engine speed, and maximum working horsepower by turning the
engine speed control switch if the VECU is in the automatic operating position.
 The switch also controls the engine speed and maximum working horsepower according to the built-in program of
VECU for each mode.
 The engine speed control switch changes the voltage input to VECU according to the position (step) selected.
Engine speed control switch
No. Wire specification Signal

1 0.85 R Power (B+)
2 0.85 W Output (SIG)
3 0.85 B Ground (GND)
4 Shield GND
Service Information

Engine speed control 275 Service Information 2014/6/11
switch, inspection
Profile:
EXC, EC210B LC [GB]
Engine speed control switch, inspection

Inspection
 Measure with the connector in the connected position.
Voltage output of engine speed control switch
Engine speed control switch step Mode Voltage (V)

1 I2 0.5
5 F1 2.5
9 H or P 4.5
Thank you for your purchase.
Have a nice day.
file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/6/11 16:56:28]

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Service Information

Document Title: Function Group: Information Type: Date:

1 Fuel suction port 11 Blow-by gas pipe 21 Coolant pump

1 Fuel filter (1.0 liters)

1 Coolant inlet (from radiator) 14 Engine speed sensor 27 Belt tensioner

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Engine, tightening torques

Engine, tightening torque

Document Title: Function Group: Information Type: Date:

1 Engine oil filler 11 Oil dipstick

21 Crankcase bleeding valve 28 Turbocharger

Document Title: Function Group: Information Type: Date:

Engine characteristic curve

Document Title: Function Group: Information Type: Date:

Basic check, Engine

Purpose of the basic check

1. Cylinder compression, test

Document Title: Function Group: Information Type: Date:

 generation of error codes

 Check error codes

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Cylinder head, description

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Cylinder head, description

Document Title: Function Group: Information Type: Date:

Determining cylinder head gasket

Measuring piston projection

 A dial gauge with a fixture is needed to measure the piston projection.

Piston projection Identification of cylinder head gasket

Document Title: Function Group: Information Type: Date:

Fitting cylinder head

2. Lightly oil the cylinder head bolts.

 1st step: 30 N·m (22.2 lbf·ft, 3.1 kgf·m)

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Document Title: Function Group: Information Type: Date:

Piston rings, description

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Valve seat angle

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Document Title: Function Group: Information Type: Date:

Internal Exhaust Gas Recirculation (IEGR), description

Checking and adjusting

Document Title: Function Group: Information Type: Date:

Go back to Index Page

1. Remove rocker cover.

 Tightening torque: 9 N·m (6.6 lbf·ft)

Document Title: Function Group: Information Type: Date:

Go back to Index Page

9998681 Rotation tool

1. Place the machine in service position B. See 091 Service positions

2. Open the engine hood.

3. Remove turbocharger inlet tube (1).

4. Remove crankcase ventilation duct (1).

5. Remove cable bracket (1).