VOLVO EW160B-2 Engine With Mounting and Equipment

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

Description D6D 200 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Description D6D
The D6D engine is a straight six cylinder, direct-injected four-stroke diesel engine, with electronically controlled fuel injection
EMS (Engine Management System).
The engine meets the emission requirements according to EURO2.
The engine number is stamped on the name plate and on the engine block's right side.
Model and serial number must always be indicated when ordering spare parts.
Service Information

Engine, removal 210 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Engine, removal
Op nbr 210-01
Lifting links, min. 1000 kg

Hose with valve
WARNING
Risk of burns - stop the diesel engine and allow it to cool down before starting any work.
NOTE!
Clamps that secure hoses and wiring should be removed and replaced when installing.
1. Turn off the electric power with the battery disconnector.
2.
Figure 1
Superstructure
1. Cover
2. Cover
Remove the covers over the diesel engine.
3. Remove the protective plates under the engine.
4. Connect a hose with valve (tool equipment) and drain the coolant from the radiator into a clean container. Filled
radiator contains approx. 22 litres.
5. Connect a hose with valve (tool equipment) and drain the hydraulic oil from the hydraulic oil tank into a clean
container. Filled tank contains approx. 190 litres.
6. Disconnect the connections to the sight glass for the hydraulic oil tank. Plug and mark.
7. Remove the hood opener.

8.
Figure 2
Framework
1. Cover
2. Framework
3. Cover
Disconnect the outer framework and lift away the frame with the covers.
9.
Figure 3
Engine/hydraulic compartment
1. Intermediate wall
Remove the intermediate wall.
10.
Figure 4
1. Framework
Remove the remaining framework.

11.
Figure 5
Radiator/engine
1. Cooling hose .6 Cooling hose

2. Cooling hose 7. Cooling hose
3. Cooling hose 8. Cabling
4. Intercooler hose 9. Induction hose to turbo
5. AC compressor 10. Induction hose to turbo
Disconnect the engine from the cooling hoses. Remove the upper intercooler hose and disconnect the lower from
the engine.
Disconnect the engine from the inductions hoses for the turbo.
Disconnect (if installed) the AC compressor from the engine, and remove the Vee-belts.
NOTE!
Do NOT loosen the hoses from the compressor.
12.
Figure 6
Exhaust pipe/muffler
1. Exhaust clamp
Loosen the exhaust clamp.

13.
Figure 7
Underside muffler bracket
1. Attaching bolts
Remove the attaching bolts for the muffler bracket and remove the muffler and bracket.
14.
Figure 8
Cover plate over starter motor
1. Cover plate
Remove the cover plate over the starter motor.
15.
Figure 9
Engine/Starter motor
1. Ground connection
2. Cabling
3. Cabling
Disconnect the cabling for the starter motor and ground connection.
16.
Figure 10
Fan pump
1. Hydraulic hose
2. Hydraulic hose
Disconnect the fan pump from the hydraulic oil hoses. Plug and mark up. (Only installed if machine is equipped
with hydraulic cooling fan.)
17.
Figure 11
Engine, side view
1. Cabling
2. Fuel line
3. Cooling hose
4. Cabling
5. Fuel line
Disconnect the engine from the cabling, fuel lines and cooling hose. Plug and mark up.
18. Remove the servo pump according to 914 Servo pump, removal.
19. Remove the working pump according to 913 Pump, removal.

20.
Figure 12
Hydraulic cooling fan
1. Elbow nipple
If hydraulically driven cooling fan (option): Remove the elbow nipple on the cooling fan and plug.
21.
Figure 13
Belt-driven cooling fan
1. Cooling fan
2. Attaching bolts
3. Belt pulley
If belt-driven cooling fan: Remove the attaching bolts for the belt pulley.
Remove the cooling fan.
22.
Figure 14
Lifting links on engine
1. Lifting links
2. Lifting eyes
Connect the lifting links in the engine's lifting eyes and in a lifting device.
Tighten up the lifting links.
23. Remove the bolted joints for the engine mounts.
24. Lift out the engine carefully.
25. Place the engine on stable supports.

Service Information

Engine, installation 210 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Engine, installation
Op nbr 210-02
14360000 Vacuum pump

Lifting links, min. 1500 kg
1. Lift in the engine carefully.
2. Fit the bolted joints for the engine mounts.

Tightening torque: 687 ±68Nm.
3.
Figure 1
Belt-driven cooling fan
1. Cooling fan
2. Attaching bolts
3. Belt pulley
If belt-driven cooling fan: Fit the cooling fan and fit the attaching bolts for the belt pulley.
4.
Figure 2
Hydraulically driven cooling fan
1. Elbow nipple
If hydraulically driven cooling fan (option): Fit the elbow nipple on the cooling fan.
5. Fit the working pump according to 913 Pump, installation.
6. Fit the servo pump according to 914 Servo pump, installing.
7.
Figure 3
Engine, side view
1. Cabling
2. Fuel line
3. Cooling hose
4. Cabling
5. Fuel line
Fit cabling, fuel lines and cooling hose.

8.
Figure 4
Fan pump
1. Hydraulic hose
2. Hydraulic hose
Fit the fan pump's hydraulic oil hoses. (Only installed if machine is equipped with hydraulically driven cooling fan.)
9.
Figure 5
Engine/starter motor
1. Ground connection
2. Cabling
3. Cabling
Fit the cabling for the starter motor and the ground connection.
10.
Figure 6
Cover plate over starter motor
1. Cover plate
Fit the cover plate over the starter motor.
11.
Figure 7
Underside muffler bracket
1. Underside muffler bracket
Fit the muffler bracket with the muffler.

Fit the attaching bolts for the bracket.
12.
Figure 8
Exhaust pipe/muffler
1. Exhaust clamp
Fit the exhaust clamp.
13.
Figure 9
Radiator/engine
1. Cooling hose .6 Cooling hose

2. Cooling hose 7. Cooling hose
3. Cooling hose 8. Cabling
4. Intercooler hose 9. Induction hose to turbo
5. AC compressor 10. Induction hose to turbo
Fit the Vee-belts and the AC compressor.

Fit the upper and lower intercooler hose.
Fit the cooling hoses.
Fit the induction hoses for the turbo.
14.
Figure 10
1. Framework
Fit the inner framework.

15.
Figure 11
Fit the intermediate wall.
16.
Figure 12
Framework
1. Cover
2. Framework
3. Cover
Fit the covers and the outer framework.
17. Fit the hood opener.
18. Fit the connections for the sight glass for the hydraulic oil level.
19. Fill the hydraulic oil tank with hydraulic oil.

The tank's capacity is approx. 190 litres.
20.
Figure 13
Expansion tank
1. Cap
2. Sight glass
Remove the cap and fill coolant in the expansion tank until the level is in the middle of the sight glass.
21.
Figure 14
Radiator
1. Filling point
Fill completely in the radiator's filling point.
22. Check oil level in the engine.

Fill if needed.
23. Fit the protective plates under the engine.

24.
Figure 15
Superstructure
1. Cover
2. Cover
Fit the covers over the diesel engine.
25. Start the diesel engine, place the digging equipment in position A, see 091 Service positions.
26. Stop the diesel engine and check the hydraulic oil level, top up if needed.
Check the coolant level, top up if needed.
Service Information

Cylinder head, description 211 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Cylinder head, description

The cylinder head is made of 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. 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

Pistons, description 213 Service Information 2014/5/7 0
Profile:
EXC, EW180B [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

Valve mechanism, 214 Service Information 2014/5/7 0
description
Profile:
EXC, EW180B [GB]
Valve mechanism, description

The engines are equipped with one inlet and one exhaust valve per cylinder.
At the upper end of the valve guide, there's an O-ring seal 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's force-feed lubrication system. The oil is supplied via the tappets and push rods.
Service Information

Valves, adjusting 214 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Valves, adjusting
Op nbr 21412
1. Park the machine in a suitable service position, see 091 Service positions.
2. Disconnect the batteries with the battery disconnecting switch.
3. Remove the belt cover.
Figure 1
Engine
1. Belt cover
4. Remove the both cover hatches over the engine.
Figure 2
Superstructure
1. Rear cover hatch

2. Front cover hatch
5. Remove the parallel stay.

Figure 3
Superstructure
1. Parallel stay
6. Loosen the oil trap.
Figure 4
Oil trap
1. Bolts
7. Loosen and remove the bolts for the valve cover.

Remove the valve cover.
Figure 5
Valve cover
The figures show valve adjustment on a removed engine.
Figure 6
1, 3, 5, 7, 9,11: exhaust valve

2, 4, 6, 8, 10, 12: inlet valves
8. Rotate the engine with a fan blade until the valves on cylinder 1 rock (break over).
9. Adjust the clearance for the valves marked with black in the figure.
Inlet valve: 0.35 ±0.05 mm (0.014 ±0.0020 in)
Exhaust valve: 0.50 ±0.05 mm (0.020 ±0.0020 in)
Figure 7
10. Tighten the lock nut.

Tightening torque: 20 Nm (14.7 lbf ft)
Check the adjustment once again with the feeler gauge.
Figure 8
Valves, adjusting
11. Rotate the engine one full revolution until the valves on cylinder 6 rock (break over). Adjust the clearance for the
valves marked with black in the figure.
Figure 9
Installing valve cover
12. Fit the valve cover with a new gasket.

Make sure that the rubber bushings for the pressure (delivery) lines are guided into place in the valve covers slots
before the cover is installed.
Figure 10
Valves
1. Gasket, valve cover

2. Bushing, delivery lines
NOTE!
After installation of valve cover check that all bushings are installed correct.
13. Install the oil trap.
Figure 11
Oil trap
1. Bolts
14. Install the parallel stay.
Figure 12
Superstructure
1. Parallel stay
15. Install the both cover hatches over the engine.
Figure 13
Superstructure
1. Rear cover hatch

16. Install the belt cover.
Figure 14
Engine
1. Belt cover
17. Turn on the electric power with the battery disconnect switch.
18. Start the engine and check for leaks.
Service Information

Engine timing gear, 215 Service Information 2014/5/7 0
description
Profile:
EXC, EW180B [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 2014/5/7 0
Profile:
EXC, EW180B [GB]
Camshaft, description
The camshaft is carried in seven bearings. The bearings' wear surfaces and cams are induction hardened.
Each bearing runs in a bearing bushing that is pressed into the cylinder block. There's an inlet, exhaust and injection cam for
each cylinder. The axial stop for the camshaft is located in the timing gear casing's cover.
Figure 1
Service Information

Crankshaft, description 216 Service Information 2014/5/7 0
Profile:
EXC, EW180B [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 2014/5/7 0
description
Profile:
EXC, EW180B [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 2014/5/7 0
description
Profile:
EXC, EW180B [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

Crankshaft, replacing front 216 Service Information 2014/5/7 0
oil seal
Profile:
EXC, EW180B [GB]
Crankshaft, replacing front oil seal

Op nbr 216-014
11668400 Installation tool

9992634 Counterhold
1161053 Lock fluid
1. Park the machine in service position C, see 091 Service positions.
2. Remove the upper front hatch over the engine.
Figure 1
Superstructure
1. Front cover hatch over the engine
Figure 2
Engine
1. Belt cover
4. Remove the outer framework and lift it of with the doors.
Figure 3
Framework
1. Door
2. Framework
3. Door
5. Remove the fan from the belt pulley.

Put the fan as far in to the cooler as it is possible.
Figure 4
Cooling fan
1. Cooling fan
2. Attaching bolts
3. Belt pulley
6. Remove the belts for the alternator and for the air conditioning compressor.
Figure 5
Engine belts
1. Belt tensioner
2. Ratchet 1/2"
NOTE!
Use a 1/2" ratchet to loosen the belt tensioner.
7. Remove the V-belt pulley for the air conditioning compressor.
Figure 6
Belt pulley
1. Belt pulley for the air conditioning compressor
8. Mount the special tool 999 2634 with two M10x60 mm screws.
Remove the poly V-belt pulley and the vibration damper.
Figure 7
Special tool mounted on the belt pulley
1. Special tool
2. Belt pulley
3. Vibration damper
9. Remove the guide cap.
Figure 8
Crankshaft
1. Guide cap
10. Make two holes in the old seal, with a sharp punch and a hammer or use a drill. Fit two screws in the holes. Use a
screw driver or a tongs to force out the old seal.
11. Mount the inner guide of the special tool, 11668400, on the crankshaft. Lubricate and fit the new oil seal on the
guide.
Figure 9
Special tool
1. Seal
2. Inner guide special tool
NOTE!
The washers belonging to the special tool are for use so the new seal wont be placed at the same position as the
old one.
12. Fit needed washers, outer guide, bearing and the nut.
Screw in the nut until stop.
Figure 10
Special tool
1. Washer
2. Outer guide
3. Bearing
4. Nut
13. Remove the special tool.

Inspect that the oil seal is correct mounted.
14. Install the vibration damper and the poly V-belt pulley.
Initial tightening torque: 45 Nm (33 lbf ft)
1st tightening angle: 60°
2nd tightening angle: 60°
Figure 11
1. Special tool
2. Belt pulley
3. Vibration damper
15. Install the V-belt pulley for the air conditioning compressor.
Figure 12
Belt pulley
16. Install belts for the alternator and for the air conditioning compressor.
Figure 13
Engine belts
1. Belt tensioner
2. Ratchet 1/2"
NOTE!
17. Install the fan on the belt pulley.

Apply lock fluid on the attaching bolts.
Figure 14
Cooler fan
1. Cooling fan
2. Attaching bolts
3. Belt pulley
18. Install the outer framework and lift it of with the doors.
Figure 15
Framework
1. Door
2. Framework
3. Door
Figure 16
Belt cover
1. Belt cover
20. Install the upper front hatch over the engine.
Figure 17
Superstructure

Service Information

Crankshaft, replacing rear 216 Service Information 2014/5/7 0
oil seal
Profile:
EXC, EW180B [GB]
Crankshaft, replacing rear oil seal

Op nbr 216-018
2. Remove the rear cover hatch over the engine.

Remove the rear hatch under the working pump.
Figure 1
Superstructure
1. Rear cover hatch
3. Remove the silencer with bracket, see 252 Silencer, replacing.
4. Remove the working pump, see 913 Pump, removal.
5. Remove the mounting plate for the working pump.
Figure 2
Engine, flywheel view
1. Mounting plate
6. Remove the connecting coupling.
Figure 3
1. Connecting coupling
7. Remove the flywheel.
Figure 4
1. Flywheel
2. Bolts
NOTE!
Flywheel weight approx. 50 kg (110 lb)
8. Make two holes in the old seal, with a sharp punch and a hammer or use a drill. Fit two screws in the holes. Use a
screw driver or a tongs to force out the old seal.
guide.
Figure 5
Special tool installed on crankshaft
1. Seal
2. Special tool, inner guide
NOTE!
old one.
Figure 6
Special tool
1. Washer
2. Outer guide
3. Bearing
4. Nut

12. Install the flywheel.

Initial tightening torque, 30–45 mm (1.82–1.77 in) bolts: 20–30 Nm (15–22 lbf ft).
Initial tightening torque, 50–85 mm (1.97–3.35 in) bolts: 30–40 Nm (22–30 lbf ft) .
2nd tightening angle: 30-45 mm (1.18-1.77 in) bolts: 30°.
2nd tightening angle: 35–85 mm (1.38–3.35 in) bolts: 60°.
Figure 7
1. Flywheel
2. Bolts
NOTE!
Flywheel weight approx. 50 kg (110 lb)
13. Install the connecting coupling.

Tightening torque: 46 Nm (34 lbf ft).
Figure 8
1. Connecting coupling
14. Install the mounting plate for the working pump.
Figure 9
1. Mounting plate
15. Install the working pump, see 913 Pump, installation.
16. Install the silencer with bracket, see 252 Silencer, replacing.
17. Install the rear cover hatch over the engine.

Install the rear hatch under the working pump.
Figure 10
Superstructure
1. Rear cover hatch

Service Information

Oil sump, replacing 217 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Oil sump, replacing

Op nbr 217-003
1161277 Black silicone

Lifting sling 1000 kg
WARNING
WARNING
Hot oil and hot engine coolant can cause severe burns!
1. Place the machine in a suitable service position, see 091 Service positions.
For better access turn the superstructure 30-45°.
2. Remove the doorstep on the right side.
3. Remover the cover under the engine.
4. Drain the oil into a suitable vessel.
5. Remove the upper front cover over the engine.
Figure 1
Superstructure
1. Upper front engine cover
6. Remove the intermediate wall between the engine and the hydraulic compartment.
Figure 2
Figure 3
Cooling fan
1. Cooling fan
2. Attaching bolts
3. Belt pulley
8. Remove the cover under the cooler.
9. Remove the intercooler pipe and hose.
10. Remove the bracket.

Figure 4
Bracket for intercooler pipe
1. Bracket
11. Loosen the front attach bolts for the engine.
12. Remove the attach bolts for the oil sump.
NOTICE
Use a safe lifting device with the proper rated capacity for the job.
When lifting be careful not to damage the fan or any cooling or hydraulic hose fitted on the engine or
working pump. Make sure that no parts is attached when lifting.
13. Lift front of the engine.

NOTE!
Do not lift the engine more than necessary to remove the oil sump.
14. Remove the oil sump.

NOTE!
Be careful not to damage the engine and the oil sump. Since the sump is glued to the engine it can be stuck on the
engine.
15. Clean the surface of the engine and the sump.
Figure 5
Engine, oil sump removed
1. Surface
16. Before fitting the new oil sump, add black silicone 1161277.
17. Install the attach bolts for the oil sump.

Tighten torque: 21 ±2 Nm
18. Lower the engine and install the attach bolts for the engine.
19. Install the bracket.
Figure 6
1. Bracket
20. Install the intercooler pipe and hose.
21. Install the cover under the cooler.
22. Install the cover under the engine.
Figure 7
Cooling fan
1. Cooling fan
2. Attaching bolts
3. Belt pulley
24. Install the intermediate wall between the engine and the hydraulic compartment.
Figure 8
25. Install the upper front cover over the engine.
Figure 9
Superstructure
26. Fill oil in the engine, see 173 Maintenance service, every 500 hours.
27. Start the engine and check for any leaks. Take care if there are any.
28. Install the doorstep on the right side.

Service Information

Engine mount front, 218 Service Information 2014/5/7 0
replacement
Profile:
EXC, EW180B [GB]
Engine mount front, replacement

Op nbr 218-03
WARNING
1.
Figure 1
Engine compartment
1. Cover
2. Cover
Remove the covers 1 and 2 over the engine, and the front cover under the engine.
Engine mount, left front.
2.
Figure 2
Engine mount, left front
1. Bolted joint
2. Bolts
3. Bolts
Remove the bolted joint 1, lock the nut on the underside with a wrench when removing.
Lift the engine slightly in the front lifting eye, remove the bolts 2 (2 pcs.) and 3 and remove the engine mount.
Replace the engine mount or the engine pads.
Refit the engine mount.
Tightening torque for bolted joint 2: 260 ±26 Nm.
Fit the removed covers.
Engine mount, right front.
3.
Figure 3
Engine mount, right front
1. Bolt
2. Bolted joint
Lift the engine slightly in the front lifting eye, remove the bolts 1 and 2 bolts on the front (hidden) and remove the
engine mount.
Tightening torque for bolted joint (hidden on front): 260 ±26 Nm.
Service Information

Engine mount rear, 218 Service Information 2014/5/7 0
replacement
Profile:
EXC, EW180B [GB]
Engine mount rear, replacement

Op nbr 218-03
WARNING
1.
Figure 1
Engine compartment
1. Cover
2. Cover
Remove the covers 1 and 2 over the engine, and the rear cover under the engine.
2.
Figure 2
Hydraulic compartment
Remove the intermediate wall 1.

Engine mount, left rear.
3.
Figure 3
Engine mount, left rear
1. Bolts
2. Bolted joint
Lift the engine slightly in the rear lifting eye, remove the bolts 1 (4 pcs.) and 3 remove the engine mount.
Engine mount, right front.
4.
Figure 4
Engine mount, right rear
1. Bolted joint
2. Bolts
Lift the engine slightly in the front lifting eye, remove the bolts 2 (4 pcs.) and remove the engine mount.
Service Information

Lubrication system, 220 Service Information 2014/5/7 0
description
Profile:
EXC, EW180B [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
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

Lubrication system, 220 Service Information 2014/5/7 0
description
Profile:
EXC, EW180B [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
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

Oil pressure relief valve, 220 Service Information 2014/5/7 0
replacing
Profile:
EXC, EW180B [GB]
Oil pressure relief valve, replacing

Op nbr 221-006
Pipe, inside diameter = 20 mm (0.08 in), length 50 mm (1.97 in)
Valve spring compressor
2. Remove the cover under the radiator.
3. Drain the coolant from the radiator into a suitable vessel.
4. Drain the coolant from the engine into a suitable vessel.
Figure 1
Drain the engine
1. Drain plug
2. Funnel
5. Remove the fuel pipe and the fuel feed pipe.

Figure 2
Engine, Oil cooler
1. Fuel pipe
2. Fuel feed pipe
6. Remove the oil cooler.
Figure 3
Engine, right side
1. Engine oil cooler

2. Connecting house
7. Remove the filter house together with the connecting house.
Figure 4
Engine, filter house and connecting house removed
1. Filter house
2. Connecting house
8. Check that the pressure relief valve functions by pressing in the valve poppet.
Figure 5
Filter house inner side
1. Pressure relief valve

2. Overflow valve
9. Pull out the spring for the overflow valve with a pair of pliers. Check that the spring, the washers and the valve
poppet are free from damage.
Figure 6
1. Poppet valve
2. Washers
3. Spring
10. Install the valve poppet together with the washers. Compress the spring radially by inserting it in a pipe with an
inside diameter of 20 mm (0.80 in). Attach the pipe together with the spring to the oil filter housing with for
example a valve spring compressor. Insert the spring into position with a drift.
Figure 7
1. Drift
2. Pipe, inside diameter = 20 mm (0.80 in)
11. Check that the spring is correctly positioned.
Figure 8
12. Install the filter house, connecting house and the oil cooler.
13. Install the fuel pipe.
14. Fill coolant, see 173 Maintenance service, every 4000 hours.
15. Install the cover under the radiator.
16. Bleed the fuel system.
17. Start the engine and check for any leakage, take care of if there are any.
Service Information

Oil pump, description 221 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Oil pump, description

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 1
1. Rotor
2. Pressure chamber
3. Suction chamber
4. Crankshaft
Service Information

Oil pump, replacing 221 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Oil pump, replacing

Op nbr 221-014

9992634 Counterhold
1161277 Black silicone
1161053 Lock fluid
Lifting sling 1000 kg
WARNING
WARNING
2. Remove the upper front hatch over the engine.
Figure 1
Superstructure
3. Remove the intermediate wall between the engine and the hydraulic compartment.
Figure 2
Figure 3
Engine
1. Belt cover
5. Remove the outer framework and lift it of with the doors.
Figure 4
Framework
1. Door
2. Framework
3. Door
6. Remove the doorstep on the right side.
7. Remove the cover under the engine.

8. Drain the oil into a suitable vessel.

Put the fan as far in to the cooler as it is possible.
Figure 5
Cooling fan
1. Cooling fan
2. Attaching bolts
3. Belt pulley
10. Remove the belts for the alternator and for the air conditioning compressor.
Figure 6
Engine belts
1. Belt tensioner
2. Ratchet 1/2"
NOTE!
11. Remove the V-belt pulley for the air conditioning compressor.
Remove the belt pulley for the coolant fan.
Figure 7
Belt pulley

2. Belt pulley for the coolant fan
12. Mount the special tool 999 2634 with two M10x60 mm screws.
Remove the poly V-belt pulley and the vibration damper.
Figure 8
1. Special tool
2. Belt pulley
3. Vibration damper
13. Remove the guide cap.

Figure 9
Crankshaft
1. Guide cap
14. Remove the cover under the cooler.
15. Remove the intercooler pipe and hose.
16. Remove the bracket.
Figure 10
1. Bracket
17. Loosen the front attach bolts for the engine.
18. Remove the attach bolts for the oil sump.
WARNING
Risk of crushing injuries
NOTICE
Use a safe lifting device with the proper rated capacity for the job.

NOTE!
Do not lift the engine more than necessary to remove the oil sump.
20. Remove the oil sump.

NOTE!
Be careful not to damage the engine and the oil sump. Since the sump is glued to the engine it can be stuck on the
engine.
21. Lower the engine.
22. Remove the suction line.
Figure 11
Engine with oil sump removed
1. Suction line
23. Remove the housing.
Figure 12
Front of engine
1. Housing
24. Remove the crank shaft seal from the housing.
25. Visually inspect the front cover and replace as necessary.

NOTE!
Rotors must turn freely.
26. Remove oil pump for cleaning of front cover.

Figure 13
Oil pump
1. Oil pump
27. Replace the complete front cover in the case of visible wear or damage of an individual component.
28. Insert external and internal rotors.

NOTE!
The groove on the internal rotor must point to the inside.
29. Install the cover and the bolts.

Tightening torque: 8.5 ± 1 Nm
Figure 14
Oil pump
1. Cover
30. Install the housing on the engine.

Figure 15
Front of engine
1. Housing
guide.
Figure 16
Special tool
1. Seal
2. Inner guide special tool
NOTE!
old one.
Figure 17
Special tool
1. Washer
2. Outer guide
3. Bearing
4. Nut

34. Install the guide cap.
Figure 18
Crankshaft
1. Guide cap
35. Install the vibration damper and the poly V-belt pulley.
Initial tightening torque: 45 Nm (33 lbf ft)
2nd tightening angle: 60°
Figure 19
1. Special tool
2. Belt pulley
3. Vibration damper
36. Install the V-belt pulley for the air conditioning compressor and the pulley for the coolant fan.
Figure 20
Belt pulley

2. Belt pulley for coolant fan
37. Install belts for the alternator and for the air conditioning compressor.
Figure 21
Engine belts
1. Belt tensioner
2. Ratchet 1/2"
NOTE!
38. Clean the surface of the engine and the sump.
Figure 22
Engine, oil sump removed
1. Surface
WARNING
Risk of crushing injuries

NOTE!
Do not lift the engine more than necessary to install the oil sump.
40. Before fitting the new oil sump, add black silicone 1161277.
41. Install the attach bolts for the oil sump.

42. Lower the engine and install the attach bolts for the engine.
43. Install the bracket.
Figure 23
1. Bracket
44. Install the intercooler pipe and hose.
45. Install the cover under the cooler.
46. Install the cover under the engine.

Apply lock fluid on the attaching bolts.
Figure 24
Cooler fan
1. Cooling fan
2. Attaching bolts
3. Belt pulley
48. Install the intermediate wall between the engine and the hydraulic compartment.
Figure 25
49. Install the outer framework and lift it of with the doors.
Figure 26
Framework
1. Door
2. Framework
3. Door
Figure 27
Belt cover
1. Belt cover
51. Install the upper front hatch over the engine.

Figure 28
Superstructure
52. Fill oil in the engine, see 173 Maintenance service, every 500 hours.
53. Start the engine and check for any leaks. Take care if there are any.
54. Install the doorstep.

Service Information

Lubrication oil pressure, 221 Service Information 2014/5/7 0
check
Profile:
EXC, EW180B [GB]
Lubrication oil pressure, check

Op nbr 221-021
11666017 Pressure gauge

11666037 Hose
13933485 Testing nipple
1. Park the machine in the service position.
WARNING
Risk of burns! Use protective work gloves.
2.
 Replace the plug (2) with nipple 13 933 485 (1).

 Connect hose 11 666 037 and pressure gauge 11 666 017
 Start the engine and warm up to operating temperature. At low idle, the oil pressure should be 0.14 - 0.34
MPa (1.4 - 3.4 bar) (20.3 - 49.3 psi).
Figure 1
Measuring point
Service Information

Fuel system, description 230 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Fuel system, description

General
The engine has an injection system where the fuel is injected into the combustion compartments via separate injection
pumps for each cylinder. The injection pressure may be as high as 1500 bar.
The fuel is delivered from the tank via the primary filter by the fuel pump via the secondary filter to the supply channel for
the unit injectors.
From the unit injectors, the fuel is delivered through the pressure (delivery) lines 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's fuel channel.
The overflow valve controls the feed pressure in the fuel system. Opening pressure is approx. 3.5 bar.
The high feed pressure ensures filling of the unit injectors.
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 feed pump, 233 Service Information 2014/5/7 0
description
Profile:
EXC, EW180B [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

Fuel filter, description 233 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Fuel filter, description

The fuel system is equipped with two filters, a primary filter with water trap, and a secondary filter.
Figure 1
Primary filter
A. Hand pump
B. Bleeder screw
The filter insert consists of a folded filter made of special paper with very good filtration capacity.
On the suction line in the fuel tank, there's also a fine filter (net type) that separates any coarse solid impurities before the
fuel is drawn into the system.
Service Information

Feed pump, checking feed 233 Service Information 2014/5/7 0
pressure
Profile:
EXC, EW180B [GB]
Feed pump, checking feed pressure

Op nbr 233-004
11666017 Pressure gauge

11666037 Hose
9993720 Nipple
2.
 Replace the banjo nipple (3) with the nipple (2).

 Connect hose 11 666 037 and pressure gauge 11 666 017.
 Start the engine. Let the engine run at high idle and read off the pressure on the pressure gauge.
 The pressure should be 0.5 ± 0.02 MPa (5.0 ±0.2 bar) (72.5 ±2.9 psi).
 In case of incorrect pressure, replace the fuel filter or check if it's clogged.
 If the incorrect pressure remains, this may be due to a defective overflow valve (1), fuel pump or fuel
supply.
 Check the fuel pump and that fuel can reach the fuel pump.
Figure 1
Measure points
Service Information

Feed pump, replacing 233 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Feed pump, replacing

Op nbr 233-002
2. Remove the upper front cover over the engine.
Figure 1
Superstructure
3. Remove the intercooler hose.
Figure 2
Engine
1. Intercooler hose
4. Remove the fan belt, see 263 Fan belt, replacement.
5. Remove the fuel pipes.

Remove the fuel feed pump
Figure 3
Fuel feed pump
1. Fuel feed pump

2. Fuel pipe
3. Attach bolts
6. Install the new fuel feed pump.

Install the fuel pipes.
7. Install the fan belt, see 263 Fan belt, replacement.
8. Install the intercooler hose.
9. Install the upper front cover over the engine.
10. Bleed the fuel system.

Service Information

Fuel system, bleeding 233 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Fuel system, bleeding

Op nbr 233-05
1.
Figure 1
Fuel filter
1. Plug
Loosen the plug 1.
2.
Figure 2
Space in front of engine
1. Hand pump
Pump with the hand pump 1 until fuel free of air flows out by the plug on the fuel filter.
Tighten the plug.
Service Information

Fuel tank, removal 234 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Fuel tank, removal

Op nbr 2341-01
WARNING
Smoking or open flames near the machine are absolutely forbidden during refuelling or when the fuel system is
open to contact with the air.
1.
Figure 1
Underside of superstructure
1. Bolts
2. Drain valve
Loosen the guard, fit the hose with the valve (in tool equipment) on the drain valve 2 and drain the fuel.
Remove the bolts 1 (4 pcs.).
2.
Figure 2
Space between counterweight and fuel tank
1. Fuel filling pump

2. Hose
3. Bolts
Disconnect the fuel filling pump 1 and hose 2 incl. coupling from the tank.
Remove the bolts 3.
3.
Figure 3
Fuel tank
1. Return line
Disconnect the return line 1, plug the connection and the line.
4.
Figure 4
Fuel tank
1. Fuel hose
2. Electric cable
Disconnect the fuel hose 1, electric cable 2 and plug the fuel hose.
5.
Figure 5
Fuel tank
1. Filter bracket
2. Connecting block
3. Level glass
Disconnect the filter bracket 1, connecting block 2 and the level glass 3 from the tank.
6.
Figure 6
Fuel tank
1. Bolts
Remove the bolts 1.
7.
Figure 7
Lifting fuel tank
1. Braces
Connect the lifting links to the braces 1 and carefully lift the tank out of the machine.
Service Information

Fuel tank, installation 234 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Fuel tank, installation

Op nbr 2341-02
WARNING
Smoking or open flames near the machine are absolutely forbidden during refuelling or when the fuel system is
open to contact with the air.
1.
Figure 1
Fuel tank
1. Fuel gauge
2. Lock device
3. Tank cap
Transfer the fuel gauge 1, lock device 2 and tank cap 3 to the new tank.
2.
Figure 2
Fuel tank
1. Coupling
Transfer the coupling 1 and drain valves in the bottom of the tank.
3.
Figure 3
Lifting fuel tank
1. Braces
Connect the lifting links to the braces 1 and carefully lift the tank into the machine.
4.
Figure 4
Underside of superstructure
1. Bolts
2. Drain valve
Fit the bolts 1 (4 pcs.) and tighten down the guard over the drain valve 2.
5.
Figure 5
Fuel tank
1. Bolts
Fit the bolts 1.
6.
Figure 6
Fuel tank
1. Filter bracket
2. Connecting block
3. Level glass
Fit the filter bracket 1, connecting block 2 and the level glass 3 on the tank.
7.
Figure 7
Fuel tank
1. Fuel hose
2. Electric cable
Fit the fuel hose 1 and electric cable 2.
8.
Figure 8
Fuel tank
1. Return line
Fit the return line 1.
9.
Figure 9
Space between counterweight and fuel tank
1. Fuel filling pump

2. Hose
3. Bolts
Fit the fuel filling pump 1 and hose 2 incl. coupling on the tank.
Fit the bolts 3.
10. Fill fuel in the tank and bleed the fuel system, see 233 Fuel system, bleeding.
Service Information

Fuel filling pump, 234 Service Information 2014/5/7 0
replacement
Profile:
EXC, EW180B [GB]
Fuel filling pump, replacement

Op nbr 2344-03
WARNING
All forms of open fire and smoking are absolutely forbidden when working on the fuel filling pump.
1.
Figure 1
Fuel filling pump
1. Bolts
2. Fuel hoses
Disconnect the fuel hoses 2, plug the hoses and connections.

Remove the bolts 1 (2 pcs.).
2.
Figure 2
Fuel filling pump
1. Connector
Unplug the connector 1 for the fuel filling pump.

Remove the pump, transfer couplings that are missing on the new pump.
3.
Figure 3
Fuel filling pump
1. Bolts
2. Fuel hoses
Fit the bolts 1 (2 pcs.) and connections 2.

Plug in the connector.
4. Test-run the fuel filling pump.

Service Information

Injectors, description 237 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Injectors, description
The injector's lower sleeve with injector nozzle is shaped to give even fuel dispersion, despite the angle of the unit injector,
and thus the injector nozzle has to face in one way only.
The injector nozzle has six holes.
Figure 1
Service Information

Unit pump, description 237 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Unit pump, description

The injector pumps are driven by the engine's camshaft. Each pump consists of two main parts: the pump part and the valve
part with solenoid valve.
Function
It's easiest to divide the events in the unit injector in four phases.
Filling phase
Filling takes place all the time that the piston moves down. The fuel valve is open since the solenoid valve is not supplied
with voltage. Therefore, fuel can be sucked from the feed channel through the open valve and into the pump cylinder.
Figure 1
Filling phase for unit pump
1. Solenoid valve
2. Fuel valve
3. Pump piston
4. Injector
Spill phase
The pump piston is on its way up. As long as the solenoid valve isn't supplied with voltage, the fuel valve remains open and
fuel flows in return to the feed channel.
Figure 2
Spill phase for unit pump
Injection phase
The pump piston is still on its way up. The solenoid valve is now supplied with voltage from the control unit and the valve
closes. Since fuel cannot flow through the valve, the pressure increases rapidly so that the injector needle lifts and injection
takes place. Injection continues for as long as the valve is closed and the pump piston moves up.
Injection timing depends on when in time the electric pulse arrives (when the fuel valve closes). The amount of fuel is
determined by the length (duration) of the electric pulse. It's the control unit that decides the pulse's duration and timing via
information it receives from the control system.
Figure 3
Injection phase for unit pump
Pressure reduction phase

The pump piston is still on its way up. The control unit terminates the electric pulse when the engine has received the fuel
amount that it needs at exactly that point in time. The fuel valve opens and the fuel in the pump part can once again flow in
return to the feed channel.
Figure 4
Pressure reduction phase for unit pump
Summary
The pump piston always sucks the same amount of fuel as it pumps out of the injector. It's only when the fuel valve is closed
that pressure builds up and injection takes place.
The electric pulse's duration and its timing determines the injected fuel amount and when injection takes place.
Service Information

Injector, replacing 237 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Injector, replacing
Op nbr 23704
9996400 Impact puller

9998007 Adapter
1. Park the machine in a suitable service position, 091 Service positions.
2. Turn off the electric power with the battery disconnect switch.
3. Remove the cover hatches over the engine.
Figure 1
Superstructure
1. Rear cover hatch

Removing
Figure 2
Superstructure
1. Parallel stay
Figure 3
Oil trap
1. Bolts
6. Remove the valve cover.
Figure 4
Valve cover
7. Remove fuel pipe between the unit pump and the injector.
Figure 5
1. Fuel pipe
NOTE!
Replace the fuel pipe every time it has been removed.
NOTE!
Pay attention to the straightness.
8. Plug the connection both by the injector and pump unit.
9. Remove nozzle holder.
Figure 6
Nozzle holder
1. Nozzle holder
10. Remove the injector by pulling it upwards.

Remove the seal ring below the injector, using the impact puller 9996400 and the adapter 9998007.
Figure 7
Special tools
1. Adapter 9998007
2. Impact puller 9996400
NOTE!
The sealing washer installed at the lower end of the injector should always be replaced.
11. Clean the injector location in the cylinder head before installing the injector.
Installing
12. Fix seal ring to the injector with a little grease.
Figure 8
Injector
1. Seal ring
13. Install the injector.

NOTE!
Install the injector with the drilled hole turned towards the valve springs.
Figure 9
Injector installed
1. Injector
14. Install retainer and torque-tighten bolt.

Tightening torque: 16 Nm (12 lbf ft).
Figure 10
Injector installed
1. Torque tighten bolt
2. Retainer
15. Remove the plug on the unit pump.
16. Install the fuel pipe and tighten the union nuts. Tightening torque: 40-50 Nm (30-37 lbf ft)
NOTE!
It is not permissible to bend the pipe.
Figure 11
Fuel delivery pipe
17. Install the valve cover together with a new gasket and torque-tighten the bolts.
NOTE!
18. Fit the oil trap.
20. Install the cover hatches over the engine.
21. Turn on the electric power with the battery disconnect switch. Start the engine and check for leaks.
Service Information

Pump unit, replacing 237 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Pump unit, replacing

Op nbr 23676
1. Park the machine in a suitable service position, 091 Service positions.
2. Turn off the electric power with the battery disconnect switch.
3. Remove both cover hatches over the engine.
Figure 1
Superstructure
1. Rear cover hatch

Figure 2
Superstructure
1. Parallel stay

Figure 3
Oil trap
1. Bolts
6. Remove the valve cover.
Figure 4
Valve cover
7. Remove fuel pipe between the unit pump and the injector.
Figure 5
Delivery pipe
1. Delivery pipe
NOTE!
Replace the fuel pipe every time it has been removed.
NOTE!
Pay attention to the straightness.
8. Plug the connections both by the injector and pump unit.
9. Loosen overflow valve. Collect the fuel that runs out. Disconnect the hose from the fuel feed pipe. If required,
carefully blow with compressed air into the fuel feed pipe to remove all fuel.
NOTICE
Avoid that remaining fuel runs into the oil sump and mixes with the oil when the pump unit is lifted away.
Removing
10. Disconnect the electrical cables from the pump unit.
Figure 6
Pump unit
1. Electrical connections
11. Disconnect the fuel feed pipes from pump elements.
Figure 7
Engine with pump units
1. Fuel feed pipe
12. Slacken the attaching bolts approx. 4 mm (0.16 in) and loosen the unit pump from the block.
Figure 8
Pump unit
NOTE!
Spring force. Make sure that the unit pump does not jump up.
13. Crank the engine until the valves are rocking for the cylinder where the unit pump is to be replaced.
14. Unscrew the attaching bolts fully and remove the unit pump.
Figure 9
Removal of pump unit
Installing
15. Check that O-rings are undamaged.

NOTE!
Always use new O-rings.
Figure 10
Pump unit
1. O-rings
16. Install the unit pump according to markings. Crank the engine so that the camshaft takes up a suitable position for
the respective unit pumps before tightening down the bolts.
Tightening torque step 1: 5 Nm (3.7 lbf ft).
Tightening torque step 2: 30 Nm (22 lbf ft).
17. Install the fuel pipe and tighten the union nuts.
Tightening torque: 40-50 Nm (30-37 lbf ft)
NOTE!
It is not permissible to bend the pipe.
18. Install the valve cover together with a new gasket and torque-tighten the bolts.
NOTE!
19. Fit the oil trap.
20. Reconnect the fuel feed pipe. The thicker copper washer should be placed between the feed pipe and the unit
pump.
22. Install the cover hatches over the engine.
23. Bleed the fuel system, see 233 Fuel system, bleeding.
24. After installation, the operation "Unit pump, calibrating" (23691-2) should be carried out using VCADS Pro.
Calibration is only necessary for the unit pump or pumps that have been replaced.
Service Information

Silencer, replacing 252 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Silencer, replacing
Op nbr 252-020
1. Park the machine in service position C, see 091 Service positions
2. Remove the rear cover hatch over the engine.
Figure 1
Superstructure
1. Rear cover hatch
3. Loosen the exhaust clamp.
Figure 2
Exhaust pipe/silencer
4. Secure the silencer and bracket with a strap.

Figure 3
Silencer and bracket secured
5. Remove the screws for the bracket.
Figure 4
Underside silencer bracket
1. Attaching bolts
6. Lift and remove the bracket with the silencer.
7. Remove the hoops and remove the silencer.
8. Install the new silencer on the bracket and install the hoops.
9. Lift the bracket with the silencer in place and install the screws.
10. Tighten the clamp.
11. Install the rear cover hatch over the engine.

Service Information

Turbocharger, description 255 Service Information 2014/5/7 0
Profile:
EXC, EW180B [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

Radiator, removal 261 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Radiator, removal
Op nbr 2611-01
WARNING
1. Turn off the battery disconnector and remove the ignition key.
2.
Figure 1
Engine compartment
1. Cover
Remove the cover 1 over the radiator and the intermediate wall (between engine and hydraulic compartment).
3.
Figure 2
Underside radiator
1. Hose
Remove the cover under the radiator, fit the hose 1 (in tool equipment) and drain the coolant into a clean
container.
4.
Figure 3
Radiator
1. Hose
2. Fan
Disconnect the hose 1 from the engine and radiator, and disconnect the fan 2 from the engine.
5.
Figure 4
Radiator
1. Hose
2. Bolted joint
3. Hose
4. Hose
Disconnect the hoses 1, 3 and 4 and remove the bolted joint 2 (2 pcs.).
6.
Figure 5
Radiator
1. Hose
2. Hose
Disconnect the hose 1 from the radiator and remove the drain hose 2.
7.
Figure 6
Radiator
1. Hose
Disconnect the hose 1 from the intercooler's cooler.
8.
Figure 7
Radiator
1. Nuts
Remove the nuts 1 and washers.
9.
Figure 8
Radiator
1. Hose
2. Clamping
Disconnect the hose 1 and clamping 2 from the radiator.
10.
Figure 9
Lifting radiator
Secure a sling to the braces and carefully lift out the radiator.
Service Information

Radiator, installation 261 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Radiator, installation
Op nbr 2611-02
1.
Figure 1
Radiator
1. Rubber bushings
When changing to a new radiator, transfer the rubber bushings 1.
2.
Figure 2
Radiator
1. Fan shroud
Transfer the fan shroud 1, side plates and drain taps at the bottom of the radiator.
3.
Figure 3
Lifting radiator
Secure a sling to the braces and carefully lift in the radiator.
4.
Figure 4
Radiator
1. Hose
2. Clamping
Connect the hose 1 and clamping 2 to the radiator.
5.
Figure 5
Radiator
1. Nuts
Fit the washers and nuts 1.

6.
Figure 6
Radiator
1. Hose
Connect the hose 1 to the intercooler's cooler and the hose to the radiator.
7.
Figure 7
Radiator
1. Hose
2. Bolted joint
3. Hose
4. Hose
Connect the hoses 1, 3 and 4 and fit the bolted joint 2 (2 pcs.).
8.
Figure 8
Radiator
1. Hose
2. Fan
Fit the fan 2 on the engine and the hose 1 on the engine and radiator.
NOTE!
Apply lock fluid on the bolts for the fan.
9.
Figure 9
Expansion tank
1. Cap
2. Sight glass
Remove the cap 1 and fill coolant in the expansion tank until the level is in the middle of the sight glass 2.
10.
Figure 10
Radiator
1. Filling point
Fill completely in the radiator's filling point 1.
11. Start the diesel engine, check for leaks, take action to fix any leaks.
Top up with coolant if needed.
12.
Figure 11
Engine compartment
1. Cover
Fit the intermediate wall (between engine and hydraulic compartment) and fit the cover 1 over the radiator.
Service Information

Expansion tank, 261 Service Information 2014/5/7 0
replacement
Profile:
EXC, EW180B [GB]
Expansion tank, replacement

Op nbr 2612-03
WARNING
1. Drain the coolant until the expansion tank is empty, see 261 Radiator, removal.
2.
Figure 1
Expansion tank
1. Hose
2. Hose
3. Bolt
4. Hose
Disconnect the hoses 1, 2 and 4.

Remove the bolt 3.
3.
Figure 2
Expansion tank
1. Bolts
2. Hose
Disconnect the hose 2 and remove the bolts 1.

Replace the tank and fit the bolts and hose.
4.
Figure 3
Expansion tank
1. Hose
2. Hose
3. Bolt
4. Hose
Fit the bolt 3.

Fit the hoses 1, 2 and 4.
5.
Figure 4
Expansion tank
1. Cap
2. Sight glass
Remove the cap 1 and fill coolant in the expansion tank until the level is in the middle of the sight glass 2.
6.
Figure 5
Radiator
1. Filling point
Fill up in the radiator's filling point 1.
7. Start the diesel engine, check for leaks, take action to fix any leaks.
Top up with coolant if needed.
Service Information

Coolant pump, replacing 262 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Coolant pump, replacing

Op nbr 262-002
2. Disconnect the electric power with battery disconnecting switch.
3. Remove the upper front cover hatch over the engine.
Figure 1
Superstructure
4. Remove the cover plate under the radiator.
5. Drain the coolant, 173 Maintenance service, every 4000 hours.

The system contains approx. 22 liter.
Figure 2
Engine
1. Belt cover
7. Remove the fuel feeding pipe.

Remove the poly V-belt.
Figure 3
Engine
1. Fuel feed pipe

2. Belt tensioner
3. Ratchet
NOTE!
8. Remove the bolts for the coolant pump.
Figure 4
Coolant pump
1. Coolant pump
2. Bolts
9. Remove the old coolant pump.
10. Install the new coolant pump with a new O-ring.
11. Install the screws for the coolant.
12. Install the poly V-belt.

13. Install the fuel feeding pipe.
15. Install the upper front cover hatch over the engine.
16. Install the cover plate under the radiator.
17. Fill coolant, see 173 Maintenance service, every 4000 hours
18. Bleed the fuel system, see 233 Fuel system, bleeding.
19. Run the engine at low idle for about 5 minutes.

Check for any leakage.
20. Turn off the engine and check the coolant level again. Top up the radiator if necessary.
Service Information

Thermostat, replacing 262 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Thermostat, replacing
Op nbr 262-098
2. Disconnect the electric power with battery disconnecting switch.
3. Remove the cover plate under the radiator.
4. Drain the coolant, see 173 Maintenance service, every 4000 hours.
The system contains approx. 22 liter (5.8 US gal).
5. Remove the upper front cover hatch over the engine.
Figure 1
Superstructure
6. Remove the attaching bolts and the cover to the thermostat house.
Figure 2
Thermostat house
1. Attaching bolts
2. Thermostat house cover
7. Remove the old thermostat.

Clean the contact edges.
Install the new thermostat.
NOTE!
The arrow on the thermostat should point upwards.
8. Install the thermostat house cover.
9. Install the upper front cover hatch over the engine.
10. Install the cover plate under the radiator.
11. Fill coolant, see 173 Maintenance service, every 4000 hours.
12. Run the engine at low idle for about 5 minutes.

Check for any leakage.
13. Turn off the engine and check the coolant level again. Top up the radiator if necessary.
Service Information

Fan belt, replacement 263 Service Information 2014/5/7 0
Profile:
EXC, EW180B [GB]
Fan belt, replacement

Op nbr 263-03
WARNING
Turn off the battery disconnect switch and remove the start key before starting to work.
1.
Figure 1
Engine
1. Guard
Remove the guard 1.
2.
Figure 2
Engine compartment
1. Cover
Remove the cover 1 over the radiator.
3.
Figure 3
Hydraulic compartment
Remove the intermediate wall 1.
4.
Figure 4
Fan shroud
1. Fan
Disconnect the fan 1 from the engine,

5.
Figure 5
Belt pulley
1. Belt
Press down the belt tensioner with an open wrench (22 mm) and remove the belt 1 from the belt pulley.
6.
Figure 6
Engine
1. Belt
Remove the belt 1 between the engine and fan.
7.
Figure 7
Belt pulley
1. Belt
Press down the belt tensioner with an open wrench (22 mm) and fit the belt 1 on the belt pulley.
8.
Figure 8
Fan shroud
1. Fan
Fit the fan 1 on the engine.

NOTE!
Apply lock fluid on the bolts.
9.
Figure 9
Engine
1. Guard
Fit the guard 1.
10. Fit the intermediate wall and cover over the radiator.
Turn on the battery disconnector.
Many thanks for your purchase.
Happy every day.
file:///C|/Users/yeqiwen/Documents/QIWEN-YE-END.txt[2014/5/7 21:23:38]

VOLVO EW160B-2 Engine With Mounting and Equipment

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VOLVO EW160B-2 Engine With Mounting and Equipment

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Service Information

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Lifting links, min. 1000 kg

1. Turn off the electric power with the battery disconnector.

Remove the covers over the diesel engine.

3. Remove the protective plates under the engine.

7. Remove the hood opener.

Remove the intermediate wall.

Remove the remaining framework.

1. Cooling hose .6 Cooling hose

Loosen the exhaust clamp.

Remove the cover plate over the starter motor.

19. Remove the working pump according to 913 Pump, removal.

23. Remove the bolted joints for the engine mounts.

24. Lift out the engine carefully.

25. Place the engine on stable supports.

Document Title: Function Group: Information Type: Date:

14360000 Vacuum pump

1. Lift in the engine carefully.

2. Fit the bolted joints for the engine mounts.

5. Fit the working pump according to 913 Pump, installation.

6. Fit the servo pump according to 914 Servo pump, installing.

Fit cabling, fuel lines and cooling hose.

Fit the cover plate over the starter motor.

1. Underside muffler bracket

Fit the muffler bracket with the muffler.

1. Cooling hose .6 Cooling hose

Fit the Vee-belts and the AC compressor.

Fit the inner framework.

Fit the intermediate wall.

Fit the covers and the outer framework.

17. Fit the hood opener.

19. Fill the hydraulic oil tank with hydraulic oil.

Fill completely in the radiator's filling point.

22. Check oil level in the engine.

23. Fit the protective plates under the engine.

Fit the covers over the diesel engine.

Document Title: Function Group: Information Type: Date:

Cylinder head, description

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Valve mechanism, description

Document Title: Function Group: Information Type: Date:

2. Disconnect the batteries with the battery disconnecting switch.

3. Remove the belt cover.

4. Remove the both cover hatches over the engine.

1. Rear cover hatch

5. Remove the parallel stay.

6. Loosen the oil trap.

7. Loosen and remove the bolts for the valve cover.

1, 3, 5, 7, 9,11: exhaust valve

10. Tighten the lock nut.

Installing valve cover

12. Fit the valve cover with a new gasket.

1. Gasket, valve cover

13. Install the oil trap.

15. Install the both cover hatches over the engine.

1. Rear cover hatch

16. Install the belt cover.

Document Title: Function Group: Information Type: Date:

Engine timing gear, description

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date: