Volvo D5 Engine 2011

Volvo D5 Engine
Compactor SD110
Engine description
 TCD 2013 L042Vm
 T = Exhaust gas turbocharger
 C = Charge air cooler
 D = Diesel
 2013 = Series
 L = in Series
Rating plate
 04 = No of cylinders The type (A), engine number
The type (B), performance data
 2V = Number of valves
 m = Mechanical injection system pump pipe nozzle

Volvo Construction Equipment SD110 compactor D5 engine
Global CST - Training
2 24-03-23
Engine description
Name plate: example

3 24-03-23
Location of the rating plate
The rating plate (C) is fixed to the

Cylinder head cover of the crank
case

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Engine serial number
The engine number (D) is stamped

Onto the crankcase and onto the
rating plate.

5 24-03-23
Cylinder numbering
Cylinder arrangement
The cylinders are counted consecutively

starting from flywheel (1)
Direction of rotation
Looking onto the flywheel rotating to the

Left counter-clockwise
Engine sides
Looking onto the fly wheel

6 24-03-23
Engine view from right
1. Crank case breather

2. Lubricating oil filling
3. Injection pump
4. Lubricating oil stick
5. Lube oil cooler
6. Lube oil replacement filter
7. Lubricating oil drain plug
8. Exchangeable fuel filter
9. V-belts
10. Generator

7 24-03-23
Engine view from left
1. Combustion air inlet

2. Coolant out let
3. Coolant inlet
4. Connection charge air cooler
5. Exhaust outlet
6. Starter

8 24-03-23
Lubricating oil diagram (example)
1. Lubricating oil sump

2. Lubricating oil pump
3. Pressure limiting valve TCD2013
4. Lube oil cooler
5. Check valve TCD 2012
6. Bypass valve
7. Bypass valve
8. Pressure control valve
9. Lubricating oil filter
10. Main lube oil channel
11. Piston cooling nozzle
12. Rocker arm
13. Internally switched exhaust gas return
14. Turbo charger
15. Air compressor
9 24-03-23
Fuel schematic (example)
1. Fuel tank
2. Fuel pre-filter
3. Fuel pump
4. Exchangeable fuel filter
5. Fuel supply line to the FCU
6. Control block fuel control unit
7. High pressure pump
8. Rail (Not applicable)
9. Injector
10. Fuel return to fuel tank

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Mechanical single injection pump system

11 24-03-23
Coolant diagram (example)
1. Cooler
2. Cooler inlet
3. Coolant pump
4. Coolant partial flow to the lubricating oil cooler
5. Lube oil cooler
6. Coolant supply for engine cooling
7. Cylinder pipe head cooling
8. Connection possibility for cab heating
9. Heat exchanger
10. Return line
11. Coolant return to thermostat
12. Coolant out let
13. Compensation line
14. Venting pipe

12 24-03-23
Schematic outlet controlled cooling system

13 24-03-23
Working description
The coolant pump (“water pump”) draws in the coolant via hose lines directly
from the cooler and delivers it first via the engine-integrated lube oil cooler,
thereafter enters the engine, flows along the cylinder, upwards into the
cylinder head and to the thermostat at the coolant outlet. From there, the
coolant is directed via special lines to the cooler inlet.
When the engine is still cold the coolant is short circuited through the engine
until thermostat response temperature has been reached (starting opening)
according to the volume of hot coolant flowing off, the water pump draws in
cold coolant from the cooler

14 24-03-23
Internal exhaust gas recirculation
1. Additional cam for exhaust gas recirculation
Inlet valve opens briefly during the outlet cycle

and emits an exhaust gas partial flow to the
suction system.
This partial volume is sucked back in the next

suction cycle

15 24-03-23
Check, valve clearance, adjust if necessary
 Let the engine cool down for at least 30 minutes before setting the
valve clearance. Lubricating oil temperature below 80 0 C
 Release screws
 Remove the cylinder head hood
 Remove the gasket
 Place the turning gear over fastening screws of the belt pulley
 Turn the crankcase until reaching valve overlap
Outlet valve is not yet closed, inlet valve begins to open

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TCD2013L042V Valve setting
1. Lock nut
2. Setting screw
3. Rotary angle disc
4. Insert
5. Magnet

17 24-03-23
TCD2013L042V
Set inlet valve
 Fit the rotary angle disc with socket wrench insert on the setting screw.
 Fix magnet of the rotation angle disc.
 Turn rotation angle disc clockwise to the stop ( rocker arm without
clearance) and set the scale to zero
18 24-03-23
TCD2013L042V
Set inlet valve
 Turn rotation angle disc anticlockwise until reaching the specified rotation
angle.

19 24-03-23
TCD2013L042V
 Secure the rotation angle disc against twisting
 Turn rotation angle disc clockwise to the stop (rocker arm without
clearance) and set scale to zero.
 Tighten locking nut
 Tightening torque 20 Nm
 Then set the second valve on the rocker arm as described above
 Perform the setting procedure on every cylinder
 Remount the cylinder head cover with a new gasket in the reverse order of
disassembly and tighten screws

20 24-03-23
Engine Speed sensor
 Volvo D5
 AGD5DA3 Water cooled, Tier -3
 HP @ 2200 = 133 (99 KW)
 Displacement: 5 liters
 Low Idle 950 + / - 50
 High idle 2200 + / - 100
Speed sensor – No adjustment,

only connector to be fitted.

21 24-03-23
Mechanical governor
Governor adjustment screws
Full load “G”

J
Torque maximum “E”
NA based fuel charge “J”

E
G Excess fuel start solenoid

22 24-03-23
Governor testing jig
Test jig available on order
Governor testing & calibration

On testing jig

23 24-03-23
Fuel injection pump replacement (Hyd Tappets)
Necessary information to replace fuel pump
1. Engine model
2. Engine serial number
3. EP code
4. Injection Timing shaft ID
Fuel pumps differ from one another, it is important to obtain specific information
Example:
Proto Paver EP code : 753 754 757 756

24 24-03-23
Spacer Calculation
TS = Thickness of shim
Ek = Installation depth
Lo = Basic pump dimension
1/ 100 mm = Pump length tolerances
The spacer size (Ts) must be calculated as follows
TS equals EK minus (LO plus “A DIVIDED BY 100

25 24-03-23
V- belt
Procedure Change Engine V belt
V – belt AVX 11 (Width 11 mm)
Belt tensioning – Automatic tensioning

Spring – loaded clamping roller

26 24-03-23
Excess Fuel Start Solenoid
Excess fuel start solenoid
1. It operates during start of starter

motor providing extra fuel for
start.
2. Key 3 position for fuel start

solenoid

27 24-03-23
Fuel shut off solenoid
Resistance 4.7 ohms
1. Fuel shut off solenoid operates when

there is ignition supply – 2nd position
2. Fuel shut off solenoid + excess fuel
solenoid in 3rd start position

28 24-03-23
Engine connector
Ford connector (EPC)

16 pole & 2 pole connector with
Engine harness
Main wiring harness of engine ends in

The two connectors

29 24-03-23
Alternator
Alternator 12 V (95Amps)
Symbol = G1
1 = W – Alternator speed
Engine speed
2 = D+ ( No charge indicator
signal
3 = IG/15 Ignition for charging
current

30 24-03-23
Starter motor
Starter Motor
Make Deutz / ISKRA
12 volts, 4.0 KW

31 24-03-23
Switch Air filter clogged
Switch Air Filter clogged
(N.O) when clogged closed
Lamp indicator, Air filter clogged

32 24-03-23
Charging
Turbo charger with charge air cooling
Advantages:
 Increase Horse Power

 Emission improved
 Compact in size

33 24-03-23
Air Filter
 Do not clean the filter element with

petrol or hot liquids.
 Renew damaged filters
 Blow out with dry compressed air
(Max 5 bar) from the inside to the
outside
 Never clean the safety cartridge

34 24-03-23
Fuel Filter
Fuel filter & Water separator

35 24-03-23
Lube oil Filter
Lube Oil Filter

36 24-03-23
Coolant hose connection
Coolant Outlet
Coolant Inlet
Temperature difference between

coolant inlet and outlet = 4-8 O C

37 24-03-23
Coolant thermostat
Checking the thermostat when removed
1. Measure dimension “a” on thermostat
Note: “a” starts of lift at approx. 83+2 (T1)

“b” end of lift at approx. 95+5 (T2)
Lift movement with indicated temp T2,

Min. 8 mm

38 24-03-23
Coolant Temperature Switch (High)
Coolant Temperature Switch (High)
Engine water temperature sensor
Lamp, indicator, High Engine Water

Temperature,

39 24-03-23
Battery
Battery 12 volts – 1 No’s
12V Charging status (Volts) = 12 – 14.4
24V Charging status (Volts) = 24 – 28.4
Acid density:
Normal 1.28 Charge status good - none
1.20 Charge status half – charge
1.12 Charge status empty- charge

40 24-03-23
D5D Engine special tools
D5D Engine Overhauling special / General tools List
Special tools
Sl No Part Number Part Name Qty

1 9986485 Engine stand 1
2 9998671 Fixture 1
3 9993714 Puller Bolt 1
4 9993717 Quick Nut 1
5 9993722 Support 1
6 9996400 Impact Puller 1
7 9996671 Oil Wrench 1
8 9998007 Adapter 1
9 9998675 Puller plate 1 Additional tools
10 9998681 Rotation Tool 1 Lifting Eye M10 - 2no
11 9998682 Fixing Tool 1 Lifting Eye M12 - 2no
12 9998695 Installation Tool 1 Safety Belt 3Mts - 2no
13 11668409 Pilers 1 E 1714 - For glow plug
14 9992000 Handle 1 Slide Calipers
15 9998672 Installation Tool 1 Steel ruler - 6 Inch
16 9998673 Installation Tool 1 Dial Indicator - Mituttoyo
17 9998678 Measuring Tool 1 Torque Wrench - 0-25 Nm
18 9998687 Installation Tool 1 Torque Wrench - 25 - 100 Nm
19 9996400 Impact Puller 1 Torque Wrench - 100 - 350Nm
20 9998674 Adapter 1 Torx Socket - 8, 10, 12, 18 , 20
21 9996662 Pressure Gauge 1 Slide Calipers
22 9996685 Clamp 2 Depth Gauge
23 9998684 Installation Tool 1 Valve Spring compressor
24 9998696 Installation Tool 1 Magnetic Base
25 11668404 Installation Tool 1 Vernier Caliper
26 9998679 Timing Tool 1 Feeler gauge
27 11668408 Setting tool 1 Micro Meter 0-25, 25-50, 50-75, 75-100
28 9998685 Setting tool 1 Piston ring pliers

41 24-03-23
Thank You & Happy Learning

42 24-03-23

Volvo D5 Engine 2011

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Volvo D5 Engine 2011

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Volvo D5 Engine

 T = Exhaust gas turbocharger

 C = Charge air cooler

 m = Mechanical injection system pump pipe nozzle

Name plate: example

Volvo Construction Equipment SD110 compactor D5 engine

The rating plate (C) is fixed to the

Volvo Construction Equipment SD110 compactor D5 engine

The engine number (D) is stamped

Volvo Construction Equipment SD110 compactor D5 engine

The cylinders are counted consecutively

Looking onto the flywheel rotating to the

Looking onto the fly wheel

Volvo Construction Equipment SD110 compactor D5 engine

1. Crank case breather

Volvo Construction Equipment SD110 compactor D5 engine

1. Combustion air inlet

Volvo Construction Equipment SD110 compactor D5 engine

1. Lubricating oil sump

Volvo Construction Equipment SD110 compactor D5 engine

Volvo Construction Equipment SD110 compactor D5 engine

Volvo Construction Equipment SD110 compactor D5 engine

Volvo Construction Equipment SD110 compactor D5 engine

Volvo Construction Equipment SD110 compactor D5 engine

1. Additional cam for exhaust gas recirculation

Inlet valve opens briefly during the outlet cycle

This partial volume is sucked back in the next

Volvo Construction Equipment SD110 compactor D5 engine

 Remove the cylinder head hood

 Remove the gasket

 Turn the crankcase until reaching valve overlap

Outlet valve is not yet closed, inlet valve begins to open

Volvo Construction Equipment SD110 compactor D5 engine

Volvo Construction Equipment SD110 compactor D5 engine

Set inlet valve

 Fix magnet of the rotation angle disc.

Set inlet valve

Volvo Construction Equipment SD110 compactor D5 engine

 Tighten locking nut

 Perform the setting procedure on every cylinder

Volvo Construction Equipment SD110 compactor D5 engine

Speed sensor – No adjustment,

Volvo Construction Equipment SD110 compactor D5 engine

Governor adjustment screws

Full load “G”

NA based fuel charge “J”

Volvo Construction Equipment SD110 compactor D5 engine

Test jig available on order

Governor testing & calibration

Volvo Construction Equipment SD110 compactor D5 engine

2. Engine serial number

4. Injection Timing shaft ID

Proto Paver EP code : 753 754 757 756

Volvo Construction Equipment SD110 compactor D5 engine

Lo = Basic pump dimension

1/ 100 mm = Pump length tolerances

The spacer size (Ts) must be calculated as follows

TS equals EK minus (LO plus “A DIVIDED BY 100

Volvo Construction Equipment SD110 compactor D5 engine

Procedure Change Engine V belt

V – belt AVX 11 (Width 11 mm)

Belt tensioning – Automatic tensioning

Volvo Construction Equipment SD110 compactor D5 engine

Excess fuel start solenoid