POWER PACK

Engine
Technical data

Type Volvo TAD1340 VE

Power Out- put 256 Kw (343 hp) / 2100 RPM

Torque 1770 Nm (1305 lb.-ft.) / 1260 RPM

Weight (Wet) 1325 kg

Number of cylinders 6 in-line

Displacement 12.78 L (780 cubic in.)

Cooling system Liquid cooled

Combustion principle Turbocharged, after cooled, direct injection.

Air filtration Donaldson, dry type

Electrical system 24V

Exhaust system purifier Catalytic purifier/silencer

37
ENGINE OIL CLASSIFICATION

• The use of engine oil brands which have not been approved may lead to increased wear or engine
damage.
• Only engine oils of the same grade and SAE class should be used when topping up.
• The SAE class (viscosity) of the engine oil must be selected according to the average air
temperature for the time of year. Temperature limits for SAE classes should be taken as a guideline
which can be exceeded or undershot temporarily.
• Mineral based or semi-synthetic oils, can be used on condition that it complies with the quality
requirements.

OIL PRESSURE

Once the operating temperature has been reached, the engine oil pressure must not fall below:
• At idling speed 2,5 bar (39 psi)
• At operational speed (1100 rpm or higher) 3,7 - 5,2 bar (54 - 75 psi)
If the pressure falls below these values, stop the engine and determine the cause.

FACTORY FILLING OIL

• Shell Rimula R4L 15W-40

STARTER MOTOR

• Voltage: 24 V
• Output: 9,0 kW

ALTERNATOR

• Voltage: 28 V
• Current rating: 140 A (or 220 A, optional)

SYSTEM DESCRIPTION

The engine is equipped with an electronically controlled fuel management (EMS 2; Electronic Management
System), turbocharger, thermostatically regulated cooling system and electronic RPM control. There are no
control racks or mechanical linkages to adjust. This system improves fuel economy and vehicle performance.
The engine has no mechanical governor. Engine horsepower, torque, idle, and engine speed are contained
in the internal electronics. Therefore, there are no mechanical governor spring adjustments for idle and high-
speed control.

The EMS 2 diagnostic function monitors all engine sensors and electronics components, and recognizes
system malfunctions in the EMS 2 system, to protect the engine and to ensure operation in the event of serious
malfunction. If a critical fault is detected, the yellow warning light or red alarm light illuminate. If there is a serious
malfunction the engine will be shut down altogether, or the control unit will reduce the power delivered. Once
again a fault code is set for guidance in any fault tracing.

See separate engine manufacturer’s Operator Guide for further information.

38
EXPLANATION OF CONCEPTS

Pre-operational mode:
• Ignition key S0004 is in position “I” and the engine is not running.

Operational mode:
• Ignition key S0004 is in position “I” and the engine is running.

Emergency stop mode:

• One of the three emergency stop buttons has been pressed.

STARTING AND STOPPING THE ENGINE

Starting the engine

Do not run the starter motor longer than 20 seconds at a time. Allow the starter motor to
cool down for one minute before a new starting attempt.

Only start the engine with securely connected batteries.

Use the ignition switch to start the engine. Every time the engine is started, a warning signal sounds for a time
period set with a parameter, after this the engine starts.

When starting takes longer than a time period set with a parameter, the starting is stopped. After this, the
ignition switch must be turned to the zero position before restarting. When the engine is running the starting
is disabled.

The system interprets that the engine is running when engine revolutions and the engine’s oil pressure are above
values set with parameters.

The emergency stop function prevents the engine from starting and running.
The parking lights are on when the ignition switch is in the parking position (for more information, see Chapter
14. General electrics).

Conditions that prevent starting:

1. The emergency stop mode is on
2. The hydraulic oil level is too low
3. The gear is selected
4. Ignition key is in position “0”
5. Main fuse is remote tripped from the cabin

Activation of the fire suppression system causes the engine to shut down automatically
(When pressure drops, pressure switch S3045 opens).

39
TURNING OFF THE ENGINE

Use the ignition switch to stop the engine.

The engine is stopped automatically when engine revolutions and the engine’s oil pressure are below the values
set with parameters.

Conditions that result in the engine being shut down:

1. The emergency stop mode is on
2. The hydraulic oil level is too low
3. Ignition key is turned to position “0”
4. Ignition key may provide incorrect information (wiring problems)

SEO = Stop Engine Override function (Not in use with Volvo engines)

The system has an engine stop delay function in case a serious malfunction occurs. This way, when you press
the SEO (Stop Engine Override) button, the engine keeps running for a time period set with a parameter, during
which the machine can be moved. Use of this function will be recorded in the VCM alarm log.

Emergency steering function (option)

If the engine stops in an unusual way (the engine stops even though it has not been switched off with the ignition
key) the emergency steering pump will be controlled if the machine has the emergency steering function (for
more information, see Chapter: Steering).

INPUTS & OUTPUTS

Inputs

Actuator Name Signal level Module Connector pin

Ignition switch Engine running position 24 V / Float Chair XC1.8
(S0004)
Ignition switch Engine stop position 24 V / Float Chair XC3.21
(S0004)
Ignition switch Parking position of the 24 V / Float Dashboard XD3.18
ignition switch (S0004)
SEO button Engine stop over- ride 24 V / Float Dashboard XD3.19

Outputs
Actuator Name Signal level Module Connector pin
Ignition switch Operating voltage of 24 V / 0 V Chair XC2.22
ignition switch
Engine Engine stopping 24 V / 0 V Dashboard XD2.7

SEO button Operating voltage of SEO 24 V / 0 V Dashboard XD2.23

button
Engine Engine starting 24 V / 0 V Middle XM1.16

Engine Engine override (SEO) GND / Float Rear XR1.18

40
OVER-SPEED PROTECTION

When the engine speed is too high (engine over- speed), a

warning window appears on the dis- play. Over-rev value is
set with a parameter.

The warning window can be removed with the Back button.

The warning window disappears al- so when the engine
speed decreases below the warning limit, or if the over-rev
alarm window appears.

When the engine over-rev rises above the over- rev alarm
limit, an alarm window appears on the display. Remove
the alarm window with the Back button. The alarm window
disappears also when the engine speed decreases below
the alarm limit.

In an over-rev situation, if converter lock is in use, it will be

released when the over-rev alarm limit is exceeded. A text on
the alarm window informs about this.

JUMP-STARTING

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

If the battery is discharged, the engine can be started using jump leads and a donor battery.
• Connect the positive terminals first and then the negative battery terminals.
• Wait 5 minutes.
• Start the engine and allow to run for a short while.
• Remove the jump leads in the reverse order.

Do not use rapid charger / welding machine to start the engine. This may cause damage to
the VCM-System.

41
 Only perform jump-starting with separate batteries. Make sure that the donor battery and
the starter battery has the same nominal voltage. Otherwise a battery could be irreparably
damaged.

Only use insulated jump leads (cable cross section approximately 70 mm²) and insulated
terminal clamps. There is a risk of short circuit.

A discharged battery can freeze at about -10 °C; it must have thawed out before jump-
starting.

RESTARTING AN OUT OF FUEL ENGINE

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in the
working area.

Wear suitable protective gloves, protective clothing and safety goggles when handling fuel.
There is a risk of a blood poisoning.

Tighten any loose connections and replace damaged fuel and hydraulic oil lines, tubes and
hoses. Leaks can cause fires.

The system does not need to be bleed unless it has been run completely dry.
Venting is then done with the hand pump on the fuel filter bracket. Work on the
fuel system must be performed on a cold engine.

1. Fill the fuel tank with the recommended grade of fuel. If only partial filling is possible, add a minimum
of 40 liters (10 gallons) of fuel to the tank.

2. Start the engine and check for leaks. Shut down the engine before correcting leaks.

See separate engine manufacturer’s Operator Guide for further information.

42
CHANGING ENGINE OIL AND FILTER

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in the
working area.

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Be careful when handling hot oil. Wear suitable protective gloves, protective clothing and safety
goggles when handling oil.

Ensure safe and environmentally protective disposal of process materials and exchange parts.

1. Ensure that the machine is on an even surface, the parking brake is applied and movement is
prevented by, for example, with wheel chocks.
2. Ensure that the bucket is lowered and the boom is resting on stops.
3. Hook up oil evacuation hose to engine oil drain (if evacuation system is installed)

4. Remove the bottom drain plug (1) and drain the engine oil.
5. Turn on oil evacuation pump and pump oil from of engine (if
evacuation system is installed).
6. When the engine is empty, install the bottom drain plug.

43
7. Position a container to catch any spilt oil from near area of
oil filters.
8. Remove oil filters ( 1, 2 and 3 ) and place them into the
container for draining.
9. Clean the mating surface of the oil filter housing. Make sure
that no pieces of old oil seal are left behind.
10. Put a thin layer of engine oil on the seal rings of the new oil
filters.
11. Install the new oil filters. Tighten the two full- flow filters ( 2
and 3 ) ½ - ¾ turns after they just touch. Tighten the bypass
filter ( 1 ) ¾-1 turn after it just touches.

12. Fill engine with oil by filling point on engine

13. Pump correct quantity (max. 35 l with filters) and type
of oil into engine. Check right oil viscosity for different
ambient temperatures from section Technical data.

14. Check oil level.

15. Start the engine an let it run for 30 seconds. Check the oil pressure from the VCM -system.
16. Shut down the engine, wait for five minutes and check the oil level.

ENGINE MOUNTS INSPECTION

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in the
working area.

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

High temperature warning. A hot surface can cause injury.

Be careful when raising the engine. Raise just enough to replace rubber mountings. Ensure that
engine / torque convertor / hydraulic pumps wiring or coolant and hydraulic hosing are not
damaged.
44
1. Ensure that the machine is on an even surface, the parking brake is applied and movement is
prevented by wheel chocks.
2. Ensure that the bucket is lowered and the boom is resting on stops.
3. Install the frame locking pin.
4. Open engine covers to gain access to the engine.
5. Visually inspect the mounts looking out for:
• Condition of rubbers (deteriorated).
• Cracks.
• Bent or damaged components.
• Broken / loose bolts.
6. Check the tension of the engine mounting bolts, both on the engine and the frame. Tightening torques:
• (B) M20: 390 Nm (lubricated)
• (D) M14: 130 Nm (lubricated)

7. Check the deflection of the rubber isolators using a

bar to lever the engine mounts.
8. Replace the worn, cracked or oil/heat effected
rubber isolators.
• To replace isolators it will be necessary to
raise the engine slightly to allow removal.

45
9. Remove the engine mounting bolts. Lift the engine by using
appropriate lifting tools. Raise just sufficient to replace
isolators. Disconnect hydraulic hoses and wiring if required.
10. Install new rubber mountings.
11. Replace engine mounting bolts and lower the Powerpack
into position.
• Take care that nothing gets caught as the engine
goes back in. Remove the lifting tools.

12. Tighten the engine mounting bolts.

• Through bolts rubber pad: 640 Nm (lubricated)
13. Check the that engine / torque convertor / hydraulic pumps wiring or coolant and hydraulic hosing are
not damaged.

Tighten any loose connections and replace damaged fuel and hydraulic oil lines, tubes and
hoses. Leaks can cause fires.

REMOVING THE ENGINE

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in the
working area.

Ensure that lifting equipment is in good condition and correctly rated.

Ensure safe and environmentally protective disposal of process materials and exchange parts.

High-pressure oil spray hazard. The high-pressure oil spray can cause serious injury. Allow the
pressure to be released from the hydraulic circuit before opening the plugs or connectors.

Be careful when handling hot oil. Wear suitable protective gloves, protective clothing and safety
goggles when handling oil.

Read the general maintenance instructions before starting to work on the electric components
(Electric system maintenance and Battery maintenance).
46
 Tighten any loose connections and replace damaged fuel and hydraulic oil lines, tubes and
hoses. Leaks can cause fires.

Powerpack consists of an engine and a torque converter. It is recommended to remove it as an entity.

1. Ensure that the machine is on an even surface, the parking brake is applied and movement is
prevented by wheel chocks.
2. Ensure that the bucket is lowered and the boom is resting on stops.
3. Install the frame locking device.
4. Before performing any maintenance work on hydraulic
system, the hydraulic oil tank must be de-pressurized.
Pressure is released by using the directional valve on top
of the hydraulic oil tank. Ensure the valve closes fully
once all pressure is relieved.

5. Before removing the powerpack, drain the oil from the torque converter and the engine. Drain oil from
the torque converter is presented in manufacturers service manual. Drain oil from engine is presented
in chapter Powerpack, section Changing engine oil and the filter.
6. Turn the main switch to the OFF position.
7. Disconnect the wire harness from the terminals of the batteries and protect the connectors.
8. Isolate fuel taps on the tank and remove the fuel lines. Cap
and plug open lines.

9. Open the pressure relief valve in the radiator cap (A).

Ensure all the pressure has been released before opening
the cap fully.
10. Open the tap on the cooler drain hose (B) and empty the
entire contents into a container

47
11. Close the tap on the radiator drain hose and clamp it back in the storage position.

WARNING
Only carry out work on the cooling system at coolant temperatures below 50 °C. Wear
approved protective gloves, protective clothing and safety goggles when handling
coolant.

12. Disconnect wiring p-clamps and fire suppression hosing from the engine cover. Remove the fire
suppression tank assembly away from the engine if necessary.

Read the Fire suppression system instructions when disconnect the system: Only authorized
service people may remove the system.

13. Before removing the engine cover, support the cover using
a hoist. This is done to prevent personal injuries if the cover
falls or moves in an unusual way. Remove engine cover
mounting bolts 10 pcs. Using a hoist remove engine cover.

14. Disconnect coolant hoses ( 1, 2 ) from the header tank.

48
15. Remove the turbocharger cover ( 1 ).

16. Remove inlet and outlet pipes from turbo charger.

• Remove the clamps from inlet rubbers on the turbo and air cleaner assembly ( 3 ).
• Disconnect coolant hoses ( 1, 2 ) from the header tank.
• Remove the clamp which is holding the main intake pipe in position.
• Lift the main intake pipe from the machine using a hoist.
• Remove the charge air intake pipe ( 4 ).
• Remove the clamps from exhaust side of the turbo charger and muffler ( 2 ).
• Lift the exhaust section from the machine using a hoist.
• Ensure that the turbo inlet and outlets are covered to prevent the entry of foreign matter.
• Remove the clamps from the air cleaner assembly ( 5 ).
• Remove (if equipped) AdBlue systems urea hoses ( 6 ). Cap and plug open hoses.

49
17. Remove the air cleaner and the mounting brackets (C)
from the right side of the machine. Lift the air cleaner
from the machine using a hoist.
• Remove the ejector suction hose line bottom of
the air cleaner before removing it.

18. Remove the engine cooler assembly. Removal of engine cooler is presented in section “Removing
the engine cooler”
• Clearly label any hosing to the cooler assembly and disconnect any other attached equipment.
• Remove any straps that may be holding hoses etc. to the engine and equipment.
19. Disconnect the hydraulic hose from the bottom of the torque
convertor. Beware oil spill from the hose and convertor. Then cap
and plug the hydraulic lines.
20. Disconnect the other lines from the torque convertor pressure
regulator, lock up port, return port and breather. Beware oil spill
from the hoses. Cap and plug disconnected hose fittings.
21. Remove the hydraulic hosing from the hydraulic pumps mounted
on the convertor and engine. Beware oil spill from the hoses when
disconnected. Cap and plug disconnected hose fittings.

22. Disconnect and clearly label the electrical wiring from

the convertor sensors.
23. Support the cardan shaft cover with an overhead
hoist and open the cover fastening screws 4 pcs.
Remove the cover.

24. Remove the cardan shaft. Cardan shaft removing is presented in chapter Powertrain, section

50
REMOVING THE CARDAN SHAFT.

25. Disconnect and clearly label the electrical wiring from the alternator and all wiring to the engine.
26. Disconnect the wiring to the starter motor and EMS2 control. It is only necessary at this stage to
remove the wiring that is connected to the frame.
27. Loosen the engine mounting bolts that go
through the mounting rubber. Set the engine
stand up near the machine ready to sit the
engine in once it has been removed.

28. Connect a suitable engine-lifting device to the

engine manufacturers lifting points. Take the
weight of the engine with a hoist.

29. Remove the engine mounting bolts and carefully lift the engine and convertor from the machine
making sure nothing gets fouled as the engine is removed.
30. Disconnect the engine and converter assembly. Converter removal is presented in chapter
Powertrain, section Torque converter replacement.

51
 Powerpack weights approx. 2000 kg

Crushing hazard. The object being lifted is heavy. Assistance may be required when lifting the
object. Ensure that lifting equipment is in good condition and correctly rated. Always obey local
rules and safety regulations.

INSTALLING THE ENGINE

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand
the following instructions before servicing the equipment. To avoid potential damage and
injuries, carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

Ensure that lifting equipment is in good condition and correctly rated.

Ensure safe and environmentally protective disposal of process materials and exchange
parts.

High-pressure oil spray hazard. The high-pressure oil spray can cause serious injury. Allow the
pressure to be released from the hydraulic circuit before opening the plugs or connectors.

Be careful when handling hot oil. Wear suitable protective gloves, protective clothing and
safety goggles when handling oil.

Read the general maintenance instructions before starting to work on the electric
components (Electric system maintenance and Battery maintenance).

Tighten any loose connections and replace damaged fuel and hydraulic oil lines, tubes and
hoses. Leaks can cause fires.

Check the correct tightening torques for the bolts and screws from appendice Tightening
torques

Crushing hazard. The objects being lifted are heavy. Assistance may be required when lifting
an object. Always obey local safety regulations.

52
 Replace the bolts and screws with similar new ones ( same size, form, fit and
function).

Powerpack consists of an engine and a torque converter. It is recommended to install it as an entity.

1. Change over the needed components from the old engine to the new one cleaning and inspecting
them for damage and wear as you proceed. ie. starter motor, alternator etc.
2. Check the condition of the engine mounts. It is recommended to replace them.
3. Replace the engine mounting bolts and lower the
powerpack into position. Ensure no persons or equipment
gets caught as the powerpack is lowered into position.
Remove the lifting device.
4. Tighten the engine mounting bolts carefully from the
frame.

5. Connect the machine wiring to the engine EMS2 - system, starter motor, alternator etc. Use the labels
and electrical drawings as a guide.
6. Connect the hosing to the hydraulic pumps replacing all o-rings and seals.
7. Connect the hosing to the torque converter.
8. Install converter drive line flange to the converter. Installing the drive line is presented in chapter
Powertrain, section Installing the cardan shaft
9. Lift the cardan shaft cover into position using a hoist. Attach the cover fastening screws.
10. Using an overhead hoist install the engine cooler assembly into position. Installation of engine cooler
is presented in section Installing the engine cooler.
11. Connect the radiator and cooler pipes to the engine. Tighten all hose clamps and pipe retaining clamps.
12. Connect the wire harness going to mask assembly.
13. Install the inlet and exhaust pipes to the turbocharger.
• Check that the turbo has no foreign objects in it. Check the general condition of the turbo.
Check blades for pitting and bearing for excessive play.
• Lift the exhaust pipe and the inlet pipe back into position using a hoist.
• Tighten the clamps to both ends of the pipes.
• Install the cover to the turbocharger.
14. Install new fuel filters ( if not already installed ). Connect the fuel lines to the engine. Turn the taps back
to the open position. See section Restarting on out of fuel engine.

Replace any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires.

15. Using an overhead hoist install the unit inspection covers over the engine.
16. Connect coolant hoses to header tank.
17. Connect the AdBlue urea hoses to the dosing module (if equipped).
53
18. Fill the radiator until the tank is full. Check the coolant level.

Do not fill the header tank too fast. Filling too fast can create air pockets.

19. Connect all wiring and hosing to the engine cover.

20. Connect fire suppression hosing to the engine cover.
21. Fill engine with oil trough the filling point on engine. Filling engine with oil is presented in section
Changing engine oil and filter .
22. Top up the hydraulic tank. Oil level should be between sight glasses
in Hydraulic oil tank (A). In brake hydraulic oil tank (B) the oil level
should be between the sight glasses.

23. Top up the transmission oil. Fill transmission with oil is presented in chapter Powertrain, section
Filling instructions.
24. Open the hydraulic hose connection and plug connections. Prime all variable displacement type
pumps case drains with hydraulic oil. Priming the pumps and bleeding the suction lines is presented
in chapter General hydraulics, section Bleeding the suction lines. When the pumps are primed attach
all the hoses which where removed from the pumps.

Do not start the engine before all piston pumps are primed and air is bled from the system.

25. Check the condition of the batteries before connecting the wire harness to the battery terminals.
Battery maintenance is presented in chapterGeneral repair instructions, section Battery maintenance
26. Turn the main switch ON.
27. Crank the engine with the ignition key and ensure oil pressure is within the correct range on the gauge.
If the engine fires up before the oil pressure comes up, immediately turn the engine off.
28. Once the correct oil pressure is reached, start the engine and check for leaks. Check that the oil
pressure for both the engine and the transmission read the correct pressure in display gauge window.
Leave the expansion tank cap open until all the air has left the system. Check the coolant level. Check
the cooling system visually for any leaks. Shut down the engine after approximately 1 minute.
29. Check all fluid levels (engine, transmission, hydraulics, coolant).
30. Restart the engine.
31. Check the A/C conditioner motor is turning when turned on.
32. Check from the VCM - system display unit that there are no active alarms.
33. Check from VCM - system display unit that the engine has no faults and all the pressures are correct.
34. Check that the machine functions are correct ( bucket can be lifted, lowered and tilted; steering is
working normally ).

54
FUEL SYSTEM

1 Air vented valve 2 Bypass valve

3 Fuel pump 4 Filter housing with hand pump
5 Main filter 6 Prefilter
7 Water trap with sensor 8 Tank
9 Fuel tank return line 10 Fuel tank intake line
11 Cooling coil 12 Engine fuel intake

55
SYSTEM DESCRIPTION

1 Fuel Tank 2 Control unit cooling coil

3 Primary fuel filter with water trap 4 Fuel pump
5 Fuel filter 6 Filter housing with hand pump
7 Fuel injectors 8 Bypass valve with purging valve

Engine is equipped with an electronically-controlled unit injector for each cylinder which works at a very
high pressure. The pressure is generated mechanically by the overhead camshaft, via the rocker arms. Actual
injection is controlled electronically by the control unit (EMS 2).

The fuel is drawn from the tank to the suction side of the fuel pump through the control unit cooling coil and
the primary filter (with water trap). The fuel pump feeds the fuel through the fuel filter to the cylinder head,
which supplies each unit injector with fuel via an annular space around each injector. The fuel then flows out
at the front edge of the cylinder head through the bypass valve. Excess fuel from the bypass valve is mixed
with fuel in the suction side in the filter housing, and drawn back to the fuel pump. The bypass valve also has
an integrated purging valve which automatically vents the system, allowing a small volume of fuel to flow back
to the tank. Fuel tank capacity is 420 l.

See the ToolMan “VOLVO Workshop manual” for further information.

56
FUEL FILTERS

Fuel prefilter and main filter remove fine particles from the fuel before it passes through the fuel injection
system.

Fuel filters are essential in protecting fuel system components from contaminants that may be in the fuel.
These contaminants can block fuel injectors causing engine malfunction and deterioration. Dirt, rust, scale
and water are the major impurities present in fuel. These impurities can originate from dirty and rusty storage
tanks and, as the vehicle ages, from corrosion within the fuel system components.

1 Main filter
2 Hand pump
3 Prefilter
4 Water trap
5 Fuel return line tap
6 Fuel intake line tap

Do not fill the new fuel filter with fuel before assembly. There is a risk that contamination could get
into the system and cause malfunctions or damage.

Replacing of the fuel filter elements is presented in the VOLVO Operator’s manual.

FUEL LINES

All hoses in and out of machinery should be replaced during major overhaul and/or after a maximum of five
years of service.

Use only genuine parts.

Replace any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires.

See the ToolMan “VOLVO Workshop manual” for further information.

57
FUEL GAUGE

The fuel level is measured with an analog sensor that is connected to the Middle module.

The fuel gauge is in the displays main window on the right-hand

side of the tachometer. The verti- cally aligned bars become green
according to the fuel level (all bars green= the tank is full). The symbol
of the gauge flashes if the fuel level is low.

It is also possible to check the fuel rate (L/h) and the total fuel used (L)
by scrolling through the help windows (?).

*For detailed information about signal level and scaling of the sensors see Chapter General Electrical System
section signal level and scaling of the sensors.

Inputs

Actuator Name Signal level Module Connector pin

Sensor Fuel level (B3011) 4...20 mA Middle XM3.8*

Outputs

Actuator Name Signal level Module Connector pin

Sensor Operating voltage of fuel level 24 V / 0 V Middle XM2.1
sensor
Sensor Earth of fuel level sensor GND Middle XM2.15

58
AIR CLEANING SYSTEM

SYSTEM DESCRIPTION

The outside air drawn into the engine passes through the air filter and is pulled into the turbocharger and
compressed. It then moves to the air-to-air charge cooler (heat exchanger) and is cooled. Next it flows to the
intake manifold and into the cylinders, where it mixes with atomized fuel from the injectors.

For optimum protection of the engine from dust and other airborne contaminants, service the dry type air
cleaners used when the maximum allowable air restriction has been reached, or every 250 hours, whichever
occurs first.

59
AIR FILTER

1 Pre-cleaner 2 Protection cap

3 Outlet tube 4 Outlet cover
5 Body 6 Safety element
7 Main element 8 Cover
9 Scavenge line

The SRB 18 air cleaner is a two-stage hybrid air cleaner with built-in high efficiency pre-cleaner and radial seal
sealing technology. SRB air cleaner is to be used with exhaust ejector. It is designed to operate with aspiration,
otherwise known as scavenging. Scavenging is accomplished by introducing a secondary airflow to the drop
tube on the air cleaner generally through the use of an ejector muffler. This flow pulls the separated contaminant
from the pre-cleaner and inserts it into the exhaust stream.

Built-in Strata pre-cleaner

The Strata pre-cleaner removes between 75 - 98% of the contaminate from the air before the air reaches the
main element.

Main element

Main element is the filter element in the air cleaner that removes around 99,9% of the air’s dust. The air flow
through the main element first.

Safety element

Safety element is the element that protects the engine during servicing of the main element and in a case of
the leak in the element.

60
Dust suction hose

The dust pre-cleaner is normally under a vacuum when the engine is running. Always to be used with a scavenge
system.

If the dust suction (scavenge) hose is removed or the suction hose has air leak the air
cleaner system will not work properly. This hose needs to be checked regularly to make
sure it is mounted tightly.

Servicing the air cleaner system

Cleaning and/or reusing dry paper type air cleaner elements is not recommended unless the cleaning method
used removes clogging without damaging the element. Inspection and cleaning of elements must be done in
accordance with the air cleaner manufacturer’s recommendations.

Gently pull the filters off the cleaner housing. Avoid knocking the filter against the housing.

See Donaldson General Maintenance and Service manual for further information about
overhauling the air filter

RESTRICTION INDICATOR

Electrical restriction indicator S3031 indicates the blockage of the air filter element. The VCM-system gives an
alarm message if the air filter gets clogged.

The indicator automatically resets itself after the filter is serviced.

See Donaldson General Maintenance and Service manual for further information about
overhauling the air filter.

EXHAUST SYSTEM
SYSTEM DESCRIPTION

Hot exhaust gas flowing from the exhaust manifold into the exhaust riser is used to drive the turbocharger.
After that the exhaust fumes will flow through the exhaust piping to the silencer which contains a exhaust
purifiers. Continuous particle burning and spark reduction take place in the exhaust purifiers. The purified
exhaust fumes exit through the exhaust piping.

The exhaust system is manufactured from stainless steel to resist corrosion. The pipe consists of double wall
construction, inner and outer metal exhaust wall. Between the double wall is heat lagging to reduce the exhaust
surface temperatures. This reduces fire risk.

Servicing the Exhaust system

Check exhaust manifold retaining bolts and other connections. See Maintenance manual for further
information.
61
EXHAUST PIPING

1 Exhaust pipe 2 Exhaust purifier

3 Band 4 Clamp
5 Clamp 6 Ejector
7 Ejector suction pipe 8 Supporting block

Exhaust purifier

The exhaust gases are led into the combined silencer and exhaust purifier (catalytic converter and clean up
section). The catalytic converter consists of ceramic structures with many small channels coated with an
active substance. The ceramic structures cannot be renovated or replaced as a separate item. The entire
exhaust purifier assembly has to be replaced if necessary. Exhaust pipes and the flexible hose(s) upstream
the purifier must be made from stainless steel, because any corrosion particles from the exhaust pipes will be
trapped in the catalyst and may cause wear or plugging of the catalyst.

Lower sulfur content in fuel allows better function of exhaust purifier. The sulfur content must not exceed 20
ppm (0,002%).

62
SERVICING THE EXHAUST PURIFIER

Exhaust purifier is basically maintenance free, no cleaning under normal operating conditions is needed.

REMOVING THE EXHAUST PURIFIER

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand
the following instructions before servicing the equipment. To avoid potential damage and
injuries, carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

High temperature warning. A hot surface can cause injury.

Ensure that lifting equipment is in good condition and correctly rated.

Exhaust purifier is mounted using supporting blocks and two mounting bands.

1. Allow the machine´s exhaust system to cool sufficiently

to handle.
2. Remove the step (1) and light cover.
3. Remove the cover on turbo charger (2 ) and fold the
cover on the engine (3).
4. Open fastening screws and remove the cover on exhaust
purifier (4).

5. Open the clamps and the mounting bands. Disconnect

the exhaust pipe from turbo charger to exhaust purifier.
• Exhaust purifier is mounted using supporting
blocks and two mounting bands.

63
6. Open clamps of tail pipe and ejector and remove them.
7. Remove exhaust pipe from the exhaust purifier.
8. Remove the exhaust purifier using a hoist.

INSTALLING THE EXHAUST PURIFIER

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

High temperature warning. A hot surface can cause injury.

Ensure that lifting equipment is in good condition and correctly rated.

1. Install the exhaust purifier using a hoist.

• Exhaust purifier is mounted using supporting
blocks and two mounting bands.
2. Connect the tail pipe to the exhaust purifier and tighten
the clamps and support.

3. Connect the exhaust pipe from exhaust purifier to the turbo

charger and tighten the clamps. Install the mounting bands
and tighten them.

64
4. Install the exhaust purifier cover (4) and tighten the fastening
screws
5. Install the cover of turbo charger (2).
6. Install the step (1) and light cover and fold down the engine
cover (3).

TURBOCHARGER

The turbocharger is designed to increase the overall power and efficiency of the engine. Power to drive the
turbocharger is extracted from the energy in the engine exhaust gas. A turbocharger can be broken down into
three basic pieces; a compressor cover, a centre housing rotating assembly, and a turbine housing.

SERVICING THE TURBOCHARGER

The good condition of the air purification system and its regular maintenance prolongs the service life of the
turbocharger. if the air filter system malfunctions, the condition of the turbocharger has to be checked and the
turbocharger replaced if necessary.

Incorrect engine shutdown procedure will greatly reduce expected turbocharger life.
Contact local engine dealer for further information about overhauling the
turbocharger.
The wrong turbocharger for the engine variant might not provide enough charge
pressure, which would reduce engine power.
65
REMOVING THE TURBOCHARGER

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

WARNING
High temperature warning. A hot surface can cause injury.

1. Remove the pipe to the charge air cooler ( 1 ).

2. Remove the turbocharger cover ( 2 ).
3. Disconnect intake and exhaust pipes ( 3 ).
• Cover the openings to protect against dust ingress
and foreign objects entering the intake system.
4. Remove oil and cooling pipes from the turbo charger ( 4 ).
Plug the lines.
5. Remove mountings bolts from the turbo charger.
6. Remove the turbo charger from the engine.

FITTING THE TURBOCHARGER

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

1. Check condition of mounting between turbocharger and manifold.

2. Clean all parts ready for fitting turbocharger.
3. Clean the gasket mounting face before fitting gasket.
66
4. Fit new gasket to turbocharger mounting flange.
5. Fit turbo charger into position on engine
6. Fit and secure mountings bolts to turbocharger.
7. Unplug and fit new gaskets to oil and cooling lines to the turbocharger.
8. Fit oil and cooling lines to turbocharger
9. Remove the protection covers from the turbocharger.
10. Ensure the turbocharger spins freely.
11. Check the pipes for damage and ensure the inside of the pipes are clean.
12. Fit the inlet side clamp and secure it.
13. Fit the exhaust side clamp and secure it.
14. Refit the turbocharger cover.
15. Start up the machine and check for leaks around the turbocharger.

Leaks around the turbocharger are very dangerous.

Check the correct tightening torque from the appendices. Tightening torques.

COOLING SYSTEM

MAIN COMPONENTS OF THE ENGINE COOLER

1 Blower pump P3311

2 Pressure relief valve V3381
3 EMS2
4 Water pump
5 Engine cooler A3361

67
SYSTEM DESCRIPTION

The engine is cooled by one cooler, A3361. Pump P3311 produces hydraulic pressure needed to rotate
cooler fan. Electronic Management System (EMS 2) controls the pump controller which is use to adjust the
blower pump. Less the EMS 2 feeds current to the pump controller, the faster the cooler fan rotate.

FUNCTIONAL DESCRIPTION OF THE COMPONENTS

Engine cooler pump P3311 (1.)

The capacity of the pump (1) is used to produce pressure

and flow for hydraulic motor in cooler A33611. The cooler
fan attached to the hydraulic motor cool the engine. Further
information about the pump is presented in chapter General
Hydraulics.

Pump controller (2) valve ( Y 3089 ) is used to adjust the pressure

of the pump according to the engine coolant temperature. The
pressure deter- mines the rotation speed of the cooler fan.

Pressure relief valve V3381

The normal maximum pressure in cooler motor circuit is 240

bar and it is controlled by Y3089. In case of a malfunction the
pressure relief valve V3381 limits the circuit pressure to 350
bar.

Engine cooler A3361

1. Charge air cooler

2. Radiator
3. Hydraulic motor

68
Radiator

The air flow created by the blower attached to the hydraulic motor cools the engine coolant.

Charge air cooler

The air flow created by the blower attached to the hydraulic engine cools the charge air flowing in the engine.

Coolant filter

The coolant filter help to maintain efficient engine heat transfer

by filtering solid contaminants from the coolant and by minimizing
corrosion and de- posits in the cooling system.
• Coolant filter must be changed every 1000 operation
hours.

WARNING
Only carry out work on the cooling system at coolant temperatures below 50 °C. Wear
approved protective gloves, protective clothing and safety goggles when handling
coolant.

CLEANING THE ENGINE COOLER CORES

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

69
 DANGER
Never open the cooler hatch, when the engine is running!

DANGER
Never start the engine when the cooler hatch is open!

WARNING
Always wear required personal protection, such as safety helmet, protective clothing,
safety boots, hearing protectors, safety goggles, etc., as dictated by company policy
or local regulations.

Be careful when using high-pressure cleaning units. Make sure you have a min. gap of half
meter between core and nozzle.

Make sure that power washer nozzle is not too close to the cooler core.

For general cleaning a high-pressure water cleaner with soap is sufficient.

1. Open the cooler hatches for proper cleaning.

2. Start the power washer and slowly move up and down the
core concentrating on a small area until the exit water is
free from dirt. HOT WATER CLEANING WITH SOAP (bio-
degradable detergent) CAN BE USED, MAX. PRESSURE
82 bar (1200 psi).
3. Continue this until the whole radiator is clean from one
side then start cleaning from the op- posite side.
4. Blow off excess water with air.

70
ENGINE COOLER TUBE AND SEALING REMOVAL

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

WARNING
Be careful when draining hot coolant. Wear suitable protective gloves, protective
clothing and safety goggles when handling coolant.

See the separate manufacturers service manual for further information.

WARNING
Only carry out work on the cooling system at coolant temperatures below 50 °C. Wear
approved protective gloves, protective clothing and safety goggles when handling
coolant.

Refer to the separate manufacturers service manual for the specifications for radiator overhaul.

71
REMOVING THE ENGINE COOLER ASSEMBLY

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

WARNING
Only carry out work on the cooling system at coolant temperatures below 50 °C. Wear
approved protective gloves, protective clothing and safety goggles when handling
coolant.

1. Ensure that the machine is on an even surface, the parking brake is applied and movement of the
machine is prevented by wheel chocks.
2. Ensure that the bucket is lowered and the boom is resting on stops.
3. Install the frame locking device.
4. Turn the main switch to the OFF position and lock it.
5. Ensure that the engine is cool.
6. Open the pressure relief valve in the header tank cap. Remove the header tank cap.
Expansion tank is equipped with a locking pressure release cap. When removing the cap, first lift the
lever to unlock the cap and wait for complete pressure evacuation before removing the cap.

Use extreme caution when removing the cap. A sudden pressure release from a heated cooling
system can result in a loss of coolant and possible personal injury (scalding, eye injury, etc.)
from the hot liquid.

72
7. Open the tap on the cooler drain hose and empty the entire
contents into a container. ( Connect the fluid quick fill system
nozzle to the adaptor, if the quick fill system is installed).

8. Close the tap on the radiator drain hose and clamp it back in the
storage position.
9. Disconnect wiring p-clamps and fire suppression hosing from the
engine cover. Remove the fire suppression tank assembly away
from the engine if necessary.
10. Support the engine covers before removal using a hoist. Remove
engine cover mounting bolts 10 pcs. Using a hoist remove engine
cover.

11. Before performing any maintenance work on hydraulic system, the hydraulic oil tank must be
depressurized. Pressure is released by using the directional valve on top of the hydraulic oil tank.
Ensure the valve closes fully once all pressure is relieved.

12. Loosen the clamps and remove the engine cooling outlet and
inlet pipes to the cooler (1). Seal the cooling system.
13. Loosen clamps and remove the outlet pipe from the cooler to the
intake manifold (2). Seal the exposed outlet system
14. Loosen clamps and remove the cooler inlet pipe from the
turbocharger to the cooler. (3). Seal the exposed intake system.

73
15. Remove any straps that may be holding hoses to the
mask, e.g. hoses to the header tank.
16. Disconnect the hydraulic hoses from cooler hydraulic
motor.
• Plug or cap the open lines.
17. Mark clearly and disconnect the electric cables.
18. Mark clearly and disconnect the wiring to the lights and
emergency stop button on the mask shroud.
19. Loosen the mounting bolts in the bottom of the mask
frame.
20. Use lifting slings and a hoist to support the mask lightly. Remove the mounting bolts.
21. Carefully lift the mask assembly from the machine making
sure that nothing catches as the assembly is removed.
• Mask assembly weighs approx. 600 kg
22. Remove the cooler assembly from mask.
• Use lifting slings and a hoist to support the cooler
lightly
• Remove the fastening screws 16 pcs.
• Carefully lift the cooler assembly from the mask.

Environment pollution hazard. Always obey local laws and environmental regulations when
recycling or disposing fluids and parts

INSTALLING THE ENGINE COOLER ASSEMBLY

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

DANGER
Work carefully around an engine that is running. Engine parts that are hot, or parts that
are moving, can cause serious injury.

Read the Fire suppression system instructions when connect the system: Only authorized
service people may install the system.

Check the correct tightening torques from the appendix - tightening torques.

74
1. Before refitting the cooler to the mask assembly, check the cooler for leaks and damages.
• Pressure test the radiator by slowly increase air pressure to a maximum pressure of 1,03 bar
(15 psi) and test for a minimum of 30 minutes.
• Check for signs of leakage around seals and gaskets in this 30 minute time frame.
• If there are no leaks, radiator is ready for installation to machine.
2. Refit the mask assembly on to the cooler.
• Check dampers condition.
• Use lifting slings and a hoist to support the mask
lightly.
• Carefully lift the mask assembly onto the cooler
making sure that nothing catches as the assembly
is refitted.
• Refit the fastening screws 16 pcs.

3. Mount the mask assembly on to the machine.

• Connect suitable lifting slings to the mask.
Carefully lift the mask assembly on to the machine.
• Tighten the mask fastening bolts. Remove the
lifting slings.
• Remove the lifting slings.

4. Connect the hydraulic hoses to the hydraulic motor.

5. Connect the wiring to the lights and emergency stop
button on the cooler shroud.
6. Connect and tighten the clamps to the engine cooling
outlet and inlet pipes to the cooler ( 1 )
7. Connect and tighten the clamps to the outlet pipe from
the cooler to the intake manifold ( 2 )
8. Connect and tighten the clamps to the cooler inlet pipe
from the turbocharger to the cooler. ( 3)

9. Sling engine covers and lift them into the position on

machine frame, fit and tensions bolts 10 pcs.

75
10. Reconnect all wiring and hosing to the engine cover.
11. Connect wiring p-clamps and fire suppression hosing to the engine cover
• Machines with optional FS1000 fire suppression system:
-- Recharge and commission fire suppression system as per Manufacturers Instructions
if fire suppression line has been disconnected.
12. Replace the coolant filter

13. Fill the radiator until the tank is full. Check the coolant level.
• Do not fill the system too fast because it tends to
create air pockets

14. Turn the main switch to ON position

15. Start the engine.
16. Check again for leaks. Run until the normal engine operating temperature is reached.
17. Stop the engine and check the coolant level. Fill if necessary.

REMOVING THE ENGINE THERMOSTAT

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

76
 WARNING
Only carry out work on the cooling system at coolant temperatures below 50 °C. Wear
approved protective gloves, protective clothing and safety goggles when handling
coolant.

1. Ensure that the machine is on an even surface, the parking brake is applied and movement is
prevented by wheel chocks.
2. Turn the main switch to OFF position
3. Ensure that the engine is cool.
4. Open the pressure relief valve in the header tank cap. Make sure all the pressure has been released.
Remove the header tank cap.
5. Drain the cooling system.
• Draining the cooling system is presented in section Removing the engine cooler.
6. Remove the heat shield screws ( 3 pcs. ) covering the
thermostat housing and take the shield out (1).
7. Remove the hose ( 2 ) from the thermostat housing

8. Remove the thermostat housing secure screws ( 2 pcs )

from the exhaust manifold.
9. Remove the thermostat housing screws ( 1 - 3 ) and take
the thermostat housing out.

10. Remove the thermostat from the housing.

Ensure safe and environmentally protective disposal of process materials and exchange parts.

77
INSTALLING THE ENGINE THERMOSTAT

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

1. Ensure the main switch is OFF

2. Visually inspect the thermostat housing for wear or damage. Clean all of the parts in clean fuel oil.
Dry all parts with compressed air.
3. Check the condition of the hoses to the thermostat, Replace, if necessary.
4. Install the new piston thermostat with new seal ring to the housing.
5. Install the thermostat housing to the exhaust manifold
and tighten all three screws by hand.

6. Install a screw (M8x20) with nut, washer and spacer

sleeve between the heel on the exhaust manifold and the
machined surfaces on the thermostat housing. Tighten
the nut so that the sleeve presses the thermostat housing
against the piston thermostat seal.

78
7. Tighten the thermostat housing screws, tightening
schedule 1-2-3.
8. Remove the tension screw.

9. Install and tighten two screws to the exhaust manifold.

10. Install the hose to the thermostat housing ( 2 )
11. Install the heat shield ( 1 ) and tighten the screws ( 3pcs.)

12. Install new coolant filter.

13. Fill the radiator with new coolant. Check for leaks.
• Do not try to fill the radiator too fast, because it tends to create air pockets.
14. Turn the main switch to ON position
15. Start the engine. Check again for leaks. Run until operating temperature is reached.
16. Stop the engine.
17. Check coolant level. Add, if necessary.

DANGER
Work carefully around an engine that is running. Engine parts that are hot, or parts that
are moving, can cause serious injury.

Check the correct tightening torques from the appendix - tightening torques.

79
REMOVING THE WATER PUMP

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in the
working area.

Do not attempt to drain the coolant until the engine has cooled down.

WARNING
Only carry out work on the cooling system at coolant temperatures below 50 °C. Wear
approved protective gloves, protective clothing and safety goggles when handling
coolant.

1. Ensure that the machine is on an even surface, the parking brake is applied and movement is
prevented by, for example, with wheel chocks.
2. Ensure that the boom is lowered and it is resting on the stops.
3. Turn the main switch to the OFF position
4. Ensure the engine is cool.
5. Open the pressure relief valve in the header tank cap. Make sure all the pressure has been released.
Remove the header tank cap.
6. Empty the cooling system.
• Draining procedure is presented in section Removing the engine cooler.

7. Loosen the clamps and disconnect the hoses going to the

water pump
• Remove the water pipe from the coolant pump and
the radiator union ( 1 ).
• Remove the coolant hose from the coolant pump ( 2 ).
• Remove the water pipe between the thermostat
housing and the coolant pump ( 3 ).

80
8. Remove the coolant filter.
9. Loosen and remove water pump housing bolts.

10. Remove the water pump from the engine by pulling it

straight out.
11. Remove the gear package from the water pump.

Ensure safe and environmentally protective disposal of process materials and exchange parts.

INSTALLING THE WATER PUMP

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

DANGER
Work carefully around an engine that is running. Engine parts that are hot, or parts that
are moving, can cause serious injury.

Ensure safe and environmentally protective disposal of process materials and exchange parts.

81
1. Install the new gear package to the water pump, using new seal rings.
• Lubricate the seal rings to make it easier to install.
2. Check for damages and clean the water pump housing.
3. Lubricate the water pump seal ring with clean engine oil. Install the seal ring to the groove in the
water pump housing.
4. Lubricate the water pump drive gear with clean engine oil.
5. Install the water pump to the engine, meshing the water pump drive gear with the bull gear.
• Ensure the water pump is in correct position before installing the bolts.
6. Install the water pump to gear case bolts and tighten the bolts evenly.
7. Reconnect the water pump hoses and tighten clamps.
8. Install new coolant filter.
9. Fill the radiator with coolant to the correct level.
10. Start the engine.
11. Run the engine to operating temperature, check for leaks.
12. Stop the engine and correct the leaks, if any.
13. Check the coolant level. Add, if necessary.

CHECKING AND ADJUSTING

NOTICE
It is very important, that the service password is not given to any unauthorized persons.
Any unauthorized use of the service menus may result in serious malfunctions. The
service password may only be given to a service person sufficiently trained by Sandvik
Mining.

CHECKING THE BLOWER PUMP PRESSURES

Only people who have been given specialized operation and service training are allowed to
perform operations, service, and adjustment procedures. Read and ensure you understand the
following instructions before servicing the equipment. To avoid potential damage and injuries,
carefully plan your work beforehand.

Only perform maintenance work when the machine is parked on a level, hard surface. Use the
appropriate tools and safety equipment for the task and be sure you understand how to use
them before performing any maintenance work. Replace or repair faulty tools and equipment.
When performing maintenance and repair work, ensure there are no unauthorized persons in
the working area.

1. Ensure that the machine is on an even surface, the parking brake is applied and movement is
prevented by wheel chocks.
2. Install the frame locking device.

82
Maximum pressure

3. Connect a 400 bar pressure gauge to the blow- er pump

test point.

4. Disconnect the electric connector Y3089 from the

blower pump controller.

5. Start the engine and operate it at full rpm. Record the gauge reading.
6. The pressure should be 240 bar. (24,0 Mpa).

Never adjust pump pressures when engine is running. The rotating cardan shaft can cause
serious injury.

7. If the readings do not match the specification:

• Shut down the engine and adjust the maximum
pressure by turning the adjustment screw (D).
8. Check the blower pump stand-by pressure.

83
Stand-by pressure

9. Connect a 400 bar pressure gauge to the blow- er pump test point.

10. Connect the electric connector Y3057 of bucket pump controller (A) to blower pump controller (B).
11. Start the engine and operate it at 1200 rpm. Record the gauge reading.
12. The pressure should be 25 bar (2,5 Mpa).

Never adjust pump pressures when engine is running. The rotating cardan shaft can cause
serious injury.

13. If the readings do not match the specification:

• Shut down the engine and adjust the stand-by
pressure by turning the adjustment screw (C).

14. Check the blower pump maximum pressure.

If necessary repeat the sections above until stand-by and maximum-pressure are correct.

When pressures are correct:

• Reconnect the electric connectors of the bucket pump
controller (A, connector Y3057) and the blower pump
controller (B, connector Y3089).

84
FORCED FUNCTIONS (REQUIRES SERVICE PASSWORD)

NOTICE
It is very important, that the service password is not given to any unauthorized persons.
Any unauthorized use of the service menus may result in serious malfunctions. The
service password may only be given to a service person sufficiently trained by Sandvik
Mining.

Forced functions windows are used for control the machine’s different functions by using the display
module’s buttons instead of the machine’s control buttons. A forced functions window can replace a broken
control actuator; for example, if the steering joystick is broken, the machine can be driven for service using
a forced functions window.

Test functions may cause unexpected movements of the machine. Always be sure when test
functions are done there is no-one beside the machine and the machine has enough free space.

Controlling the engine

The window is used for forcing the following functions:

boom control, bucket control, throttle, gearing, machine
control and starting/stopping the engine and braking (only
machines with five modules).

Choose the functions to be forced on the right- hand side

column (Off = function not forced, On = function forced).
On the left-hand side column, set the value according to
which the function is forced.

Forcing engine starting/stopping:

1. Select Engine Start/Stop as the function to be forced.
2. Set the forcing values for the control. Set the status of engine cranking in the left-hand side field (0 =
engine not started, 1 = engine started).
3. Set the status of engine running in the middle field (0 = engine not running, 1 = engine running).
4. Start the forcing by pressing and holding the SEND button. The forcing stays active until you release
the button. All forcings are deactivated also when you leave the window.
5. Stop the engine by setting the value 0 in the middle field and pressing the SEND button.
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A forced function controls the engine regardless of the situation, only emergency stop prevents the controlling.

Pressing the SEND button forces all the functions that are selected to be forced. If
you force multiple functions simultaneously, make sure that the forcing values are
logical.

Forcing the digital outputs of the modules

This window is used for forcing the digital outputs of each connector of a module on or off.
1. On the module menu (I/O Force), select the connector of the module whose outputs you want to force.
2. Press the Ok button, the forcing window of the connector you selected opens. The connector pin
values are shown according to their status when the window was opened.
3. Switch the output (or outputs) to be forced on or off. ”1” forces the output on, ”0” forces the output off.
4. Start the forcing by pressing and holding the SEND button. The forcing stays active until you release
the button.

The SEND button forces all the digital outputs of the connector that has been
selected to the status defined on the window.

Function Module Connector pin

Operating voltage of ignition switch Chair XC2.2
Engine stopping Dashboard XD2.7
Operating voltage of SEO button Dashboard XD2.23
Engine starting Middle XM1.16
Engine override (SEO) Rear XR1.18

The digital output of the operating voltage of the fuel level sensor:

Function Module Connector pin

Operating voltage of the fuel level sensor Middle XM2.1

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DIAGNOSTICS

Gauge windows

The sensor data on engine control is shown on gauge window 2:

• Engine oil pressure
• Engine coolant temperature
• Engine oil temperature
• Engine hours
• Transmission hours

Active alarms and warnings are shown with the following symbols on the gauge window (the symbols appear
on the left hand side of the symbol for the sensor that the alarm or warning applies to) :

Symbol Explanation
Warning description can be seen in alarm log.

Alarm description can be seen in alarm log.

The top of the gauge window also shows the bucket counter reading, the distance the machine has travelled,
and the clock.

Testing the buttons

This window is used for testing the position data of the ignition
switch and the functioning of the SEO button. When the function
is activated, the picture of a button on the right-hand side of the
symbol becomes black.
The positions of the ignition switch:

P Parking
I Electric power on
III Starting the engine

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The measurement data of the modules (requires service password)

NOTICE
It is very important, that the service password is not given to any unauthorized persons.
Any unauthorized use of the service menus may result in serious malfunctions. The
service password may only be given to a service person sufficiently trained by Sandvik
Mining.

The measurement data windows shows the values and statuses of the connector pins. The windows are used
as help in trouble shooting. Select the connector of the module you want on the measurements menu window
and press the Ok button. The measurement data window of the connector opens.

The connector pins for controlling the engine are listed in the ”Inputs” and ”Outputs” section Starting and
stopping the engine.

GENERAL TROUBLESHOOTING

General troubleshooting is presented in the engine manufacturer’s manual.

VCM SYSTEM TROUBLESHOOTING

Module No Alarm text Alarm log

Chair 64 No data received in SAE J 1939 from ECM X

Description 1: Contact failure between J1939 and CAN bus

Action 1: wire harness
• Disconnect connectors XC4.7 and XC4.8. Measure voltages of both connectors against earth.
• The voltage should be around 2-3 V. The machine’s power must be turned on and ignition key turned
into position 1 (power on).
• If there is no voltage in the connector pin, repair the cable.

Action 2: wire harness

• Turn the ignition key to position 0.
• Measure resistance between connector pins XC4.7 and XC4.8. Resistance should be around 55-65
Ohm.
• If resistance differs from the above, check terminal resistor and wire harness.

Action 3: wire harness

• Contact Sandvik Mining.

Module No Alarm text Alarm log

Chair 99 Engine over-rev warning X

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Description 1: Engine revolutions exceed warning limit
Action 1: Engine
• Decrease revolutions below warning limit.

Module No Alarm text Alarm log

Dashboard 65 Engine stop signal short to ground X
Dashboard 66 Engine stop signal short to external voltage X

Description 1: Short circuit in engine stop output.

Action 1: Coupling
• Remove the connector pin XD2.7 of the Dashboard module.
• Check whether the alarm stops, when you force the output in question in the I/O Forcing window
• (See section Forced functions, Forcing the digital outputs of the modules).
• If the alarm stopped, the fault is in wire harness, short circuit to earth.
• Repair the wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the Dashboard module is broken. Change the module.

Description 2: Voltage in the uncontrolled output of engine stop.

Action 1: Coupling
• Remove the connector pin XD2.7 of the Dashboard module.
• Check whether the alarm stops, when you force the output in question in the I/O Forcing window
• (See section Forced functions, Forcing the digital outputs of the modules).
• If the alarm stopped, the fault is in wire harness, short circuit to operating voltage.
• Repair the wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the Dashboard module is broken. Change the module.

Module No Alarm text Alarm log

Middle 87 Fuel level sensor (B3011) high error X
Middle 88 Fuel level sensor (B3011) low error X

Description 1: The sensor current value is too high, the cable or sensor has shorted to the voltage
Action 1: wire harness
• Measure the voltage from the sensor pole A, must be the same as the machine’s operating voltage.
• If not, fault in wire harness or Middle module connector pin XM2.1 (this will give a separate alarm).

Action 2: wire harness

• Measure the connection from sensor pole B to GND. The cable is connected to Middle module
connector pin XM2.15.

Action 3: wire harness

• Detach the cable for Middle module connector pin XM3.8 and measure the current to earth. With a
full tank, should be approx. 20 mA and with an empty fuel tank should be approx. 4 mA.

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Action 4: Module
• If the actions 1-3 do not correct the malfunctioning, the Middle module must be broken. Change the
module.

Description 2: The sensor current value is too low, the cable or sensor has shorted to GND
Action 1: wire harness
• Measure the voltage from the sensor pole A, must be the same as the machine’s operating voltage.
• If not, fault in wire harness or Middle module connector pin XM2.1 (this will give a separate alarm).

Action 2: wire harness

• Measure the connection from sensor pole B to GND. The cable is connected to Middle module
connector pin XM2.15.

Action 3: wire harness

• Detach the cable for Middle module connector pin XM3.8 and measure the current to earth. With a
full tank, should be approx. 20 mA and with an empty fuel tank should be approx. 4 mA.

Action 4: Module
• If the actions 1-3 do not correct the malfunctioning, the Middle module must be broken. Change the
module.

Module No Alarm text Alarm log

Middle 103 Engine start signal short to ground X
Middle 105 Engine start signal short to external voltage X

Description 1: Short circuit in the engine start output.

Action 1: Coupling
• Remove the Middle module connector pin XM1.16.
• Check whether the alarm stops when you force the output in question in the I/O Forcing window
• (See section Forced functions, Forcing the digital outputs of the modules).
• If the alarm stopped, the fault is in wire harness, short circuit to earth.
• Repair the wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the Middle module is broken. Change the module.

Description 2: Voltage in the uncontrolled output of engine start.

Action 1: Coupling
• Remove the Middle module connector pin XM1.16.
• Check whether the alarm stops, when you force the output in question in the I/O Forcing window
• (See section Forced functions, Forcing the digital outputs of the modules).
• If the alarm stopped, the fault is in wire harness, short circuit to operating voltage.
• Repair the wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the Middle module is broken. Change the module.

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Module No Alarm text Alarm log
Middle 110 Module supply pin XM2/1 short to ground X
Middle 111 Module supply pin XM2/1 short to external voltage X

Description 1: Short circuit in voltage supply

Action 1: Coupling
• Detach the Middle module connector pin XM2.1.
• Turn off the system’s operating voltage and turn the operating voltage on again.
• If the alarm is not repeated, the fault is in wire harness, short circuit to earth.
• When you have repaired the wire harness, restart the VCM System.

Action 2: Module
• If action 1 does not correct the malfunction, the Middle module must be broken. Change the module.

Description 2: Voltage in uncontrolled output of voltage supply

Action 1: Coupling
• Detach the Middle module connector pin XM2.1.
• If the alarm stops, the fault is in wire harness, short circuit to supply voltage.
• Repair the wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the Middle module must be broken. Change the module.

Module No Alarm text Alarm log

Rear 61 Engine bypass SEO used X

Description 1: Engine bypass (SEO) used

Action 1: Engine bypass
• No action needed. This will be recorded in the alarm log.

Module No Alarm text Alarm log

Rear 62 Engine Bypass signal short to ground X
Rear 63 Engine Bypass No Supply X

Description 1: Short circuit in the engine bypass output.

Action 1: Coupling
• Remove the Rear module connector pin XR1.18.
• Check whether the alarm stops when you force the output in question in the I/O Forcing window
• (See section Forced functions, section Forcing the digital outputs of the modules).
• If the alarm stopped, the fault is in wire harness, short circuit to earth.
• Repair the wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the Rear module is broken. Change the module.

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Description 2: No voltage in engine bypass output.
Action 1: Coupling
• Remove the Rear module connector pin XR1.18.
• Check whether the alarm stops when you force the output in question in the I/O Forcing window
• (See section Forced functions, Forcing the digital outputs of the modules).
• If the alarm stopped, the fault is in wire harness, short circuit to operating voltage.
• Repair the wire harness

Action 2: Module
• If action 1 does not correct the malfunction, the Rear-module is broken. Change the module.

Module No Alarm text Alarm log

Front 39 Rammer boom function not allowed. Engine not running.

Description: The engine not running.

Action 1: Engine.
• Start the engine

Action 2: Fault is in the engine’s SAE J1939 bus.

• Check the engine’s data that the rotation speed and oil pressure are correct. For more information,
see chapter Powerpack, section “Forced functions”.

Module No Alarm text Alarm log

Middle 200 Engine fan pump coil short-cut (high FB current) X
Middle 201 Engine fan pump control signal wire broken (no FB) X

Description: Impedance error in the engine fan valve coil.

Action 1: Wire harness
• Check on the diagnostics window for control movements whether there is current value for the coil
(see section Diagnostics, Diagnostics window for control movements).
• If the value is zero, detach the Middle module connector pin XM2.4, and measure the current
between the wire and earth (mA) with a multimeter.
• If there is no current, measure the pins XM1.4 between XM2.4.
• If the coil’s impedance is correct, the resistance between connector pins XM1.4and XM2.4 is
approximately 12-24 Ohm.

Action 2: Module
• If actions do not correct the malfunctioning, the Middle module is broken. Change the module.

Module No Alarm text Alarm log

Middle 202 Uncontrolled Engine fan pump signal (FB without control) X

Description: Uncontrolled Engine fan pump signal (FB without control).

Action 1: Wire harness
• Check on the diagnostics window for control movements whether the current value for the coil
changes when the movement is controlled and whether the value resets when the control joystick is
in the middle position (see section Diagnostics, Diagnostics window for control movements).
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• Remove the Middle module connector pin XM2.4 and measure the current with a multimeter against
earth (mA).
• If there is current without controlling the fault is in wire harness.

Action 2: Module
• If action 1 does not correct the malfunction, the Middle module is broken. Change the module.

Module No Alarm text Alarm log

Middle 203 Wrong parameter value in Engine fan pump control X

Description: Parameter error in the Engine fan pump’s control values.

Action 1: Parameter values
• Return the default / user parameters. For more information, see Chapter General electrical control,
section Parameter control.

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