Volvo EC500F L5 D13J Engine Cylinder Compression Test

Here is the instruction show you guide on how to perform cylinder compression test for Volvo EC500F L5 D13J EU Stage V and D13 US Tier 4 final MY2019 engine.

 

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Steps:

1.Place the machine in service position

2.Open the engine hood.

3.Remove the crankcase ventilation hose (1 clamp, 2 bolts).

4.Remove the valve cover (20 bolts).

5.The valve clearance has to be correct in order to obtain a correct reading of the compression pressure. If needed, adjust the valves

6.Remove the injectors

NOTE!

Do not remove the injector sleeves.

7.Clean the injector sleeves with the brush/brushes included in the set: 88800550 Brush set.

8.Check that all 88800511 Adapter (steel sleeve) (6 pcs.) have their O-rings. Lubricate the O-rings. Install 88830235 Nipple (6 pcs.) to all 88800511 Adapter (steel sleeve).

9.Install 88800511 Adapter (steel sleeve) with 88830235 Nipple on the unit injector’s space in the cylinder head. Tighten the adapters using the unit injector’s attaching yoke.

Tightening torque: 40 Nm (30 lbf ft)

Connect the associated 9998665 Adapter to 88800511 Adapter (steel sleeve) with 88830235 Nipple in the first cylinder.

NOTE!

Remember that the torque is only to keep the adapter in place during the test.

10.Install the rocker arm shaft using 88800352 Lifting tool and 88880003 Bracket. Tighten the bolts uniformly along the entire rocker arm shaft so that it is not installed incorrectly, and check that the push rods fit correctly with the camshaft bearing

11.Fasten the cable tie so that the unit injector’s rocker arm is held in place by the rocker arm. This is done so that the camshaft does not touch the rocker arm and cause engine damage.

12.Insert the VCB control valve dummy. Check that the seal ring is installed correctly before the bolts on the VCB control valve dummy are tightened.

Testing compression pressure

NOTE!

When cranking the engine with the starter motor, the parking brake must be applied.

13.Set your equipment for compression testing:

9988539 Pressure gauge to 9998665 Adapter on the first cylinder.

Crank the engine using the starter motor for 5–10 seconds until the needle on the compression gauge stops (max. compression value).

Repeat the procedure for all the other cylinders.

The difference in compression pressure should not exceed 15%.

 

NOTE!

Do not run the starter motor for longer than 10 seconds at a time. Let the starter motor rest for 60 seconds between cranks.

Assembling

14.Remove the VCB control valve dummy. Loosen the bolts on the rocker arm shaft uniformly along the entire rocker arm shaft, so that the shaft is not subjected to uneven loading. Remove the bolts and put away: 88800352 Lifting tool and 88880003 Bracket. Remove the rocker arm shaft carefully.

15.Remove the compression gauge 9988539 Pressure gauge, 9998665 Adapter, 88830235 Nipple and 88800511 Adapter (steel sleeve).

16.Install the injectors

17.Install the valve cover. Tightening torques

18.Install the crankcase ventilation hose.

19.Close the engine hood.

20.Restore the machine and check function.

More repair case for Volvo machine,please refer to Volvo excavator trouble repair