Información de servicio

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Árbol de levas, sustitución 215 Información de servicio 19/08/2019
Perfil:
EC480D L Volvo

Árbol de levas, sustitución

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Válido para opción/configuración

Modelo: Nº de opción Opción Configuración
EC480D L Volvo 8288863 Engine D13H EU Stage IIIB
EC480D L Volvo 8290446 Engine D13H US Tier 4 interim

Válido para números de serie

Modelo: Lugar de producción Inicio de número de fabricación Parada de número de fabricación
EC480D L Volvo Changwon 210001 260000

Op nbr 215-042

Total procedure time (hr): 8.50

Tool::
88800352 Herramienta de elevación
9993590 Piñón
9998264 Herramienta de elevación
88880003 Fijación

Sealant 11705751

7 bolts M12x80 mm or spacers

NOTA:
To ensure that the correct spare parts are ordered, the article number must agree with the number stamped into the front
end of the camshaft.

This operation also includes tools and times necessary for applicable parts of the following actions:

Válvulas, reglaje

Removing

1. Place the machine in the service position B, see Posiciones de servicio.

2. Remove the DPF hood, radiator hood and the rear cover.

3. Remove the engine room cowl frame with the engine hood using a lifting device.

4. Remove the exhaust pipe.

5. Remove the crankcase ventilation hose.

 Figure 1
Crankcase ventilation hose

6. Remove the valve cover.

Figure 2
Bolts, valve cover

7. Remove the plates between the engine room and the pump room.

Figure 3

1. Plate

8. Remove the protective cover from the flywheel housing.

9. Install 9993590 Piñón and a ratchet handle.

 Figure 4

1. Ratchet handle
2. 9993590 Piñón
3. Extension bar

10. Rotate the engine in its rotational direction (clockwise) until the piston in cylinder no 1 is at top dead centre, TDC
on the camshaft.

Figure 5
TDC marking on camshaft
 Figure 6

1. 0–marking

11. Disconnect the hoses and pipes to make the bolts for the engine’s lifting bracket accessible.

Figure 7
Disconnecting hoses and pipes to make bolts accessible

12. Use a lifting device and remove the lifting bracket.

Weight: approx. 18 kg (40 lbs).
 Figure 8
Engine lifting bracket

13. Remove the upper timing gear case.

Figure 9
Bolts, upper timing gear case and vibration damper

14. Remove the camshaft’s vibration damper.

NOTA:
Handle the vibration damper with care. Damage to the vibration damper can cause vibrations and engine damage.

15. Check that the engine transmission has the correct setting. Put a Ø6 mm drill in the transmission plate's settings
hole. The drill must then have the two marked teeth on each side.
Remove the camshaft gear.
 Figure 10
Camshaft gear

1. Marked teeth
2. Drill, Ø6 mm

16. Remove the exhaust brake valve (VEB-dummy).

Figure 11
Exhaust brake valve (VEB-dummy)

17. Loosen the bolts on the rocker arm shaft an equal amount of turns so that the rocker arm shaft does not distort.
Remove the bolts and fit: 88800352 Lifting tool and 88880003 Bracket.
Remove the rocker arm shaft.
 Figure 12

1. 88800352 Herramienta de elevación

18. Remove the remaining bolts holding the camshaft. Remove the camshaft’s bearing cap using 9996400 Extractor de
impacto and 9998674 Adaptador.
NOTA:
Check that the bearings caps are marked 1–7. The cap for cylinder no 1 is farthest from the engine’s flywheel end.

Figure 13
Bearing cap numbering
 Figure 14
Bearing cap, removing

19. Carefully lift out the camshaft with the 9998264 lifting tool. Weight approx.: 40 kg (88 lbs).

Figure 15
Lifting the camshaft

20. Remove the bearing shells from the bearing brackets. Check the bearing brackets and the bearing shells for wear.

Installing

21. Lubricate the lower bearing shells with engine oil and insert them in the bearing brackets.

Figure 16
Lubrication lower bearing shells
NOTA:
Use new bearing shells and axial bearings for the seventh cap. The new camshaft must not be run with old
bearings. Only oil the bearing shell's contact surface with the camshaft. The surface between the bearing bracket
and the bearing shell must be dry.
22. Fit the new camshaft carefully with 9998264 Herramienta de elevación.
Remove the lifting tool from the camshaft.

23. Fit the bearing caps to the respective bearing brackets, in accordance with their mark. Fit the bolts, but do not
tighten them.
NOTA:
Check that the camshaft rotates freely after fitting each bearing cap. If the camshaft rotates slowly, check the last
fitted bearing cap.

24. Use M12x80 mm bolts or fit spacers to bearing caps 6 and 7 as shown in the photo: one 40 mm (1.6 inch) long
and 19 (0.75 inch) mm internal Ø and two that are 40 mm (1.6 inch) long with around 12 mm (0.5 inch) internal Ø
and max 18 mm (0.7 inch) external Ø. Actions to be taken to ensure that the camshaft is in the correct position for
adjustment of the gear backlash.

Figure 17
Spacers

25. Check that the piston in cylinder 1 is at top dead centre, 0°, on the flywheel. The TDC mark on the camshaft must
be between the marks on the bearing cap.

26. Fit the crankshaft gear and the camshafts’ vibration damper. Check that the engine transmission has the correct
setting. Put a Ø6 mm drill in the transmission plate's settings hole. The drill must then have the two marked teeth
on each side.
Fit new bolts and torque tighten according to specification, see Transmisión del motor, par de apriete.
NOTA:
Use new bolts.
 Figure 18

1. Marked teeth
2. Drill, Ø6 mm

NOTA:
Handle the vibration damper with care. Damage to the vibration damper can cause vibrations and engine damage.

Gear backlash, check

27. Fit a dial indicator with a magnetic stand so that the probe tip on the dial test indicator rests on a tooth of the
camshaft pulley. Lock the idler gear with a screwdriver. Check the gear backlash by turning the camshaft pulley in
both directions. Read off the value on the dial indicator. For correct value, see Transmisión del motor,
especificación. If the backlash is not correct you must readjust. Torque-tighten the bolts according to Transmisión
del motor, par de apriete.

Figure 19

Gear backlash, adjusting

28. Loosen the bolts on the idler gear and insert new bolts. Use new bolts as they can only be angle tightened once.
Put a 0.10 mm (0.0039 in) feeler gauge on the pressure side between the camshaft gear and the idler gear. Adjust
the idler gear so that the feeler gauge is difficult to withdraw. Tighten the bolts according to: Transmisión del
 motor, par de apriete.

Figure 20

29. Check the gear backlash once again with the dial indicator.

Installing (continued)

30. Remove the spacers.

31. Lubricate the valve yoke and the camshaft cams with engine oil.

32. Fit the rocker arm shaft using 88800352 Lifting tool. Tighten the bolts along the entire rocker arm shaft evenly so
that it is not installed unevenly and to check that the push rods fit the camshaft bearing properly. Torque tighten
the camshaft and rocker arm shaft according to specification, see: Eje de balancín, par de apriete.
Weight rocker arm shaftapprox.: 36 kg (79 lbs).

33. Add sealant to the mating surfaces according to the figure and install the upper timing gear case.

Figure 21
Sealant added to the mating surfaces

1. Sealant

34. Install the exhaust brake valve (VEB-dummy).

35. Adjust the valves according to Válvulas, reglaje.

36. Use a lifting device and install the engine’s lifting bracket.
Weight: approx. 18 kg (40 lbs).

37. Connect the hoses and pipes.

38. Install the protective cover for the flywheel housing.

39. Install the valve cover. Torque-tighten the bolts according to Tapa de válvulas, pares de apriete.

40. Install the crankcase ventilation hose.

41. Install the exhaust pipe.

42. Install the engine cowl frame, muffler hood and the radiator hood.