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Volvo EC360C L EC360CL Excavator Service Repair Manual Instant Download.pdf

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Service Information
Document Title: Function Group: Information Type: Date:
Engine, description 200 Service Information 2014/12/23
Profile:
EXC, EC360C L [GB]
Engine, description
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The D12D is the model number of the Volvo 12 liter engine.
The engine is a 6-cylinder, 4-stroke, direct injection diesel with a 12 liter cylinder volume, turbocharger, charge air
cooler and electronic controlled fuel injection, EMS (Engine Management System).
The serial number of the engine is to be found stamped in the cylinder block on the rear left side.
The cylinder head is of cast iron and manufactured in one piece which is necessary in order to provide stable
bearings for the overhead camshaft.
The cylinder liner is sealed against the coolant casing with rubber rings.
The D12D has a four-valve system and overhead camshaft.
The engine timing gear transmission is located at the front of the engine on a 10 mm thick steel plate bolted to the
cylinder block.
The crankshaft is drop forged and has induction hardened bearing surfaces and fillets.
The engine is force fed lubricated by an oil pump which is gear driven from the engine crankshaft via an
intermediate gear
The fuel system for D12D has electronic control with unit injectors one for each cylinder and which operate at a very
high pressure.
The fuel feed pump is a gear driven type and is driven from the engine timing gear with the same gear.
Figure 1
Engine, structure
1 Hand pump 9 Air conditioner compressor 17 Fuel feed pump
2 Water separator 10 Lifting bracket 18 Oil pan
3 Fuel filter 11 Coolant temperature sensor 19 Engine oil drain valve
4 From radiator 12 Flywheel housing 20 Fan belt
5 Engine oil filler 13 Speed sensor 21 Crankshaft pulley
6 From charge air cooler 14 Starter motor 22 Fan drive and pulley
7 Alternator belt 15 Breather 23 Belt tensioner
8 Alternator 16 E-ECU 24 Engine oil filter
Service Information
Document Title: Function Group: Information Type: Date:
Engine, identification 200 Service Information 2014/12/23
Profile:
EXC, EC360C L [GB]
Engine, identification
Identification plate
The engine model, serial number and performance data are stamped on an identification plate which is attached on the
cylinder head cover. The engine model designation and serial number must be indicated when ordering spare parts.
Figure 1
Engine identification plate location
Service Information
Document Title: Function Group: Information Type: Date:
Engine, removing 210 Service Information 2014/12/23
Profile:
EXC, EC360C L [GB]
Engine, removing
Op nbr 210-070
9998257 Lifting tool
9998547 Lifting device
WARNING
Risk of burns - stop the diesel engine and allow it to cool down before starting any work.
WARNING
Removal of residual pressure from the circuit must be done prior to any maintenance.
NOTE!
Cable ties and clamps that secure hoses and electrical wiring must be removed and then replaced when installing.
1. Place the machine in the service position B. See091 Service positions
2. Turn off the battery disconnect switch.
3. Loosen two screws and connect hose (1). and then drain the hydraulic oil into a suitable collection container.
Figure 1
Hydraulic oil tank, drain
4. Drain the coolant in a collection container.
5. Remove under cover (1).
Figure 2
Removal, under cover
6. Remove silencer hood (1).
Figure 3
Removal, silencer hood
7. Remove screws (1) and open radiator hood (2).
Figure 4
Opening, radiator hood
8. Remove the rear cover of the engine hood.
Figure 5
Removal, cover
9. Open the engine hood and remove the cowl mounting screws.
10. Remove cowl (1) using a lifting device.
11. Disconnect wire harness connector (2), hoses (3), and remove expansion tank (1) with the bracket.
Figure 6
Removal, expansion tank
12. Remove foot step (1).
Figure 7
Removal, step
13. Disconnect radiator hose (2) and upper charge air cooler hose (1).

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Volvo EC360C L EC360CL Excavator Service Repair Manual Instant Download.pdf

  • 1. Service Information Document Title: Function Group: Information Type: Date: Engine, description 200 Service Information 2014/12/23 Profile: EXC, EC360C L [GB] Engine, description            The D12D is the model number of the Volvo 12 liter engine. The engine is a 6-cylinder, 4-stroke, direct injection diesel with a 12 liter cylinder volume, turbocharger, charge air cooler and electronic controlled fuel injection, EMS (Engine Management System). The serial number of the engine is to be found stamped in the cylinder block on the rear left side. The cylinder head is of cast iron and manufactured in one piece which is necessary in order to provide stable bearings for the overhead camshaft. The cylinder liner is sealed against the coolant casing with rubber rings. The D12D has a four-valve system and overhead camshaft. The engine timing gear transmission is located at the front of the engine on a 10 mm thick steel plate bolted to the cylinder block. The crankshaft is drop forged and has induction hardened bearing surfaces and fillets. The engine is force fed lubricated by an oil pump which is gear driven from the engine crankshaft via an intermediate gear The fuel system for D12D has electronic control with unit injectors one for each cylinder and which operate at a very high pressure. The fuel feed pump is a gear driven type and is driven from the engine timing gear with the same gear. Figure 1 Engine, structure
  • 2. 1 Hand pump 9 Air conditioner compressor 17 Fuel feed pump 2 Water separator 10 Lifting bracket 18 Oil pan 3 Fuel filter 11 Coolant temperature sensor 19 Engine oil drain valve 4 From radiator 12 Flywheel housing 20 Fan belt 5 Engine oil filler 13 Speed sensor 21 Crankshaft pulley 6 From charge air cooler 14 Starter motor 22 Fan drive and pulley 7 Alternator belt 15 Breather 23 Belt tensioner 8 Alternator 16 E-ECU 24 Engine oil filter
  • 3. Service Information Document Title: Function Group: Information Type: Date: Engine, identification 200 Service Information 2014/12/23 Profile: EXC, EC360C L [GB] Engine, identification Identification plate The engine model, serial number and performance data are stamped on an identification plate which is attached on the cylinder head cover. The engine model designation and serial number must be indicated when ordering spare parts. Figure 1 Engine identification plate location
  • 4. Service Information Document Title: Function Group: Information Type: Date: Engine, removing 210 Service Information 2014/12/23 Profile: EXC, EC360C L [GB] Engine, removing Op nbr 210-070 9998257 Lifting tool 9998547 Lifting device WARNING Risk of burns - stop the diesel engine and allow it to cool down before starting any work. WARNING Removal of residual pressure from the circuit must be done prior to any maintenance. NOTE! Cable ties and clamps that secure hoses and electrical wiring must be removed and then replaced when installing. 1. Place the machine in the service position B. See091 Service positions 2. Turn off the battery disconnect switch. 3. Loosen two screws and connect hose (1). and then drain the hydraulic oil into a suitable collection container. Figure 1 Hydraulic oil tank, drain 4. Drain the coolant in a collection container. 5. Remove under cover (1).
  • 5. Figure 2 Removal, under cover 6. Remove silencer hood (1). Figure 3 Removal, silencer hood 7. Remove screws (1) and open radiator hood (2). Figure 4 Opening, radiator hood 8. Remove the rear cover of the engine hood.
  • 6. Figure 5 Removal, cover 9. Open the engine hood and remove the cowl mounting screws. 10. Remove cowl (1) using a lifting device. 11. Disconnect wire harness connector (2), hoses (3), and remove expansion tank (1) with the bracket. Figure 6 Removal, expansion tank 12. Remove foot step (1). Figure 7 Removal, step 13. Disconnect radiator hose (2) and upper charge air cooler hose (1).
  • 7. Figure 8 Removal, radiator and charge air cooler hose 14. Disconnect hose (1) of engine oil remote filter bypass. Figure 9 Disconnect, hose 15. Remove radiator fan guard (1). Figure 10 Removal, radiator fan guard 16. Remove radiator fan (1).
  • 8. Figure 11 Removal, radiator fan 17. Disconnect turbocharger inlet hose (1). Figure 12 Disconnect, hose 18. Disconnect cab heater hoses on the engine block and coolant pump. Figure 13 Disconnect, hose 1. Cab heater hose on engine block 19. Open the machine right side cover. 20. Remove the main pump. See 913 Hydraulic pump, replacing 21. Disconnect the fuel line hoses (4 pcs). NOTE!
  • 9. Ports must be plugged after disassembling hoses. Figure 14 Disconnect, hose 22. Remove the pump gearbox coupling. See 442 Pump gearbox coupling assembly, replacing 23. Disconnect starter motor wire harness (1). Figure 15 Removal, wire harness 24. Disconnect inlet hose (2), outlet hose (1) on the engine PTO pump. Figure 16 Removal, inlet and outlet hose WARNING Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage. 25. Remove the compressor from the engine.
  • 10. Figure 17 Removal, compressor 26. Disconnect the wire harness for all engine sensors. 27. Remove cover (1) and disconnect main wire harness (2). Figure 18 Removal, cover 28. Disconnect radiator lower hose (1) and charge air cooler lower hose (2). Figure 19 Disconnect, radiator and charge air cooler hose 1. 2. Radiator hose Charge air cooler hose 29. Disconnect the engine oil remote hose (1).
  • 11. Figure 20 Disconnect, hose 30. Remove the engine mounting screws (4 places). Figure 21 Removal, mounting screws WARNING The parts are heavy. Take appropriate safety precautions. 31. Fit tool 9998257 and connect 9998547 and a lifting device to the engine and remove the engine slowly.
  • 12. Service Information Document Title: Function Group: Information Type: Date: Engine, installing 210 Service Information 2014/12/23 Profile: EXC, EC360C L [GB] Engine, installing Op nbr 210-072 9998257 Lifting tool 9998547 Lifting device NOTE! Cable ties and clamps that secure hoses and electrical wring must be removed and then replaced when installing. WARNING The parts are heavy. Take appropriate safety precautions. 1. Fit tool 9998257 and connect lifting device 9998547 and hoist the engine slowly and install the engine. 2. Install the engine mounting screws (4 places). NOTE! Pay attention to the positioning of the brackets, cushions, and mounting screws (front/rear) when assembling. Figure 1 Installation, engine 3. Connect engine oil remote hose (1).
  • 13. Figure 2 Connect, hose 4. Connect radiator lower hose (1) and charge air cooler lower hose (2). Figure 3 Connect, hose 1. 2. Radiator hose Charge air cooler hose 5. Install cover (1) and connect main wire harness (2). Figure 4 Installation, wire harness and cover 6. Connect wire harness for all sensors to the engine. 7. Install the compressor to the engine.
  • 14. Figure 5 Installation, compressor 8. Connect inlet hose (2) and outlet hose (1) of the engine PTO pump. Figure 6 Connect, hose 9. Connect wire harness (1) to the starter motor. Figure 7 Connect, wire harness 10. Connect the fuel line hoses (4 pcs).
  • 15. Figure 8 Connect, fuel hose 11. Install the pump gearbox coupling. See 442 Pump gearbox coupling assembly, replacing 12. Install the main pump. See 913 Hydraulic pump, replacing 13. Connect the cab heater hoses to the engine block and water pump rear side. Figure 9 Connect, hose 1. Cab heater hose on engine block 14. Connect turbocharger inlet hose (1). Figure 10 Connect, hose 15. Install radiator fan (1).
  • 16. Figure 11 Installation, radiator fan 16. Install radiator fan guard (1). Figure 12 Installation, radiator fan guard 17. Connect hoses (1) for remote engine oil bypass filter. Figure 13 Connect, hose 18. Connect radiator hose (2) and charge air cooler hose (1) on upper side.
  • 17. Figure 14 Connect, hose 19. Install foot step (1). Figure 15 Installation, foot step 20. Connect wire harness connector (2), hoses (3), and install expansion tank (1) with the bracket. Figure 16 Connect, wire harness and hose 21. Install the cowl using a lifting device. 22. Install the cowl mounting screws. 23. Install the engine rear cover.
  • 18. Suggest: If the above button click is invalid. Please download this document first, and then click the above link to download the complete manual. Thank you so much for reading
  • 19. Figure 17 Installation, cover 24. Install screws (1) and open radiator hood (2). Figure 18 Installation, radiator hood 25. Install silencer hood (1). Figure 19 Installation, silencer hood 26. Fill the hydraulic oil. See 173 Hydraulic system, changing oil 27. Fill the coolant through the expansion tank. See 261 Coolant, changing 28. Turn on the battery disconnect switch. 29. Start the engine and check for leaks and repair if needed.