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Volvo EC480D L EC480DL Excavator Service Repair Manual Instant Download.pdf

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Service Information
Document Title: Function Group: Information Type: Date:
Engine, identification 200 Service Information 2014/7/14
Profile:
EXC, EC480D L [GB]
Engine, identification
Identification plate 1
A decal with the software's ID-number, the engine's serial number and assembly plant is located on the valve cover to
ensure installation of correct ECU on the engine in production. On the back of the ECU, there is a decal indicating its
hardware number.
Identification plate 2
Engine designation, serial number, part number and assembly plant are stamped in one field on the engine block's left front
edge.
Assembly plants:
A = Skövde, Sweden
E = Curitiba, Brazil
F = Flen, Sweden
L = Lyon, France
Identification plate 3
The engine control unit (ECU) has its component number on a plate on the back.
Identification plate 4
The certification decal is located on the valve cover as well as on the left side of the machine's front frame.
Figure 1
Service Information
Document Title: Function Group: Information Type: Date:
Component locations 200 Service Information 2014/7/14
Profile:
EXC, EC480D L [GB]
Component locations
Figure 1
Engine, front side
1 Flywheel housing 7 Engine oil filter
2 P.T.O (Power Take Off) port 8 Oil pan
3 Valve cover 9 EGR cooler
4 Turbocharger 10 Starter motor
5 Turbocharger actuator 11 TDC mark checking port
6 Venturi pipe
Figure 2
Engine, back side
12 Fan pulley 20 Crankcase ventilation separator
13 Pre-heating coil 21 Oil level sensor
14 Engine oil filling port 22 Alternator
15 Dipstick gauge 23 Air conditioner compressor
16 Crankcase ventilation tube 24 Air pump
17 Air compressor 25 Air pump belt
18 Fuel feed pump 26 Alternator/Compressor belt
19 E-ECU 27 Fan belt
Service Information
Document Title: Function Group: Information Type: Date:
E-ECU, MID 128, changing
non-programmed ECU
200 Service Information 2014/7/14
Profile:
EXC, EC480D L [GB]
E-ECU, MID 128, changing non-programmed ECU
Op nbr 200-068
1. Park the machine in the service position A, see .
091 Service positions
2. Connect the VCADS Pro computer to the machine, and perform operation '28423-3 MID 128 control unit,
programming'.
3. When VCADS Pro 'MID 128 ECU, programming' window appears, follow the instructions for replacing E-ECU.
4. Turn OFF battery disconnect switch.
5. Remove the engine hood rear cover screws.
Figure 1
1. Screws
6. Remove the bracket.
Figure 2
1. Bracket
2. CNEI connector
7. Disconnect the CNEI connector.
8. Remove the air hose.
Figure 3
9. Remove screws from wire harness clamps, and disconnect the wiring harness connectors from E-ECU.
Figure 4
1. Screws
10. Remove screws fixing the fuel pipe and E-ECU.
Figure 5
1. Screw
2.
3.
Pipe
Screw
Put the fuel pipe away.
11. Remove 4 screws fixing the E-ECU and replace the E-ECU.
12. Install fuel pipe and screws.
Connect wire harness connectors to the E-ECU, and install wire harness clamp screws.
13. Install the air hose and bracket.
14. Install the engine hood rear cover, and the screws.
15. After replacing E-ECU, press OK button of VCADS Pro operation '28423-3 MID 128 control unit, programming'.
Now VCADS Pro starts the programming of software and parameters to the new E-ECU.
16. Start the machine and check that no error messages appear.

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Volvo EC480D L EC480DL Excavator Service Repair Manual Instant Download.pdf

  • 1. Service Information Document Title: Function Group: Information Type: Date: Engine, identification 200 Service Information 2014/7/14 Profile: EXC, EC480D L [GB] Engine, identification Identification plate 1 A decal with the software's ID-number, the engine's serial number and assembly plant is located on the valve cover to ensure installation of correct ECU on the engine in production. On the back of the ECU, there is a decal indicating its hardware number. Identification plate 2 Engine designation, serial number, part number and assembly plant are stamped in one field on the engine block's left front edge. Assembly plants: A = Skövde, Sweden E = Curitiba, Brazil F = Flen, Sweden L = Lyon, France Identification plate 3 The engine control unit (ECU) has its component number on a plate on the back. Identification plate 4 The certification decal is located on the valve cover as well as on the left side of the machine's front frame. Figure 1
  • 2. Service Information Document Title: Function Group: Information Type: Date: Component locations 200 Service Information 2014/7/14 Profile: EXC, EC480D L [GB] Component locations Figure 1 Engine, front side 1 Flywheel housing 7 Engine oil filter 2 P.T.O (Power Take Off) port 8 Oil pan 3 Valve cover 9 EGR cooler 4 Turbocharger 10 Starter motor 5 Turbocharger actuator 11 TDC mark checking port 6 Venturi pipe
  • 3. Figure 2 Engine, back side 12 Fan pulley 20 Crankcase ventilation separator 13 Pre-heating coil 21 Oil level sensor 14 Engine oil filling port 22 Alternator 15 Dipstick gauge 23 Air conditioner compressor 16 Crankcase ventilation tube 24 Air pump 17 Air compressor 25 Air pump belt 18 Fuel feed pump 26 Alternator/Compressor belt 19 E-ECU 27 Fan belt
  • 4. Service Information Document Title: Function Group: Information Type: Date: E-ECU, MID 128, changing non-programmed ECU 200 Service Information 2014/7/14 Profile: EXC, EC480D L [GB] E-ECU, MID 128, changing non-programmed ECU Op nbr 200-068 1. Park the machine in the service position A, see . 091 Service positions 2. Connect the VCADS Pro computer to the machine, and perform operation '28423-3 MID 128 control unit, programming'. 3. When VCADS Pro 'MID 128 ECU, programming' window appears, follow the instructions for replacing E-ECU. 4. Turn OFF battery disconnect switch. 5. Remove the engine hood rear cover screws. Figure 1 1. Screws 6. Remove the bracket. Figure 2 1. Bracket
  • 5. 2. CNEI connector 7. Disconnect the CNEI connector. 8. Remove the air hose. Figure 3 9. Remove screws from wire harness clamps, and disconnect the wiring harness connectors from E-ECU. Figure 4 1. Screws 10. Remove screws fixing the fuel pipe and E-ECU. Figure 5 1. Screw
  • 6. 2. 3. Pipe Screw Put the fuel pipe away. 11. Remove 4 screws fixing the E-ECU and replace the E-ECU. 12. Install fuel pipe and screws. Connect wire harness connectors to the E-ECU, and install wire harness clamp screws. 13. Install the air hose and bracket. 14. Install the engine hood rear cover, and the screws. 15. After replacing E-ECU, press OK button of VCADS Pro operation '28423-3 MID 128 control unit, programming'. Now VCADS Pro starts the programming of software and parameters to the new E-ECU. 16. Start the machine and check that no error messages appear.
  • 7. Service Information Document Title: Function Group: Information Type: Date: E-ECU, MID 128, changing pre-programmed ECU 200 Service Information 2014/7/14 Profile: EXC, EC480D L [GB] E-ECU, MID 128, changing pre-programmed ECU Op nbr 200-070 1. Park the machine in the service position A, see . 091 Service positions 2. Connect VCADS Pro computer to the machine, and perform operation '17030-2 Parameter, programming'. 3. Use the function 'save all parameters to job card'. 4. Turn OFF battery disconnect switch. 5. Remove the engine hood rear cover screws. Figure 1 1. Screws 6. Remove the bracket. Figure 2 1. 2. Bracket CNEI connector
  • 8. 7. Disconnect the CNEI connector. 8. Remove the air hose. Figure 3 1. Hose 9. Remove screws from wire harness clamps, and disconnect the wire harness connectors from E-ECU. Figure 4 1. Screw 10. Remove screws fixing the fuel pipe and E-ECU. Put the fuel pipe away. Figure 5
  • 9. 1. 2. 3. Screw Pipe Screw 11. Remove 4 screws fixing the E-ECU and replace the E-ECU. 12. Install the fuel pipe, and screws. Connect wire harness connectors to the E-ECU, and install wire harness clamp screws. 13. Install the air hose and bracket. 14. Install the engine hood rear cover, and the screws. 15. Connect VCADS Pro computer to the machine, and perform operation 17030-2 Parameter, programming'. Now the customer parameters are changed according to the job card saved at step 3. 16. Start the machine and check that no error messages appear.
  • 10. Service Information Document Title: Function Group: Information Type: Date: Engine characteristic curve 210 Service Information 2014/7/14 Profile: EXC, EC480D L [GB] Engine characteristic curve Engine characteristic curve Figure 1 Engine characteristic curve, SAE J1349 Gross power
  • 11. Service Information Document Title: Function Group: Information Type: Date: Engine, removing 210 Service Information 2014/7/14 Profile: EXC, EC480D L [GB] Engine, removing Op nbr 210-070 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 components. NOTE! Disconnected hoses, lines and connections must be plugged. Oil that drains from hoses, lines and connections should be collected in a container. 1. Place the machine in the service position B. See091 Service positions 2. Turn off the battery disconnect switch. 3. Drain the coolant in a collection container. See . 261 Coolant, changing 4. Open the engine hood and remove the bracket from the cowl frame. Figure 1 1. Bracket 5. Remove the DPF hood, radiator hood and the rear cover
  • 12. Figure 2 1. 2. 3. 4. DPF hood Engine hood Engine room rear cover Radiator hood 6. Remove the engine room cowl frame with the engine hood using a lifting device. 7. Disconnect the wire harness connector and the hoses. Figure 3 1. 2. Wire harness connector Hose 8. Remove the expansion tank with the bracket. 9. Remove the clamps and then remove the charge air cooler tube and the radiator hoses.
  • 13. Figure 4 1. 2. 3. Charge air cooler upper tube Radiator upper hose Radiator breathing hose 10. Remove the engine room under covers. Figure 5 1. Engine room under cover 11. Release the pressure in the air compressed system by pushing up a valve on the air tank. Figure 6 1. Release valve
  • 14. 2. Air tank 12. Disconnect the radiator under hose and remove the charge air cooler under tube. Figure 7 1. 2. Radiator under hose Charge air cooler under tube 13. Remove the screws and separate the shroud from the radiator assembly. Move the shroud to the engine side. Figure 8 1. 2. Shroud Radiator assembly 14. Remove the main pump. See 913 Hydraulic pump, replacing 15. Remove pump room covers.
  • 15. Figure 9 1. Pump room cover 16. Disconnect the hoses, remove the mounting screws and the engine PTO pump. NOTE! Plug the P.T.O (Power take off) hole to protect from foreign substances. Figure 10 1. 2. 3. Hose Screw Engine PTO pump 17. Disconnect the fuel line hoses (4 pcs). NOTE! Ports must be plugged after disassembling hoses. Figure 11 1. Hose 18. Disconnect the hose connected to the air cooler and the compressor head.
  • 16. Figure 12 1. 2. 3. 4. 5. Compressor head Air cooler Hose Hose Hose 19. Disconnect hoses connected to the air pump. Figure 13 1. 2. Air pump Hose 20. Disconnect the wire-harness connector on the inlet air sensor.
  • 17. Figure 14 1. 2. Inlet air temperature/pressure sensor Connector 21. Remove the clamps and the air inlet hose. Figure 15 1. Turbocharger air inlet hose 22. Remove the foot step. Figure 16 23. Remove the clamps and the exhaust flexible tube. Figure 17
  • 18. 1. Exhaust flexible tube NOTE! Leave the markings on the tube before removing to remember the direction of flow direction. 24. Remove the air conditioner compressor belt and disconnect the wire harness. WARNING Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage. Figure 18 1. 2. 3. Air conditioner compressor Alternator/compressor belt Wire harness 25. Remove the compressor and lay it down on the frame. 26. Disconnect the cab heater hose on the engine block. Figure 19 1. Cab heater hose 27. Disconnect the engine oil remote hoses.
  • 19. Figure 20 1. Engine oil remote hose 28. Disconnect the starter motor wire harness. Figure 21 1. Starter motor wire harness 29. Remove the connectors from the fuel filter and the water separator. Figure 22 1. Connector 30. Remove the cover and the clamps and then disconnect the main wire harnesses.
  • 20. 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
  • 21. Figure 23 1. 2. 3. Cover Clamp Wire harness 31. Remove the four mounting screws. Figure 24 32. Lift the engine just a little using a lifting device, and after confirming safety around, lift it up and out slowly to the work stand.