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Volvo L90E Wheel Loader Service Repair Manual Instant Download.pdf

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Service Information
Document Title: Function Group: Information Type: Date:
Engine, description 200 Service Information 2014/4/28
Profile:
WLO, L90E [GB]
Engine, description
L90E is equipped with a four-stroke, straight six-cylinder turbocharged and direct-injected diesel engine with an air-cooled
intercooler.
Fuel is injected with unit injectors. The unit injectors are positioned at an angle above the pistons and are controlled via the
camshaft and the engine control unit's (E-ECU) software.
D6D is equipped with dry replaceable cylinder liners. The engine is of the low-emission type.
The engine's serial number is stamped on the name plate, on the cylinder block's side and on the valve cover. The engine's
model designation and serial number must be indicated when ordering spare parts.
The cylinders are numbered with cylinder one closest to the flywheel. The engine's rotational direction is counter-clockwise,
seen from the flywheel end. Firing order: 1-5-3-6-2-4.
Figure 1
Service Information
Document Title: Function Group: Information Type: Date:
Engine, removing 210 Service Information 2014/4/28
Profile:
WLO, L90E [GB]
Engine, removing
Op nbr 210-070
9998547 Lifting tool
Sling 4 m (13.1 ft), 4 pcs.
Sling 2 m (6.6 ft), 2 pcs.
Sling 1 m (3.3 ft)
Ratchet block
Lifting eyes, 4 pcs.
1. Remove the engine hood, see .
821 Engine hood, removing
2. Drain the engine oil at the drain point.
Volume: See 030 Engine, capacities
Figure 1
1. Drain point for engine oil
Machine's right side
3. Disconnect:



the upper radiator hose from the engine.
the clamp for the preheating coil.
the coolant hose by loosening the hose clamp at the engine.
Remove:
 the intermediate wall


the protective plate and guide plates
the bolts for the coolant collecting pipe
Figure 2
1.
2.
3.
4.
5.
6.
7.
Upper radiator hose
Partition wall
Protective plate
Guide plate
Clamp for preheating coil
Coolant hose
Bolts for coolant collecting pipe
Behind machine, under the hood
4. Disconnect:



Disconnect the upper radiator hose.
Loosen the upper radiator bracket.
Disconnect the clamp for the charge-air pipe.
NOTE!
Place a suitable spacer under the fan drum so that the radiator doesn't fall backward.
Remove:



the protective plate for the engine-ECU
the connection EAEB for the engine-ECU and the leadthrough plates. Move the connection out through
the hole. Protect the connectors
the dryer filter from the bracket and move it to the side so that the hood goes clear
Figure 3
1.
2.
3.
4.
5.
6.
7.
Upper radiator hose
Upper radiator bracket
Clamp for charge-air pipe
Protective plate
Connection EAEB
Leadthrough plates
Receiver drier
Machine's left side
5. Disconnect the hose for the fuel feed pump. Remove the AC compressor and fold it aside.
NOTE!
The hoses may not be folded.
Figure 4
1.
2.
Hose to fuel feed pump
AC compressor
Machine's right side
Engine removal
6. Disconnect:



the coolant hose from the transmission oil cooler.
the connection for the charge-air pipe.
the hoses from the coolant collecting pipe.
Remove:






the connection for the alternator and clamps for the cabling
the brackets for the charge-air pipe. Retain the spacers behind the rear bracket. Remove the pipe.
the clamps for the coolant hoses. Retain the spacers. Cut off the cable tie.
the bracket for connector RL.
electric connections for the starter motor
the clamp for the engine oil level sensor and the connector
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Coolant hose for transmission oil cooler
Charge air pipe
Connector
Clamp for engine oil level sensor
Connections for alternator
Clamp for cabling
Clamps for coolant hoses
Electric connections for starter motor
Bracket for connector
Connection for charge-air pipe
Bracket for charge-air pipe
Hoses for coolant collecting pipe
Under the machine
7. Remove protective plate.

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Volvo L90E Wheel Loader Service Repair Manual Instant Download.pdf

  • 1. Service Information Document Title: Function Group: Information Type: Date: Engine, description 200 Service Information 2014/4/28 Profile: WLO, L90E [GB] Engine, description L90E is equipped with a four-stroke, straight six-cylinder turbocharged and direct-injected diesel engine with an air-cooled intercooler. Fuel is injected with unit injectors. The unit injectors are positioned at an angle above the pistons and are controlled via the camshaft and the engine control unit's (E-ECU) software. D6D is equipped with dry replaceable cylinder liners. The engine is of the low-emission type. The engine's serial number is stamped on the name plate, on the cylinder block's side and on the valve cover. The engine's model designation and serial number must be indicated when ordering spare parts. The cylinders are numbered with cylinder one closest to the flywheel. The engine's rotational direction is counter-clockwise, seen from the flywheel end. Firing order: 1-5-3-6-2-4. Figure 1
  • 2. Service Information Document Title: Function Group: Information Type: Date: Engine, removing 210 Service Information 2014/4/28 Profile: WLO, L90E [GB] Engine, removing Op nbr 210-070 9998547 Lifting tool Sling 4 m (13.1 ft), 4 pcs. Sling 2 m (6.6 ft), 2 pcs. Sling 1 m (3.3 ft) Ratchet block Lifting eyes, 4 pcs. 1. Remove the engine hood, see . 821 Engine hood, removing 2. Drain the engine oil at the drain point. Volume: See 030 Engine, capacities Figure 1 1. Drain point for engine oil Machine's right side 3. Disconnect:    the upper radiator hose from the engine. the clamp for the preheating coil. the coolant hose by loosening the hose clamp at the engine. Remove:  the intermediate wall
  • 3.   the protective plate and guide plates the bolts for the coolant collecting pipe Figure 2 1. 2. 3. 4. 5. 6. 7. Upper radiator hose Partition wall Protective plate Guide plate Clamp for preheating coil Coolant hose Bolts for coolant collecting pipe Behind machine, under the hood 4. Disconnect:    Disconnect the upper radiator hose. Loosen the upper radiator bracket. Disconnect the clamp for the charge-air pipe. NOTE!
  • 4. Place a suitable spacer under the fan drum so that the radiator doesn't fall backward. Remove:    the protective plate for the engine-ECU the connection EAEB for the engine-ECU and the leadthrough plates. Move the connection out through the hole. Protect the connectors the dryer filter from the bracket and move it to the side so that the hood goes clear Figure 3 1. 2. 3. 4. 5. 6. 7. Upper radiator hose Upper radiator bracket Clamp for charge-air pipe Protective plate Connection EAEB Leadthrough plates Receiver drier Machine's left side 5. Disconnect the hose for the fuel feed pump. Remove the AC compressor and fold it aside.
  • 5. NOTE! The hoses may not be folded. Figure 4 1. 2. Hose to fuel feed pump AC compressor Machine's right side Engine removal 6. Disconnect:    the coolant hose from the transmission oil cooler. the connection for the charge-air pipe. the hoses from the coolant collecting pipe. Remove:       the connection for the alternator and clamps for the cabling the brackets for the charge-air pipe. Retain the spacers behind the rear bracket. Remove the pipe. the clamps for the coolant hoses. Retain the spacers. Cut off the cable tie. the bracket for connector RL. electric connections for the starter motor the clamp for the engine oil level sensor and the connector
  • 6. Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Coolant hose for transmission oil cooler Charge air pipe Connector Clamp for engine oil level sensor Connections for alternator Clamp for cabling Clamps for coolant hoses Electric connections for starter motor Bracket for connector Connection for charge-air pipe Bracket for charge-air pipe Hoses for coolant collecting pipe Under the machine 7. Remove protective plate.
  • 7. Figure 6 1. Protective plate 8. Remove the bolts for the rubber cushion. Figure 7 1. Bolts for rubber cushion 9. Machine's left side Disconnect:   the coolant hose. the fuel return hose. Retain the spacer behind the clamp. Plug the opening. Remove:     the connection for the engine heater connector.[ 1]  electric connections for the preheating coil the drain hose for engine oil the bolts for the framework. Connect sling in the framework and lift away.
  • 8.  the 48-pin connector. Protect the connector. Cut off the cable ties to release the cable harness. Figure 8 1. 2. 3. 4. 5. 6. 7. Coolant hose Connection for engine heater connector 48 pin connector Fuel return hose Electric connections for preheating coil Drain hose for engine oil Bolts for framework 10.
  • 9.    Mark up and loosen the electric connections for the secondary steering pump. [ 2]  Disconnect the secondary steering pump. Disconnect the hydraulic pump and move it to the side, complete with all hydraulic hoses and strap it down in that position. Figure 9 1. 2. 3. Secondary steering pump Electric connections for secondary steering pump Hydraulic pump 11. Remove the front part of the rear mudguard. Remove the plates that cover the hydraulic tank. Figure 10 1. 2. Front part of rear mudguard Plates 12. Remove the bolts and the spacers. Lift up the framework approx. 3 cm (1.2 in).
  • 10. Figure 11 1. 2. 3. Bolt Spacers Framework 13. Place the spacers on the frame and lower the framework. Fit the bolts and tighten them slightly. Figure 12 1. 2. 3. Spacer Framework Bolt 14. Connect the engine to the overhead crane with lifting device 9998547 according to the figure.
  • 11. Figure 13 15.    Remove the bolts, 4 pcs., for the rubber cushion. Remove the bolts for the engine mount. Two on each side. Lift the engine sufficiently so that the rubber cushion and engine mount can be removed. Figure 14 1. 2. Bolt, rubber cushion Engine mount 16. Lift the engine sufficiently so that it can pass freely over the engine member. Make sure that the connection is not trapped or crushed.
  • 12. Figure 15 1. Connection 17. Secure with a jack under the transmission. Figure 16 18. Attach a ratchet block in the left rear cab mount with a sling. Route the chain under the transmission to the right side of the cab. Attach the hook in the right rear cab mount with a sling. Use a suitable spacer as protection between the chain and transmission. Tighten up the transmission with the ratchet block. Under the machine 19. Place a container under the connection for the return pipe under the transmission. Loosen the flange bolts one turn.
  • 13. Figure 17 1. Connection for return pipe 3. Flange bolts 20. Remove the clamp bracket that holds the return pipe on the flywheel housing. Bend the return pipe approx. 10 mm (0.4 in) to the side, and pull down the return pipe approx. 30 mm (1.2 in). Figure 18 1. 2. Clamp bracket Return pipe 21. Tighten the flange bolts and plug the connections.
  • 14. Figure 19 3. Flange bolts 22. Remove the bolts between the engine and transmission, 12 bolts. 23. Remove the engine. Weight: 575 kg (1268 lb). [ 1] optional equipment [ 2] Optional equipment
  • 15. Service Information Document Title: Function Group: Information Type: Date: Engine, installing 210 Service Information 2014/4/28 Profile: WLO, L90E [GB] Engine, installing Op nbr 210-072 9998547 Lifting tool Sling 0.4 m (1.3 ft) Sling 1 m (3.3 ft) Lifting eyes, 4 pcs. Ratchet block 1. Fit a new O-ring on the transmission. 2. Connect the engine to the lifting device at the correct angle according to the figure. Connect a small ratchet block according to the figure so that the engine can be angled slightly. Lift and align the engine with the transmission. Weight: 575 kg (1268 lbs).
  • 16. Figure 1 1. Sling 3. Install the bolts for the engine at the transmission. 12 pcs. Tightening torque: 60 ±10 Nm (44 ±7 lbf ft) 4. Remove the jack, ratchet block and sling under the transmission. 5. Fit:    the rubber cushion and engine mount. the bolts and torque them. Note the spacers. Tightening torque 85 ±18 Nm (63 ±13 lbf ft). the bolts and torque them. Tightening torque 275 ±45 Nm (202 ± 33 lbf ft) Carefully lower the engine and fit the engine mount in the guide on the rubber cushion. Figure 2 1. 2. 3. 4. 5. Bolt for rubber cushion Rubber cushion Bolt for engine mount Engine mount Guide Under the machine 6. Install the bolts for the rubber cushion. Tightening torque 85 ±18 Nm (63 ±13 lbf ft)
  • 17. Figure 3 1. Bolt for rubber cushion 7. Install the protective plate). Figure 4 1. Protective plate 8. Disconnect the lifting device from the engine and run aside the overhead crane. Machine's left side 9. Fit:        the drain hose for the engine. electric connections for the preheating coil. the fuel return hose with clamp and spacer. 48-pin connector. Secure the cable harness with cable ties at suitable points on the valve cover. the connection for the engine heater connector. [ 1]  the coolant hose. the hydraulic pump.
  • 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.    the secondary steering pump.[ 2]  the electric connections for the secondary steering pump. the framework Figure 5 1. 2. 3. 4. 5. 6. 7. Coolant hose Connection for engine heater connector 48 pin connector Fuel return hose Electric connections for preheating coil Drain hose for engine oil Bolts for framework