download service repair workshop manual

1. Service Information
Document Title: Function Group: Information Type: Date:
General description 200 Service Information 2014/4/22
Profile:
WLO, L220E [GB]
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General description
The engine is a straight six-cylinder, turbocharged, four-stroke and direct-injected diesel engine with an air-cooled
intercooler.
It has an overhead camshaft, four valves per cylinder and unit injectors.
The engine designation is D12DLBE3.
The engine is of low-emission version.
Figure 1
The cooling fan with vane motor is located in front of the radiator and is driven hydrostatically with a variable piston pump,
Pump 3, (P3).
The speed of the fan is controlled by the vehicle ECU (V-ECU), which receives information about temperature in the
following systems:







Coolant temperature, radiator
Coolant temperature, engine
Transmission oil temperature
Hydraulic oil temperature
Temperature in front and rear axle (only when machine is equipped with axle oil cooler).
Induction air temperature
Charge-air temperature

2. Hydrostatically controlled cooling fan speed gives the engine high power as well as low sound level, since the cooling fan
does not work at max. rpm as often.
The cooling system is based on a concept where cooling for engine, transmission, hydraulics and axle oil cooling (optional
equipment) are integrated.
These systems' cooling depends on the cooling fan speed.
Engine identification
Identification plate 1
Engine designation, serial number, part number and assembly plant are stamped in one field on the engine block's left rear
edge
Identification plate 2
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.
Assembly plants:
A = Skövde, Sweden
E = Curitiba, Brazil
F = Flen, Sweden
L = Lyon, France
Identification plate 3
The certification decal is located on the valve cover as well as on the machine frame.
Figure 2
Engine identification, D12D

3. Service Information
Document Title: Function Group: Information Type: Date:
General description 200 Service Information 2014/4/22
Profile:
WLO, L220E [GB]
Go back to Index Page
General description
The engine is a straight, six-cylinder, four-stroke, direct-injection, turbocharged diesel engine with an air-cooled intercooler.
It is provided with an overhead camshaft, four valves per cylinder and unit injectors.
The engine type designation is D12CLBE2.
The engine is of the low-emission version.
Information about the engine and in which machine it is installed is stamped-in both on the right side of the cylinder block
and on a plate next to the stamped-in information. It can also be found on a label on the engine ECU (E-ECU).
Figure 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
Machine connection, for example L220E
Euro 2, emission version
Product number
Diesel
Cylinder capacity
Generation
Serial number
Place of manufacture
Machine chassies number
The cooling fan with vane motor is positioned behind the radiator and is hydrostatically driven by a variable piston pump,
Pump 3, (P3).

4. The fan speed is controlled by the vehicle ECU (V-ECU), which receives information about the temperature in the following
systems:







Coolant temperature, radiator
Coolant temperature, engine
Transmission oil temperature
Hydraulic oil temperature
Temperature in the front and rear axles (only if the machine is equipped with axle oil coolers.)
Induction air temperature
Charge air temperature
The hydrostatically controlled cooling fan speed results in higher engine output and a low sound level, as the cooling fan
does not often work at maximum speed.
The cooling system is based on a concept where the cooling of the engine, transmission, hydraulics and axle oil cooling,
(optional equipment) is integrated.
The cooling of these systems are dependent on the cooling fan speed.

5. Service Information
Document Title: Function Group: Information Type: Date:
Engine, removing 210 Service Information 2014/4/22
Profile:
WLO, L220E [GB]
Go back to Index Page
Engine, removing
Op nbr 21070
9998257 Lifting tool
9998547 Lifting device
Bolt M14 x 35 mm, 2 pcs
Lifting eye M16, 4 pcs
1. Remove the engine hood, see 821 Engine hood, removing
2. WARNING
Risk of burns when removing the header tank cap because of excess pressure in the cooling system.
Remove the cap from the header tank.
Drain the coolant. Use the drain hose stored in the right-hand battery box or the toolbox on the machine.
Volume:approx. 41 litres (10.8 US gal) (approx. 3 litres (2.6 US gal) will remain in the engine block)
Drain the oil if necessary. Use the drain hose stored in the toolbox on the machine.
Volume: approx. 48 litres (2.7 US gal).
Remove the clamp securing the oil drain plug.
Figure 1
1.
2.
Draining the coolant
Draining the engine oil

6. Figure 2
1. Clamp
3. Disconnect the oil pipe between the flywheel housings and the hydraulic transmissions from the flywheel housing.



Disconnect the hose to the cab heater from the engine block.
Remove the charge air pipe. Remove the header tank.
Remove the upper radiator hose.
Disconnect the cable to the optional engine heater.
Figure 3
1.
2.
3.
4.
5.
Oil pipe
Hose to cab heater
Charge air pipe
Header tank
Upper radiator hose

7. 4. WARNING
Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage.
Remove the condenser and place it on the radiator.








Detach the receiver drier. Remove the protective plate.
Detach the lower radiator hose from the engine.
Disconnect the fuel lines from the fuel pump and fuel filter.
Remove the charge air pipe and the hose between the preheating coil and radiator.
Remove the relay and clamps along with the bracket located on the member behind the hydraulic tank.
Disconnect the connector from the E-ECU, the cables from the starter motor and the connector from the
oil level sensor.
Undo the alternator at the adjustment point for the belt tensioner. Remove the belt.
Unplug the connectors by the A/C compressor.
Remove the A/C compressor from the engine.
Figure 4
1.
2.
Receiver drier
Protective plate

8. Figure 5
1 Lower radiator hose 6 Connector, E-ECU
2 Fuel line, fuel pump 7 Wiring, starter motor
3 Fuel connection, fuel filter 8 Connector, oil level sensor SE213
4 Charge air pipe, preheating coil 9 Alternator, compressor, connectors
5 Relay, clamp
5. Remove the side panels.
Figure 6
6. Remove the partition wall.
Partition wall, weight: approx. 45 kg (approx. 100 lbs).

9. Figure 7
7. Secure the hydraulic transmission in place with a sling and a ratchet blocks as illustrated.
Figure 8
Hydraulic transmission secured (engine removed)
8. Fit tool 9998257 and connect 9998547 and a lifting device to the engine.

10. Figure 9
1.
2.
3.
9998257
9998547
Bolts M14 x 35, 2 pcs
9. Remove the retaining bolts securing the hydraulic transmission.
NOTE!
To remove one of the bolts, remove the protective plate by the gear selector valve.
Figure 10
1. Protective plate
10. Remove the bolts securing the engine mounting.
Remove the engine.
Engine's weight, including oil: approx. 1350 kg (approx. 3000 lbs).

11. Figure 11
11. If changing the engine, transfer the components required to the new engine.
NOTE!
Never transfer a component that could cause a malfunction.

12. Service Information
Document Title: Function Group: Information Type: Date:
Engine, removing 210 Service Information 2014/4/22
Profile:
WLO, L220E [GB]
Go back to Index Page
Engine, removing
Op nbr 210-070
9998547 Lifting tool
Sling, 3 m, 2 pcs.
Sling, 4 m, 1 pcs.
Lifting eye M12, 2 pcs.
Washer M12, 2 pcs.
Nut M12, 2 pcs.
Shackle, 6 pcs.
Ratchet block, 750 kg
The operation also includes tools and times for steps to which references are given.
1. Place the machine in service position, see .
191 Safety rules when servicing
2. Turn off the main electric power with the battery disconnect switch.
WARNING
Risk of burns when removing the header tank cap because of excess pressure in the cooling system.
3. Remove the cap from the expansion tank.
Drain the coolant. Use the drain hose located in the machine's toolbox.
Volume, see .
260 Cooling system volume
Figure 1

13. 1.
2.
Drain point for coolant
Drain for engine oil
4. Remove the engine hood, see .
821 Engine hood, removing
5. Drain the engine oil. Use the drain hose located in the machine's toolbox.
Volume, see .
210 Engine, volume
6. Remove the side panels by the engine and remove the clamp that holds the oil drain.
Figure 2
1. Clamp
7. Drain the transmission oil. Volume, see 030 Hydraulic transmission, volume
8. Remove the oil pipe from the flywheel housing.
Figure 3
1. Oil pipe
Left side

14. Figure 4
1. Charge-air pipe 6. Cable, engine heater
2. Radiator hose 7. Radiator hose, lower
3. Hose 8. Filter housing
4. Connector (SE2603) 9.Plate
5. Radiator hose, upper
9. Remove the charge-air pipe.
10. Disconnect the upper and lower radiator hose from the engine.
11. Disconnect the cable to the optional engine heater.
12. Disconnect the hose at the cylinder head and the hose at the expansion tank.
Unplug the connector for the coolant level sensor (SE2603) on the expansion tank.
13. Remove the plate by the oil filters.
14. Remove the filter housing from the intermediate wall and remove the clamp.
Right side

15. Figure 5
1. Upper radiator hose 5. Charge-air pipe
2. Radiator hose 6. Air hose
3. Bottom plate 7. Bracket
4. Breather hose 8. Guard
15. Remove the protection for the AC compressor.
16. Disconnect the hose from the radiator.
17. Remove the clamps for the breather hose and drain hose. Disconnect the hose from the breather filter.
18. Disconnect the air hose from the alternator.
WARNING
Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage.
19. Disconnect the charge-air pipe in the space between the radiator and the intermediate wall. Remove the bolts that
hold the preheating coil. Fold aside the heating coil and remove the pipe.
20. Disconnect the bracket for the AC hoses from the intermediate wall.
21. Disconnect the radiator hose and remove the bottom plate.
22. Remove the intermediate wall.
Weight approx.: 65 kg (143 lbs)

16. Figure 6
1.
2.
3.
Lifting eye M12, 2 pcs.
Shackle M16, 2 pcs.
Sling, 4 m (13 ft)
23.
Figure 7
1.
2.
Tensioning strap
Bracket with oil filter
Tighten up the oil filters against the engine with a tensioning strap.
24. Disconnect the connectors for the AC compressor and alternator.

17. Figure 8
1.
2.
Connector, MA802
Connector, RD
25. Loosen the belt tensioner and remove the belt. Disconnect the AC compressor and lay it on the frame.
26. Mark the hose connections on the fuel filter bracket. Disconnect the fuel hoses from the fuel filters and collect the
fuel that drains.
Disconnect the connectors SE2301 and SE2302 and remove their clamps
Remove the bracket with the filters.
Figure 9
1.
2.
SE2301
SE2302
27. Disconnect the connectors EMS and EL and remove their clamping. Disconnect the cables on the starter motor.

18. Figure 10
1.
2.
3.
Connector EL
Connector EMS
Starter motor connections
28. Remove the clamps. Disconnect the hose and connector RT.
Figure 11
1.
2.
Hose
Connector, RT
29. Remove the cover for the box with the main fuses and disconnect the cables and their clamps. See fig.

19. Figure 12
1. Cables
30. Disconnect the bracket and move it aside.
31. Disconnect the bridge for the contacts to the shift solenoids from the transmission.
Figure 13
32. Remove the air filters for the transmission and rear axle.
Secure the hydraulic transmission with lifting eyes, shackle, sling and ratchet block.

20. Figure 14
(Engine removed.)
1.
2.
3.
4.
Lifting eye M12, 2 pcs.
Shackle M16, 1 pc.
Sling, 4 m (13 ft)
Ratchet block, 750 kg
NOTE!
Do not tighten up the transmission.
33. Install tool 9998547 on the engine.
Figure 15
1. Lifting tool
34. Remove the bolts for the engine mount.

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22. Figure 16
35. Remove the bolts on the hydraulic transmission, except the two upper bolts.
Tighten up the transmission using the lifting device.
Remove the two upper bolts. Remove the engine.
Engine's weight: 1250 kg (2756 lbs)
36. If changing the engine, transfer the components required to the new engine.
NOTE!
Never transfer a component that could cause a malfunction.