Volvo L220E Wheel Loader Service Repair Manual Instant Download

1
Service Information
Document Title General description Function Group 200 Information Type Service Information Date 2014/4/22
Profile WLO, L220E GB Profile WLO, L220E GB Profile WLO, L220E GB Profile WLO, L220E GB
Go back to Index Page 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 General description Function Group 200 Information Type Service Information Date 2014/4/22
Profile WLO, L220E GB Profile WLO, L220E GB Profile WLO, L220E GB 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
• 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).

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• 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.

6
Service Information
Document Title Engine, removing Function Group 210 Information Type Service Information Date 2014/4/22
Profile WLO, L220E GB Profile WLO, L220E GB Profile WLO, L220E GB 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
WARNING
2.
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. Volumeapprox. 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
• Draining the coolant
• Draining the engine oil

7

• Figure 2
• 1. Clamp
• 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
• Oil pipe
• Hose to cab heater
• Charge air pipe
• Header tank
• Upper radiator hose

8
WARNING
4.
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
• Receiver drier
• Protective plate

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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
Charge air pipe, preheating coil Relay, clamp 9 Alternator, compressor, connectors
5. Remove the side panels.
Figure 6 6. Remove the partition
wall. Partition wall, weight approx. 45 kg
(approx. 100 lbs).
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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.
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Figure 9 1. 9998257 2. 9998547 3. 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).
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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.
13
Service Information
Document Title Engine, removing Function Group 210 Information Type Service Information Date 2014/4/22
Profile WLO, L220E GB Profile WLO, L220E GB Profile WLO, L220E GB 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.
• Place the machine in service position, see 191
  Safety rules when servicing.
• 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
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• Drain point for coolant
• Drain for engine oil
• Remove the engine hood, see 821 Engine hood,
  removing.
• Drain the engine oil. Use the drain hose located
  in the machine's toolbox. Volume, see 210
  Engine, volume.
• Remove the side panels by the engine and remove
  the clamp that holds the oil drain.

• Figure 2
• 1. Clamp
• Drain the transmission oil. Volume, see 030
  Hydraulic transmission, volume
• Remove the oil pipe from the flywheel housing.

Figure 3 1. Oil pipe Left side
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Figure 4

1. Charge-air pipe
2. Radiator hose
3. Hose
4. Connector (SE2603)
5. Radiator hose, upper

1. Cable, engine heater
2. Radiator hose, lower
3. Filter housing 9.Plate

• Remove the charge-air pipe.
• Disconnect the upper and lower radiator hose from
  the engine.
• Disconnect the cable to the optional engine
  heater.
• 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.
• Remove the plate by the oil filters.
• Remove the filter housing from the intermediate
  wall and remove the clamp.
• Right side

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Figure 5

1. Upper radiator hose
2. Radiator hose
3. Bottom plate
4. Breather hose

1. Charge-air pipe
2. Air hose
3. Bracket
4. Guard

1. Remove the protection for the AC compressor.
2. Disconnect the hose from the radiator.
3. Remove the clamps for the breather hose and drain
   hose. Disconnect the hose from the breather
   filter.
4. Disconnect the air hose from the alternator.

WARNING

• Do not disconnect or loosen connections for the
  air conditioning unit (AC). Risk of gas leakage.
• 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.
• Disconnect the bracket for the AC hoses from the
  intermediate wall.
• Disconnect the radiator hose and remove the
  bottom plate.
• Remove the intermediate wall. Weight approx. 65
  kg (143 lbs)

17

• Figure 6
• Lifting eye M12, 2 pcs.
• Shackle M16, 2 pcs.
• Sling, 4 m (13 ft)

• 23.
• Figure 7
• 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.

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• Figure 8
• Connector, MA802
• Connector, RD
• Loosen the belt tensioner and remove the belt.
  Disconnect the AC compressor and lay it on the
  frame.
• 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. SE2301 2. SE2302 27. Disconnect the
connectors EMS and EL and remove their clamping.
Disconnect the cables on the starter motor.
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• Figure 10
• Connector EL
• Connector EMS
• Starter motor connections
• 28. Remove the clamps. Disconnect the hose and
  connector RT.

• Figure 11
• Hose
• Connector, RT
• 29. Remove the cover for the box with the main
  fuses and disconnect the cables and their clamps.
  See fig.

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• Figure 12
• 1. Cables
• Disconnect the bracket and move it aside.
• 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.
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• Figure 14
• (Engine removed.)
• 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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• Figure 16
• 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)
• If changing the engine, transfer the components
  required to the new engine.
• NOTE!
• Never transfer a component that could cause a
  malfunction.

24
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com