Volvo EC300D LD EC300DLD Excavator Service Repair Manual Instant Download

1
Service Information
Document Title Spark plug, checking Function Group 254 Information Type Service Information Date 2015/2/12
Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB

• Spark plug, checking
• Op nbr 254-047
• Place the machine in service position B, see, 091
  Service positions.
• Turn off the battery disconnection switch.
• Open the engine hood.

DANGER
Risk of electrocution. Contact with live parts
will cause death or serious injury. Never touch
live electrical parts.
WARNING
Risk of burns as well as damage to the spark plug
cables when removing them before the parts have
cooled down.
DANGER
Risk of electrocution. Contact with live parts
will cause death or serious injury. Never touch
live electrical parts. 4. Remove the spark plug
cables from the spark plugs.

• Figure 1
• Burner
• Spark plug cable
• Glow plug cable

2

1. Remove the spark plugs.
2. Check the electrode gap on the spark plugs, see
   254 Exhaust aftertreatment system,
   specifications.
3. Install the spark plugs. Tightening torque, 254
   Exhaust aftertreatment system, tightening
   torques. Install the spark plug cables.
4. Restore the machine.

3
Service Information
Document Title Spark plug, replacing Function Group 254 Information Type Service Information Date 2015/2/12
Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB
Spark plug, replacing Op nbr 254-046
DANGER
Risk of electrocution. Contact with live parts
will cause death or serious injury. Never touch
live electrical parts.
WARNING

• Risk of burns as well as damaging the spark plug
  cables when removing them before the parts have
  cooled down.
• Park the machine in service position B, see 091
  Service positions.
• Open the engine hood.
• Switch off the battery disconnect switch.
• Cut the clamps and disconnect the spark plug
  cables from the burner side.

• Figure 1
• Burner
• Spark plug cable
• Spark plug control unit
• 5. Remove the spark plugs.

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• Figure 2
• 1. Spark plug
• Check the electrode gap on the new spark plugs,
  see 254 Exhaust aftertreatment system,
  specifications.
• Install the new spark plugs. Tightening torque,
  254 Exhaust aftertreatment system, tightening
  torques Install the spark plug cables.
• Close the engine hood.

6
Service Information
Document Title Burner, replacing Function Group 254 Information Type Service Information Date 2015/2/12
Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB
Burner, replacing Op nbr 254-033
WARNING
Risk of burns - stop the diesel engine and allow
it to cool down before starting any work.
WARNING

• Exhaust system components get very hot and can
  cause severe burns.
• Place the machine in the service position B. See
  091 Service positions.
• Turn the battery disconnect switch to off
  position.
• Open the engine hood.
• Remove the clamps on both side.

Figure 1 1. Clamp 5. Remove the spark plug
cables and the glow plug cable.
7

• Figure 2
• Burner
• Spark plug cable
• Glow plug cable
• 6. Loosen the clamp on the air supply line.

Figure 3 1. Clamp 7. Remove the clamp, loosen
the nut and then disconnect the pipe.
Figure 4 1. Clamp
8

• Pipe
• Nut
• 8. Remove the clamp, loosen the nut and then
  disconnect the fuel pipe.

• Figure 5
• Clamp
• Fuel pipe
• Nut
• 9. Remove the clamp, loosen the nut and then
  disconnect the air pipe.

• Figure 6
• Nut
• Air pipe
• Clamp
• 10. Remove the clamp, loosen the nut and then
  disconnect the fuel pipe.

9

• Figure 7
• Nut
• Fuel pipe
• Clamp
• 11. Disconnect the temperature sensor.

• Figure 8
• Nut
• Frame temperature sensor
• 12. Remove the mounting bracket and the burner.
  Move the burner to the work stand.

10

• Figure 9
• Screw
• Burner
• Mounting bracket
• 13. Remove the spark plugs, glow plug and the
  spark plug unit from the old burner and then
  transfer them to a new burner.

• Figure 10
• Spark plug
• Spark plug unit
• Glow plug
• Install the new burner to the machine.
• For assembling, reverse the disassembly
  procedure.
• Close the engine hood.

11
Service Information
Document Title Turbocharger, description Function Group 255 Information Type Service Information Date 2015/2/12
Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB
Turbocharger, description The function of the
turbocharger is to compress air and press it into
the engine cylinders. Turbocharging increases the
temperature of the air so that the compressed air
is cooled before entering the inlet manifold. The
turbocharger is pressure-lubricated from the
engine's oil system. For more information, see
220 Lubrication system, description
?

• Figure 1
• Turbocharger with wastegate valve
• Turbine housing
• Wastegate valve
• Compressor rotor housing
• Air inlet
• Compressed air outlet
• Exhaust inlet
• Exhaust outlet
• The turbocharger is driven by the exhausts that
  pass through the turbine housing on their way out
  into exhaust system. The exhaust flow causes the
  turbine rotor in the turbine housing to rotate.
• The compressor rotor is mounted on the same shaft
  as the turbine rotor. The compressor rotor is
  located in a housing which is connected between
  the air cleaner and the charge-air cooler. When
  the compressor rotor turns, air is sucked from
  the air cleaner. The air is compressed and forced
  into the engine cylinders.
• Wastegate valve
• The turbocharger is equipped with a wastegate
  valve, in the form of a pneumatic actuator
  connected via a rod to a valve unit mounted
  inside the turbine housing. The wastegate valve
  is controlled by the charge-air pressure. It lets
  a small amount of the exhausts to by-pass the
  turbine wheel at high engine speeds (high
  charge-air pressure). This allows the turbo to
  limit its maximum charge-air output.
• Parameters
• There are no parameters for this function.
• Supplementary information

250 Inlet and exhaust system, description
?
12
Function check There are no function checks for
this function. Diagnostics Detailed information
about the following relevant warnings and error
codes is available under the diagnostics tab.
Component Control unit Message ID
FX1007 MID128 PID102
FX1007 MID128 PID105
13
Service Information
Document Title Turbocharger, replacing Function Group 255 Information Type Service Information Date 2015/2/12
Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB
Turbocharger, replacing Op nbr 255-071
WARNING
Risk of burns - stop the diesel engine and allow
it to cool down before starting any work.
WARNING

• Exhaust system components get very hot and can
  cause severe burns.
• Place the machine in the service position B, see
  091 Service positions
• Turn the battery disconnect switch to off
  position.
• Remove the burner, see 254 Burner, replacing.
• Remove the clamp on the air pipe.

• Figure 1
• Bracket
• Clamp
• 5. Remove the clamp and air inlet hose from the
  turbocharger.

14

• Figure 2
• Pipe
• Clamp
• Air inlet hose
• 6. Remove the clamps on the turbocharger outlet
  hose and disconnect the lubrication line pipes.

• Figure 3
• Clamp
• Pipe (Oil supply line)
• Pipe (Oil return line)
• 7. Remove the four nuts and then remove the
  turbocharger with the gasket.

Figure 4 8. Install a new turbocharger with new
gaskets.
15

• For assembling, reverse disassembly procedure.
• NOTE!
• Use only new gaskets and copper washer when
  installing.
• After the work is completed, start the engine and
  check for leaks.

16
Service Information
Document Title Preheating coil, replacing Function Group 256 Information Type Service Information Date 2015/2/12
Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB
Preheating coil, replacing Op nbr 256-006
WARNING
Risk of burns - stop the diesel engine and allow
it to cool down before starting any work. 1.
Open the cover for the battery disconnect switch
on the right side of the machine.
Figure 1 2. Ensure the battery disconnect
switch is at OFF position.

• Figure 2
• Open the engine hood.
• Disconnect the wire harness connector.

17
Figure 3 1. Wire harness connector 5. Remove
the clamp and disconnect the charge air cooler
hose.

• Figure 4
• Clamp
• Charge air cooler hose
• 6. Disconnect the wire-harness.

Figure 5 1. Wire-harness
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7. Remove the clamp and disconnect the venturi
hose. Remove the mounting nuts

• Figure 6
• Nut
• Clamp
• Venturi hose
• 8. Remove the pre-heating coil and replace it as
  a new one.
• NOTE!
• Check the pre-heater coil gaskets (both side) and
  replace them if necessary.

• Figure 7
• Connect the hoses and install the clamps.
• Connect the wire harness connector.
• Close the engine hood.

19
Service Information
Document Title Air cleaner, cleaning filter element Function Group 256 Information Type Service Information Date 2015/2/12
Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB

• Air cleaner, cleaning filter element
• Op nbr 256-001
• Open the side door on the left side of the
  machine.
• Open the air cleaner cover.
• Pull out the air cleaner primary filter and
  carefully tap the end of the filter against a
  soft and clean surface.
• NOTE!
• Press with both thumbs on primary filter at the
  same time as you pull it out. This is to prevent
  the secondary filter from coming out with the
  primary filter.

• Figure 1
• Clean the filter using clean and dry compressed
  air with a max. pressure of 500 kPa (5 bar) (73
  psi).
• NOTE!
• If there is the smallest hole, scratch, crack or
  other damage, the filter must be replace with a
  new one.
• Install the primary filter and cover.
• Close the side door.

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Service Information
Document Title Air cleaner, primary filter replacing Function Group 256 Information Type Service Information Date 2015/2/12
Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB Profile EXC, EC300D LD GB

• Air cleaner, primary filter replacing
• Op nbr 256-003 NOTE!
• Replace the primary filter after cleaning 5 times
  maximum, or at least once every year.
• Open the side door on the left side of the
  machine.
• Open the air cleaner cover.
• Remove air cleaner primary filter and clean the
  filter housing.
• NOTE!
• Press with both thumbs on primary filter at the
  same time as you pull it out. This is to prevent
  the secondary filter from coming out with the
  primary filter.

• Figure 1
• Install a new primary filter
• Close the air cleaner cover and side door.

22
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