Volvo EC330B Manual

EC330B/EC360B/EC460B/EC70OB SERVICE TRAINING
This material is combined as below.
01_General
02_Engine
02-1_D10B Engine(EC330B-EC360B)
02-2_D12C Engine(EC330B-EC460B)
02-3_D12D Engine(EC330B-EC460B)
02-3_D16E Engine(EC700B)
03_Electric system
03-1_Before IECU application(EC330B-EC460B)
03-2_IECU application(EC330B-EC460B)
03-3_D12D Engine application(EC330B-EC460B)
03-4_EC700B
04_Power Transmission
04-1_Swing motor(EC330B/EC360B)
04-2_Swing motor(EC460B)
04-3_Swing motor(EC700B)
04-4_Travel motor_Old(EC330B/EC360B)
04-5_Travel motor_New(EC330B/EC460B)
04-6_Travel motor(EC460B)
04-7_Travel motor(EC700B)
05_Brake System
06_Steering System
07_Frame & Undercarriage
08_Aircon
09_Hydraulic
09-1_Hydraulic_D10B & D12C(EC330B/EC360B)
09-2_Hydraulic_D12D(EC330B-EC360B)
09-3_Hydraulic_D12C(E460B)
09-4_Hydraulic_D12D(EC460B)
09-5_Hydraulic(EC700B)
09-6_Hydraulic common

Design Change Overview(EC330B-EC360B)
1-Before I-ECU application
-D10B Engine, EMS1(Tier 2): Initial Production
-D12C Engine, EMS1(Tier 2)
-Instrument panel and MDU
-Old alternator
2-I-ECU application
-D12C Engine, EMS1(Tier 2)
-IECU(Programmable)
-New alternator
3-D12D application
-D12D Engine, EMS2(Tier 3): EU & NA only. Machine serial number starts from 80001
-D12D Engine, EMS1(Tier 3 based Tier 2): International region
-IECU(Programmable)
-New alternator
Picture text:

Design Change Overview(EC460B)
1-Before I-ECU application
-D12C Engine, EMS1(Tier 2)
-Instrument panel and MDU
-Old alternator
2-I-ECU application
-D12C Engine, EMS1(Tier 2)
-IECU(Programmable)
-New alternator
3-D12D Engine application
-D12D Engine, EMS2(Tier 3): EU & NA only. Machine serial number starts from 80001.
-D12D Engine, EMS1(Tier 3 based Tier 2): International region
-IECU(Programmable)
-New alternator
Picture text:

Design Change Overview(EC700B)
-D16E Engine, EMS2(Tier 3)
-IECU(Programmable)
-New alternator
Picture text:

Engine(D10B)
Picture text:

Engine specification
Model: D10B EAE2
Power(kW): 198 at 1700 rpm
Power(hp): 269 hp at 1700 rpm
Torque: 1345 Nm at 1400 rpm
Bore x Stroke: 120.65mm x 140mm
DISPLACEMENT: 9600 cc
Type: 4 cycle-diesel-turbo & charge air cooled
Picture text:

External view(1)
1. EMS(E-ECU)
2. Fuel inlet
3. Water outlet
4. Engine PTO
5. Fan drive & Pulley
6. Engine oil cooler
7. Engine oil filter(full)
8. Breather
9. Engine oil filter(bypass)
10. Fuel filter
11. Fuel feed pump
Picture text:

External view(2)
1. Fuel pump
2. Turbochargher
3. Cooler block heater
4. Cab heater supply
5. Coolant filter heater
6. Starter
7. Fuel shut-off solenoid
8. Dipstick
9. Oil drain valve
10. Oil pan
11. Coolant filter return
12. Cab heater return
Picture text:

E-ECU Sensors
1. E-ECU
2,3. Speed sensor
4. Coolant temp.
5. Needle movement
6. Coolant level
7. Inlet air press. & temp.
8. Boost air press. & temp.
9. Oil press. & temp.
10. Fuel press. & temp.
Picture text:

E-ECU circuit
Communication line is at the Red color connector!(Connector B)
Picture text:

Fuel system
The injection pump is bolted onto a separate bracket on the left side of the engine.The injectors (1) used
are made by Bosch. Their opening pressure is adjusted by means of washers of varying thickness inserted
above the spring.
The fuel filter (2) is attached to a filter bracket. A bleeder nipple is also placed on the bracket (3).
From the feeder pump fuel is forced through the filter and into the injection pump feed side via the fuel
shut-off valve. Return fuel from the injection pump goes via the fuel shut-off valve and overflow valve (8)
to the tank. The leak-off line from the injectors is connected to the injection pump via the suction line
connection.
1. Injector
2. Fuel filter
3. Bleeder nipple
4. Sensor fuel temp/pressure
5. Tank strainer
6. Cooling loop, ECU
7. Feeder pump
8. Overflow valve
Picture text:

Fuel system-Injector
1 Needle movement sensor
2 Feed pump
3 Manual feed pump
4 Overflow valve
5 Fuel cut-off valve(Off condition)
6 Fuel cut-off valve(On condition)
Picture text:

Fuel system-Injection pump
1 Fuel rack control solenoid
2 Fuel rack(injection quantity control)
3 Injection timing control solenoid
4 Lever
5 Delivery valve
6 Timing sleeve
7 Speed sensor
8 Toothed wheel
Picture text:

Fuel system-Injection control
Injection timing is adjusted by timing sleeve location.
Injection quantity is adjusted by fuel rack operation.
Picture text:

Engine(D12C)
Picture text:

Engine specification
D=Diesel engine
12=Cylinder volume in litres
C=Generation
E=Excavator application
C=Version
E2= Valid to Tier-2 & Euro-2
1. EC330B-EC360B
D12CECE2(For NA), D12CEDE2(For EU), D12CEEE2(For other region)
Power: 198Kw at 1700rpm
MAX Torque: 1345Nm at 1400rpm
2. EC460B
D12CEAE2(For NA), D12CEBE2(For EU), D12CEFE2(For other region)
Power: 239Kw at 1900rpm
MAX Torque: 1600Nm at 1400rpm
D12 is the model number of the volvo 12 liter engine.
The engine is a 6-cylinder, 4-stroke, direct injection diesel with a 12 liter cylinder volume, turbocharger,
charged air cooler and electronic controlled fuel injection, EMS (Engine Management System).
The serial number of the engine is to be found stamped in the cylinder block on the rear left side.
The cylinder head is of cast iron and manufactured in one piece which is necessary in order to provide
stable bearings for the overhead camshaft.
The cylinder liner is sealed against the coolant casing with rubber rings.
The D12C has a four-valve system and overhead camshaft.
The engine timing gear transmission is located at the front of the engine on a 10 mm thick steel plate
bolted to the cylinder block.
The crankshaft is drop forged and has induction hardened bearing surfaces and fillets.
The engine is force fed lubricated by an oil pump which is gear driven from the engine crankshaft via an
intermediate gear
The fuel system for D12C has electronic control with unit injectors one for each cylinder and which operate
at a very high pressure.

External view(1)
External view & component location
1. E-ECU
2. Dip stick
3. Fuel filter
4. Start motor
5. Breather
6. Oil drain valve
7. Alternator
Picture text:

External view(2)
External view & component location
1. Turbocharger
2. Air inlet
3. Water outlet
4. Coolant filter connection
5. Water inlet
6. Oil filter(by-pass)
7. Oil filter(full flow)
8. Exhaust outlet
Picture text:

E-ECU Sensors
The D12C has a total of eight sensors. Three of these have dual functions. This gives a total of 11
functions.
The dual function sensors are:
2 Turbo boost pressure/air temperature in inlet manifold.
5 Air temperature before intercooler and pressure drop indicator. Located in the union pipe between the
air filter housing and the turbocharger inlet.
8 Oil pressure/temperature.
The other sensors are:
1 Fuel pressure sensor. Senses the pressure after the fuel filter.
3 Camshaft position sensor. Located in the upper timing mechanism cover.
4 Engine coolant level. Located in the expansion tank.
6 Engine coolant temperature. Located in the rear end of the cylinder head.
7 Engine speed sensor. Located in the fly wheel cover.
Apart from the sensors above, the system includes a sensor for Atmospheric Pressure, located inside the
EECU.
Picture text:

EECU electric circuit(Old)
Communication between the control units go via two data buses.
The two data buses have different functions. One is used for the control signals of system and is
designated SAE J1939.
The other databus, SAE J1708, is used for information and diagnostics. The link also functions as a back
up for the other databus if this for any reason does not function.
The Engine Management System (EMS) consists of a control unit (EECU) mounted to the engine, sensors
and a wiring harness. The EECU, Engine Electronic Control Unit, is connects to both the data bus SAE
J1939 and SAE J1708.
The unit receives signals from the Vehicle Control Unit, VECU.
It sends signals to control various functions on the engine and communicates with other control units via
the databuses.
Picture text: