2 Engine With Mounting and Equipment PDF

Service Information
Document Title: Function Group: Information Type: Date:

Engine, description 200 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
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Engine, description
Machine serial no. EC330B: 10001 ~ 10235, EC360B: 10001 ~ 10828
The engine is a straight six cylinder, four stroke, direct injection diesel with 9.6 liter cylinder volume, turbocharged, inter
cooled and electronic controlled fuel injection, EMS (Engine Management System), with a cast iron block and cylinder head.
The cylinder block and head are designed with internal passages formed as sets for lubrication and cooling.
An engine driven power take off for a hydraulic pump can be provided for the D10 as extra equipment.
Structure, fuel filter side view
Figure 1
Engine, fuel filter side view
1. Fuel feed pump

2. Fuel filter
3. Engine oil filter (bypass)
4. EMS (Engine Management System)
5. Fuel inlet
6. Water outlet
7. Engine PTO (Power Take Off)
8. Fan drive and pulley
9. Oil cooler
10. Engine oil filter (full)
11. Breather
Structure, turbocharger side view

Figure 2
Engine, turbocharger side view
1. Fuel pump
2. Turbocharger
3. Cooler block heater (1 3/4″ -16UN - 2B)
4. Cab heater supply (1/2″ - 14UPSI)
5. Engine lifting eye
6. Coolant filter heater (1/2″ - 14UPSI)
7. Starter
8. Fuel shut off solenoid
9. Dipstick
10. Oil drain valve
11. Oil pan
12. Coolant filter return (M 22 × 1.5)
13. Cab heater return (M 22 × 1.5)
Structure, top view
Figure 3
Engine, top view
1. Air intake port

2. Oil filter (bypass)
3. Coolant vent
4. Air exhaust port
Structure, front side view
Figure 4
Engine, front side view
1. Dipstick gauge
2. Water inlet
3. Alternator
Structure, rear side view
Figure 5
Engine, rear side view
1. Fuel filter
2. Oil filter (bypass)
3. Oil cooler
4. Flywheel housing
Service Information

Profile:
EXC, EC360B LC [GB]
Engine, description
 D12C EC(D,E)E2 is the model number of the volvo 12 liter engine for the EC330B/360B excavator.
 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 EC(D,E)E2 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 EC(D,E)E2 has electronic control with unit injectors one for each cylinder and which
operate at a very high pressure.
 The fuel feed pump is a gear driven type and is driven from the engine timing gear with the same gear.
Engine, structure
Figure 1
Engine, structure 1
View A :fuel pump side View B : front side Detail C : Power Take Off (option)
1 Fan drive and pulley 7 Speed sensor 13 Lifting bracket
2 Fuel pump 8 Starter 14 To charged air cooler
3 EMS (Engine Management System) 9 Breather 15 Fan belt
4 Dipstick gauge 10 Oil pan 16 Crankshaft pulley
5 Fuel feed pump 11 Oil drain valve 17 Belt tensioner
6 Remote fuel filter 12 From charged air cooler 18 Power take off drive
Figure 2
Engine, structure 2
View A : top side View B : turbocharger side View C : rear side

1 From charged air cooler 6 Alternator 11 Turbocharger
2 Engine oil filter 7 To charged air cooler 12 Flywheel
3 Flywheel housing 8 Valve cover 13 Power take off (option)
4 Starter 9 Lifting bracket 14 Coolant pump
5 Breather 10 Oil filler cap
Service Information

Profile:
EXC, EC360B LC [GB]
Engine, description
Machine serial no. EC330B: 10713 ~ , 80001 ~ , EC360B: 12152 ~ , 80001 ~
Model Engine model number Machine serial number

EC330B D12DEBE2 10712 ~
D12DEBE3 80001 ~
EC360B D12DEBE2 12152 ~
D12DEBE3 80001 ~
 D12DEBE2 and D12DEBE3 are 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 D12DEBE2 and D12DEBE3 have 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 D12DEBE2 and D12DEBE3 have electronic control with unit injectors one for each cylinder and
which operate at a very high pressure.
 The fuel feed pump is a gear driven type and is driven from the engine timing gear with the same gear.
Figure 1
D12DEBE2 Engine, structure
A Water from engine B To charged air cooler

1 Crankshaft pulley 9 Fuel filter 17 Breather
2 Belt tensioner 10 Alternator 18 Starter
3 Water from engine 11 Fan drive and pulley 19 Speed sensor
4 Lifting bracket 12 Air-condenser compressor 20 Fuel pump
5 ITo charged air cooler 13 Alternator belt 21 Engine oil filter
6 Fuel feed pump 14 Fan belt 22 Water separator
7 E-ECU 15 Oil pan 23 Flywheel housing
8 Coolant temperature sensor 16 Oil drain valve 24 Engine oil filter
Figure 2
D12DEBE3 Engine, structure
A Form charged air cooler B To charged air cooler

1 Crankshaft pulley 9 Fuel filter 17 Breather
2 Belt tensioner 10 Alternator 18 Starter
3 Intake to charged air cooler 11 Fan drive and pulley 19 Speed sensor
4 Lifting bracket 12 Air-condenser compressor 20 Fuel pump
5 To charged air cooler 13 Alternator belt 21 Engine oil filter
6 Fuel feed pump 14 Fan belt 22 Water separator
7 E-ECU 15 Oil pan 23 Flywheel housing
8 Coolant temperature sensor 16 Oil drain valve 24 Engine oil filter
Service Information

Engine characteristic curve 210 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Engine characteristic curve

Engine characteristics
Item Specification
Rated power 250 ps / 1700 rpm
Maximum torque 128 kgf·m / 1400 rpm
Minimum fuel consumption 150 g /ps·hr
Rated fuel consumption 157 g / ps·hr
Figure 1
Engine, characteristic curve
A. Power (PS)
B. Torque (kg·m)
C. Engine speed (rpm)
D. Fuel consumption (g/ps·hr)
Service Information

Profile:
EXC, EC360B LC [GB]

Item Specifications
Rated power 250 ps/ 1700 rpm
Maximum torque 138 kgf·m /1275 rpm
Minimum fuel consumption 149 g/ps·h
Rated fuel consumption 153 g/ps·h
Figure 1
A. Power (PS)
B. Torque (kg·m)
C. Engine speed (rpm)
D. Fuel consumption (g/ps·hr)
Service Information

Profile:
EXC, EC360B LC [GB]

Model Serial number

D12DEBE2 Engine
EC330B 10713 ~
EC360B 12152 ~
Item Specifications
Rated output (Net) 245 kW 333 PS/ 1800 rpm ( 328 HP/ 1800 rpm)
Maximum torque (Net) 1720 N m / 175 kgf m/ 1350 rpm (1269 lbf ft / 1350 rpm)
Fuel consumption 144 g / PS·h at 1800 rpm
Figure 1

Model Serial number

D12DEBE3 Engine
EC330B, EC360B 80001 ~
Item Specifications
Rated output (Net) 245 kW 333 PS/ 1800 rpm ( 328 HP/ 1800 rpm)
Maximum torque (Net) 1720 N m / 175 kgf m/ 1350 rpm (1269 lbf ft / 1350 rpm)
Fuel consumption 144 g / PS·h at 1800 rpm
Figure 2
A Fuel consumption : g/kWh (g/PS–HR) C Engine speed (RPM)

B Torque : Nm (kg–m) D Power kW (PS)
Service Information

Basic check, Engine 210 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Basic check, Engine

NOTE!
Certain tests and checks are performed with unlocked safety locking lever. Make sure that the machine cannot operate
unexpectedly when the safety locking lever is unlocked.
Purpose of the basic check

The purpose of the basic check is to provide fast and accurate information about the general condition of the engine.
The basic check should be performed and evaluated according to instructions in the PC-tool VCADS Pro.
Tests included in the basic check
The basic check which is divided into the following tests should be performed after reading out error codes and checking
parameters.
Tests:
1. Cylinder compression, test

The purpose of the test is to show if any cylinder has a deviating compression pressure. The test replaces the old
pressure check method but does not give any absolute values.
2. Cylinder balancing, test
The purpose of the test is to show if there is any deviation in the fuel injection to a cylinder.
3. Feed pressure, test
The purpose of the test is to check that the feed pressure is as per specification.
4. Sensor, test
The purpose of the test is to check the function of all sensors.
Service Information

Troubleshooting 210 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Troubleshooting
General about troubleshooting
When a malfunction is suspected or has been confirmed, it is important to identify the cause as soon as possible.
The starting point for all troubleshooting is that there is some type of trouble symptom or malfunction.
Malfunctions can be indicated by:
 generation of error codes

 detection of a malfunction symptom.
Troubleshooting work
The first step in troubleshooting is to gather information from the operator concerning the malfunction symptoms, see
Electrical and information system, Collection of basic data. Then, attempt to pin-point the cause by checking in a certain
order, for more information, see Electrical and information system, troubleshooting strategy.
The different checking steps are:
 Check error codes

 Check parameters
 Perform basic check
Troubleshooting information
The following is included in Electrical and information system and is used when troubleshooting:
1. Troubleshooting strategy
Describes troubleshooting work, step by step.
2. Troubleshooting, assistive devices
Brief summary of the assistive devices that are available for troubleshooting.
3. Functional checks and tests, VCADS Pro
Brief description of VCADS Pro. For a detailed description, see VCADS Pro User’s Manual.
4. Error code information
Contains information regarding error code design, lists of all error codes and error code information about each
error code.
5. Components, troubleshooting and specifications
Contains methods and measuring values for troubleshooting of components. Also includes wiring diagrams and
certain specifications.
6. Parameters
Incorrectly set parameters may cause malfunction symptoms. The parameter list includes all limit and command
values for parameters.
7. Control units, functional description
Describes the functions of the control units, inputs and outputs as well as communication between the various
control units.
8. Control units, active and passive measuring
Contains measuring values for active and passive measuring of the ECUs.
9. Software functions
Describes the pre-requisite conditions for the control and monitoring functions that are performed by the software
in the ECUs.
Service Information

Valves, adjusting 214 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Valves, adjusting
Op nbr 214-012
88820003 Setting tool

9993590 Gear wheel
Feeler gauge
WARNING
Risk of burns - stop the diesel engine and allow it to cool down before starting any work.
1. Place the machine in service position B. See 091 Service positions
2. Open the engine hood.
3. Remove step (1).
Figure 1
Removal, step
4. Remove crankcase ventilation hose (1).

Figure 2
Removal, crankcase ventilation hose
5. Remove valve cover (1).
Figure 3
Removal, valve cover
6. Remove the protective cover on the flywheel housing and install tool 9993590, an extension and a ratchet handle.
Figure 4
9993590, extension and ratchet handle
Adjusting inlet valve
7. Turn the flywheel with tool 9993590 until the nearest dash marking on the camshaft is between the marks on the
bearing cap.
NOTE!
The number identifies the cylinder for which both inlet and exhaust valves are in correct position for adjusting.
NOTE!
Cylinder 1 is closest to the engine timing gear.
Figure 5
Camshaft marking
8. Loosen lock nut (2) on the rocker arm and adjust screw (1) to get the correct valve clearance according to
214 Valve mechanism, double rocker arm and tighten the lock nut. Tightening torque: see
214 Valve mechanism, tightening torques
Figure 6
1. Adjusting screw
2. Lock nut
3. Feeler gauge
Adjusting exhaust valve
9. Loosen lock nut (2) on the rocker arm and adjust screw (1) to get the correct valve clearance according to
214 Valve mechanism, double rocker arm and tighten the lock nut. Tightening torque: see
Figure 7
1. Adjusting screw
2. Lock nut
3. Feeler gauge
10. Check-measure the valve clearance according to 214 Valve mechanism, double rocker arm.
NOTE!
Before checking the double rocker arm's clearance, check that the exhaust valve clearance is correct according to
214 Valve mechanism, double rocker arm.
Checking, double rocker arm (IEGR)
11. Loosen the drain nipple and drain air and oil from the double rocker arm.
Figure 8
1. Draining nipple
12. Insert the go-side of gauge 88820003 between the double rocker arm's contact surface and the camshaft's basic
circle. The go-side must be able to pass between the arm contact surface and the camshaft, if the IEGR-"lift" is not
too great.
Figure 9
Go-and-stop gauge 88820003
1. Stop-side of gauge
2. Go-side of gauge
13. Insert the stop-side of 88820003 between the double rocker arm's contact surface and the camshaft's basic circle.
The stop-side must not be able to pass between the contact arm surface and the camshaft. If it does, the IEGR-"lift"
is too small.
NOTE!
If the go-side of the gauge passes between the double rocker arm's contact surface and the camshaft's basic circle
and if the stop-side does not, the clearance for the double rocker arm is correct. If not, the double rocker arm must
be adjusted as follows:
14. Tighten the drain nipple. Tightening torque: see 214 Valve mechanism, tightening torques
15. Adjust the other valves and check-measure the double rocker arm clearance in the same way.
NOTE!
The drain nipple on the double rocker arm must be open during the adjustment procedure.
Figure 10
Double rocker arm
1. Follower arm (IEGR-rocker arm)

2. Exhaust rocker arm
3. Stop nut
4. Sleeve
5. Nipple
6. Lock nut
7. Piston
Adjusting, double rocker arm (IEGR)
16. Keep the camshaft in the same position as when adjusting the valve clearance. Hold piston (7) and loosen lock nut
(6) with an Allen head wrench.
17. Insert adjusting tool 88820003 between the double rocker arm's contact surface and the camshaft's basic circle.
Turn piston (7) with an Allen key so that zero clearance is obtained between the double rocker arm, the tool, and
the camshaft.
NOTE!
Zero clearance means that the adjusting tool does not slide smoothly between the double rocker arm and the
camshaft.
Figure 11
Adjusting tool 88820003
18. Tighten lock nut (6) while firmly holding piston (7) in the correct position. Tightening torque: see
19. Check-measure according to steps 8–12.
20. Install the valve cover, see 211 Valve cover, tightening torque
21. Close the engine hood.
22. Restore the machine to operating condition.

Service Information

Oil level sensor, changing 217 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]EXC, EC360B LC [GB]
Oil level sensor, changing

Op nbr 217-005
9998547 Lifting tool

9998648 Fixture
9986485 Support
WARNING
WARNING
Removal of residual pressure from the circuit must be done prior to any maintenance.
NOTE!
Cable ties and clamps that secure hoses and electrical wiring must be removed and then replaced when installing.
1. Place the machine in the service position B. See 091 Service positions
2. Turn off the battery disconnect switch.
3. Remove the engine. See 210 Engine, removing

NOTE!
Place the engine on the work stand.
4. Drain the engine oil into a collection container.
5. Remove engine oil dipstick gauge (1).
6. Remove oil level sensor connector (2) and disconnect crankcase ventilation hose (1) from the oil pan.
Figure 1
Removal, oil level sensor connector and crankcase ventilation hose
7. Remove the oil pan mounting screws and then remove the oil pan from the engine block.
8. Remove oil level/temperature sensor (2) with connector (1) from the oil pan and then replace with a new one.
Figure 2
Removal, oil level/temperature sensor and connector
NOTE!
Do not reuse the O-ring.
NOTE!
Make sure that there is no leakage from the O-ring when assembling.
9. Install the oil pan to the engine block.
10. Fit oil level sensor connector (2) and connect crankcase ventilation hose (1) to the oil pan.
Figure 3
Installation, oil level sensor connector and crankcase ventilation hose
11. Install engine oil dipstick gauge (1).
12. Fill the engine with the specified oil.

NOTE!
Pay attention to the position of direction for cushion and mounting screws (front/rear) when assembling.
13. Install the engine and start the engine. Check for leaks and repair if needed. See 210 Engine, installing
Service Information

Engine mounting 218 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Engine mounting
WARNING
Switching of control units between machines, when troubleshooting or repairing, must not take place under any
conditions without reprogramming. Incorrect individual settings in the control unit can result in personal injuries
and machine damage. Reprogramming and read-out of software is done using VCADS Pro.
Figure 1
Engine mounting
A Cushion - upper (Front) : Violet and white C Cushion - upper (Rear) : Blue and white
B Cushion - lower (Front) : Violet and white D Cushion - lower (Rear) : Blue and white
NOTE!
Check the color markings for cushion installation.
Front (fan side) – Rear (flywheel side)
Tightening torque unit: N m (kgf m) (lbf ft)
No. Mounting position Tightening torque

1 Engine mounting cushion Front 686 ±68 (70 ±7) (505 ±50)
2 Engine mounting bracket Front 261 ±26 (26.7 ±2.7) (193 ±19.5)
3 Engine mounting cushion Rear 882 ±68 (90 ±7) (650 ±65)
4 Engine mounting bracket Rear 261 ±26 (26.7 ±2.7) (193 ±19.5)
Service Information

Profile:
EXC, EC360B LC [GB]
Engine mounting
WARNING
Turbocharger side view
Figure 1
Engine mounting, turbocharger side view
Front fan side view

Figure 2
Engine mounting, front fan side view
Rear flywheel side view
Figure 3
Engine mounting, rear flywheel side view
Cushion
Figure 4
Cushion mounting
NOTE!
 A - details
: Front fan side – Violet and white
 B - details
: Rear flywheel side – Blue and white
Tightening torque, unit: kgf·m (lbf·ft)

1 Engine mounting bracket (front) 19.0 ± 1.9 (137 ± 14)
* Apply loctite # 243
2 Engine mounting bracket (rear) 9.5 ± 0.95 (69 ± 7)
3 Engine mounting cushion 70 ± 7 (505 ± 51)
4 90 ± 9 (650 ± 65)
Service Information

Profile:
EXC, EC360B LC [GB]
Engine mounting
WARNING
Turbocharger side view
Figure 1
Engine mounting, fuel pump side view
Front fan side view

Figure 2
Engine mounting, front fan side view
Rear flywheel side view
Figure 3
Engine mounting, rear flywheel side view
Cushion
Figure 4
Cushion mounting
NOTE!
 A - details
: Front fan side – Violet and white
 B - details
: Rear flywheel side – Blue and white
Tightening torque, unit: kgf·m (lbf·ft)

1 Engine mounting bracket (front) 26.7 ± 2.7 (193 ± 20)
2 Engine mounting bracket (rear)
3 Engine mounting cushion 70 ± 7 (505 ± 51)
4 90 ± 9 (650 ± 65)
Service Information

Lubricating system, 220 Service Information 2014/7/2 0
description
Profile:
EXC, EC360B LC [GB]
Lubricating system, description

The engine is pressure-lubricated by means of gear-driven pump operating from the crankshaft of the engine via an
intermediate gear. The lubrication system has two full-flow filters operating in parallel fitted to a common filter bracket on
the right side of the engine. The oil cooler is also fitted to this bracket. The oil flow by four spring loaded valves.
 Reduction valve for maximum oil pressure

 Bypass valve for the oil cooler
 Overflow valve for the oil filter
 Piston cooling valve
Service Information

Lubrication system, 220 Service Information 2014/7/2 0
description
Profile:
EXC, EC360B LC [GB]
Lubrication system, description

The engine is force fed lubricated by a pump which is gear driven from the engine crankshaft via an intermediate gear.
The lubrication system has two full filters and by-pass filter.
The oil flow is regulated by six valves.
Three of the valves are a unit valve type
These are color coded to eliminate incorrect assembly.
It is possible that this color coding will be replaced by a number representing the opening pressure of the valve.
Figure 1
Lubricating oil flow diagram
1 Regulator valve (marked blue) 4 Overflow valve for full flow filter
2 Overflow valve for by-pass filter 5 Over pressure valve (marked yellow)
3 Piston cooling valve (marked orange) 6 Bypass valve for oil cooler (thermostat valve)
Service Information

Lubricating system, 220 Service Information 2014/7/2 0
description
Profile:
EXC, EC360B LC [GB]
Lubricating system, description

The gear pump (9) forces the lubrication oil, via the oil cooler (7) built into the cooling casing, through the right side filter
housing to the full-flow filters (13) and by-pass filter (14). The oil is then directed to the engine block main channel
(collecting pipe) and is distributed via channels to all lubrication points in the engine. The camshaft and rocker arm
mechanism is lubricated via a channel through the cylinder block and cylinder head, while the oil passes through the control
valve (6).
The air compressor (4) and PTO are lubricated by way of an external pipe from the right side filter housing. The turbo (5) is
lubricated by way of a pipe from the right side by-pass filter housing. The electric oil level sensor is mounted on the side of
the oil sump and is connected to the chassie cable harness on the D12C engine.
Figure 1
Lubricating oil flow diagram
1 Overflow valve filters (later 2 Piston cooling valve 3 Overflow valve filters (early
engines) engines)
4 Air compressor 5 Turbo 6 Control valve
7 Oil cooler 8 Nozzles 9 Gear pump
10 Safety valve 11 Pressure limiting valve 0.48 Mpa (4.8 12 Oil cooler by-pass valve
bar)
13 Full-flow filters 14 By-pass filter with built in overflow
valve
Service Information

Lubrication oil pump and 221 Service Information 2014/7/2 0
oil cooler, description
Profile:
EXC, EC360B LC [GB]
Lubrication oil pump and oil cooler, description

The oil pump is a gear type and is made entirely of aluminium and bolted to the engine front main bearing cap.
The pump housing and rear end plate are machined together and cannot be replaced separately.
The suction tube is also made of aluminium while the pressure pipe is of steel. Both are sealed with rubber seals to the
pump rear end plate.
The oil cooler is attached directly onto the cylinder block, inside the cover for cylinder block coolant channel and is thus fully
immersed in the coolant.
Figure 1
Oil pump and oil cooler
1 Engine 4 Supply pipe

2 Oil cooler 5 Suction tube
3 Oil pump
Service Information

Fuel system, description 230 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Fuel system, description

 The injection pump is bolted onto a separate bracket on the left side of the engine. It is powered by the engine
timing mechanism via a mechanical injection timing adjuster and a short shaft. The injectors used are made by
Bosch, type KBEL. Their opening pressure is adjusted by means of washers of varying thickness inserted above the
spring.
The fuel filter is attached to a bracket at the front of the engine. A bleeder nipple is also placed on the bracket. Even
when the sensor for fuel temperature/pressure is fitted on the bracket.
 A large proportion of the fuel passes through the overflow valve to the return pipe of the tank. This fuel through
flow cools the injection pump and ensures a more uniform fuel temperature. Fuel is drawn up from the tank,
through the tank strainer and through the control units cooling loop to the feeder pump inlet.
From the feeder pump fuel is forced through the filter and into the injection pump feed side. The leak-off line from
the injectors is connected to the feeder pump suction side.
Service Information

Profile:
EXC, EC360B LC [GB]

The fuel system for the D12C EC(D,E)E2 has an electronic control with unit injectors one for each cylinder and which operate
at a very high pressure.
The high pressure is created mechanically from the overhead camshaft via rocker arms.
The figure shows the fuel flow for the feeder system and its major components.
The feed pump is a gear driven type and is driven from the engine timing gear.
The drive shaft has two seals, one for fuel and one for oil inside the pump there are three valves, the pressure regulation
valve, a non-reverse valve for the hand pump, plus a valve for return fuel to the tank.
A water separator installed to protect the fuel system components provides a means to drain off water and contaminants
collected from the system.
Figure 1
Fuel flow system
1 Water separator 5 Hand pump 9 Fuel to injector 13 Over flow valve

2 Fuel suction line 6 Remote fuel filter 10 Feed pump Drain hose
3 Fuel tank 7 Cooling circuit for control unit 11 Injector
4 Fuel return line 8 E-ECU 12 Over flow valve
Service Information

Profile:
EXC, EC360B LC [GB]

Fuel line
The fuel is drawn with help of the fuel feed pump (1) through the tank unit (2), via fuel pre- filter (4) and water separator (5)
into the fuel filter housing (3). The fuel is then routed through the engine ECU’s cooling loop (6) to the overflow valve (7),
where the fuel from the tank is mixed with the fuel returned from the fuel channel (8) in the cylinder head, and then forward
to the suction side of the fuel feed pump (1).
The fuel feed pump (1) press fuel to the fuel filter housing (3), through the main filter (9) to the cylinder head fuel channel
(8). This channel provides every unit injector (10) with fuel via a ring formed passage around every unit injector in the
cylinder head. The overflow valve (7) regulates the fuel feed pressure to the unit injectors.
Fuel feed pump valves
The fuel feed pump has two valves: Safety valve (11), which allows fuel to flow back to suction side when the fuel pressure
become too high e.g. when the fuel filter is clogged. Check valve (12) opens when the hand pump in the filter housing (13) is
used.
Automatic deaeration
If air has entered the system, automatic deaeration occurs when the engine is started. The air is pushed through the
deaeration valve (14) down to the tank via the fuel return hose (15) from cylinder head. Deaeration of fuel filters when
changing filters is controlled by the valves (19), (25) and (14) in the filter housing.
Manual hand pump
The manual hand pump (13) in the filter housing is used to pump fuel (non-running engine), when the fuel system is empty.
The check valve (24) for the hand pump is placed within the fuel filter housing.
Manual water drain
WIF (water in fuel) –sensor (16) will via the ECU give an indication on the instrument panel. This indicates that it is necessary
to manually drain the water-separator (5) using the drain valve (18).
Miscellaneous
(20) Fuel pressure measuring point used for fault localization
(21) Pressure indicator
(22) Optional bowl heater
Figure 1
Fuel flow system
A from fuel tank B to ECU cooling C from fuel pump

D to unit injector E Bleeder line from backpressure check F Bleeder line to fuel tank
valve
G Fuel lift pump H Fuel pressure sensor I Sensor water in fuel
J Fuel heater K Drain L Heater power
M Heater ground N Water probe feed O Water probe signal
Service Information

Feed system, principles 230 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Feed system, principles

A diagram of fuel flow on the feed side is shown here. The fuel is drawn up the feed pump (1) through the water separator at
the tank side, past non-return valve (6), through cooling loop (5) (if the control unit has cooling) up to the overflow valve (8)
and from there, together with the return fuel which pass through the overflow valve, to the feed pump suction side.
The pump forces the fuel to the filter housing, past both of the non-return valve (10) for the hand pump (2) and through the
filter (3), to the cylinder head fuel galley.
There is a circular groove round each unit injector (9). Overflow valve (8) maintains a constant pressure for the fuel feed to
the injectors.
There are three valves in the feed pump, Regulator valve (11) lets the fuel flow back to the suction side when the pressure
becomes too high. Non-reverse valve (13) opens directly to the fuel tank. There are two bleeding nipples, one on the
cylinder head and one on the filter head (15).
A third nipple (16) is used to drain the fuel system.
Figure 1
Feed system
1 Feed pump 5 Cooling circuit for control unit 9 Injector 13 Non reverse valve
2 Hand pump 6 Non-return valve 10 Non-return valve 14 Bleeder screw
3 Remote fuel filter 7 water separator 11 Regulator valve 15 Bleeder screw
4 Control unit 8 Over flow valve 12 Via valve 16 Bleeder screw
Service Information

Feed system, principles 230 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Feed system, principles

Figure 1
Feed system
1 Fuel feed pump 2 tank unit 3 fuel filter housing

4 fuel pre- filter 5 water separator 6 engine ECU’s cooling loop
7 overflow valve 8 fuel channel 9 main filter
10 injector 11 Safety valve 12 Check valve
13 filter housing 14 deaeration valve 15 fuel return hose
16 WIF (water in fuel) –sensor 17 - 18 drain valve
19, valves 20 Fuel pressure measuring point used for 21 Pressure indicator
25 fault localization
22 Optional bowl heater 23 - 24 check valve
Service Information

Feed pump, checking feed 233 Service Information 2014/7/2 0
pressure
Profile:
EXC, EC360B LC [GB]
Feed pump, checking feed pressure

Op nbr 233-004
11666052 Pressure gauge

14290266 Hose
9993720 Nipple
14341364 Adapter
936442 Measuring nipple
1. Remove the plug and connect 936442, 14462 Hose and 11666052 Pressure gauge to the fuel filter housing.
Figure 1
1. 936442
2. 14290266
2. Make sure that the control lockout lever is in locked position. Start the engine and check the feed pressure.
NOTE!
Feed pressure is 45 ~ 50 psi (low idle rpm) and 70 ~ 75 psi (high idle rpm) respectively.
NOTE!
In case low feed pressure is suspected, check the feed pressure with loaded engine. Keep in mind that the pressure
gauge reading may be delayed.
In case pressure is too high:
If the pressure is too high, the overflow valve has to be checked.
In case pressure is too low:
If the feed pressure is low, the cause may be clogged suction line, defective feed pump, clogged fuel filter,
defective overflow valve, or the pump sucks air on the suction side.

Service Information

Fuel system, bleeding 233 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Fuel system, bleeding

Op nbr 233-001
2. Turn off the main electric power with the battery disconnect switch.
3. Turn the priming pump counterclockwise to unlock the plunger. Pump approximately 200 to 300 strokes until a
heavy resistance can be felt. Push the plunger down and turn clockwise to lock into position. Then bleed the fuel
system.
Figure 1
1. Priming pump on filter head.
NOTE!
Air bleeding may not be performed using the starter motor.
4. Turn on the electric power, start the engine and let it idle at low idle speed for a few minutes. If the engine is
difficult to start, bleed again with the priming pump.
NOTE!
The priming pump must not be used when the engine is running.
Service Information

Feed pump, replacing 233 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Feed pump, replacing

Op nbr 233-002
Feed pump, removing

NOTE! Take care of fuel spills by using collection containers.
2. Remove the engine hood.
Figure 1
Removal, engine hood
3. Disconnect hose fittings (1, 2) on the feed pump.

NOTE!
Cover the ends of the hoses to prevent impurities from entering the fuel system.
Figure 2
Removal, hose fitting
4. Remove the feed pump.

Figure 3
Removal, feed pump
Feed pump, installing
5. Change gaskets.
6. Install a feed pump with a new one.
7. Install the fuel hoses on the feed pump.

NOTE!
O-rings disassembled should be replaced with new ones.
8. Bleed the fuel system.
9. Start the engine and check for leaks.
10. Install the cover.

Service Information

Fuel filters, replacing 233 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Fuel filters, replacing

Op nbr 233-014
9996672 Oil filter wrench
A reduction in engine power can be caused by a clogged fuel filter. If the filter becomes clogged quickly, check fuel for
contamination and clean fuel tank if necessary.
2. Loosen the fuel filter with a filter wrench, and remove.
Figure 1
Removal, filter
1. Fuel filter
2. Filter wrench (Tool part no.: 9996672)
3. Clean the sealing surface of the filter head.
4. Lightly oil the rubber seal of the new filter, or moisten with diesel fuel.
5. Screw on the filter by hand until the seal makes contact, then tighten another half turn.
6. Perform the air bleeding operation. See 233 Fuel system, bleeding
Service Information

Fuel filter extra, replacing 233 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Fuel filter extra, replacing

Op nbr 233-015
11666167 Disassembly tool

9996672 Oil filter wrench
A reduction in engine power can be caused by a clogged fuel filter. If the filter becomes clogged quickly, check fuel for
contamination and clean fuel tank if necessary.
2. Disconnect wire harness connector (1).
Figure 1
Disconnect, wire harness connector
3. Loosen drain valve (2) to drain the sedimentl from water separator bowl (1).
Figure 2
Draining, fuel
4. Loosen the fuel separator bowl with a filter wrench, and remove.
Figure 3
Removal, fuel separator bowl
1. Water separator bowl

2. Filter wrench (Tool part no.: 11666167)
5. Loosen the fuel separator filter with a filter wrench, and remove.
6. Clean the sealing surface of the filter head.
7. Lightly oil the rubber seal of the new filter, or moisten with diesel fuel.
8. Screw on the filter by hand until the seal makes contact, then tighten another half turn. (Tool part no.: 9996672)
9. Screw on the filter bowl by hand until the seal makes contact, then tighten another half turn. (Tool part no.:
11666167)
10. Perform the air bleeding operation. See 233 Fuel system, bleeding
Service Information

Fuel tank, description 234 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Fuel tank, description

Model Type Machine serial number
EC330B A 10001 ~ 10429
B 10430 ~
80001 ~
EC360B A 10001 ~ 11249
B 11250 ~
80001 ~
Figure 1
Structure, fuel tank
1 Fuel tank 6 Hose 11 Level gauge

2 Cap 7 Screw 12 Tool box
3 Screen filter 8 Plain washer 13 Hydraulic tank
4 Drain valve 9 Spring washer 14 Screw
5 Clamp 10 Shim 15 Air breather
 When mounting the tank, adjust the height by use of shim (10).
 Maintain the clearance (" * " marked) within 10 mm (0.4 inch)
Tightening torque
Item no. Unit Remarks

Nm kgf m lbf ft
4 15.7 ~ 18.6 1.6 ~ 1.9 11.6 ~ 13.7 Drain valve Type A
44.1 ±4.9 4.5 ±0.5 32.5 ±3.6 Drain valve Type B
5 5.9 0.6 4.3 Clamp
7 511.9 ±51 52.2 ±5.2 377 ±38 Apply loctite #277
11 14.7 ±2 1.5 ±0.2 10.8 ±1.4 Level gauge
14 63.7 ±6.8 6.5 ±0.7 46.9 ±5.1 Screw
15 104.9 ±9.8 10.7 ±1 77.3 ±7.2 Connect Type B
1.4 ~ 1.6 0.14 ~ 0.16 1.0 ~ 1.2 Filter
63.7 ±6.9 6.5 ±0.7 46.9 ±5.1 Screw
Service Information

Fuel filler pump, 234 Service Information 2014/7/2 0
description
Profile:
EXC, EC360B LC [GB]
Fuel filler pump, description

 The pump outlet is plumbed directly to the fuel tank to reduce the risk of introducing contamination.
 The master switch must be in the ON position to operate the fuel filling pump.
NOTE!
The filter at the end of fuel filling pump inlet hose is a strainer, and will not filter impurities from the fuel. When filling use
CLEAN fuel only!
NOTE!
Do not operate the fuel filling pump without fuel or for extended periods of time.
NOTE!
Drain the fuel from the suction hose before putting it in the storage compartment.
NOTE!
In case the pump has been disassembled, assemble the pump so the that the sharp portion of the vane faces the
counterclockwise direction.
Figure 1
Structure, fuel filling pump (35 liter)
Figure 2
Structure, fuel filling pump (50 liter/minute + auto shut-off)
A. Auto shut-off controller

B. PVC Tube
Service Information

Fuel lines, description 235 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Fuel lines, description

The fuel level sensor is installed in the fuel tank.
When the fuel level gauge indicates EMPTY, there is still approximately 80 Liter (21.1 gal) remaining.
Fuel flow
Tank → Water separator → Fuel feed pump → Fuel filter → Fuel injection pump → Nozzle → Tank
Figure 1
Fuel line (Machine serial no.: EC330B: 10001 ~ 10235, EC360B: 10001 ~ 10828)
1. Suction hose
2. Water separator
3. Return hose
Figure 2
Fuel line (Machine serial no.: EC330B: 10236 ~ , 80001 ~ , EC360B: 10829 ~ , 80001 ~ )
1. Suction hose
2. Water separator
3. Return hose
Service Information

Water separator heater, 235 Service Information 2014/7/2 0
description
Profile:
EXC, EC360B LC [GB]
Water separator heater, description

In the winter season the engine may misfire due to the frozen fuel. The fuel can be heated up by the coil in the water
separator.
Figure 1
Water separator heater (optional equipment)
1. Fuel filter
2. Heated bowl
3. Fuel filter housing
Service Information

Inlet system, description 250 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Inlet system, description

Machine serial no.: EC330B: 10001 ~ 10235, EC360B: 10001 ~ 10828
Figure 1
Inlet system, structure
1. Turbocharger
2. Inlet hose
3. Air cleaner
Service Information

Profile:
EXC, EC360B LC [GB]

 The air required for combustion is filtered by the precleaner, air cleaner filter, and then supplied to the engine
combustion chamber through the turbocharger.
 For operator convenience the clogging of the inlet system is sensed and activates a warning lamp on the dash
board.
Figure 1
Inlet system, structure
Tightening torque Tightening torque

1 Air cleaner - 5 Sensor -
2 Precleaner - 6 Clamp 0.6 ~ 0.8 kgf·m
(4.33 ∼ 5.78 lbf·ft)
3 Clamp 0.6 ~ 0.8 kgf·m 7 Clamp 0.6 ~ 0.8 kgf·m
(4.33 ∼ 5.78 lbf·ft) (4.33 ∼ 5.78 lbf·ft)
4 Clamp 0.6 ~ 0.8 kgf·m 8 Turbocharger -
(4.33 ∼ 5.78 lbf·ft)
Service Information

Profile:
EXC, EC360B LC [GB]

Machine serial no.: EC330B: 10713 ~ , 80001 ~ , EC360B: 12152 ~ , 80001 ~
 The air required for combustion is filtered by the precleaner, air cleaner filter, and then supplied to the engine
combustion chamber through the turbocharger.
 For operator convenience the clogging of the inlet system is sensed and activates a warning lamp on the dash
board.
Figure 1
Inlet system
No. Item Tightening torque No. Item Tightening torque

1 Air cleaner - 5 Sensor -
2 Precleaner - 6 Clamp 5.8 ~ 7.8 N m (0.6 ~ 0.8 kgf m) (4.33
∼ 5.78 lbf ft)
3 Clamp 5.8 ~ 7.8 N m (0.6 ~ 0.8 kgf m) 7 Clamp 5.8 ~ 7.8 N m (0.6 ~ 0.8 kgf m) (4.33
(4.33 ∼ 5.78 lbf ft) ∼ 5.78 lbf ft)
4 Clamp 5.8 ~ 7.8 N m (0.6 ~ 0.8 kgf m) 8 Turbocharger -
(4.33 ∼ 5.78 lbf ft)
Service Information

Exhaust system, description 250 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Exhaust system, description

Figure 1
Exhaust system, structure
1. Turbocharger
2. Muffler
Service Information

Profile:
EXC, EC360B LC [GB]

 The exhaust system is designed so that exhaust noise is remarkably reduced when the exhaust gas is passed
through the manifold and muffler.
Figure 1
Exhaust system
Tightening torque Tightening torque

1 Screw 11.3 ± 1.1 kgf·m 6 Nut (Clamp) 6.9 ~ 10.4 kgf·m
(81.59 ± 7.94 lbf·ft) (49.82 ∼ 75.09 lbf·ft)
2 Screw 6.5 ± 0.7 kgf·m 7 Tube -
(46.93 ± 5.05 lbf·ft)
3 Nut 1.8 ± 0.2 kgf·m 8 Clamp -
(13 ± 1.4 lbf·ft)
4 Muffler - 9 Turbocharger -
5 Pipe -
Service Information

Profile:
EXC, EC360B LC [GB]

 The exhaust system is designed so that exhaust noise is remarkably reduced when the exhaust gas is passed
through the manifold and muffler.
Figure 1
Exhaust system
Item no. Tightening torque Item no. Tightening torque

1 Screw 110.8 ±10.7 N m (11.3 ±1.1 kgf m) 5 Nut (Clamp) 67.6 ~ 107.9 N m (6.9 ~ 10.4 kgf m
(81.59 ±7.94 lbf ft) (49.82 ∼ 75.09 lbf ft))
2 Nut 63.7 ±6.8 N m (6.5 ±0.7 kgf m) (46.93 6 Tube -
±5.05 lbf ft)
3 Muffler - 7 Clamp 32.3 ±2.9 N m (3.3 ±0.3 kgf m) (23.8
±2.1 lbf ft)
4 Pipe - 8 Turbocharger -
Service Information

Turbocharger, inspection 255 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Turbocharger, inspection
Op nbr 255-002
If the engine looses a lot of charge pressure, it becomes weak. The best way of checking the engine performance is to check
the stall speed of the machine. If the engine looses a little charge pressure, this will not noticeably affect the performance.
The engine may possibly emit a little more black smoke. A slightly impaired charge, because of a small air leakage in the
charge-air system, may manifest itself as a high-frequency whistling noise at full load. This may be confused with a bearing
noise.
1. Remove any plate, heat shields or similar, which may prevent detachment of hoses and pipes to and from the
turbocharger.
2. Disconnect the inlet hose from the turbocharger.
Figure 1
Principle illustration
1. Inlet hose
2. Exhaust pipe
3. Charge air pipe
3. Check the compressor rotor. In case of damage to the compressor rotor, replace turbocharger. See
255 Turbocharger, replacing.
4. Remove charge air hose between the charge air pipe and intercooler.
5. Check if there is oil in a fluid form in the charge air hose, as this would be an indication of worn bearings and seals
in the turbocharger.
6. Detach the exhaust pipe from the turbocharger.
7. Check the turbine rotor. If the turbine rotor is damaged, replace turbocharger, see 255 Turbocharger, replacing.
8. Restore the machine.

Service Information

Turbocharger, replacing 255 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Turbocharger, replacing
Op nbr 255-071
WARNING
Removal
3. Remove foot step (1).
Figure 1
Removal, foot step
4. Remove expansion tank (3) and bracket (2) as an assembly.
Figure 2
Removal, expansion tank and bracket
1. Turbocharger
2. Bracket
3. Expansion tank
5. Remove clamp (1) assembled to the turbocharger side.
Figure 3
Removal, clamp
6. Remove silencer hood (1).
Figure 4
Removal, silencer hood
7. Remove two U-bolts for silencer mounting, and exhaust pipe (2), then remove as an assembly from turbocharger
(3). Remove turbocharger (3).
Figure 5
Removal, U-bolts, turbocharger and exhaust pipe
1. Silencer
2. Exhaust pipe
3. Turbocharger
8. Disconnect hose (2) connected to the air cleaner and hose (1) connected to the charge air cooler.
Figure 6
Disconnect, hose
9. Remove pressure (delivery) oil pipe (2) and return oil pipe (1) on the turbocharger.
Figure 7
Removal, pressure (delivery) oil pipe
10. Remove bracket (1) for engine oil dipstick gauge mounting on the engine block.
Figure 8
Removal, bracket
11. Remove the mounting screws for exhaust manifold (1), then remove exhaust manifold (1) and turbocharger (2) as
an assembly.
Figure 9
Removal, screws
NOTE!
Pay attention not to lose disassembled gaskets. Especially, the gasket on the return oil pipe must not drop into the
charge air cooler pipe.
12. Remove turbocharger (1) from exhaust manifold (2).
Figure 10
Removal, turbocharger
13. Clean all sealing surfaces.

NOTE!
In case of turbocharger failure, all inlet pipes and hoses must be checked and cleaned. Remains of broken turbo
vanes in the inlet pipes can result in engine failure.
Installation
NOTE!
Always use new seals (gaskets) when installing.
14. Fit the new turbocharger to exhaust manifold.
15. Install the turbocharger and exhaust manifold to the engine block.
16. Install the engine oil dipstick tube bracket on the engine block.
17. Fit the return oil pipe to the turbocharger.
18. Fill the turbocharger with clean oil, use an oil can.
NOTE!
Make sure that no impurities enter the connection. Use a strainer when filling.
19. Connect the pressure (delivery) oil pipe to the turbocharger.
20. Connect the hoses to the air cleaner and to the charge air cooler.
21. Install the exhaust pipe on the turbocharger.
22. Install the silencer.
23. Install the silencer hood.
24. Start the engine and check for leaks.

Service Information

Air cleaner and precleaner, 256 Service Information 2014/7/2 0
description
Profile:
EXC, EC360B LC [GB]
Air cleaner and precleaner, description

Figure 1
Air cleaner and precleaner
A Standard B Oil bath air cleaner - Option

1 Precleaner 1 Rain cap
2 Air sensor 2 Air sensor
3 Air cleaner 3 Air cleaner - oil bath
4 Vacuator 4 Air cleaner
5 Vacuator
Service Information

Air cleaner and precleaner, 256 Service Information 2014/7/2 0
description
Profile:
EXC, EC360B LC [GB]
Air cleaner and precleaner, description

Figure 1
Air cleaner and precleaner
1 Rain cap
2 Air sensor
3 Oil bath air cleaner
4 Air cleaner
5 Vacuator
Service Information

Charge air cooler, 258 Service Information 2014/7/2 0
description
Profile:
EXC, EC360B LC [GB]
Charge air cooler, description

Model Machine serial number
EC330B 10236 ~ 10712
EC360B 10829 ~ 12151
Figure 1
1 Clamp tightening torque: 1.0 ±0.1 kgf m 6 Radiator

(7.2 ±0.72 lb ·ft)
2 Gap (Clamp to clamp): 205 mm 7 Condenser and receiver dryer
3 Gap (Clamp to charge air cooler center: 292.5 mm 8 Gap (Radiator core to charge air cooler core): 119.5 mm
4 Gap (Clamp to Radiator center): 86.5 mm 9 O-ring
5 Charge air cooler 10 Hose

EC330B 10718 ~
80001 ~
EC360B 12067 ~
80001 ~
Figure 2
1 Clamp tightening torque: 13.7 ±3.9N m (1.4 ±0.4 kgf 6 Radiator
m) (10.1 ±2.9 lbf ft)
2 Gap (Clamp to clamp): 205 mm (8 inch) 7 Condenser and receiver dryer
3 Gap (Clamp to charge air cooler center): 290 mm 8 Gap (Radiator core to charge air cooler core): 119.5 mm
(11.4 inch) (4.7 inch)
4 Gap (Clamp to Radiator center): 87 mm (3.4 inch) 9 O-ring
5 Charge air cooler 10 Hose
Service Information

Cooling system, description 260 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Cooling system, description

EC330B 10001 ~ 10235
EC360B 10001 ~ 102828
The radiator core is a plate fin type and the charge air cooler is a wave fin type. Air is drawn into the engine compartment
passing through the radiator and charge air cooler as the fan rotates.
The charge air cooler is installed to the radiator frame.
WARNING
Before removing the radiator cap, stop the engine and let it cool down sufficiently. When removing it, turn it slowly
to release the pressure.
Figure 1
1. Radiator
2. Gauge
3. Inlet hose
4. Charge air cooler
5. Outlet hose

EC330B 10236 ~ 10712
EC360B 10829 ~ 12151
Figure 2
1 Gap (Fan to radiator core): 89 mm 5 Charge air cooler

2 Gap (Radiator to charge air cooler core): 119.5 mm 6 Condenser and receiver dryer
3 Clamp (Tightening torque : 0.5 ~ 0.6 kgf m (3.61 ~ 4.33 lb ·ft) 7 Coolant level gauge (Tightening torque: 3 ~
4 Radiator 3.5 kgf m (21.7 ~ 25.3 lbf ft)
NOTE!
Never tighten clamp (3) exceeding specified torque. It may cause leakage.
Service Information

Profile:
EXC, EC360B LC [GB]

 A water cooling system maintains the temperature of the cylinder wall and lubricant at an optimum level so that the
engine can be operated at maximum efficiency. Coolant is force circulated through the radiator, cylinder head and
cylinder block by the internally mounted water pump.
 Coolant will not circulate through the radiator until the engine reaches operating temperature. When the
thermostat reaches 82 °C (180 °F), it will open, allowing flow from the head to the radiator.
Service Information

Profile:
EXC, EC360B LC [GB]

EC330B 10713 ~
80001 ~
EC360B 12152 ~
80001 ~
Coolant flow
The radiator core is a plate fin type and the charge air cooler is a wave fin type. Air is drawn into the engine compartment
passing through the radiator and charge air cooler as the fan rotates.
The charge air cooler is installed to the radiator frame.
WARNING
Before removing the radiator cap, stop the engine and let it cool down sufficiently. When removing it, turn it slowly
to release the pressure.
Figure 1
Radiator and cooler, descripion
1 Gap (Fin to radiator core): 130 mm (5.1 inch) 5 Charge air cooler
2 Gap (Radiator to charge air cooler core): 119.5 mm (4.7 inch) 6 Condenser and receiver dryer
3 Clamp (Tightening torque: 9.8 ~ 11.7 N m (1.0 ~ 1.2 kgf m) (7.2 ~ 7 Coolant level
1.2 lbf ft)
4 Radiator
NOTE!
Never tighten clamp exceeding specified torque. It may cause leakage.
Service Information

Radiator, replacing 261 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Radiator, replacing
Op nbr 261-008
WARNING
1. Place the machine in the service position F. See 091 Service positions
2. Drain coolant from radiator and prepare for radiator replacing.
3. Remove cowl (A), radiator fan guard and radiator fan (B).
Figure 1
Engine cowl
4. First remove lower hoses (C) connected to radiator and engine, and upper hoses (D).
5. Remove screw (E) fixing strut rod support under radiator.
6. Remove screw (F) fixing radiator.

Screw torque: 793 Nm (80.8 kgf m) (584 lbf ft)
Figure 2
Engine, radiator
7. Remove radiator lifting slowly.
8. Remove the radiator box guide and remove the intercooler placing it on the workbench.
9. Replace radiator with a new one.
10. For assembling, reverse disassembling procedure.
11. After completing the work, start the engine and then check for leaks.
Service Information

Coolant pump, replacing 262 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Coolant pump, replacing

Op nbr 262-002
WARNING
NOTE!
Cable ties and clamps that secure hoses and electrical wiring must be removed and then replaced when installing.
Removal
2. Drain the coolant. See 261 Coolant, changing
4. Remove the expansion tank with hoses and wire harness. See 261 Expansion tank, replacing
5. Remove turbocharger inlet hose (1).
Figure 1
Removal, hose
1. Turbocharger inlet hose

2. Turbocharger inlet pipe
6. Remove four mounting screws (1) for the main control valve cover and then open cover (2).
Figure 2
Removal, screws
7. Remove clamp (2) and screws (1). Remove the pipe from air cleaner outlet hose (3).
Figure 3
Removal, pipe
8. Remove coolant pipe (1).
Figure 4
Removal, coolant pipe
9. Remove engine oil dipstick gauge (2), and pipe (1) connected to the expansion tank hose.
Figure 5
Removal, engine oil dipstick gauge and pipe
10. Remove pipe (1) connecting to the thermostat housing.
Figure 6
Removal, pipe
11. Disconnect heater hose (1) from the coolant pump housing.
Figure 7
Disconnect, hose
12. Disconnect radiator lower hose (1) from the coolant pump housing.
Figure 8
Disconnect, hose
13. Remove four screws (3) and then remove coolant pump assembly (1) from the timing gear housing (2).
Figure 9
Removal, coolant pump assembly
14. Remove coolant pump (1) from coolant pump housing (2).
Figure 10
Removal, coolant pump
Installation
15. Fit the new coolant pump to the coolant pump housing.
NOTE!
Do not reuse the O-ring. Replace with a new one.
16. Install coolant pump assembly (1) to timing gear housing (2) then insert and tighten four screws (3).
Figure 11
Installation, coolant pump
NOTE!
Do not reuse the O-ring. Replace with a new one.
17. Connect radiator lower hose (1) to the coolant pump housing.
Figure 12
Connect, hose
18. Connect heater hose (1) to the coolant pump housing.
Figure 13
Connect, hose
19. Install pipe (1) connected to the thermostat housing.

Figure 14
Installation, pipe
NOTE!
Do not reuse the gasket. Replace the gasket with a new one.
20. Fit engine oil dipstick gauge (2), and pipe (1) connected to the expansion tank hose.
Figure 15
Installation, engine oil dipstick gauge and pipe
NOTE!
Do not reuse the seal. Replace the seal with a new one.
NOTE!
Coat the new seal with grease.
21. Install coolant pipe (1).
Figure 16
Installation, pipe
NOTE!
Do not reuse the gasket. Replace the gasket with a new one.
22. Install the pipe and tighten screws (1). Fit the hose to the pipe with clamp (2).
Figure 17
Installation, pipe and hose
23. Tighten mounting screws (1) for main control valve cover (2) and then close the cover.
24. Install turbocharger inlet hose (1).
25. Install the expansion tank with hoses and wire harness. See 261 Expansion tank, replacing
26. Fill the coolant through the expansion tank. See 261 Coolant, changing
27. Start the engine and check the coolant level. Inspect for leaks and repair if needed.
Service Information

Thermostat, replacing 262 Service Information 2014/7/2 0
Profile:
EXC, EC360B LC [GB]
Thermostat, replacing
Op nbr 262-098
9998619 Drift
Flange bolt (M 8 x 20)
Flange bolt (M 8)
3. Slowly loosen the expansion tank cap and drain coolant from radiator.
NOTE!
Close the drain valve after draining the coolant in about 4 minutes.
4. Disconnect hose (1) on the expansion tank and remove bracket (2).
Figure 1
Removal, hose and bracket
1. Hose
2. Bracket
3. Thermostat housing
5. Remove two screws (1) from the exhaust manifold located closest to the thermostat housing.
Figure 2
Removal, screws
1. Exhaust manifold's front attaching screws
6. Remove the thermostat housing, gasket and the thermostat.

NOTE!
Check the bolts for the thermostat housing, these must be of tensile strength class 10.9, if not or if there is any
doubt, replace them.
7. Remove the thermostat seal. Tap on the seal with a drift, turn and remove the seal.
8. Clean all sealing surfaces.
9. Fit a new seal ring on installation tool 999 8619.

NOTE!
The seal's plane surface must face the installation tool.
Figure 3
Fitting, seal ring
1. Seal ring
10. Install the seal ring by pressing on the installation tool with a pry bar until the tool bottoms out in the engine block.
11. Install the new thermostat.
12. Fit a new gasket on the thermostat housing . Tighten the screws by hand and check that the gasket is in the correct
position.
Figure 4
Fitting, thermostat housing
13. Install the screws on the exhaust manifold.

Tightening torque: 52 Nm (38.3 lbf ft)
14. Fit a flange bolt (M 8 x 20) and a flange nut between the exhaust manifold and the thermostat housing.
Screw the flange nut against the thermostat housing so the housing is firmly seated to the cylinder head.
Figure 5
Fitting, flange bolt
1. Flange bolt (M 8 x 20) and flange nut
15. Tighten the thermostat housing's screws in two steps.

Tightening torque, step 1: 10 Nm (7.4 lbf ft).
Tightening torque, step 2: 30 Nm (22.1 lbf ft).
Figure 6
Tightening diagram for thermostat housing
16. Connect hose (1) to the expansion tank and fit bracket (2).
Figure 7
Installation, hose and bracket
1. Hose
2. Bracket
3. Thermostat housing
17. Fill the engine with coolant.
18. Start and run the engine until warm, check for leaks.
If needed, adjust the coolant level.

Service Information

Fan belt and/or alternator 263 Service Information 2014/7/2 0
belt, replacing
Profile:
EXC, EC360B LC [GB]
Fan belt and/or alternator belt, replacing

Op nbr 263-012
WARNING
2. Turn belt tensioner (2) clockwise using a socket handle (1/2”), remove belt (1) and then install a new belt.
Figure 1
1. Belt
2. Belt tensioner (socket handle installation position)
NOTE!
The belt adjuster tension is very strong. Therefore pay attention to prevent injury after removing belt.
3. Close the engine hood.

Service Information

Engine block heater, Service Information 2014/7/2 0
description
Profile:
EXC, EC360B LC [GB]
Engine block heater, description

EC330B 10236 ~ 10712
EC360B 10829 ~ 12151
 The coolant heater (engine block) are practical engine starting aids for severe cold weather.
 The heater is designed for external power supply (AC 120 V).
Figure 1
Engine coolant heater
Watt (W) Voltage (V)

1 Heater location Engine block
2 Heater 1500 120
3 Cable assembly - 120 (15 A)
4 Clamp - -

EC330B 10713 ~
80001 ~
EC360b 12152 ~
80001 ~
 The coolant heater (engine block) are practical engine starting aids for severe cold weather.
 The heater is designed for external power supply (AC 240 V).
Figure 2
No. Item Watt (W) Voltage (V)

A Heater location Engine block -
Heater - 240
Cable assembly - 240 (A)
Clamp - -
Service Information

Normal condition 270 Service Information 2014/7/2 0
(Automatic position)
Profile:
EXC, EC360B LC [GB]
Normal condition (Automatic position)

EC330B 10001 ~ 10712
EC360B 10001 ~ 12151
Engine rpm will be controlled by the engine speed control switch on the control panel.
Emergency case
1. When the control system is defective, set the auto/manual switch to the MANUAL position.
2. Emergency switch up (high position) to set engine speed "H" mode.
3. Emergency switch down (low position) to set engine speed "I2" mode.
NOTE!
After repairing, set the auto/manual switch down to AUTOMATIC position.
Figure 1
Engine control, description
1 Engine speed control switch 3 Emergency switch
2 1/2 pump flow selector switch 4 Auto/Manual switch

EC330B 10713 ~
80001 ~
EC360B 12152 ~
80001 ~
Figure 2
Engine control, description
1 Engine speed control switch 3 Emergency switch

2 1/2 pump flow selector switch 4 Auto/Manual switch
Service Information

Engine speed control 275 Service Information 2014/7/2 0
switch, description
Profile:
EXC, EC360B LC [GB]
Engine speed control switch, description
Figure 1
Engine speed control switch
 The operator can easily control the work mode, engine speed, and maximum working horsepower by turning the
engine speed control switch if the VECU is in the automatic operating position.
 The switch also controls the engine speed and maximum working horsepower according to the built-in program of
VECU for each mode.
 The engine speed control switch changes the voltage input to VECU according to the position (step) selected.
Engine speed control switch
No. Wire specification Signal

1 0.85 R Power (B+)
2 0.85 W Output (SIG)
3 0.85 B Ground (GND)
4 Shield GND
Service Information

Engine speed control 275 Service Information 2014/7/2 0
switch, inspection
Profile:
EXC, EC360B LC [GB]
Engine speed control switch, inspection

Inspection
 Measure with the connector in the connected position.
Voltage output of engine speed control switch
Engine speed control switch step Mode Voltage (V)

1 I2 0.5
5 F1 2.5
9 H or P 4.5
Thank you for your purchase.
Have a nice day.
file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/7/2 9:31:39]

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Service Information

Document Title: Function Group: Information Type: Date:

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1. Fuel feed pump

Structure, turbocharger side view

Structure, top view

1. Air intake port

Structure, front side view

Structure, rear side view

Document Title: Function Group: Information Type: Date:

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View A : top side View B : turbocharger side View C : rear side

Document Title: Function Group: Information Type: Date:

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Model Engine model number Machine serial number

A Water from engine B To charged air cooler

A Form charged air cooler B To charged air cooler

Document Title: Function Group: Information Type: Date:

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Engine characteristic curve

Document Title: Function Group: Information Type: Date:

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Engine characteristic curve

Document Title: Function Group: Information Type: Date:

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Engine characteristic curve

Model Serial number

Engine characteristic curve

Model Serial number

A Fuel consumption : g/kWh (g/PS–HR) C Engine speed (RPM)

Document Title: Function Group: Information Type: Date:

Basic check, Engine

Purpose of the basic check

1. Cylinder compression, test

Document Title: Function Group: Information Type: Date:

 generation of error codes

 Check error codes

Document Title: Function Group: Information Type: Date:

88820003 Setting tool

1. Place the machine in service position B. See 091 Service positions

2. Open the engine hood.

3. Remove step (1).

4. Remove crankcase ventilation hose (1).

5. Remove valve cover (1).

Adjusting inlet valve

Adjusting exhaust valve

Checking, double rocker arm (IEGR)

1. Follower arm (IEGR-rocker arm)

Adjusting, double rocker arm (IEGR)

21. Close the engine hood.

22. Restore the machine to operating condition.

Document Title: Function Group: Information Type: Date:

Oil level sensor, changing

9998547 Lifting tool

2. Turn off the battery disconnect switch.

3. Remove the engine. See 210 Engine, removing

4. Drain the engine oil into a collection container.

5. Remove engine oil dipstick gauge (1).

9. Install the oil pan to the engine block.

11. Install engine oil dipstick gauge (1).

12. Fill the engine with the specified oil.

Document Title: Function Group: Information Type: Date:

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