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Service Information
Document Title: Function Group: Information Type: Date:
Engine Tier 3 introduction 200 Service Information 2014/3/19
Profile:
SSL, MC80B [GB]
Engine Tier 3 introduction
Model Engine Part number Variant
MC60B D2.2 DCBE3 11852928 Standard hydraulics
Pilot Standard hydraulics
MC70B D2 DCAE3 11852929 Standard hydraulics
Self level hydraulics
Pilot Standard hydraulics
Pilot Self level hydraulics
Pilot High Flow self level
MC80B D3.4 DCBE3 11852930 Standard hydraulics
Self level hydraulics
Pilot Standard hydraulics
Pilot Self level hydraulics
MC90B/MC110B D3.4 DCCE3 11852931 Standard hydraulics
Self level hydraulics
Pilot Standard hydraulics
Pilot Self level hydraulics
Pilot High Flow self level
MC90B/MC110B HF D3.4 DCGE3 11852932 Standard hydraulics
Self level hydraulics
Pilot Standard hydraulics
Pilot Self level hydraulics
Pilot High Flow self level
Service Information
Document Title: Function Group: Information Type: Date:
Engine for MC80B, MC90B
and MC110B, description
200 Service Information 2014/3/19
Profile:
SSL, MC80B [GB]
Go back to Index Page
Engine for MC80B, MC90B and MC110B, description
The engine is a vertical in-line, four cylinder, four stroke, water-cooled diesel engine with a direct injection system. The
engines for MC90B and MC110B are also equipped with a turbocharger of radial flow type. The valve mechanism receives its
movement from the camshaft via rods and rocker arms. Turning direction is counter-clockwise seen from the flywheel. Firing
order is 1-3-4-2 and the first cylinder is on the flywheel side.
The fuel system is direct injection via a rotary high pressure pump, a so called MP pump. The pump has only one plunger
cylinder to pressurize the fuel and a distribution shaft which regulates the fuel flow to each cylinder.
The lubrication system consists of forced lubrication with a trochoid pump.
The air system consists of a dual element, self cleaning air cleaner.
The cooling of the engine is performed by a high capacity radiator and a hydraulic oil cooler. The type of fluid used in the
cooling system consists of 50% ethylene glycol and 50% water, which gives an anti-freeze protection.
Figure 1
Engine, MC80B (Volvo D3.4A CAE2SW3U)
Figure 2
Engine, MC90B and MC110B (Volvo D3.4A CAE2SW1U,
engine with high flow; Volvo D3.4A CAE2SW2U)
Service Information
Document Title: Function Group: Information Type: Date:
Engine, description 200 Service Information 2014/3/19
Profile:
SSL, MC80B [GB]
Go back to Index Page
Engine, description
MC80B (D3.4DCAE2)
The engine is a vertical in-line, four cylinder, four stroke, water-cooled diesel engine with a direct injection system. The valve
mechanism receives its movement from the camshaft via rods and rocker arms. Turning direction is counter-clockwise seen
from the flywheel. Firing order is 1-3-4-2 and the first cylinder is on the flywheel side.
The fuel system is fed by an electric fuel pump that supplies the fuel to the electronic fuel injection pump.
The lubrication system consists of forced lubrication with a trochoid pump.
The air system consists of a dual element, self cleaning air cleaner.
The cooling of the engine is performed by a high capacity radiator and a hydraulic oil cooler.
Figure 1
Service Information
Document Title: Function Group: Information Type: Date:
E-ECU, MID 128, changing
non-programmed ECU
200 Service Information 2014/3/19
Profile:
SSL, MC80B [GB]
E-ECU, MID 128, changing non-programmed ECU
Op nbr 200-068
VCADS Pro VCADS Pro Service Tool
88890180 Interface
88890027 Cable
This operation also includes required tools and times for applicable parts of the following operations:
 191 Service position 1
1. Place the machine in service position, see .
191 Service position 1
2. Connect VCADS Pro and start the operation 28423-3 MID 128 ECU, programming.
3. Unplug the connectors from E-ECU.
Figure 1
E-ECU
4. Change E-ECU.
5. Plug in the connector.
6. Turn on the voltage with the battery disconnect switch.
7. Finish VCADS Pro operation 28423-3 MID 128 ECU, programming.
8. Start the machine and check that no error messages appear.
9. Restore the machine to operating condition.
Service Information
Document Title: Function Group: Information Type: Date:
E-ECU, MID 128, changing
pre-programmed ECU
200 Service Information 2014/3/19
Profile:
SSL, MC80B [GB]
E-ECU, MID 128, changing pre-programmed ECU
Op nbr 200-070
VCADS Pro VCADS Pro Service Tool
88890180 Interface
88890027 Cable
This operation also includes required tools and times for applicable parts of the following operations:
 191 Service position 1
1. Place the machine in service position, see .
191 Service position 1
2. The new control unit has basic set parameters for the machine. If it is possible to read out customer parameters,
connect VCADS Pro and start the operation 17030-3 Parameter, programming. Save all read parameters to job card.
The operation is used to read out customer parameters from the old control unit to enable later comparison with
parameters in the new control unit.
3. Unplug the connector from E-ECU.
Figure 1
E-ECU
4. Change E-ECU.
5. Plug in the connector.
6. Turn on the voltage with the battery disconnect switch.
7. If customer parameters have been read out from the old control unit, compare these to the parameters in the new
control unit.


Connect VCADS Pro and perform the operation 17030-3 Parameter, programming. Save all read
parameters to job card.
Compare parameter settings on the job cards.
 Perform operation 17030-3 Parameter, programming and change customer parameters according to job
card for the old control unit.
8. Start the machine and check that no error messages appear.
9. Restore the machine to operating condition.
Service Information
Document Title: Function Group: Information Type: Date:
Engine, removing 210 Service Information 2014/3/19
Profile:
SSL, MC80B [GB]
Engine, removing
Op nbr 210-070
11668023 Lifting tool
9993902 Disassembly tool
9993903 Disassembly tool
WARNING
Hot oil and hot engine coolant can cause severe burns!
1. Put the machine in service position 1, see .
191 Service position 1
2. Turn off the electric power with the battery disconnect switch.
NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
3. Open the drain valve and drain the coolant into a suitable container.
Volume, approx.: 10 l (2.7 US gal)
Figure 1
4. Carefully open the filler cap on the radiator to speed up the draining.
Figure 2
1. Radiator cap
5. When the radiator is drained, close the drain valve.
6. Disconnect the lower end of the gas spring.
Figure 3
1. Gas spring
7. Remove the engine cover from the crossmember.
Figure 4
1. Engine cover mounting
8. Disconnect the radiator overflow hose from the radiator and drain the overflow bottle into a container.
Figure 5
1.
2.
3.
Radiator fill cap
Over flow hose
Over flow bottle
NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
Applies to engines equipped with High flow:
Open the hydraulic fluid drain plug and drain the hydraulic fluid into a suitable container (approx. 70 l, 18.5 US gal)
Figure 6
1. Hydraulic fluid drain plug beneath the left hand tower
9. Disconnect the return hose from the main hydraulic oil filter. Drain the oil cooler via the hose into a container. Plug
the connections.
Figure 7
1.
2.
Main hydraulic oil filter
Return hose
10. Disconnect the support cable from the hydraulic oil cooler.
Figure 8
1.
2.
3.
4.
Hydraulic oil cooler
Radiator
Support cable
Latch
11. Disconnect the right side swivel connection from the radiator by sliding the lock washer inwards.Use 9993902
Disassembly tool and 9993903 Disassembly tool. Use a suitable container to collect any spillage. Plug the
connections.
Figure 9
1. Swivel joint
12. Open the latches holding the cooling assembly together. Lift the oil cooler from the radiator. Carefully place the oil
cooler on a flat surface.
Weight, approximately: 20 kg (44 lb)
13. Disconnect the upper radiator hose from the engine block. Plug the connections.
Figure 10
1.
2.
3.
Upper radiator hose
Fan guard
Lower radiator hose
14. Disconnect the lower radiator hose from the engine block.
15. Remove the fan guard from the radiator.
16. Remove the screws from the radiator mounts. Carefully remove the radiator and place the radiator on a flat surface.
Weight, approx.: 40 kg (88 lb)
NOTE!
Use care when handling the radiator.
To prevent damage to the radiator drain connection, do not place the radiator on its bottom surface without
support blocks used on each side.
Figure 11
1.
2.
Lower radiator mounts
Upper radiator mounts
If the machine is equipped with cab heater, disconnect the hoses from the water pump.
Figure 12
1.
2.
Water pump
Cab heat hose
17. Disconnect the connector from the air cleaner restriction sensor.
Figure 13
1. Air cleaner restriction sensor
18. Disconnect the air intake hose from the engine intake manifold
Figure 14
Engine without Turbo
1.
2.
Air intake hose
Engine intake manifold
NOTICE
Always cover open air connections with a plastic bag and rubber bands. Gravel, dust and other particles in
these connections may result in engine failure!
If the machine is equipped with turbo, disconnect the air intake hose from the turbo.
Figure 15
Engine with turbo
1.
2.
Air intake hose
Turbo
19. Remove the air cleaner assembly from the mounting bracket.
20. Remove the exhaust pipe between the exhaust manifold and the muffler. Plug the exhaust manifold.
Figure 16
Engine without turbo
1.
2.
3.
4.
Exhaust pipe
Exhaust manifold
Muffler
Tail pipe
If the machine is equipped with turbo, remove the exhaust pipe between the turbo and the muffler. Plug the
connections to the turbo.
Figure 17
Engine with turbo
1.
2.
3.
4.
Exhaust pipe
Turbo
Muffler
Tail pipe
21. Remove the muffler out of the engine compartment
22. Disconnect the engine harness from the chassis harness.
Figure 18
1. Chassis harness connector to engine
23. Disconnect the preheater wire from the engine.
Figure 19
1. Preheater wire
24. Disconnect the throttle cable from the fuel injection pump lever.
Figure 20
1.
2.
3.
Throttle cable
Fuel injection pump lever
Clamp
25. Tag and disconnect the cables from the starter soleniod. Tag and disconnect the ground wires from the starter
flange.
Figure 21
1.
2.
3.
4.
Starter
Positive (B+)
Manoeuvre
Ground
26. Close the valve on the fuel supply line at the water separator.
Figure 22
1.
2.
3.
Water separator
Valve
Fuel supply line
27. Tag, disconnect and plug the fuel supply– and fuel return line from the engine.
Figure 23
1.
2.
Fuel supply line
Fuel return line
Applies to machines equipped with AC:
NOTICE
Refrigerant under pressure. Do not disconnect any hoses or connections on the air conditioning, thereby
involuntary releasing refrigerant.
28. Slightly loosen the screws holding the compressor to the mounting bracket and pivot the compressor towards the
engine. Remove the belt from the crankshaft pulley.
Figure 24
1.
2.
Crankshaft pulley
Compressor
29. Release the hoses between the compressor and the AC unit from the clamp.
Figure 25
AC unit hoses
30. Disconnect the connector from the AC.
31. Remove the compressor from the mounting bracket and put it aside.
Figure 26
Applies to engines equipped with High flow:
32. Tag, remove and plug the hoses from the high flow pump.
Suggest:
If the above button click is invalid.
Please download this document
first, and then click the above link
to download the complete manual.
Thank you so much for reading
Figure 27
1. High flow pump connection
Continued:
NOTE!
The engine must be lifted from the machine using an overhead hoist, rated at a minimum capacity of 500 kg (1100
lb).
33. Connect the lifting tool 11668023 to the front and rear lift eyes. Remove all slack in the lift equipment to prevent
the engine from unintended movement during removal.
Figure 28
Lifting tool
34. Remove screws, bushings and nuts from the rear and front engine mount.
35. Lift and move the engine slightly toward the rear of the machine until the transmission universal drive joint drops
free of the splined transmission drive shaft.
Figure 29
1.
2.
Transmission universal drive joint
Splined transmission drive shaft
NOTE!
Weight approximately: 340 kg (750 lb).
36. Slowly and carefully lift the engine from the machine.
37. Place the engine on engine stands or similar, strong and stable enough to support the weight of the engine.

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Volvo MC80B Skid Steer Loader Service Repair Manual Instant Download.pdf

  • 1. Service Information Document Title: Function Group: Information Type: Date: Engine Tier 3 introduction 200 Service Information 2014/3/19 Profile: SSL, MC80B [GB] Engine Tier 3 introduction Model Engine Part number Variant MC60B D2.2 DCBE3 11852928 Standard hydraulics Pilot Standard hydraulics MC70B D2 DCAE3 11852929 Standard hydraulics Self level hydraulics Pilot Standard hydraulics Pilot Self level hydraulics Pilot High Flow self level MC80B D3.4 DCBE3 11852930 Standard hydraulics Self level hydraulics Pilot Standard hydraulics Pilot Self level hydraulics MC90B/MC110B D3.4 DCCE3 11852931 Standard hydraulics Self level hydraulics Pilot Standard hydraulics Pilot Self level hydraulics Pilot High Flow self level MC90B/MC110B HF D3.4 DCGE3 11852932 Standard hydraulics Self level hydraulics Pilot Standard hydraulics Pilot Self level hydraulics Pilot High Flow self level
  • 2. Service Information Document Title: Function Group: Information Type: Date: Engine for MC80B, MC90B and MC110B, description 200 Service Information 2014/3/19 Profile: SSL, MC80B [GB] Go back to Index Page Engine for MC80B, MC90B and MC110B, description The engine is a vertical in-line, four cylinder, four stroke, water-cooled diesel engine with a direct injection system. The engines for MC90B and MC110B are also equipped with a turbocharger of radial flow type. The valve mechanism receives its movement from the camshaft via rods and rocker arms. Turning direction is counter-clockwise seen from the flywheel. Firing order is 1-3-4-2 and the first cylinder is on the flywheel side. The fuel system is direct injection via a rotary high pressure pump, a so called MP pump. The pump has only one plunger cylinder to pressurize the fuel and a distribution shaft which regulates the fuel flow to each cylinder. The lubrication system consists of forced lubrication with a trochoid pump. The air system consists of a dual element, self cleaning air cleaner. The cooling of the engine is performed by a high capacity radiator and a hydraulic oil cooler. The type of fluid used in the cooling system consists of 50% ethylene glycol and 50% water, which gives an anti-freeze protection. Figure 1 Engine, MC80B (Volvo D3.4A CAE2SW3U) Figure 2 Engine, MC90B and MC110B (Volvo D3.4A CAE2SW1U, engine with high flow; Volvo D3.4A CAE2SW2U)
  • 3. Service Information Document Title: Function Group: Information Type: Date: Engine, description 200 Service Information 2014/3/19 Profile: SSL, MC80B [GB] Go back to Index Page Engine, description MC80B (D3.4DCAE2) The engine is a vertical in-line, four cylinder, four stroke, water-cooled diesel engine with a direct injection system. The valve mechanism receives its movement from the camshaft via rods and rocker arms. Turning direction is counter-clockwise seen from the flywheel. Firing order is 1-3-4-2 and the first cylinder is on the flywheel side. The fuel system is fed by an electric fuel pump that supplies the fuel to the electronic fuel injection pump. The lubrication system consists of forced lubrication with a trochoid pump. The air system consists of a dual element, self cleaning air cleaner. The cooling of the engine is performed by a high capacity radiator and a hydraulic oil cooler. Figure 1
  • 4. Service Information Document Title: Function Group: Information Type: Date: E-ECU, MID 128, changing non-programmed ECU 200 Service Information 2014/3/19 Profile: SSL, MC80B [GB] E-ECU, MID 128, changing non-programmed ECU Op nbr 200-068 VCADS Pro VCADS Pro Service Tool 88890180 Interface 88890027 Cable This operation also includes required tools and times for applicable parts of the following operations:  191 Service position 1 1. Place the machine in service position, see . 191 Service position 1 2. Connect VCADS Pro and start the operation 28423-3 MID 128 ECU, programming. 3. Unplug the connectors from E-ECU. Figure 1 E-ECU 4. Change E-ECU. 5. Plug in the connector. 6. Turn on the voltage with the battery disconnect switch. 7. Finish VCADS Pro operation 28423-3 MID 128 ECU, programming. 8. Start the machine and check that no error messages appear. 9. Restore the machine to operating condition.
  • 5. Service Information Document Title: Function Group: Information Type: Date: E-ECU, MID 128, changing pre-programmed ECU 200 Service Information 2014/3/19 Profile: SSL, MC80B [GB] E-ECU, MID 128, changing pre-programmed ECU Op nbr 200-070 VCADS Pro VCADS Pro Service Tool 88890180 Interface 88890027 Cable This operation also includes required tools and times for applicable parts of the following operations:  191 Service position 1 1. Place the machine in service position, see . 191 Service position 1 2. The new control unit has basic set parameters for the machine. If it is possible to read out customer parameters, connect VCADS Pro and start the operation 17030-3 Parameter, programming. Save all read parameters to job card. The operation is used to read out customer parameters from the old control unit to enable later comparison with parameters in the new control unit. 3. Unplug the connector from E-ECU. Figure 1 E-ECU 4. Change E-ECU. 5. Plug in the connector. 6. Turn on the voltage with the battery disconnect switch. 7. If customer parameters have been read out from the old control unit, compare these to the parameters in the new control unit.   Connect VCADS Pro and perform the operation 17030-3 Parameter, programming. Save all read parameters to job card. Compare parameter settings on the job cards.
  • 6.  Perform operation 17030-3 Parameter, programming and change customer parameters according to job card for the old control unit. 8. Start the machine and check that no error messages appear. 9. Restore the machine to operating condition.
  • 7. Service Information Document Title: Function Group: Information Type: Date: Engine, removing 210 Service Information 2014/3/19 Profile: SSL, MC80B [GB] Engine, removing Op nbr 210-070 11668023 Lifting tool 9993902 Disassembly tool 9993903 Disassembly tool WARNING Hot oil and hot engine coolant can cause severe burns! 1. Put the machine in service position 1, see . 191 Service position 1 2. Turn off the electric power with the battery disconnect switch. NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. 3. Open the drain valve and drain the coolant into a suitable container. Volume, approx.: 10 l (2.7 US gal) Figure 1 4. Carefully open the filler cap on the radiator to speed up the draining.
  • 8. Figure 2 1. Radiator cap 5. When the radiator is drained, close the drain valve. 6. Disconnect the lower end of the gas spring. Figure 3 1. Gas spring 7. Remove the engine cover from the crossmember.
  • 9. Figure 4 1. Engine cover mounting 8. Disconnect the radiator overflow hose from the radiator and drain the overflow bottle into a container. Figure 5 1. 2. 3. Radiator fill cap Over flow hose Over flow bottle NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Applies to engines equipped with High flow: Open the hydraulic fluid drain plug and drain the hydraulic fluid into a suitable container (approx. 70 l, 18.5 US gal)
  • 10. Figure 6 1. Hydraulic fluid drain plug beneath the left hand tower 9. Disconnect the return hose from the main hydraulic oil filter. Drain the oil cooler via the hose into a container. Plug the connections. Figure 7 1. 2. Main hydraulic oil filter Return hose 10. Disconnect the support cable from the hydraulic oil cooler.
  • 11. Figure 8 1. 2. 3. 4. Hydraulic oil cooler Radiator Support cable Latch 11. Disconnect the right side swivel connection from the radiator by sliding the lock washer inwards.Use 9993902 Disassembly tool and 9993903 Disassembly tool. Use a suitable container to collect any spillage. Plug the connections. Figure 9 1. Swivel joint 12. Open the latches holding the cooling assembly together. Lift the oil cooler from the radiator. Carefully place the oil cooler on a flat surface. Weight, approximately: 20 kg (44 lb) 13. Disconnect the upper radiator hose from the engine block. Plug the connections. Figure 10 1. 2. 3. Upper radiator hose Fan guard Lower radiator hose
  • 12. 14. Disconnect the lower radiator hose from the engine block. 15. Remove the fan guard from the radiator. 16. Remove the screws from the radiator mounts. Carefully remove the radiator and place the radiator on a flat surface. Weight, approx.: 40 kg (88 lb) NOTE! Use care when handling the radiator. To prevent damage to the radiator drain connection, do not place the radiator on its bottom surface without support blocks used on each side. Figure 11 1. 2. Lower radiator mounts Upper radiator mounts If the machine is equipped with cab heater, disconnect the hoses from the water pump. Figure 12 1. 2. Water pump Cab heat hose 17. Disconnect the connector from the air cleaner restriction sensor.
  • 13. Figure 13 1. Air cleaner restriction sensor 18. Disconnect the air intake hose from the engine intake manifold Figure 14 Engine without Turbo 1. 2. Air intake hose Engine intake manifold NOTICE Always cover open air connections with a plastic bag and rubber bands. Gravel, dust and other particles in these connections may result in engine failure! If the machine is equipped with turbo, disconnect the air intake hose from the turbo.
  • 14. Figure 15 Engine with turbo 1. 2. Air intake hose Turbo 19. Remove the air cleaner assembly from the mounting bracket. 20. Remove the exhaust pipe between the exhaust manifold and the muffler. Plug the exhaust manifold. Figure 16 Engine without turbo 1. 2. 3. 4. Exhaust pipe Exhaust manifold Muffler Tail pipe If the machine is equipped with turbo, remove the exhaust pipe between the turbo and the muffler. Plug the connections to the turbo.
  • 15. Figure 17 Engine with turbo 1. 2. 3. 4. Exhaust pipe Turbo Muffler Tail pipe 21. Remove the muffler out of the engine compartment 22. Disconnect the engine harness from the chassis harness. Figure 18 1. Chassis harness connector to engine 23. Disconnect the preheater wire from the engine. Figure 19 1. Preheater wire 24. Disconnect the throttle cable from the fuel injection pump lever.
  • 16. Figure 20 1. 2. 3. Throttle cable Fuel injection pump lever Clamp 25. Tag and disconnect the cables from the starter soleniod. Tag and disconnect the ground wires from the starter flange. Figure 21 1. 2. 3. 4. Starter Positive (B+) Manoeuvre Ground 26. Close the valve on the fuel supply line at the water separator.
  • 17. Figure 22 1. 2. 3. Water separator Valve Fuel supply line 27. Tag, disconnect and plug the fuel supply– and fuel return line from the engine. Figure 23 1. 2. Fuel supply line Fuel return line Applies to machines equipped with AC: NOTICE Refrigerant under pressure. Do not disconnect any hoses or connections on the air conditioning, thereby involuntary releasing refrigerant. 28. Slightly loosen the screws holding the compressor to the mounting bracket and pivot the compressor towards the engine. Remove the belt from the crankshaft pulley. Figure 24 1. 2. Crankshaft pulley Compressor
  • 18. 29. Release the hoses between the compressor and the AC unit from the clamp. Figure 25 AC unit hoses 30. Disconnect the connector from the AC. 31. Remove the compressor from the mounting bracket and put it aside. Figure 26 Applies to engines equipped with High flow: 32. Tag, remove and plug the hoses from the high flow pump.
  • 19. Suggest: If the above button click is invalid. Please download this document first, and then click the above link to download the complete manual. Thank you so much for reading
  • 20. Figure 27 1. High flow pump connection Continued: NOTE! The engine must be lifted from the machine using an overhead hoist, rated at a minimum capacity of 500 kg (1100 lb). 33. Connect the lifting tool 11668023 to the front and rear lift eyes. Remove all slack in the lift equipment to prevent the engine from unintended movement during removal. Figure 28 Lifting tool 34. Remove screws, bushings and nuts from the rear and front engine mount. 35. Lift and move the engine slightly toward the rear of the machine until the transmission universal drive joint drops free of the splined transmission drive shaft. Figure 29 1. 2. Transmission universal drive joint Splined transmission drive shaft NOTE! Weight approximately: 340 kg (750 lb). 36. Slowly and carefully lift the engine from the machine. 37. Place the engine on engine stands or similar, strong and stable enough to support the weight of the engine.