download service repair workshop manual

1. Service Information
Document Title: Function Group: Information Type: Date:
Engine Tier 3 introduction 200 Service Information 2014/3/29
Profile:
SSL, MC70B [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 MC60B and
MC70B, description
200 Service Information 2014/3/29
Profile:
SSL, MC70B [GB]
Go back to Index Page
Engine for MC60B and MC70B, description
The engine is a vertical in-line, four cylinder, four stroke, water-cooled diesel engine with a direct injection system. The
engine for MC70B is 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. It 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, MC60B (Volvo D2.2A CAE2SW1U)
Figure 2
Engine, MC70B (Volvo D2.0A CAE2SW1U)

3. Service Information
Document Title: Function Group: Information Type: Date:
Engine, description 200 Service Information 2014/3/29
Profile:
SSL, MC70B [GB]
Go back to Index Page
Engine, description
MC70B (D2DCAE3)
The engine is a vertical in-line, four cylinder, four stroke, water-cooled diesel engine with a direct injection system. The
engine is 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 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 2014/3/29
Profile:
SSL, MC70B [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 2014/3/29
Profile:
SSL, MC70B [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 2014/3/29
Profile:
SSL, MC70B [GB]
Go back to Index Page
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!
NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
1. Put the machine in service position 1, see .
191 Service position 1
2. Switch the battery master switch off.
3. Open the drain valve and drain the coolant to a suitable container.
Figure 1
4. Carefully open the fill cap on the radiator to speed up the draining.

8. 5. When the radiator is drained, close the drain valve
6. Applies to engine equipped with high flow:
Open the drain valve and drain the hydraulic oil in a suitable container.
Figure 2
7. Remove the gas spring from the upper radiator support.
Figure 3
1. Gas spring
8. Remove the screw, moulding, stop, clamps and cover that holds the engine cover onto the chassis.
9. Remove the engine cover from the crossmember.

9. Figure 4
1. Engine cover mounting
10. Disconnect the radiator overflow hose from the radiator and drain the overflow bottle into the container.
Figure 5
1.
2.
3.
Radiator fill cap
Over flow hose
Over flow bottle
11. Transfer the coolant to a container with a cover and label the container as "Used Antifreeze". Dispose of the coolant
at an approved recycling facility.
12. Disconnect and plug up the return hose from the hydraulic cooler. Use 9993902 Disassembly tool and 9993903
Disassembly tool.
NOTE!
Some hydraulic oil may still be in the system.

10. Figure 6
13. Disconnect and plug up the swivel connection on the right side of the radiator.
Figure 7
14. Unbolt the cable from oil cooler.
15. Open the latches holding the cooling assembly together. Lift the oil cooler from the radiator. Carefully place the oil
cooler on a flat surface.
Figure 8
1.
2.
Oil cooler
Radiator

11. 3.
4.
Cable
Latch
16. Disconnect the upper radiator hose from the engine block.
Figure 9
17. Remove the fan guard.
18. Disconnect the lower radiator hose from the engine block.
Figure 10
1.
2.
Lower radiator hose
Upper radiator hose
19. Remove the locknuts and the washers from the bottom of the radiator.
20. Remove the capscrews, washers and locknuts from the top of the radiator.

12. Figure 11
1.
2.
Lower radiator mounts
Upper radiator mounts
21. Carefully lift the radiator assembly.
NOTE!
Use care when handling the radiator/oil cooler assembly. To prevent damage to the radiator drain valve, do not
place the radiator on its bottom surface without support blocks used on each side.
Figure 12
22. Disconnect the wires to the air cleaner restriction sensor.
Figure 13

13. 1. Restriction sensor
23. Loosen the hose clamp that secures the air intake hose to the engine induction manifold and remove the intake
hose. Plug or cover the induction manifold intake port to prevent entry of dirt or debris into the engine. Remove
the air cleaner assembly out of the frame.
Engine equipped with turbo remove the hose between air cleaner and turbo charger.
NOTE!
Remove the hose between the air cleaner and the turbo charger on engines equipped with turbo.
Figure 14
Picture shows MC60B
24. Loosen the capscrews holding the muffler and the capscrews holding the exhaust mainfold.
On engine equipped with turbo remove the exhaust manifold between muffler and turbo charger.
Figure 15
1.
2.
Muffler
Exhaust manifold
25. Remove the muffler assembly.

14. Figure 16
Picture shows MC70B
26. Disconnect the engine harness from the main chassis harness.
Figure 17
27. Tag and remove the wires from the positive (+) terminal on the starter.
Figure 18
1.
2.
3.
Positive (+) terminal
Starter flange
Negative (-) cable

15. 28. Tag and remove the negative (-) cable and ground wire from the starter flange.
29. Tag and remove the wire to the alternator.
Figure 19
30. Tag and remove the wire to the pre-heater.
Figure 20
1. Pre-heater
31. Close the valve on the fuel supply line at the water separator.
Figure 21

16. 1. Crane fuel supply
32. Tag, disconnect and plug the fuel supply– and fuel return line at the engine block.
Figure 22
1.
2.
Fuel return
Fuel supply
33. Disconnect the throttle cable from the fuel injection pump lever.
Figure 23
1.
2.
Throttle cable
Govenor lever
34. Applies to engine equipped with high flow.
Remove the high flow hoses.

17. Figure 24
35. Connect the lifting equipment 11668023 to the front (1) and rear (2) lift eyes. Remove all slack in the lift equipment
to prevent the engine from unintended movement during removal of the engine mounting hardware.
NOTE!
The engine must be lifted using an overhead or frame type hoist and lift sling or frame, rated at a minimum
capacity of 500 kg (1100 lb).
Figure 25
36. Remove capscrews from the rear engine mount.
Figure 26
37. Remove the capscrews from the front engine mount.

18. Figure 27
38. 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.
Weight, approximately: 240 kg (530 lb)
Figure 28
39. Slowly and carefully lift the engine from the machine.
40. Place the engine on engine stands or similar, strong and stable enough to support the weight of the engine.
NOTE!
If this engine is to be replaced, it may be necessary to remove all the hardware that will be used on the
replacement engine. These components may not be included with the replacement engine.

19. Service Information
Document Title: Function Group: Information Type: Date:
Engine, removing 210 Service Information 2014/3/29
Profile:
SSL, MC70B [GB]
Go back to Index Page
Engine, removing
Op nbr 210-070
11668023 Lifting tool
WARNING
Hot oil and hot engine coolant can cause severe burns!
NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
1. Park the machine in the service position 1, see 191 Service position 1
2. For lifting the loader arm when engine is not running see 191 Manual lifting of loader arm
3. Switch of the battery.
4. Open the drain valve and drain the coolant to a suitable container.
Figure 1
1. Drain valve
5. Carefully open the fill cap on the radiator to speed up the draining.
6. When the radiator is drained, close the drain valve.
7. Transfer the coolant to a container with a cover and label the container as "Used Antifreeze". Dispose of the coolant
at an approved recycling facility.

20. 8. Applies to engine equipped with high flow:
WARNING
Hydraulic oil is toxic and may be hot and highly pressurised. If jets of oil should penetrate the skin, medical
advice must be sought immediately. Allow the machine to cool and use protective equipment when
handling hydraulic oil.
Open the drain valve and drain the hydraulic oil in a suitable container.
Figure 2
9. Remove the cover on the right side over the engine.
Figure 3
10. Remove the gas spring from the lower support.
11. Remove the engine cover from the cross-member.
12. Disconnect the radiator overflow hose from the radiator.
Secure the hose so that the coolant remains in the overflow bottle.

21. Figure 4
1.
2.
3.
Radiator fill cap
Overflow hose
Overflow bottle
13. Applies to engine equipped with high flow:
Disconnect, tag and plug up the return hose from the hydraulic cooler.
NOTE!
Some hydraulic oil may still be in the system.
14. Disconnect, tag and plug the hose at the high flow pump.
Figure 5
Figure 6
1.
2.
High Flow pump
Alternator
1.
2.
3.
Drain Valve
Radiator mounting
Oil return hose

22. 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

23. 15. Disconnect the upper radiator hose from the engine block.
Figure 7
1.
2.
Lower radiator hose
Upper radiator hose
16. Disconnect the lower radiator hose from the engine block.
17. Disconnect the hoses for cab heating from the engine (Option).
Figure 8
1.
2.
Supply hose
Return hose
18. Loosen the fan guard and let it stay on the fan blades.
19. Remove the capscrews, lock nuts and the washers from the bottom of the radiator.