service repair manual

1. Service Information
Document Title: Function Group: Information Type: Date:
Engine D9B, description
and operation
200 Service Information 2014/12/24
Profile:
GRD, G970 [GB]
Engine D9B, description and operation
D9B - tier 3 compliant
The D9B engine configuration consists of a four stroke, straight six cylinder, turbocharged, direct injected diesel engine with
charge air cooling and wet, replaceable cylinder liners.
The engine has an overhead camshaft and unit injectors, which are centered above the pistons and controlled by the
camshaft and a control unit (E-ECU).
The D9 uses V-ACT (Volvo Advanced Combustion Technology). The V-ACT D9B engine features a flexible high pressure fuel
injection with dual solenoid injectors and optimized air handling with a fixed geometry turbocharger. Electronically
controlled IEGR (Internal Exhaust Gas Recirculation) reduces NO formation and lowers emissions without the need for
exhaust after treatment. Volvo's latest engine management system, EMS2 is used to control all engine electronic functions.
The cylinders are numbered consecutively beginning at the pulley end. Engine rotational direction is counterclockwise as
seen from the flywheel end.
Figure 1
D9B

2. Service Information
Document Title: Function Group: Information Type: Date:
VCADS Pro, MID 128,
programming E-ECU
200 Service Information 2014/12/24
Profile:
GRD, G970 [GB]
VCADS Pro, MID 128, programming E-ECU
Op nbr 200-009
MID 128, E-ECU for D9
1. 







Turn on battery disconnect switch.
Start up the computer.
Connect VCADS Pro computer to the data link port in the machine.
Create a new job card.
Perform the operations no 28423-2 MID 128 ECU, programming.
Save performed work.
Shut down the computer and disconnect the adapter cable from data link port.
Turn off battery disconnect switch.

3. Service Information
Document Title: Function Group: Information Type: Date:
Engine, removing 210 Service Information 2014/12/24
Profile:
GRD, G970 [GB]
Engine, removing
Op nbr 210-070
9998547 Lifting tool
Lifting strap 2m, qty. 2
Puller
Engine, removal - D9 models G970, G976 and G990
1. Place the machine in the .
191 Service position
WARNING
Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage.
2. Remove the hydraulic oil tank covers and engine side doors. Refer to .
821 Engine hood, removing
3. Remove the engine lower side panel on both sides of the machine. On the right side of the machine, drain the
washer bottle. Tag and disconnect the hoses. Remove the washer bottle with the lower side panel.
Figure 1
Washer bottle and lower side panel
WARNING
Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot
coolant may rush out and cause severe burns.
4. Remove the expansion tank pressure cap. Add a 3/8" nipple to the draining valve.
NOTE!
Be sure that the valve does not turn.
NOTICE

4. Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
5. Connect a drain hose to the nipple. Drain the engine coolant into a suitable container. Refer to
.
260 Cooling system, volume (Models G930 - G940)
Figure 2
Draining the engine coolant
WARNING
Hot oil and hot engine coolant can cause severe burns!
6. Drain the engine oil. Refer to .
210 Engine D7, volume
WARNING
Only use lifting devices with adequate capacity.
7. Attach a safe lifting device to the engine hood assembly. Refer to .
821 Engine hood, removing
NOTE!
Be sure to seal all charge air tubes as soon as they are removed from the machine.

5. Figure 3
Left side of engine
1.
2.
3.
4.
5.
6.
7.
Wiring harness
Air intake tube
Air temperature restriction indicator
Bolt
Exhaust pipe
Charge air tube
Turbocharger
Left side
8. 





Disconnect the air intake tube at the turbocharger
Disconnect the wiring harness from the engine hood assembly.
Disconnect the exhaust pipe at the turbocharger
Disconnect the air temperature restriction indicator
Disconnect the coolant lines from the expansion tank.
Remove the bolts attaching the engine hood to the engine support frame legs. Refer to
.
821 Engine hood, removing

6. NOTE!
Be sure to seal all charge air tubes as soon as they are removed from the machine.
Figure 4
Right side of engine
1.
2.
3.
4.
Wiring harness
Bolt
Right rear engine support leg
Adapter - preheater to charge air cooler
Right side
9. 








Disconnect the wiring harness from the engine hood assembly.
Remove the bolts retaining the engine hood assembly to the engine support frame legs
Disconnect the wiring harness from the rear engine support frame leg.
Remove the right rear engine support frame leg
Remove the right rear motor mount to frame bolts
Disconnect the alternator wiring harnesses
Disconnect the wiring harnesses at the air conditioner, if equipped with air conditioning
Remove the adapter connecting the preheater to the charge air cooler
Relieve the tension from the accessory drive belt. Remove the belt from the alternator and air conditioning

7. 


compressor
Remove the mounting bolts from the air conditioning compressor to the mounting bracket
NOTE!
Pay attention to hose routing, particularly in the right rear corner of the machine. It will be helpful in the
procedure.
210 Engine, installing
NOTE!
Do not discharge the air conditioning compressor. Set the air conditioning compressor to the side without
opening the system.
Remove the alternator
NOTE!
Use a suitable container to collect any fuel that may leak out.
NOTE!
Clearly identify all hoses and connections prior to disconnecting them.
Disconnect the fuel lines at the fuel cooler ECU, pump outlet connection, the secondary filter return line
connection and the wiring harness at the filter head. Cut all cable ties
Figure 5
Fuel line connections
10. Remove the left rear engine support leg mounting bolts. Disconnect the wiring harness clamps from the leg. Cut all
cable ties. Remove the leg form the machine.
11. Disconnect the wiring harness to the starter. Cut all cable ties.
12. Remove the mounting bolts securing the charge air tube to the engine. Remove the clamps on both ends of the

8. charge air tube. Remove the charge air tube.
13. Loosen the clamps and disconnect the two heater coolant hoses. Disconnect the upper and lower radiator hoses.
WARNING
Only use lifting devices with adequate capacity.
14. Use an appropriate lifting strap and attach it to the rear cooling module. Before removing the mounting bolts, take
up the slack in the lifting strap, in order to support the cooling module. Weight 363 kg (800 lbs)
15. Remove the four mounting bolts from the cooling module. Cut the plastic ties that hold the hydraulic hoses in
place in order to gain enough slack to lift the cooling module.
16. Carefully raise the cooling module and move it to the rear of the machine; enough to give clearance between the
engine and the cooling module. Rest the cooling module securely on the fuel tank.
NOTE!
Pay attention when lowering the cooling module on top of the fuel tank. Avoid pinching the hoses to the fuel
sender and the hydraulic hoses to the coolers.
NOTE!
It may be necessary to remove the fuel cap or place blocking under the back of the cooling module in order to
prevent resting the cooling module on the fuel fill spout.
17. Remove the engine clutch drain.
Figure 6
1. Engine clutch drain
18. Install devices to support the pump drive prior to engine removal. Mount the support devices using the flange bolt
on both sides of the pump drive.

9. Figure 7
1.
2.
Support device
Wooden block
NOTE!
It is not necessary to remove the upper driveshaft or the protective cover.
19. Place wooden blocking under the upper driveshaft to prevent it from falling.
WARNING
Only use lifting devices with adequate capacity.
20. Attach a safe lifting device to the engine. Use toll number 9998547.Engine weight 1089 kg (2400 lbs)
21. Remove the bolts from under the rear engine mount.
Figure 8
Rear engine mount bolts from underneath the machine
22. Remove the bolts at the left rear engine support cross member bracket. Allow the support bracket to roll out of the
way once the weight is taken off of it.
23. Remove the bolts retaining the pump drive to the engine. Be sure to remove the top bolt last.

10. 24. Remove the front engine mount bolts.
Figure 9
Front engine mount bolt
25. Carefully, remove the engine from the machine and set it in an engine stand.
26. Transfer all necessary parts from the engine to the replacement engine.

11. Service Information
Document Title: Function Group: Information Type: Date:
Engine, installing 210 Service Information 2014/12/24
Profile:
GRD, G970 [GB]
Engine, installing
D9 - models G970, G976 and G990
Op nbr 210-072
9998547 Lifting tool
Lifting strap 2m, qty. 2
1. Install a new O-ring between the pump drive and the flywheel housing. Ensure that the O-ring is lubricated.
WARNING
Only use lifting devices with adequate capacity.
2. Using a safe lifting device, carefully place the engine into position. Weight 1089 kg (2400 lbs).
3. Reinstall the front engine mount bolts and the rear engine mount cross member bolts to help in alignment
purposes. Do not tighten the bolts at this point.
4. Reinstall the bolts that retain the pump drive to the engine. Torque to specification, where possible.
5. Reinstall the bolts on both sides of the rear engine mount cross member. Torque to specification.
Figure 1
Rear engine mount cross member bolts
6. Reinstall the two rear engine mount bolts. Torque to specification.

12. Figure 2
Rear engine mount bolts shown from underneath machine
7. Tighten and torque the front engine mount bolts to specification.
Figure 3
Front engine mount bolt
8. Remove the lifting devices. Remove the block positioned under the driveshaft.
9. Reinstall the clutch drain using a new O-ring.
Figure 4
1. Engine clutch drain

13. WARNING
Only use lifting devices with adequate capacity.
10. Using a safe lifting device, move the cooling module back into position. It may be necessary to use an alignment
tool to aid in positioning the cooling module. Weight 363 kg (800 lbs)
11. Reinstall the bolts that mount the cooling module to the machine frame. Remove the lifting device from the
cooling module.
NOTE!
Reinstall the fuel cap, if it was removed.
12. Reconnect and clamp the two coolant heater hoses. Reconnect and clamp the upper and lower hoses to the
radiator. Reconnect the cylinder head vent hose. Use cable ties to secure the hoses.
13. Reinstall the charge air tube from the turbocharger to the charge air cooler.
14. Reconnect the wiring harnesses to the starter. Use cable ties to secure the wiring harnesses.
15. Reinstall the post into the mounting bracket. Reinstall the left rear support post mounting bolts. Do not tighten the
bolts at this point. Reconnect the wiring harness clamps to the post.
NOTE!
Replace all sealing washers at the fuel line connections.
16. Reconnect the fuel lines at the fuel ECU cooler, the pump outlet connection and the secondary filter return line
connection. Reconnect the wiring harness to the filter head. Use cable ties to secure the fuel line connections.
Figure 5
Fuel line connections
NOTE!

14. To prevent damage, remove the oil filler cap. Cover the oil filler tube to prevent contamination.
17. Reinstall the air conditioning compressor. Replace the oil filler cap.
18. Reinstall the alternator. Use cable ties to secure the wiring harnesses.
19. Reinstall the accessory drive belt on the alternator and air conditioning compressor.
20. Reinstall the charge air cooler adapter. Torque to specification.
21. Reconnect the engine wiring harnesses to the right side of the engine. Use cable ties to secure the wiring
harnesses.
22. Reinstall the right rear engine support frame leg. Install the mounting bolts. Do not tighten the bolts at this point.
16 kg (35 lbs)
WARNING
Only use lifting devices with adequate capacity.
23. Using a safe lifting device, reinstall the engine hood assembly.Weight 136 kg (300 lbs) Refer to
. Reinstall the engine hood doors and hydraulic tank covers.
821 Engine hood, installing
24. Torque tighten the bolts on both rear engine mount brackets.
25. Reinstall the engine lower side panels on both sides of the machine. On the right side, reconnect the washer bottle.
Use cable ties to secure the hoses.
26. Fill the engine oil. Refer to . Install a new engine oil filter. Be sure to pour fresh oil into the
210 Engine D7, volume
new filter for lubrication.
27. Fill the engine coolant. Refer to .
260 Cooling system, volume (Models G930 - G940)
28. Start and warm the engine. Check for any leaks.
29. Place the machine back in service.

15. 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

16. Service Information
Document Title: Function Group: Information Type: Date:
Camshaft and flywheel
signals, checking with
VCADS Pro and
oscilloscope
210 Service Information 2014/12/24
Profile:
GRD, G970 [GB]
Camshaft and flywheel signals, checking with VCADS Pro and
oscilloscope
Op nbr 210-090
9990014 Break out harness
9990062 Cable
88890040 Oscilloscope
VCADS Pro VCADS Pro Service Tool
88890180 Interface
1. Connect 88890040 Oscilloscope to the VCADS Pro computer and perform 28420-3, Flywheel and camshaft signals,
test.
NOTE!
Instructions for how to connect the equipment are described in the VCADS Pro operation.
NOTE!
To be able to start the oscilloscope operation when USB-interface is default in VCADS Pro, then 88890180 Interface
must be connected to the computer. However, in this case the interface does not have to be connected to the
machine.
For computers with only one USB-port, the interface configuration must be changed to 9998555. However, in this
cases the interface does not have to be connected to the machine.
Detailed user support is available under the menu Help in the software.
NOTE!
The function “Save” overwrites the original file. Therefore, choose “Save as...” to save the read-off.