Información de servicio

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Engine, removing 210 Información de servicio 10/06/2020
Perfil:
A30D Volvo

Engine, removing
Applies to machine equipped with engine D10, with serial number according to the table.

Machine Place of manufacture, serial number

EU US Brazil
A25D 11001–12999 61001–61118 71001–71999
A30D 10001–11999 60001–60093 70001–72999

Op nbr 21070-1

Total procedure time (hr): NaN

9998547 Lifting device

11668015 Lifting tool
11668016 Lifting tool
11668020 Retainer plates (3 pcs.)
9993590 Gear
9993681 Bracket, right
9993682 Bracket, left

Torque wrench 0–400 Nm (0–295 lbf ft)

E-tool E-1763

1. Place the machine in service position.

2. Turn off the electric power with the battery disconnect switch.

WARNING
Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage.

3. Lower the front grill and pump up the engine hood.

Figure 1
Front grill
 4. Remove the front and rear underbody skid plates.

Figure 2
Underbody skid plates

1. Front underbody skid plate

2. Rear underbody skid plate, left
3. Rear underbody skid plate, right
4. Front cross member
5. Rear cross member

5. Remove the front and rear cross members. Weight approx. 15 kg(33 lbs).

WARNING
Risk of burns. The fluid may be hot.

6. Remove the cap for the expansion tank.

Figure 3

7. Connect the tool E1763 and drain the coolant, volume: 65 litres (17 US gal). The drain is located on the engine's
left side.
NOTE!
The cooling system is not protected against freezing after draining. Pockets of water may still remain.
 Figure 4
Draining coolant

8. When the expansion tank is empty, open the air bleeder nipple on top of the engine.

Figure 5

1. Air bleeder nipple

9. Drain the engine oil. Volume: approx. 37 litres (10 US gal)

NOTE!
The oil drain hose is inserted in the pipe for the ladder on the inside of the front grill.

Figure 6

10. Disconnect the drain hose by the oil sump. Plug and fold it to the side.
 Figure 7

11. Remove the connector for sensor SE9101.

Figure 8

WARNING
Risk of crushing injuries

12. Remove the two rear hydraulic pumps and the O-rings. Lower the hydraulic pumps and unload the suction lines by
securing the hydraulic pumps in the machine's frame in a suitable manner.
IMPORTANT! Unload the suction lines by securing the hydraulic pumps in the machine's frame in a suitable
manner.

Figure 9

13. Remove and mark up the connectors for PWM valves PWM2601 and PWM2602.
 Figure 10

14. Remove the front hydraulic pump and the O-ring. Weight: approx. 40 kg(88 lbs). Lower the hydraulic pump and
unload the suction line by securing the hydraulic pump in the machine's frame in a suitable manner.

Figure 11

15. Remove the pressure hose from the front hydraulic pump. Plug the hose and the connection on the hydraulic
pump.

16. Unplug the connectors for temperature sensors SE2601 and SE2602, and for oil level monitor SE2205.

Figure 12

1. SE2601
2. SE2602
3. SE2205

17. Remove the air connection for MA2501. The connection is at the bottom left of the front edge of the engine.
 Figure 13

18. Remove the induction hose for the turbo.

Figure 14

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!

19. Loosen and remove the bolt for the front radiator bracket.

Figure 15

20. Remove the outer screw for the headlight. Fold out the headlight and swing out the radiator.
 Figure 16

21. Disconnect the exhaust pipe at the turbine housing and at the joint by the transmission. Disconnect the bracket
from the frame. Remove the front pipe and the flex pipe.

Figure 17

22. Remove the coolant hoses (4 hoses) from the engine.

Figure 18
Coolant hoses (4 hoses)

23. Loosen and mark up the hoses (2 pcs.) for the cab heat.
 Figure 19
Hoses for cab heat

Work in cab

24. Remove the floor mats.

25. Disconnect air and electrical connections from the operator's seat.

26. Remove the operator's seats. Weight 40 kg (88 lbs).

27. Remove the rear and middle floor plate. Weight: 25 kg (55 lbs).

28. Remove the plastic cover from the steering column. Remove the lock pin from the universal joint on the steering
shaft. Remove the bolt and split the steering shaft.

Figure 20

29. Loosen and move aside the retarder pedal, throttle pedal and differential lock switch (SW4604).

Figure 21
30. Loosen and press down the brake pedal through the front floor plate without disconnecting the air connections.

Figure 22

31. Mark the position of the steering shaft in relation to the steering gear. Bend down the striker plates and remove the
2 bolts. Remove the steering shaft from the steering gear's flange.

Figure 23

32. Make sure that the steering shaft cannot come apart. Use cable ties or similar. Remove the front floor plate.

Figure 24

33. Mark and unplug the connectors for the brake pedal (SE5202, SE5203, SE5204, SW2505).
 Figure 25
Brake pedal connectors

1. SW5205
2. SE5203
3. SE5204
4. SE5205

34. Remove the clamps for the brake hoses from the lever bracket. Remove the air connections from the left and right
brake boosters. Angle back the brake pedal.

35. Remove the right side panel in the cab.

Figure 26

36. Loosen the pipes on the retarder valve and turn them the to the right.
NOTE!
Performed to facilitate mounting of tools 9993681 and 9993682.

Figure 27
37. Fit tool 9993681 (right) and 9993682 (left) on the transmission.

Figure 28

38. Fit lifting tool 116668015. Secure the transmission in the tool with two ratchet blocks. This is done to keep the
transmission in place when the engine is removed.

Figure 29

39. Remove the protective covers from the flywheel housing.

 Figure 30

1. Flywheel degree markings.

2. Rotating the crankshaft Tool 3590 is placed in the hole in the flywheel housing. A standard ratchet
handle is used, that can be combined with a universal joint and extension from a 1/2″ socket wrench set if
needed.
3. Removing and mounting bolts between flex plate-torque converter.

40. Remove the bolts between the flex plate and the transmission's torque converter. Use tool 9993590 to rotate the
crankshaft. Rotate the crankshaft so that two bolts can be removed at a time.

Figure 31

41. Remove the hoses (2) from the retarder oil cooler at the right rear edge of the engine.
 Figure 32

42. Mark up and remove the front hoses on the retarder valve. Remove the connector for temperature sensor SE4204.
Plug the hoses and connections on the retarder valve.

Figure 33

1. SE4204

43. Remove the lubrication oil filter. Remove the belt guard.

44. Remove and plug the fuel lines.

Figure 34

45. Remove the connector for the engine control unit (E-ECU) by pressing in the lock and raising the catch.
 Figure 35

46. Remove connector EM for the control unit's cable harness quick-coupling.

47. Loosen connections B+ and D- for the alternator.

Figure 36

NOTE!
If the machine is equipped with air conditioning, loosen the compressor and fold it to the side without opening the system.
Otherwise, there is a risk of gas leaks.

WARNING
See "Safety when working with air conditioning", section S and Service Manual "Air conditioning R134a".

48. Mark up and remove the connections for the starter motor and the ground cable.

Figure 37
View from below

49. Remove the connections for the intercooler.

 Figure 38

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!

50. Loosen the bolts at the front edge of the intercooler and fold out the intercooler.

51. Remove the connections for the compressor.

Figure 39

52. Remove sensor SE2603 for the expansion tank.

Figure 40

53. Remove the expansion tank (bolts are located on the inside of the radiator bow) and the coolant pipe.
 Figure 41

1. Expansion tank
2. Coolant hose

54. Unplug the connector for sensor SE2501/2502. The sensor is located on the pipe to the inlet.

Figure 42

55. Remove the preheating relay from the radiator bow and lay it on the engine.

Figure 43

56. Remove the preheating cable from the relay.

 Figure 44

57. Raise the front grill and remove the lock pin and the pin for the gas spring. Remove the stops on the bow for the
front grill and turn them down.

Figure 45

WARNING
Do not walk on the ladder when bows have been removed.

58. Loosen the headlight. Loosen and swing out the right bow.

Figure 46

59. Loosen and lower the left bow.

 Figure 47

60. Secure the engine using lifting device 9998547 and lifting tool 11668016. Weight: approx. 2200 kg(4850 lbs).

Figure 48

1. Lifting device 9998547

2. Lifting tool 11668016

61. Check that the transmission is adequately secured. Then loosen the bolts between the transmission and the
flywheel housing.

Figure 49

62. Remove the bolts for the rear engine mounts.

 Figure 50

63. Remove the bolts for the front engine mount.

Figure 51

64. Pull the transmission back as far as possible. Secure the transmission tool with a tensioning strap. Pull the engine
forward.

NOTE!
Check that the torque converter releases from the flex plate and not from the transmission.

65. Fit retainer plates 11668020.

 Figure 52

1. Retainer plate 11668020 (3 pcs.)

NOTE!
It is important to secure the torque converter since it may otherwise easily slide out of position and be damaged.

66. Carefully lift the engine. Tilt the engine back slightly. Check that no hoses are deformed. Weight: 1580 kg (3483
lbs)

67. Lift out the engine.

Figure 53

68. Lower the engine onto 3 axle stands.