Service Manual Backhoe Loader B-Series, 1 Service and Maintenance

VOLVO CONSTRUCTION EQUIPMENT

Service manual

BL60B/BL61B/BL70B/BL71B

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2304

594.5 1189 2300

2369 136

CONTENT 1 Service and Maintenance

Foreword This booklet is part of a complete service manual. Read the foreword in the service manual.

WARNING Always read the booklet Safety before proceeding.

PUB 20026861-B 2011.09

1

Table of contents 16 LUBRICANT; FUEL; OTHER FLUID 160 General Recommended lubricants, oils .................................................................... 7 Coolant ....................................................................................................... 8

17 SERVICE 170 General, common info about 171 - 179 Service position 1 ....................................................................................... 9 Service position 2 ..................................................................................... 11 Service position 3 ..................................................................................... 12 Service ...................................................................................................... 13 Safety when servicing ............................................................................... 13 Service points ........................................................................................... 14 173 Maintenance Maintenance service, first 100 hours ........................................................ 15 Maintenance service, first 1000 hours ...................................................... 18 Maintenance service, daily ....................................................................... 21 Maintenance service, every 50 hours ....................................................... 22 Maintenance service, every 250 hours ..................................................... 23 Maintenance service, every 500 hours ..................................................... 25 Maintenance service, every 1000 hours ................................................... 28 Maintenance service, every 2000 hours ................................................... 32 Maintenance service, every 6000 hours ................................................... 33 Transmission, checking oil level ............................................................... 34 Fuel, coolant and oil leakage, check ......................................................... 35 Pipes, couplings and hoses, check ........................................................... 35 Hydraulic cylinders, check for oil leakage ................................................. 35 Gas springs, doors, rear window, check function ..................................... 35 Turbocharger inclusive inlet and exhaust systems, leakage, check ......... 36 Stabiliser legs, check wear pads (BL61B, BL71B) ................................... 36 Coolant, changing ..................................................................................... 37 Draining .................................................................................................. 37 Valves, adjusting ....................................................................................... 39 Adjust inlet valve clearance .................................................................... 44 Adjust exhaust valve clearance .............................................................. 45 Battery, current capacity, electrolyte level, cables and connections, especially connections at starter motor, check ......................................... 48 Engine radiator, oil cooler and condensor (if installed), clean .................. 49 Coolant level, checking ............................................................................. 50 Air cleaner primary filter, changing ........................................................... 51 Air cleaner, secondary filter replacing ....................................................... 52 Fuel filters, primary and secondary filter, replace ..................................... 53 Primary fuel filter, replacing .................................................................... 53 Secondary fuel filter, replacing ............................................................... 53 Fuel system, bleeding ............................................................................... 55 Fuel system, water trap, check/drain ........................................................ 56 Cab filter, replace (clean when necessary) ............................................... 57 Axles, checking oil level ............................................................................ 58 Front axle ................................................................................................ 58 Rear axle ................................................................................................ 58 Axle breather, cleaning ............................................................................. 59 Axle hubs, checking oil level ..................................................................... 60 Tyres, wear and air pressure, checking .................................................... 61 Wheel nuts, check torque ......................................................................... 61 Bolted joints, check tightening torque ....................................................... 61 Hydraulic oil tank breather filter, replace .................................................. 62 Axles, changing oil .................................................................................... 63 3

Axle hubs, changing oil ............................................................................. 64 Transmission, replacing oil filter ............................................................... 65 Transmission breather filter, replacing ...................................................... 65 Hydraulic system, replacing filter .............................................................. 66 Engine, changing oil and filter ................................................................... 67 Transmission, changing oil ....................................................................... 69 Transmission suction filter, replacing ........................................................ 70 Hydraulic system, pressure release .......................................................... 71 Hydraulic system, changing oil ................................................................. 72 Draining .................................................................................................. 72 Filling ...................................................................................................... 72 Hydraulic system, changing oil ................................................................. 74 Draining .................................................................................................. 74 Filling ...................................................................................................... 74 Hydraulic pressure, check ........................................................................ 76 Checking Δp open centre ....................................................................... 76 Checking and adjusting backhoe relief valve (backhoe, HP pressure) ................................................................................................. 77 Checking and adjusting loader relief valve (loader HP pressure) ........... 77 Checking steering pressure .................................................................... 78 Hydraulic pressure, check ........................................................................ 79 Checking and adjusting servo pressure .................................................. 79 Checking stand–by pressure (HP-LS) .................................................... 80 Checking and adjusting Δp (spring pressure in FR–valve) ..................... 80 Checking and adjusting power regulation (spring pressure in LR– valve) ...................................................................................................... 81 Checking and adjusting HP pressure (max. pressure) ........................... 83 Checking steering pressure .................................................................... 84 Hydraulic system, checking oil level ......................................................... 85 Transmission 2WD, oil pressures, checking ............................................. 86 Checking forward clutch pressure .......................................................... 86 Checking reverse clutch pressure .......................................................... 87 Checking lubrication pressure ................................................................ 87 Checking differential lock pressure ......................................................... 88 Transmission 4WD, oil pressures, checking ............................................. 88 Checking forward clutch pressure .......................................................... 89 Checking reverse clutch pressure .......................................................... 90 Checking lubrication pressure ................................................................ 90 Checking 4WD pressure ......................................................................... 90 Checking differential lock pressure ......................................................... 91 Powershift Transmission (option), oil pressures, checking ...................... 92 Checking forward clutch pressure .......................................................... 92 Checking reverse clutch pressure .......................................................... 93 Checking lubrication pressure ................................................................ 93 Checking differential lock pressure ......................................................... 94 Control valve supply pressure ................................................................ 95 Gear clutch pressure .............................................................................. 95 Engine speed ............................................................................................ 97 Hydraulic locking cylinders for sideshift mechanism, check (BL61B, BL71B) ...................................................................................................... 98 Boom lock functions, check ...................................................................... 99 Boom lock functions, check .................................................................... 100 Extendible dipper (if installed) wear pads, check .................................... 101 Stabilisers, loader, backhoe, front axle oscillation pivot and front axle steering pivots, lubricate ......................................................................... 101 Propeller shaft, lubrication ...................................................................... 101 Accumulator, check pre-charging pressure ............................................ 102 Checking precharging pressure ............................................................ 102 Reducing precharging pressure ............................................................ 103 Raising precharging pressure ............................................................... 103 Restoring system .................................................................................. 103 4

Engine oil level, checking ....................................................................... 104 Test-run and check ................................................................................. 105 Brake test ................................................................................................ 106 Service brake, checking ........................................................................ 106 Parking brake, checking ....................................................................... 106 Service brake, checking pressure ........................................................... 108 Checking pressure ................................................................................ 108 Bleeding brakes .................................................................................... 109 Seat belt, replace .................................................................................... 110 Service journal (included in Operator's manual), fill in ............................ 111

5

STANDARD PARTS, SERVICE 16 LUBRICANT; FUEL; OTHER FLUID 160 General Recommended lubricants, oils For questions about oils, lubricants, and extreme outdoor temperatures, contact your dealer for more information.

NOTICE BIO-OIL and mineral oil (carbon-hydrogen-oil) must be disposed of separately. Mixing is prohibited! Oil grade ENGINE

HYDRAULIC SYSTEM Steering system Working hydraulics

Volvo Ultra Diesel Engine oil VDS-3 or Volvo Super Diesel Engine Oil or VDS-3 or VDS-2 plus ACEA-E7 or VDS-2 plus API CI-4 or VDS-2 or VDS + ACEA-E3 or ACEA: E7, E4 or API: CI-4, CH-4, CG-4 For recommended change intervals according to the oil’s grade and sulphur content in the fuel, see page Fuel.

Recommended viscosity at varying ambient temperatures C 30 F 22

20 10 0 +10 +20 +30 +40 +50 4 +14 +32 +50 +68 +86 +104 +122

SAE 5W-30 SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-50 V1038303

Fig.1

Volvo Super Hydraulic Oil As an alternative there is also Volvo Biodegradable Hydraulic Oil 46. Contact your dealer for more information.

ISO VG 32 HV ISO VG 46 HV ISO VG 68 HV V1038304

Fig.2

FRONT and Volvo WB 101 REAR AXLES, Volvo Wet Brake Transaxle Oil TRANSMISSIO N and HUBS

°C –30 °F –22

–20 –4

–10 +14

0 +32

+10 +50

+20 +68

+30 +40 +50 +86 +104 +122

WB101 V1097344

Fig.3

COOLING SYSTEM

Volvo Coolant VCS

Volvo Coolant VCS should be used only. (For correct mixture, see page Coolant).

7

Coolant Use only Volvo VCS coolant when topping up or changing coolant. Do not mix different coolants or use anti-corrosion additives as this could damage the engine. When using concentrated coolant combined with water, the mixture should be 40-60 % concentrate and 60-40 % water. The percentage of coolant in the mixture must not be below 40 %; see the table below. Anti-freeze protection down to

Percentage of coolant concentrate

-20 °C

40 %

–35 °C

50 %

–46 °C

60 % The coolant concentrate must not be mixed with water that has a high lime (hard water), salt or metal content. The water for the cooling system must also meet the following requirements:

Part name

Value

Total amount of solids

< 340 ppm

Total hardness

< 9.5° dH

Chlorine

< 40 ppm

Sulfate

< 100 ppm

pH value

5.5–9

Silicate

< 20 mg SiO2/litre

Iron

< 0.10 mg FE/litre

Manganese

< 0.05 mg Mn/litre

Electrical conductive capacity

< 500 µS/cm

Organic content, CODMn

< 15 mg/litre Use premixed coolant if you do not know the quality of the water. Do not blend different premixed coolants as this could damage the engine.

8

17 SERVICE 170 General, common info about 171 179 Service position 1 Op. no. 191-021

WARNING If work must be done on the machine before it has cooled down; beware of hot fluids and hot components that can cause severe burns. 1

Place the machine on firm and level ground. Apply the parking brake.

2

Lower the stabilisers.

3

Retract the backhoe boom fully into travelling position. Engage the backhoe boom lock with the backhoe boom lock switch. On machines equipped with pilot control, the boom lock will be engaged automatically, see 191, Backhoe, boom lock.

NOTICE 4 V1083369

WARNING When servicing the machine with the loader boom raised, the safety strut must always be placed in support position. An unsupported loader boom can drop suddenly and cause serious personal injuries.

Fig.4 Service position 1 1 backhoe in travelling position, loader boom raised

Lift up the loader boom and secure it with the loader safety strut. See 191, Loader boom, safety strut. 5

Stop the engine.

6

Attach a yellow-black warning label or a red flag to the steering wheel while service work is in progress. Add the message "Service work: Forbidden to start the engine".

7

WARNING If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious personal injuries. Carefully release the pressure in pressure lines to avoid risks. See 191, Safety for work on hydraulic systems.

8

Remove the ignition key.

9

Turn off the battery disconnect switch.

9

10

10

Block the rear wheels in a suitable manner (i.e. with wheel chock).

11

Open the engine hood.

Service position 2 Op. no. 191-022

WARNING If work must be done on the machine before it has cooled down; beware of hot fluids and hot components that can cause severe burns.

V1083372

Fig.5 Service position 2 1 backhoe in travelling position, loader boom lowered to the ground

1


2


3

Retract the backhoe boom fully into travelling position. Engage the backhoe boom lock with the backhoe boom lock switch. On machines equipped with pilot control, the boom lock will be engaged automatically, see 191, Backhoe, boom lock.

4

Lower the loader boom fully down to the ground.

5

Stop the engine.

6


7


8


9


10


11


11

Service position 3 Op. no. 191-025


V1083373

Fig.6 Service position 3 1 backhoe fully extended, loader boom lowered to the ground

1


2


3

Extend the backhoe arm fully, so that it is lowered to the ground.

4


5

Stop the engine.

6


7


12

8


9


10


11


Service The machine must receive thorough care to function to the lowest cost. Intervals for maintenance and lubrication refer to the machine under normal environment and operating conditions. Maintenance work described in this service manual can be done by a therefor trained person. A brand name authorized workshop should be used for other adjustments and repairs.

Safety when servicing For Safety when servicing, see the Safety Section, Section S.

13

Service points

1

2

11 12

5

18 17

10

9

8

3

7

4

5

6

13

16

14

15

V1095272

Fig.7 Service points

1

Cab air filter

10

Transmission oil filter

2

Hydraulic oil, filler cap and ventilation filter

11

Hydraulic system oil filter

3

Air cleaner

12

Air cleaner intake

4

Coolant expansion tank

13

Hydraulic oil level glass

5

Coolant package, radiator, oil cooler and condenser (if fitted)

14

Washer fluid reservoir

6

Secondary fuel filter

15

Battery disconnect switch

7

Engine oil filter

16

Battery/batteries

8

Primary fuel filter including water trap

17

Transmission oil level dipstick/filler point

9

Fuel, filler point

18

Engine oil level dipstick/filler point

14

173 Maintenance Maintenance service, first 100 hours Op. no. 173-036 1

Place the machine in Service position 1, see Service position 1 page 9.

2

Transmission, checking oil level page 34

NOTICE The check has to be carried out between 5 and 10 minutes after the engine has been stopped with engine on working temperature. 3

Fuel system, water trap, check/drain page 56

NOTICE The fuel system should be drained, when the water had enough time to collect in the water separator. Drain the water separator as first step in the morning before starting the machine. 4

Fuel, coolant and oil leakage, check page 35

5

Pipes, couplings and hoses, check page 35

6

Hydraulic cylinders, check for oil leakage page 35

7

Gas springs, doors, rear window, check function page 35

8

Turbocharger inclusive inlet and exhaust systems, leakage, check page 36

9

Stabiliser legs, check wear pads (BL61B, BL71B) page 36

10

Battery, current capacity, electrolyte level, cables and connections, especially connections at starter motor, check page 48

11

Coolant level, checking page 50

12

Fuel filters, primary and secondary filter, replace page 53

13

Fuel system, bleeding page 55

14

Tyres, wear and air pressure, checking page 61

15

Wheel nuts, check torque page 61

16

Bolted joints, check tightening torque page 61

17

Axles, changing oil page 63

18

Axles, checking oil level page 58

19

Axle breather, cleaning page 59

20

Axle hubs, changing oil page 64

21

Axle hubs, checking oil level page 60

22

Remove the floor mat in the cab.

23

Remove the cab floor plate in front of the seat.

15

1

24

Transmission, replacing oil filter page 65

25

Hydraulic system, replacing filter page 66

26

Turn on the battery disconnect switch.

V1094146

Fig.8 battery disconnect switch position 0: battery disconnect switch off position 1: battery disconnect switch on

NOTICE Before checking the hydraulic oil filter for leakage, the machine must be warmed up.

16

27

Start the engine and let it idle for some minutes.

28

Operate the loader boom and backhoe.

29

Stop the engine and turn off the battery disconnect switch.

30

Check the transmission oil filter for leakage.

31

Check the hydraulic oil filter for leakage.

32


33


34

Stop the engine.

35


36

Check the engine oil drain plug for leaks.

37


38

Start the engine and warm up the hydraulic oil to a temperature of 40–50 °C (104–122 °F). A way of quickly warming up the hydraulic oil to the correct temperature is to run the bucket cylinder piston rod to the outer and inner end positions, and at the same time move the dipper arm out and in.

39


40

Hydraulic system, checking oil level page 85

41

Fit the cab floor plate in front of the seat.

42

Fit the floor mat in the cab.

43

Engine speed page 97

44

Hydraulic locking cylinders for sideshift mechanism, check (BL61B, BL71B) page 98

45

Boom lock functions, check page 99

46

Extendible dipper (if installed) wear pads, check page 101

47


48


49

Stabilisers, loader, backhoe, front axle oscillation pivot and front axle steering pivots, lubricate page 101

50

Propeller shaft, lubrication page 101

51

Engine oil level, checking page 104

52


53

Test-run and check page 105

54

Check the function of the parking brake, see Brake

55

Hammer (if installed), hydraulic circuit, check flow and pressures See Operator´s Manual of the hammer

56

Hammer (if installed), lubricate every two hours See Operator´s Manual of the hammer

57

Hammer (if installed), lower tool bushing, check for wear See Operator´s Manual of the hammer

58

Hammer (if installed), tool retaining pin and the tool, check See Operator´s Manual of the hammer

59

Hammer (if installed), hydraulic hoses and connections, check See Operator´s Manual of the hammer

60

Hammer (if installed), seals and accumulator membranes, replace See Operator´s Manual of the hammer

61

Service journal (included in Operator's manual), fill in page 111

test page 106

17

Maintenance service, first 1000 hours Op. no. 173-042 1


NOTICE The fuel system should be drained, when the water had enough time to collect in the water separator. Drain the water separator as first step in the morning before starting the machine.

18

2


3


4


5


6


7


8


9


10

Engine radiator, oil cooler and condensor (if installed), clean page 49

11


12

Air cleaner primary filter, changing page 51

13

Air cleaner, secondary filter replacing page 52

14


15


16

Cab filter, replace (clean when necessary) page 57

17


18


19


20

Hydraulic oil tank breather filter, replace page 62

21


22


23


24


25


26


27


28


29


30

1


V1094146


NOTICE Before draining the engine oil and checking the hydraulic oil filter for leakage, the machine must be warmed up. 31


32


33


34


35


36

Engine, changing oil and filter page 67

37


38


39

Stop the engine.

40


41


42

Transmission, changing oil page 69

NOTICE Replace the transmission suction filter before refilling transmission oil. 43

Transmission suction filter, replacing page 70

44




46


47


48

Hydraulic system, pressure release page 71

49


50

Hydraulic system, changing oil page 72 19

51


52


53


54

Hydraulic pressure, check page 76

55


56

Start the engine and warm up the transmission oil to a temperature of 70–80 °C (158–176 °F). A way of quickly warming up the transmission oil to the correct temperature is to have the parking brake on, service (foot) brake on, start the engine and keep it ticking over at low idle speed (900 rpm), select the 4th gear and move the forward/reverse lever to forward. Rev the engine for short periods to a maximum of 1500-1700 rpm, to bring the oil up to working temperature.

NOTICE Do not exceed a maximum duration of 30 seconds each time. After this 30 second period, put the forward/reverse lever in neutral for 15 seconds, then repeat the procedure. 57


58

Check the transmission pressures. If the machine is equipped with 2WD transmission, see Transmission 2WD, oil pressures, checking page 86. If the machine is equipped with 4WD transmission, see Transmission 4WD, oil pressures, checking page 88. If the machine is equipped with Powershift transmission, see

Powershift Transmission (option), oil pressures, checking page 92.

20

59


60


61


62


63


64


65


66


67


68


69


70


71


72

Service brake, checking pressure page 108

73

Check the function of the service and parking brake, see

74

Accumulator, check pre-charging pressure page 102

75


76


77


78


79


80


81


Brake test page 106

Maintenance service, daily Op. no. 173-002 1


2


NOTICE The check has to be carried out between 5 and 10 minutes after the engine has been stopped with engine on working temperature.

1 V1094146


3


4


5


6


7


8


9


21

Maintenance service, every 50 hours

NOTICE Following maintenance services are included in this procedure: Maintenance service, daily Op. no. 173-004 1


2



1 V1094146


22

3


4


5


6


7


8


9


10


11


12


13


14

Hammer (if installed), lower tool bushing, check for wear

15


16



NOTICE Following maintenance services are included in this procedure: Maintenance service, daily Maintenance service, every 50 hours Op. no. 173-007 1




3



1 V1094146


4


5


6


7


8


9


10


11


12


13


14


15


16


17


18


19


20


21


22


23

Propeller shaft, lubrication page 101 23

24

24


25


26



NOTICE Following maintenance services are included in this procedure: Maintenance service, daily Maintenance service, every 50 hours Maintenance service, every 250 hours Op. no. 173-010 Tools: 11666135 Gas filling kit 11666051 Pressure gauge 14290266 Hose E-Tool: E1708, see 080, E 1708, Checking point. 1




3




5


6


7


8


9


10


11


12


13


14


15


16


25

1

17


18


19


20


21


22


V1094146


NOTICE Before draining the engine oil and checking the hydraulic oil filter for leakage, the machine must be warmed up.

26

23


24


25


26


27


28


29


30


31


32


33

Stop the engine.

34


35


36


37


38


39


40


41


42


43


44


45


46


47


48

Brake test page 106

49


50


51


52


53


54


55


56


57


27


NOTICE Following maintenance services are included in this procedure: Maintenance service, daily Maintenance service, every 50 hours Maintenance service, every 250 hours Maintenance service, every 500 hours Op. no. 173-012 Tools: 88830055 Pressure checking set 11666135 Gas filling kit 11666051 Pressure gauge 14290266 Hose E-Tool: E1708, see 080, E 1708, Checking point Additional parts for hydraulic pressure testing: VOE935084 Nipple VOE935552 Hose Additional parts for transmission pressure testing: VOE936440 testing nipple VOE933859 T-nipple VOE935650 plug VOE935331 nipple VOE936439 testing nipple 1


NOTICE The fuel system should be drained, when the water had enough time to collect in the water separator. Drain the water separator as first step in the morning before starting the machine.

28

2


3


4


5


6


7


8


9


10


11


12

Air cleaner primary filter, changing page 51

1

13


14


15

Cab filter, replace (clean when necessary) page 57

16


17


18


19

Hydraulic oil tank breather filter, replace page 62

20


21


22


23


24


25


26


27


28


29


V1094146


NOTICE Before draining the engine oil and checking the hydraulic oil filter for leakage, the machine must be warmed up. 30


31


32


33


34


35


36


37


38

Stop the engine.

39


40


41

Transmission suction filter, replacing page 70

42


43

Turn on the battery disconnect switch. 29

44


45


46

Hydraulic system, pressure release page 71

47


48

Hydraulic system, changing oil page 72

49


50


51


52

Hydraulic pressure, check page 76

53


54

Start the engine and warm up the transmission oil to a temperature of 70–80 °C (158–176 °F). A way of quickly warming up the transmission oil to the correct temperature is to have the parking brake on, service (foot) brake on, start the engine and keep it ticking over at low idle speed (900 rpm), select the 4th gear and move the forward/reverse lever to forward. Rev the engine for short periods to a maximum of 1500-1700 rpm, to bring the oil up to working temperature.

NOTICE Do not exceed a maximum duration of 30 seconds each time. After this 30 second period, put the forward/reverse lever in neutral for 15 seconds, then repeat the procedure. 55


56

Check the transmission pressures. If the machine is equipped with 2WD transmission, see Transmission 2WD, oil pressures, checking page 86. If the machine is equipped with 4WD transmission, see Transmission 4WD, oil pressures, checking page 88. If the machine is equipped with Powershift transmission, see

Powershift Transmission (option), oil pressures, checking page 92.

30

57


58


59


60


61


62


63


64


65


66


67


68


69


70


71

Check the function of the service and parking brake, see

72


73


74


75


76


77


78


79


80


Brake test page 106

31


NOTICE Following maintenance services are included in this procedure: Maintenance service, daily Maintenance service, every 50 hours Maintenance service, every 250 hours Maintenance service, every 500 hours Maintenance service, every 1000 hours Op. no. 173-014 Tools: 11666135 Gas filling kit 88830055 Pressure checking set 11666051 Pressure gauge 14290266 Hose 885530 Rotation tool 885812 Timing tool E-Tool: E1708, see 080, E 1708, Checking point Additional parts for hydraulic pressure testing: VOE935084 Nipple VOE935552 Hose Additional parts for transmission pressure testing: VOE936440 testing nipple VOE933859 T-nipple VOE935650 plug VOE935331 nipple VOE936439 testing nipple 1



Place the machine in Service position 1, see 191, Service position 1.

3

Valves, adjusting page 39

NOTICE Only adjust the valve clearance with cold engine. While the engine is cooling down, the first steps of the Maintenance service, every 1000 hours can be performed. 4

32

Perform the Maintenance service, every 1000 hours page 28 and replace the secondary air filter of the engine together with the primary air filter, see Air cleaner, secondary filter replacing page 52. Change the transmission oil and replace the transmission breather filter together with the transmission oil filter, seeTransmission, changing oil page 69 and Transmission breather filter, replacing page 65.


NOTICE Following maintenance services are included in this procedure: Maintenance service, daily Maintenance service, every 50 hours Maintenance service, every 250 hours Maintenance service, every 500 hours Maintenance service, every 1000 hours Maintenance service, every 2000 hours Op. no. 173-022 Tools: 88830055 Pressure checking set 11666135 Gas filling kit 11666051 Pressure gauge 14290266 Hose 885530 Rotation tool 885812 Timing tool Tools for hydraulic pressure testing: VOE935084 Nipple VOE935552 Hose Tools for transmission pressure testing: VOE936440 testing nipple VOE933859 T-nipple VOE935650 plug VOE935331 nipple VOE936439 testing nipple 1




NOTICE Only change coolant or adjust the valve clearance with cold engine. While the engine is cooling down, the first steps of the Maintenance service, every 2000 hours can be performed. 3

Coolant, changing page 37

4

Maintenance service, every 2000 hours page 32

33

Transmission, checking oil level Op. no. This is part of other procedure



Use the dipstick to check the transmission oil level.

2

Fully unscrew the dipstick and remove it.

3

The measured level should be between the max. and min. marks. Fill in new oil if necessary. For oil specifications, see Recommended lubricants, oils page 7.

Fig.15 transmission, checking oil level 1 oil filler port with dipstick

T

V1088102

Fig.16 transmission oil dipstick T = Thread: When the dipstick is fully unscrewed, the thread should NOT be visible.

Max.

Min.

V1090437

Fig.17 dipstick with marks

34

Fuel, coolant and oil leakage, check Op. no. This is part of other procedure 1

Check the machine for fuel, coolant and oil leakage. Look especially under the engine, transmission, axles and axle hubs, main hydraulic valve and the loader/backhoe unit.

Pipes, couplings and hoses, check Op. no. This is part of other procedure 1

Check all hydraulic pipes, couplings and hoses for damage and wear.

2

Check the hoses connected to the brake.

Hydraulic cylinders, check for oil leakage This is part of other procedure Op. no. 1

Check the hydraulic cylinders of the loader and backhoe unit for signs of oil leakage. Check the cylinders for scores and marks. If any faults are found, contact a workshop authorized by Volvo CE. The replacement of cylinders or cylinder seals should be carried out by a workshop authorized by Volvo CE.

Gas springs, doors, rear window, check function Op. no. This is part of other procedure 1

Check the functionality of the engine hood gas springs, the cabine doors and rear windows.

35

Turbocharger inclusive inlet and exhaust systems, leakage, check Op. no. This is part of other procedure 1

Check the oil pipes connected to the turbocharger for leakage.

2

Check the exhaust system for leakage.

3

Check the hose from air filter to turbocharger for leakage and porosity.

4

Check the fastening clamps of the hose from air filter to turbocharger.

Fig.18 Turbocharger inclusive inlet and exhaust systems 1 airfilter hose 2 turbocharger 3 exhaust system 4 oil pipes

Stabiliser legs, check wear pads (BL61B, BL71B) Applies to models: BL61B, BL71B

Op. no. This is part of other procedure 1

Check the thickness of the wear pads.

2

Change the wear pads, if they have reached the minimum thickness.

NOTICE Minimum thickness = adjusting bracket is fully tightened to the stabiliser

CAUTION Do not operate the machine if the wear pads are worn out. Serious damage to the stabiliser legs will occur. Fig.19 1 retaining nuts 2 adjusting bracket 3 wear pad

36

Coolant, changing Op. no. This is part of other procedure

Draining

CAUTION The engine must turned off and be cold before changing the coolant.

CAUTION Never fill a hot engine with cold coolant, as this may cause the cylinder block or the cylinder head to crack. Failure to change coolant will cause clogging of the cooling system and the risk of engine damage. 1

Loosen the fastening screws and remove the radiator grille.

Fig.20 radiator grille

37

1

2

2

Place a suitable container under the machine to collect the coolant.

3

Install a hose to the draining nipple and place the other end of the hose in the container. The draining nipple is located under the radiator.

4

Remove the cap of the expansion tank.

5

Loosen the draining nipple and drain the coolant in the container.

V1071109

Fig.21 Coolant, draining nipple

CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.

Fig.22 Coolant expansion tank

6

Fasten the draining nipple and remove the hose.

7

Reassemble the radiator grille and fasten the retaining screws.

8

CAUTION Volvo Coolant VCS must never be mixed with any other coolant or corrosion protection to avoid damage to the engine. Fill the expansion with coolant to the COLD FILL mark. Volvo coolant VCS should be used only. See Coolant page 8.

9

38

Assemble the expansion tank cap.

Valves, adjusting This is part of other procedure Op. no. 885530 Rotation tool 885812 Timing tool

NOTICE Only adjust the valve clearance with cold engine. 1

Unplug both pressure sensor connectors from the air filter.

2

Loosen and slide the clamp to the right.

3

Loosen and remove the two air filter retaining screws.

4

Remove the hose (see fig. step 1) from the air filter and remove the air filter.

Fig.23 air filter, disassembly 1 pressure sensor connectors 2 clamp 3 hose

Fig.24 air filter, disassembly 1 retaining screws

39

5

Loosen the clamp of the exhaust pipe.

6

Loosen the retaining screws (4 pcs.). Remove the screws and the exhaust pipe from the turbocharger.

7

Loosen and remove the retaining screws (1) of the bracket.

8

Remove the bracket together with the expansion tank.

Fig.25 exhaust pipe, disassembly 1 clamp 2 exhaust pipe

Fig.26 exhaust pipe, disassembly 1 retaining screws

Fig.27 coolant expansion tank, disassembly 1 retaining screws

40

9

Loosen and remove the retaining screws together with the protection plate.

10

Loosen the cable ties (2) of the coolant hose.

11

Loosen and remove the retaining screws (3) together with the protection plate (1).

12

Loosen and remove the retaining screws (5 pcs.) of the fan guard.

13

Remove the fan guard.

Fig.28 protection plate, disassembly 1 retaining screws

Fig.29 protection plate/coolant hose, disassembly 1 protection plate 2 cable ties 3 retaining scews

41

14

Loosen and remove the retaining screws (4 pcs.) of the fan adapter.

15

Move the adapter together with the fan to the side.

16

Attach the rotation tool on the crankshaft. 885530 Rotation tool

17

Unscrew the screws (1) and remove crankcase ventilation (2).

Fig.30 fan adapter, disassembly 1 fan adapter 2 retaining screws

Fig.31 rotation tool attached to crankshaft 1 crankshaft 2 rotation tool

1

2

1

V1044254

Fig.32 crankcase ventilation channel

42

1

18

Remove the cover plate (1) with wiring.

19

Unscrew the cylinder head cover screws and remove with gasket.

V1044255

Fig.33 cover plate, removing

CAUTION Valve adjustment with the engine running is not allowed since the valves may strike the piston, causing severe damage. 1 2 3 4 5 6 7 8

2

1

3

4 V1022560

Fig.34 exhaust/inlet valves 1 exhaust valves: (EX) 1, 3, 5, 7 2 inlet valves: (IN) 2, 4, 6, 8

20

Rotate the engine by use of the rotation tool until the valves on cylinder no. 1 stand at "valve overlap".

NOTICE Valve overlap means: exhaust valve not yet closed, inlet valve begins to open.

EX

IN

Fig.35 exhaust valve not yet closed, inlet valve begins to open IN = inlet vavle EX = outlet valve

43

Adjust inlet valve clearance Adjust valve clearance in accordance with the black mark on the adjustment chart for each cylinder. Inlet valve: (IN) 90°

1

2

3

4 V1022563

Fig.36 inlet valves, adjustment chart

21

2

Undo the lock nut (1) and screw in the adjustment screw (2) until it makes contact.

NOTICE The rocker arm must make contact (no gap) with the thrust washer (arrow) of the spring disc.

1

V1044256

Fig.37 valve, adjustment

22

Position the rotation angle disc on the adjuster screw. Secure the magnet of the rotation angle disc to the cylinder head. Set the rotation angle disc to "Null" in the direction of the arrow.

NOTICE Take care not to turn the adjustment screw.

V1060095


23

V1060096


44

Turn the adjustment screw anticlockwise 90°.

24

Counterhold the adjustment screw and tighten the lock nut to 20 ± 2 Nm (14.8 ± 1.5 lbf ft). Remove the rotation angle disc.

V1060097


Adjust exhaust valve clearance 25

1

2

3

Rotate the engine one revolution again until the valves of cylinder no. 4 are at "valve overlap". Adjust valve clearance in accordance with the black mark on the adjustment chart for each cylinder. Exhaust valve: (EX)150°

NOTICE

4

Follow steps 6 to 9 for adjusting exhaust valve clearance. V1022564

Fig.41 exhaust valves, adjustment chart

26

Remove the rotation tool.

27

Clean the sealing surfaces of the cylinder head.

28

Fit a new gasket to the cylinder head cover.

29

Fit the cylinder head cover and tighten the screws alternately to 13 Nm (9.6 lbf ft).

30

Fit the cover plate (1) with wiring.

31

Fit the crankcase ventilation. Tighten the screws to 20 ± 2 Nm (14.8 ± 1.5 lbf ft.

32

Assemble the fan adapter and the retaining screws (4 pcs.).

33

Fasten the retaining screws. See 260, Cooling system, tightening torques for recommended tightening torque.

34

Assemble the fan guard and the retaining screws (5 pcs.).

35

Fasten the retaining screws. See 260, Cooling system, tightening torques for recommended tightening torque.

Fig.42 fan adapter, assembly 1 fan adapter 2 retaining screws

45

36

Assemble the protection plate (1) and the retaining screws (3).

37

Tighten the retaining screws.

38

Fasten the coolant hose on the fan guard by use of two cable ties (2).

39

Assemble the exhaust pipe and the retaining screws (4 pcs.) to the turbocharger.

Fig.43 protection plate/coolant hose, assembly 1 protection plate 2 cable ties 3 retaining screws

NOTICE Tighten the screws by hand, so that the exhaust pipe can´t be moved.

Fig.44 exhaust pipe, assembly 1 retaining screws

46

40

Assemble the exhaust pipe to the manifold.

41

Assemble and tighten the clamp.

42

Tighten the turbocharger retaining screws.

43

Assemble the hose to the air filter.

44

Assemble the air filter and the retaining screws to the bracket. Tighten the screws.

45

Assemble the clamp to the hose and air filter (see fig. step 43). Tighten the clamp.

46

Plug in both pressure sensor connectors.

47

Start the engine and check for leaks and proper operation.

Fig.45 exhaust pipe, assembly 1 clamp 2 exhaust pipe

Fig.46 air filter, assembly 1 connector 2 clamp 3 hose

Fig.47 air filter, assembly 1 retaining screws

47

Battery, current capacity, electrolyte level, cables and connections, especially connections at starter motor, check Op. no. This is part of other procedure 1

Before performing any work on the battery, read the following document: 191, Safety when working with batteries.

2


3

Check that the cable terminals and pole studs are clean, well tightened and coated with petroleum jelly or similar.

4

1

2

The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately. Wash the affected area with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention.

3

Remove the cell caps. 5

Check the charging status for all battery cells with an acid tester.

6

Check the electrolyte level. Top up with distilled water if necessary.

4

5 Fig.48 current capacity, check 1 cell cap 2 level indicator 3 maximum level 4 minimum level 5 level indicator

48

WARNING

NOTICE The electrolyte level should stand approx. 10 mm (0.4 in) above the cell plates. Check the level indicator.

V1092347

7

Reassemble the cell caps.

Engine radiator, oil cooler and condensor (if installed), clean Op. no. This is part of other procedure

1

1

Loosen the fastening screws and remove the radiator grille.

2

Loosen the catches on either side of the radiator, pull the oil cooler and condenser to the front.

3

Clean the oil cooler and the condenser. Clean the front and the rear side.

NOTICE The core of the coolers can be easily damaged if not handled carefully.

NOTICE Always repair water or oil leaks immediately, to prevent dust buildup on wet surfaces.

V1090839

2 Fig.49 engine radiator, cleaning 1 radiator catches 2 grille with fastening screws

Type of dirt

Cleaning method

Dry dust

Compressed air

Mud

Water jet

Oily dust

Perchlorethylene

4

Place the oil cooler and condenser back in position and lock them with the catches.

5

Reassemble the radiator grille and fasten the retaining screws.

49

Coolant level, checking Op. no. This is part of other procedure 1

Check that the coolant is between the two marks on the expansion tank. Top up if necessary.

NOTICE The level should be up to the HOT mark when the engine is warm. The level must never be below the COLD FILL mark.

Fig.50 coolant expansion tank with marks

50

Air cleaner primary filter, changing Op. no. This is part of other procedure

NOTICE Clean the air filter cover by pressing the rubber manifold, located at the bottom on the air cleaner cover. This job should be carried out when required.

NOTICE Do not, under any circumstances, run the engine without a filter or with a damaged one. 1

Pull the yellow locking tab to release the cover lock, turn the filter cover counter-clockwise and remove it.

2

Remove the primary air filter.

3

Empty and clean the filter cover.

4

NOTICE

Fig.51 engine air filter 1 filter cover 2 locking tab 3 rubber manifold

If the secondary air filter has to be changed, too, change it before assembling the new primary air filte. See Air cleaner, secondary filter replacing page 52. Mount a new air filter. 5

Mount and fasten the cover by turning it clockwise and lock the locking tab.

6

Check that all hose and pipe connections from the air cleaner to the engine induction manifold are tight.

Fig.52 primary air filter

51

Air cleaner, secondary filter replacing Op. no. This is part of other procedure.

Fig.53 secondary air filter

52

1

Remove the filter cover and the primary filter. See Air cleaner primary filter, changing page 51.

2

Remove the secondary filter.

3

Assemble a new secondary filter.

4

Mount the primary filter and the filter housing. See Air cleaner primary filter, changing page 51.

Fuel filters, primary and secondary filter, replace Op. no. This is part of other procedure.

Primary fuel filter, replacing 1

Place a suitable container under the primary fuel filter to collect draining fuel.

2

Connect a hose to the draining nipple and place the other end of the hose in the container.

3

Open the draining valve and drain all fuel from the primary fuel filter and the water trap.

CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. 4

Remove the primary fuel filter by the use of a filter clamp.

5

Install a new filter onto the filter head. When installing the filter, it should be tightened by hand.

Fig.54 Primary filter and water trap 1 Hand pump 2 Draining nipple 3 Primary filter

Secondary fuel filter, replacing

NOTICE The filter is top filled with fuel. Observe when changing the fuel filter. 6

Place a suitable container under the secondary fuel filter to collect spilling fuel.

53

Fig.55 Secondary fuel filter

54

7

Remove the secondary fuel filter by the use of a filter clamp.

8

Fill the new filter with fuel, lubricate the seal and hand tighten plus 3/4 turn.

Fuel system, bleeding Op. no. This is part of other procedure. Do not bleed the system when the engine is warm. 1

Fill the fuel tank with fuel, leaving room for expansion.

2


3


4

Open the draining valve, so that fuel can leak out. Pump the hand pump until fuel, free from air bubbles flows out.


Close the draining valve and remove the hose.

Fig.56 primary fuel filter 1 hand pump 2 draining nipple 3 water trap

55

Fuel system, water trap, check/drain Op. no. This is part of other procedure 1

Check if there is water on the bottom of the water trap. Drain the water if necessary by taking out the following steps.

2


3


4

Open the draining valve and pump with the hand pump until all water has been forced out of the water trap. When fuel instead of water starts to flow, close the draining valve.

CAUTION Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. 5 Fig.57 Primary fuel filter 1 Hand pump 2 Draining nipple 3 Water trap

56

Remove the hose.

Cab filter, replace (clean when necessary) Op. no. This is part of other procedure

CAUTION Take care of filters, oils and liquids in an environmentally safe way.

NOTICE Use a respirator (dust mask) during any work with the filter. 1

Unlock and remove the filter housing from the fender.

2

Place it on a clean surface.

3

Loosen the locking devices (1, 4) and remove the plate (3).

4

Replace or clean (if necessary) the filters (2).

NOTICE If cleaning is required: Shake the filters carefully without damaging them. Avoid using compressed air, vacuum cleaner or water.

4

3

2

5

Assemble the plate and fasten the locking devices.

6

Assemble and lock the filter housing.

1 V1094339

Fig.58 cab filter, replace 1 locking device 2 filters 3 plate 4 locking device

57

Axles, checking oil level Op. no. This is part of other procedure

1

2

3

4

V1090584

Fig.59 Axles, checking oil levels 1 rear axle breather 2 Oil filler/oil level plug 3 Oil filler/oil level plug 4 front axle breather

Front axle 1

NOTICE Standard 2WD front axle does not contain any oil. Loosen the front axle breather (4) to release internal pressure.

2

Remove the oil filler/oil level plug (3).

3

The oil should be up to the hole. Fill with oil if necessary.

4

Refit the filler plug.

Rear axle

58

5

Loosen the rear axle breather (1) to release internal pressure.

6

Remove the oil filler/oil level plug (2).

7

The oil should be up to the hole. Fill with oil if necessary. For oil specifications, see Recommended lubricants, oils page 7.

8

Refit the filler plug.

Axle breather, cleaning Op. no. This is part of other procedure The axle breathers are located on top of both the front and the rear axle.

1

V1049382

Fig.60 Front axle breather location 1 Breather

1

1

Remove the breathers.

2

Use turpentine, paraffin or petrol to clean the breather.

3

Re-fit the breather. Tightening torque: 8–10 Nm (5.9–7.4 lbf ft)

V1049383

Fig.61 Rear axle breather location 1 Breather

NOTICE Take care of waste oil and liquids in an environmentally safe way.

59

Axle hubs, checking oil level Op. no. This is part of other procedure

NOTICE Standard 2WD front axle does not contain any oil. 1

WARNING Only use lifting devices with adequate capacity.

NOTICE See your Operator´s manual section Specifications for the weight of your machine. Raise the machine so that the front wheels are off the ground. Use a suitable lifting device.

2 1

2

Place a suitable support under the axle.

3

Rotate the wheel hub so that the oil level marking (1) is horizontal.

4

Clean the area around the drain plug (2). Place a suitable container under the drain plug.

5

Remove the drain plug (2). The oil should be up to the oil level mark (1). Fill up with oil if necessary. For oil specifications, see Recommended lubricants, oils page 7.

OIL LEVEL

V1019816

Fig.62 Hubs 1 Oil level marking 2 Drain plug

60


Reassemble the drain plug. See section 461, Front axle, tightening torque for correct tightening torque.

7

Repeat the steps 3–6 for the opposite hub.

8

Remove the support and lower the front wheels to the ground.

Tyres, wear and air pressure, checking Op. no. This is part of other procedure 1

See your Operator´s Manual section Tyres for detailed instructions.

Wheel nuts, check torque Applies to models: BL60B, BL61B, BL71B

Op. no. This is part of other procedure.

NOTICE After (re)installing a wheel, retighten the wheel nuts after 8 hours of travelling/operating. 1

Check the wheel nuts torque, see 771, Wheels, tightening torques for recommented tightening torque.

V1092389

Fig.63 Wheel

Bolted joints, check tightening torque Op. no. This is part of other procedure 1

Check the tightening torque of the propeller shaft connections with the rear axle and transmission. See 451, Propeller shaft, tightening torque.

2

Check the tightening torque of the propeller shaft connections with the front axle and transmission (4–WD machines only). See 451, Propeller shaft, tightening torque.

3

Check the mounting of the rear axle. See 463, Axles to frame, tightening torques.

4

Check the mounting of the transmission. See 436, Transmission mounts, tightening torque.

5

Check the mounting of the engine. See 200, Engine, tightening torque.

61

Hydraulic oil tank breather filter, replace Op. no. This is part of other procedure The breather filter is a part of the tank cap and can not be separated from the cap. 1

Fig.64 Hydraulic oil tank breather filter, replace

62

Replace the tank cap.

Axles, changing oil Op. no. This is part of other procedure Front axle differential 1

NOTICE Standard 2WD front axle does not contain any oil. Place a suitable container under the drain plug.

2

Clean the area around the oil drain plug and the oil filling and level plug.

3

Remove the oil drain plug and the oil filling plug. Drain the oil.


2

1

4

Re-fit the oil drain plug after the oil has been drained. See section 461, Front axle, tightening torque for correct tightening torque.

5

Fill the axle with new oil. For oil specifications, see Recommended lubricants, oils page 7. See section 461, Front axle, capacities for axle oil capacity.

6

Re-fit the oil filling plug. See section 461, Front axle, tightening torque for correct tightening torque.

V1019818

Fig.65 Front axle differential 1 Oil filling/level plug 2 Oil drain plug

Rear axle differential 7

Place a suitable container under the oil drain plug.

8

Clean the area around the oil drain plug and filling plug.

9

Remove the drain plug and the oil filling plug. Drain the oil.


1

2

Fig.66 Rear axle differential 1 Oil filling and level plug 2 Oil drain plug

10

Re-fit the drain plug after the oil has been drained. See section 463, Rear axle, tightening torques for correct tightening torque.

11

Fill the axle with new oil. For oil specifications, see Recommended lubricants, oils page 7. See section 463, Rear axle, capacities for axle oil capacity.

12

Re-fit the oil filling plug. See section 463, Rear axle, tightening torques for correct tightening torque.

V1049370

63

Axle hubs, changing oil Op. no. This is part of other procedure

NOTICE Standard 2WD front axle does not contain any oil. 1

WARNING Only use lifting devices with adequate capacity.

NOTICE See your Operator´s manual section Specifications for the weight of your machine. Raise the machine so that the front wheels are off the ground. Use a suitable lifting device. 2

Place a suitable support under the axle.

3

Rotate the wheel hub so that it is in the drain position.

4

Clean the area around the drain plug (2). Place a suitable container under the drain plug.

5

Remove the drain plug (2) and drain the oil in the container.


1

V1092556

Fig.67 Wheel hub in drain position 1 Drain plug

1

V1092557

Fig.68 Wheel hub in fill/level position 1 oil level mark

64

6

Rotate the wheel hub so that it is in the fill/level position.

7

Fill the axle hub with new oil. The oil should be up to the oil level mark (1). For oil specifications, see Recommended lubricants, oils page 7. See section 461, Front axle, capacities for oil capacity.

8

Reassemble the drain plug. See section 461, Front axle, tightening torque for correct tightening torque.

9

Repeat the steps 3–8 for the opposite hub.

10

Remove the support and lower the front wheels to the ground.

Transmission, replacing oil filter Op. no. 1

Remove the transmission oil filter by use of a filter clamp.

2

Apply oil to the new gasket. For oil specifications, see Recommended lubricants, oils page 7.

3

Screw on a new filter until the gasket just touches the sealing surface. Then tightening a further half of a turn by hand.

V1019812

Fig.69 Transmission oil filter

Transmission breather filter, replacing Op. no. This is part of other procedure 1

Replace the breather filter.

V1050632

1 Fig.70 1 Transmission breather filter

65

Hydraulic system, replacing filter Op. no. This is part of other operation. The hydraulic oil filter is located on the right-hand side behind the rear axle. 1

Place a container under the filter to catch any spillage.

2

Remove the hydraulic oil filter, by using a filter clamp. The hydraulic oil filter is of disposable type, therefore always replace it with a new filter.


V1061302

Fig.71 1 Drain plug 2 Hydraulic oil filter

66

3

Fill the new filter with hydraulic oil and apply oil to the gasket. For oil specifications, see Recommended lubricants, oils page 7.

4

Screw on the filter until the gasket just touches the sealing surface. Then tighten a further half turn by hand.

Engine, changing oil and filter Op. no. This is part of other operation.


WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin.

NOTICE Drain the engine oil while the engine is still warm. 1

Remove the engine oil dipstick.

2

Place a container under the drain hole, loosen and remove the drain plug. The drain plug is located on the left–hand side of machine at the base of the sump.

3

Drain the oil in the container.

Fig.72 Engine, draining 1 oil filler port with dipstick

1


Reassemble the drain plug securely.

V1090867

Fig.73 Engine, draining 1 drain plug

67

5

Loosen and remove the oil filter by use of an filter clamp.

NOTICE Take care of used liquids and filters in an environmentally safe way. 6

Fill the new engine oil filter with oil and apply oil to the filter seal. For engine oil specification, see Recommended lubricants, oils page 7.

7

Assemble the new engine oil filter until the rubber seal just touches the filter head, then tighten by hand a further 3/4 turn.

8

Fill the engine with engine oil through the oil filler port. Refill with correct grade of oil up to the MAX level on the dipstick. Allow time for the oil to settle in the engine. For engine oil specification, see Recommended lubricants, oils page 7. For engine oil capacity see 200, Engine, capacities.

9

Reassemble the engine oil dipstick.

Fig.74 Engine oil filter

Max.

Min.

V1090437


68

Transmission, changing oil Op. no. This is part of other procedure

NOTICE The transmission oil should be warm before draining. 1

Fully unscrew the dipstick and remove it.

2

Place a container under the transmission drain plug. The drain plug is located at the bottom of the transmission on the right side of the machine.

3

Remove the drain plug.

Fig.76 transmission, changing oil 1 oil filler port with dipstick

T

V1088102

Fig.77 transmission oil dipstick T = Thread: When the dipstick is fully unscrewed, the thread should NOT be visible.


1 V1049277

Fig.78 Transmission drain plug 1 Drain plug

4

Drain the oil completely from the transmission.

5

Refit the drain plug.

6

Replace the suction filter before refilling transmission oil. See Transmission suction filter, replacing page 70.

7

Fill the transmission oil through the filler port until the oil level is between the Min and Max marks on the fully unscrewed dipstick, see section 430, Transmission, capacities. For oil specifications, see Recommended lubricants, oils page 7.

8

Refit the dipstick. 69

Transmission suction filter, replacing Op. no. This is part of other procedure

NOTICE Transmission oil must be drained before removing the suction filter. See Transmission, changing oil page 69.

NOTICE The suction filter can be accessed from under the machine.

NOTICE Take care of waste oil and liquid in an environmentally safe way.

V1050660

Fig.79 Suction filter

70

1

Place a suitable container under the filter holder.

2

Remove the suction filter cover.

3

Remove the suction filter and the O–ring.

4

Assemble the new suction filter with a new O–ring.

5

Refit the suction filter cover. Tightening torque: 23 Nm (16.9 Ibf ft).

Hydraulic system, pressure release Op. no. This is part of other procedure

NOTICE When the engine has been stopped, there remains an accumulated pressure in the system. The remaining pressure in the system must be lowered, so-called depressurization (releasing pressure), before hose connections, plugs, etc. are opened in the hydraulic system or brake system.

WARNING If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious personal injuries. 1

For machines equipped with mechanical control: Turn the ignition key to position 0. For machines equipped with pilot control: Turn the ignition key to position I.

2

Operate the loader, backhoe and stabiliser controls with full strokes (forwards and rearwards), to release the accumulated pressure in the hydraulic system.

71

Hydraulic system, changing oil Applies to models: BL60B, BL61B

Op. no. This is part of other procedure

Draining

1

1

2

Place a container under the hydraulic oil pump.

NOTICE The hydraulic system is drained by removing the suction line from the hydraulic oil pump. 2

Loosen the retaining screws, remove the suction line from the hydraulic oil pump and point it immediately towards the container to collect the oil.

CAUTION Take care of filters, oils and liquids in an environmentally safe way. 3

Drain the oil completely from the system.

V1093286

Fig.80 hydraulic oil pump 1 hydraulic oil pump 2 suction hose

Filling

Fig.81 Tank cap

72

4

Fill the hydraulic oil pump through the inlet from the suction line. For oil specifications, see Recommended lubricants, oils page 7.

5

Assemble the suction line and fasten the retaining screws. See 913, Hydraulic pump, tightening torque for recommended tightening torque.

6

Remove the tank cap.

7

Fill the hydraulic system with oil through the filler neck. For oil specifications, see Recommended lubricants, oils page 7.

8

Refit the tank cap.

9

Start the engine and let it idle for 2 minutes.

10

Operate the control levers for the loader boom and backhoe cylinders to their end positions smoothly.

11

Stop the engine.

12

Check the hydraulic oil level through the oil level glass. Top up with oil when required.

13

Check that there are no leaks.

Fig.82 oil level glass

73

Hydraulic system, changing oil Applies to models: BL70B, BL71B


Draining 1

Place a container under the hydraulic oil drain plug.

NOTICE The drain plug is located under the machine on the bottom of the lower hydraulic tank. 2

Remove the drain plug and drain the hydraulic oil.

CAUTION Take care of filters, oils and liquids in an environmentally safe way. 3

Refit the drain plug.

Fig.83 oil tank with drain plug 1 oil tank 2 rear axle 3 drain plug

Filling 4

Remove the bleed plug on top of the hydraulic pump.

5

Remove the tank cap.

6

Fill the hydraulic system with oil through the filler neck. For oil specifications, see Recommended lubricants, oils page 7.

V1093164

Fig.84 hydraulic pump with bleed plug

NOTICE Check the bleed plug of the pump. When oil is coming out, refit the bleed plug on top of the hydraulic pump.

Fig.85 Tank cap

74

7

Refit the tank cap.

8

Start the engine and let it idle for 2 minutes.

9

Operate the control levers for the loader boom and backhoe cylinders to their end positions smoothly.

10

Stop the engine.

11

Check the hydraulic oil level through the oil level glass. Top up with oil when required.

12

Check that there are no leaks.


75

Hydraulic pressure, check Applies to models: BL60B, BL61B

This is part of other procedure Op. no. Tools: 88830055 Pressure checking set Additional parts for hydraulic pressure testing: VOE935084 Nipple VOE935552 Hose

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries

CAUTION Do the work in an environmentally safe manner.

Checking Δp open centre 1

Connect a pressure sensor (60 MPa (600 bar) (8702 psi)) between the HP pressure check port (2) and the digital pressure gauge.

NOTICE The check ports are located on the backhoe control valve mounting bracket. 2

Connect a pressure sensor (60 MPa (600 bar) (8702 psi)) between the LS pressure check port (1) and the digital pressure gauge.

NOTICE The check ports are located on the backhoe control valve mounting bracket. Fig.87 HP/LS pressure check ports 1 LS pressure check port 2 HP pressure check port

3

Reset the digital pressure gauge to zero, see special instruction.

4

Start the engine and raise it to the recommended engine speed for checking Δp open centre pressure, see 910, Hydraulic system, specification.

5

Read off HP and LS pressure.

NOTICE Do not activate any hydraulic function while checking the pressure.

76

6

Turn off the engine.

7

Calculate the Δp open centre pressure: Δp open centre pressure = HP pressure — LS pressure See 910, Hydraulic system, specificationfor correct stand-by pressure.

8

If the check value is incorrect, the open centre valve shoud be replaced.

Checking and adjusting backhoe relief valve (backhoe, HP pressure) 9


NOTICE The check ports are located on the backhoe control valve mounting bracket.

Fig.88 Mounting bracket, backhoe control valve 1 LS pressure relief valve 2 HP pressure check port 3 LS pressure check port

10


11

Start the engine and raise it to the recommended engine speed for checking the backhoe HP pressure, see 910, Hydraulic system, specification.

12

Close the excavator bucket to end position. Keep the joystick activated when the bucket is in end position and read off the HP pressure.

13

See 910, Hydraulic system, specification for correct backhoe HP pressure.

14

NOTICE Do not adjust the settings of the valve block during warranty period. Contact Volvo CE Customer Support for more information. If the measured value is incorrect: Remove the security seal from the LS-pressure relief valve (1) and loosen the lock nut. Adjust the adjusting screw on the LS-pressure relief valve.

NOTICE Screw out to decrease the pressure.

NOTICE Screw in to increase the pressure. 15


16

Tighten the lock nut and assemble a new security seal.

Checking and adjusting loader relief valve (loader HP pressure) 17


NOTICE The check ports are located on the backhoe control valve mounting bracket. 18


19

Start the engine and raise it to the recommended engine speed for checking the loader HP pressure, see 910, Hydraulic system, specification.

77

20

Tilt out the loader bucket to end position. Keep the joystick activated when the bucket is in end position and read off the HP pressure.

21

See 910, Hydraulic system, specification for correct loader HP pressure.

NOTICE Do not adjust the settings of the valve block during warranty period. Contact Volvo CE Customer Support for more information. If the measured value is incorrect, the loader LS-pressure relief valve needs to be adjusted. See steps 23 – 30. Otherwise proceed with step 31.

1

2

22

Remove the security seal from the LS-pressure relief valve (1) and loosen the lock nut.

23

Adjust the adjusting screw on the LS-pressure relief valve.




25


26


V1093563

Fig.89 loader control valve, adjusting LS-pressure 1 loader control valve 2 LS-pressure relief valve

Checking steering pressure 27

Connect a pressure sensor (60 MPa (600 bar) (8702 psi)) between the HP pressure check port and the digital pressure gauge.

NOTICE The check ports are located on the backhoe control valve mounting bracket.

Fig.90 HP/LS pressure check ports 1 LS pressure check port 2 HP pressure check port

78

28


29

Start the engine and raise it to the recommended engine speed, see 910, Hydraulic system, specification.

30

Turn the steering wheel to the right or left to full lock and read off the HP pressure. See 910, Hydraulic system, specification for correct steering pressure.

31


32

If the measured value is incorrect: The steering valve should be replaced.

33

Remove the checking equipment.

Hydraulic pressure, check Applies to models: BL70B, BL71B

This is part of other procedure Op. no. Tools: 88830055 Pressure checking set Additional parts for hydraulic pressure testing: VOE935084 Nipple VOE935552 Hose

WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries

CAUTION Do the work in an environmentally safe manner.

Checking and adjusting servo pressure 1

Connect a pressure sensor (6.0 MPa (60 bar) (870 psi)) between the servo pump´s servo pressure check port (1) and the digital pressure gauge.

2


3

Start the engine and raise it to the recommended engine speed for checking the servo pressure, see 910, Hydraulic system, specification.

4

Read off the servo pressure. See 910, Hydraulic system, specification for correct servo pressure.

5

NOTICE Do not adjust the settings of the servo pump during warranty period. Contact Volvo CE Customer Support for more information. If the measured value is incorrect: Remove the cap nut and adjust the adjusting screw (2) on the servo pump.

Fig.91 servo pump 1 servo pressure port with check port 2 servo pressure adjusting screw




7

Fit the cap nut.

8


79

Checking stand–by pressure (HP-LS) 9


NOTICE The check ports are located on the main control valve mounting bracket. 10

Connect a pressure sensor (60 MPa (600 bar) (8702 psi)) between the LS pressure check port (1) and the digital pressure gauge.

NOTICE The check ports are located on the main control valve mounting bracket. Fig.92 HP/LS pressure check ports 1 LS pressure check port 2 HP pressure check port

11


12

Start the engine and raise it to the recommended engine speed for checking the stand—by pressure, see 910, Hydraulic system, specification.

13

Read off HP and LS pressure.

NOTICE Do not activate any hydraulic function while checking the pressure. 14


15

Calculate the stand-by pressure: stand-by pressure = HP pressure — LS pressure See 910, Hydraulic system, specification for correct standby pressure.

Checking and adjusting Δp (spring pressure in FR–valve) 16


NOTICE The check ports are located on the main control valve mounting bracket. 17

Connect a pressure sensor (60 MPa (600 bar) (8702 psi)) between the LS pressure check port and the digital pressure gauge.

NOTICE The check ports are located on the main control valve mounting bracket. Fig.93 HP/LS pressure check port 1 LS pressure check port 2 HP pressure check port

80

18


19

Start the engine and raise it to the recommended engine speed for checking Δp, see 910, Hydraulic system, specification.

20

Slowly roll back the loader bucket with constant pressure on the control lever Read off HP and LS pressure.

NOTICE Δp is checked while moving one function with a slow and constant speed. HP pressure must be below 100 bar to avoid being involved in power regulation of the pump. 21

Calculate Δp: Δp = HP pressure — LS pressure See 910, Hydraulic system, specification for correct Δp value.

22

NOTICE Do not adjust the settings of the hydraulic pump during warranty period. Contact Volvo CE Customer Support for more information. If the measured value is incorrect: Remove the plug (2) from the FR—valve (1) and loosen the lock nut. Adjust the adjusting screw on the FR—valve.


Fig.94 Adjusting Δp (FR-valve) 1 FR-valve 2 plug and lock nut


Tighten the lock nut and assemble the plug.

24


Checking and adjusting power regulation (spring pressure in LR–valve) 25

Connect a pressure sensor (60 MPa (600 bar) (8702 psi)) at the HP pressure check port and the digital pressure gauge.

NOTICE The check ports are located on the main control valve mounting bracket.

81

26

Disconnect the pipe (1) and the pipe fitting (2) from the LRvalve. Seal the pipe with a plug.

27

Connect the nipple and the hose to the LR-valve. VOE935084 Nipple VOE935552 Hose

NOTICE Before fitting the nipple to the LR-valve, the thread length of the nipple must be shortened by approx. 5mm.

Fig.95 Pump housing 1 pipe 2 pipe fitting

28

Remove the cover and place the hose down into the hydraulic oil tank as shown in the figure.

29


30

Start the engine and raise it to the recommended engine speed for checking the spring pressure in LR–valve, see

910, Hydraulic system, specification

31

Raise one stabilizer leg, keep the joystick activated when the stabilizer leg is in end position and read off the HP pressure.

32

See 910, Hydraulic system, specification for correct spring pressure in LR–valve.

Fig.96 Filler neck, hydraulic tank 1 Cover

NOTICE Due to the hose connecting the LR-valve to tank a pressure loss of approx. 2-3 bar (30-43 psi) will occur. Consider the pressure loss when comparing the measured pressure to the specification. 33

NOTICE Do not adjust the settings of the hydraulic pump during warranty period. Contact Volvo CE Customer Support for more information. If the measured value is incorrect: Remove the plug from the LR-valve and loosen the lock nut. Adjust the adjusting screw on the LR-valve.


NOTICE

Fig.97 Adjusting power regulation (LR–valve) 1 Adjusting screw

82

Screw in to increase the pressure. 34

Tighten the lock nut and fit the plug.

35


36

Disconnect the nipple and the hose.

37

Assemble the pipe and the pipe fitting.

Fig.98 Pump housing 1 pipe 2 pipe fitting

Checking and adjusting HP pressure (max. pressure) 38



Fig.99 Mounting bracket, main control valve 1 LS pressure relief valve 2 HP pressure check port 3 LS pressure check port

39


40

Start the engine and raise it to the recommended engine speed for checking the HP pressure, see 910, Hydraulic system, specification.

41

Raise one stabilizer leg, keep the joystick activated when the stabilizer leg is in end position and read off the HP pressure.

42

See 910, Hydraulic system, specification for correct HP pressure.

43

NOTICE Do not adjust the settings of the valve block during warranty period. Contact Volvo CE Customer Support for more information. If the measured value is incorrect: Remove the security seal from the LS-pressure relief valve (1) and loosen the lock nut. Adjust the adjusting screw on the LS-pressure relief valve.




45


83

Checking steering pressure 46



Fig.100 HP/LS pressure check ports 1 LS pressure check port 2 HP pressure check port

84

47


48

Start the engine and raise it to the recommended engine speed, see 910, Hydraulic system, specification.

49

Turn the steering wheel to the right or left to full lock and read off the HP pressure. See 910, Hydraulic system, specification for correct steering pressure.

50


51

If the measured value is incorrect: The steering valve should be replaced.

52


Hydraulic system, checking oil level Op. no. This is part of other procedure The level glass is positioned under the engine hood, on the right side of the hydraulic oil tank. 1

Remove the loader arm safety strut.

2

Start the engine.

3

Fully retract the stabilisers.

4


5

Place the backhoe unit as shown in the image.

6

Stop the engine.

7

Check the level glass for current oil level.

V1020198

Fig.101 Service position for oil level check

NOTICE The red dot in the middle of the glass describes the normal level of hydraulic oil in the oil tank. If the hydraulic oil is not visible in the glass, locate the leak and replace the broken part and refill the system. If the problem remains, contact a Volvo CE dealer.


85

Transmission 2WD, oil pressures, checking Applies to models: BL60B, BL61B

This is part of other procedure Op. no. Tools: 88830055 Pressure checking set Additional parts for transmission pressure testing: VOE936440 testing nipple VOE933859 T-nipple VOE935650 plug VOE935331 nipple VOE936439 testing nipple

3

2

1

V1093853

Fig.103 2WD transmission, pressure check ports 1 lubrication, pressure check port 2 forward clutch, pressure check port 3 reverse clutch, pressure check port

Checking forward clutch pressure

86

1

Remove the plug and fit the testing nipple (part no. 936440) to the forward clutch pressure check port.

2

Connect a pressure sensor (6.0 MPa (60 bar) (870 psi)) between the pressure check port and the digital pressure gauge.

3


4

Start the engine and raise it to the recommended engine speed for checking the forward clutch pressure, see 430, Gearbox 2WD, specifications.

5

Read off the pressure. See 430, Gearbox 2WD, specifications for correct forward clutch pressure.

6


7

Remove the checking equipment and refit the plug, for recommended tightening torque see 430, Transmission, tightening torques.

Checking reverse clutch pressure 8

Remove the plug and fit the testing nipple (part no.936440) to the reverse clutch pressure check port.

9


10


11

Start the engine and raise it to the recommended engine speed for checking the reverse clutch pressure, see 430, Gearbox 2WD, specifications.

12

Read off the pressure. See 430, Gearbox 2WD, specifications for correct reverse clutch pressure.

13


14


Checking lubrication pressure 15

Remove the plug and fit the testing nipple (part no.936440) to the lubrication pressure check port.

16


17


18

Start the engine and raise it to the recommended engine speed for checking the lubrication pressure, see 430, Gearbox 2WD, specifications.

19

Read off the pressure. See 430, Gearbox 2WD, specifications for correct lubrication pressure.

20


21

Remove the checking equipment and refit the plug , for recommended tightening torque see 430, Transmission, tightening torques.

87

Checking differential lock pressure 22

Disassemble the hose from the differential lock supply port.

23

Connect the T-nipple (part no. 933859) to the supply hose.

24

Fit the plug (part no. 935650) to the T-nipple.

25

Fit the nipple (part no. 935331) to the T-nipple.

26

Fit the testing nipple (part no. 936439) to nipple.

27


28


29

Start the engine and raise it to the recommended engine speed for checking the differential lock pressure, see 430, Gearbox 2WD, specifications.

30

Read off the pressure. See 430, Gearbox 2WD, specifications for correct differential lock pressure.

31


32


33

Reassemble the hose to differential lock supply port, for recommended tightening torque see 463, Rear axle, tightening torques.

Fig.104 rear axle, differential lock supply port 1 supply hose 2 differential lock supply port

1

2

5

4

3 V1094071

Fig.105 checking equipment connected to supply hose 1 pressure sensor 2 T-nipple (part no. 933859) 3 plug (part no. 935650) 4 nipple (part no. 935331) 5 testing nipple (part no. 936439)

Transmission 4WD, oil pressures, checking This is part of other procedure Op. no. Tools: 88830055 Pressure checking set Additional parts for transmission pressure testing: VOE936440 testing nipple VOE933859 T-nipple VOE935650 plug VOE935331 nipple 88

VOE936439 testing nipple

4

3

2

1

V1093905

Fig.106 4WD transmission, pressure check ports 1 4WD, pressure check port 2 lubrication, pressure check port 3 forward clutch, pressure check port 4 reverse clutch, pressure check port

Checking forward clutch pressure 1


2


3


4

Start the engine and raise it to the recommended engine speed for checking the forward clutch pressure, see 430, Gearbox 4WD, specifications.

5

Read off the pressure. See 430, Gearbox 4WD, specifications for correct forward clutch pressure.

6


7


89


Remove the plug and fit the testing nipple (part no. 936440) to the reverse clutch pressure check port.

9


10


11

Start the engine and raise it to the recommended engine speed for checking the reverse clutch pressure, see 430, Gearbox 4WD, specifications.

12

Read off the pressure. See 430, Gearbox 4WD, specifications for correct reverse clutch pressure.

13


14



Remove the plug and fit the testing nipple (part no. 936440) to the lubrication pressure check port.

16


17


18

Start the engine and raise it to the recommended engine speed for checking the lubrication pressure, see 430, Gearbox 4WD, specifications.

19

Read off the pressure. See 430, Gearbox 4WD, specifications for correct lubrication pressure.

20


21


Checking 4WD pressure

90

22

Remove the plug and fit the testing nipple (part no. 936440) to the 4WD pressure check port.

23


24


25

Start the engine and raise it to the recommended engine speed for checking the 4WD pressure, see 430, Gearbox 4WD, specifications.

26

Read off the pressure. See 430, Gearbox 4WD, specifications for correct 4WD pressure.

27


28




30


31


32


33


34


35


36

Start the engine and raise it to the recommended engine speed for checking the differential lock pressure, see 430, Gearbox 4WD, specifications.

37

Read off the pressure. See 430, Gearbox 4WD, specifications for correct differential lock pressure.

38


39


40


Fig.107 rear axle, differential lock supply port 1 supply hose 2 differential lock supply port

1

2

5

4

3 V1094071


91

Powershift Transmission (option), oil pressures, checking This is part of other procedure Op. no. Tools: 88830055 Pressure checking set Additional parts for transmission pressure testing: VOE936440 testing nipple VOE933859 T-nipple VOE935650 plug VOE935331 nipple VOE936439 testing nipple

Fig.109 Powershift transmission, pressure check ports 1 reverse clutch, pressure check port 2 forward clutch, pressure check port 3 lubrication, pressure check port

Checking forward clutch pressure

92

1


2


3


4

Start the engine and apply the service brakes.

5

Shift the forward/reverse lever into position F.

6

Raise the engine to the recommended engine speed for checking the forward clutch pressure, see 420, Powershift transmission, specifications.

7

Read off the pressure. See 420, Powershift transmission, specifications for correct forward clutch pressure.

8

Turn off the engine and shift the forward/reverse lever into position N.

9



Remove the plug and fit the testing nipple (part no. 936440) to the reverse clutch pressure check port.

11


12


13


14

Shift the forward/reverse lever into position R.

15

Raise the engine to the recommended engine speed for checking the reverse clutch pressure, see 420, Powershift transmission, specifications.

16

Read off the pressure. See 420, Powershift transmission, specifications for correct reverse clutch pressure.

17


18



Remove the plug and fit the testing nipple (part no. 936440) to the lubrication pressure check port.

20


21


22


23

Shift the forward/reverse lever into position N.

24

Raise the engine to the recommended engine speed for checking the lubrication pressure, see 420, Powershift transmission, specifications.

25

Read off the pressure. See 420, Powershift transmission, specifications for correct lubrication pressure.

26


27


93



29


30


31


32


33


34


35

Start the engine and raise it to the recommended engine speed for checking the differential lock pressure, see 420, Powershift transmission, specifications.

36

Read off the pressure. See 420, Powershift transmission, specifications for correct differential lock pressure.

37


38


39


Fig.110 rear axle, differential lock supply port 1 differential lock supply port 2 supply hose

1

2

5

4

3 V1094071


94

Control valve supply pressure

Fig.112 Powershift transmission, pressure check port 1 brake pressure port with fitting 2 hose

40

Disassemble the hose from the brake pressure port fitting and seal the hose.

41

Fit the nipple (part no. 935331) to the brake pressure port fitting.

42


43


44


45


46

Shift the forward/reverse lever into position N

47

Raise the engine to the recommended engine speed for checking the control valve supply pressure, see 420, Powershift transmission, specifications.

48

Read off the pressure. See 420, Powershift transmission, specifications for correct control valve supply pressure.

49


50

Remove the checking equipment and reassemble the hose to the brake pressure port fitting. For recommended tightening torque see 430, Transmission, tightening torques.

Gear clutch pressure

NOTICE Repeat the following 9 steps for 1st, 2nd, 3rd and 4th gear. Use the regarding pressure check port for the gear to check.

95

51

Remove the plug and fit the testing nipple (part no. 936440) to the gear clutch pressure test port.

52

Connect a pressure sensor (6.0 MPa (60 bar) (870 psi)) between the gear pressure check port and the digital pressure gauge.

53


54


55

Select a gear and shift the forward/reverse lever into position F.

56

Raise the engine to the recommended engine speed for checking the gear clutch pressure test port. see 420, Powershift transmission, specifications.

NOTICE Fig.113 Gear clutch pressure check ports 1 4th gear pressure check port 2 2nd gear pressure check port 3 1st gear pressure check port

Fig.114 Gear clutch pressure check ports 1 3rd gear pressure check port

96

Abort test if transmission oil temperature is getting to high (indicated by high temperature warning light), and allow the transmission to cool down to normal operating temperature before resuming tests. 57

Read off the pressure. See 420, Powershift transmission, specifications for correct gear clutch pressure. Repeat the procedure with reverse selected on the gear selector.

58


59


Engine speed Op. no. This is part of other procedure 1

Start the engine and check the low idle on the side instrument panel. Use the up and down arrows until the engine speed is shown in the display. Low idle: 925 +/- 25 rpm

2

Check the high idle and stop the engine. High idle: 2325 +/- 25 rpm

Fig.115 side istrument panel 1 Up and down arrows 2 display

97

Hydraulic locking cylinders for sideshift mechanism, check (BL61B, BL71B) Applies to models: BL61B, BL71B

Op. no. This is part of other procedure Check the functionality of the sideshift mechanism locking cylinders. 1

Start the engine.

2

Press the sideshift locking switch (side panel) in lower position.

Fig.116 Sideshift locking switch

The sideshift locking cylinders will release the backhoe unit.

Fig.117 Locking cylinders, sideshift mechanism

3

Press the sideshift locking switch in upper position.

The sideshift locking cylinders will lock the backhoe unit. 4

98

Stop the engine.

Boom lock functions, check Applies to models: BL60B, BL61B


Fig.118 boomlock switch

1

Start the engine.

2

Press the backhoe boomlock switch (side panel) in lower position. The boom lock clamp will release the backhoe unit.

3

Press the backhoe boomlock switch in upper position. The boom lock clamp will lock the backhoe unit.

4

Stop the engine.

Fig.119 Boom lock functions, check (view from cab) 1 Boom lock clamp

99

Boom lock functions, check Applies to models: BL70B, BL71B

Op. no. This is part of other procedure 1

Start the engine.

2

Machines with pilot excavator control: Unlock the backhoe joystick unit and pull it to the operator´s seat. Machines with mechanical excavator control: Press the backhoe boomlock switch (side panel) in lower position.

Fig.120 boomlock switch

Fig.121 Boom lock functions, check (view from cab) 1 Boom lock clamp

The boom lock clamp will release the backhoe unit. 3

Machines with pilot excavator control: Lock the backhoe joystick unit by pushing it to the rear window. Machines with mechanical excavator control: Press the backhoe boomlock switch in upper position.

The boom lock clamp will lock the backhoe unit. 4

100

Stop the engine.

Extendible dipper (if installed) wear pads, check Op. no. This is part of other procedure 1

Remove the safety strut from the loader boom.

2

Start the engine.

3

Lower the loader bucket to the ground.

4

Place the dipper in a vertical position.

5

Extend the extendible dipper.

NOTICE The extendible dipper should start to move slowly. If it either does not move, or drops quickly, adjustment of the wear pads has to be made, see section “Extendible dipper (optional equipment) wear pads” in your Operator´s Manual. 6


Stabilisers, loader, backhoe, front axle oscillation pivot and front axle steering pivots, lubricate Op. no. This is part of other procedure 1

See your Operator´s Manual for detailed lubrication instructions, sections Lubrication and service chart and Lubrication points.

Propeller shaft, lubrication Op. no. This is part of other procedure 1

See your Operator´s Manual for detailed lubrication instructions, sections Lubrication and service chart and Lubrication points.

101

Accumulator, check pre-charging pressure This is part of other procedure Op. no. Tools: 11666135 Gas filling kit

NOTICE The hydraulic oil pressure in the accumulators must first have been released.

4

NOTICE When checking and reducing the accumulator precharging pressure, there is no need for the gas cylinder to be connected.

3

2 1

L65759A

Fig.122 Filling accumulator, removed from machine 1 Gas filling set 2 Accumulator 3 Nitrogen gas 4 Shut-off valve

Checking precharging pressure

1 2

102

Remove the cap nut from the accumulator valve.

2

Unscrew the hexagon socket head bolt in the accumulator valve approx. a turn counter-clockwise. Use a 6 mm hexagon key.

3

Screw tool 11666135 Gas filling kit onto the accumulator by hand. Make sure that there is an O-ring in position in the tool.

NOTICE

3

In certain cases it may be necessary to loosen the accumulator brackets and move the accumulator in order to be able to install the tool.

L65760A

Fig.123 1 Gas valve 2 Unloading valve 3 Non-return valve

1

4

Close the unloading valve (2).

5

Open the valve (1) counter-clockwise. When the pressure gauge begins to indicate, the valve should be opened one further turn. The pressure gauge shows the filling pressure in the accumulator. The non-return valve (3) prevents the gas from flowing out.

Reducing precharging pressure 6

Carefully open unloading valve (2). Gas flows out of the tool.

Raising precharging pressure 7

Connect the hose to shut-off valve on the nitrogen cylinder.

8

Open shut-off valve on the nitrogen cylinder.

9

The gas valve (1) on the accumulator should be opened carefully to allow gas to flow into the accumulator.

NOTICE Gradually adjust the pressure, so as not to overload gas valve 1. 10

Close shut-off valve (4)(Fig.1) on the nitrogen cylinder, and read off the pressure on the gauge.

11

Repeat this procedure until the correct precharging pressure has been reached. Wait for approx. 5 minutes, to allow temperature differences to be levelled out and again check the pressure.

Restoring system 12

When the required pressure has been reached, the accumulator gas valve should be closed clockwise to stop with the aid of tool 1.

13

Remove the tool from the accumulator. Check-tighten the hexagon socket head bolt in the gas valve.Tightening torque: 20 N m (14.75 lbf ft)

14

Check that the gas valve does not leak. Use a soap and water solution.

15

Put an O-ring in the cap nut and install the cap nut.

103

Engine oil level, checking Op. no. This is part of other procedure


NOTICE The check should be carried out when the oil is cold and has had time to run down to the oil pan. 1

Use the dipstick to check the engine oil level.

2

The measured level should be between the max. and min. marks. Fill in new oil if necessary. For oil specifications, see Recommended lubricants, oils page 7.

Fig.124 engine, checking oil level 1 oil filler port with dipstick

Max.

Min.

V1090437


104

Test-run and check Op. no. This is part of other procedure 1

Start and stop functions (including pre-heating function)

2

Instruments

3

Lights

4

Direction indicators

5

Hazards flashers

6

Wipers

7

Washers

8

Horn

9

Reversing alarm

10

Steering System

11

Gear positions

12

Differential lock

13

Brake system (parking brake)

14

Brake system (service brake)

15

Climate control systems, check function

16

Decals/Plates and reflectors

17

Optional equipment

105

Brake test Op. no. This is part of other procedure Conditions for service and parking brake test • Brake test must only be done within an area where it cannot cause accidents (risk of being run into from behind etc.). • Acceptable values can only be obtained if the test is carried out on dry asphalt, dry concrete or other similar surfaces. • Make sure that the working area around the machine is clear from people. • The machine must not be loaded. • The stabilisers must be retracted. • Wheel chocks etc. must be removed from the wheels.

Service brake, checking Carry out the brake test as required. Always use the seat belt when using the machine. 1

The service (foot) brake should stop the machine at a speed of 32 km/h (20 mph) within 16 m (54 ft 6 in), or from a speed of 40 km/h (25 mph) within a distance of 22 m (72 ft).

2

If the machine does not stop within these distances, troubleshoot and repair the service brake system.

Parking brake, checking Carry out the brake test as required. Always use the seat belt when using the machine.

106

3

Start the engine.

4

Apply the parking brake. The parking brake control lamp illuminates on the front instrument panel.

1

5

Press on the spring plate (1) with a suitable tool, in the direction that the arrow indicates, to activate the transmission. When it is activated, the parking brake lamp on the front panel should switch off.

6

Select the 3rd gear and move the forward/reverse lever to forward.

7

Increase the speed of the engine to 1500 rpm. If the machine does not move, the parking brake is working correctly.

8

Press the brake pedal, release the throttle pedal and put the forward/reverse lever in neutral position.

9

Stop the engine.

10

Release the parking brake and apply it again for normal parking brake functionality and to deactivate the transmission.

11

If the machine has been moving during the test, the parking brake must be adjusted: Release the parking brake and perform a half turn with the red lever handle as shown in the figure.

V1100760

Fig.126 parking brake lever 1 spring plate

NOTICE Repeat the parking brake test/adjustment until the machine doesn´t move anymore during testing.

NOTICE V1096693

Fig.127 parking brake, adjusting

Adjust the parking brake cable, if the lever handle can´t be turned any further but the machine is still moving. See section 550, Parking brake cable, adjusting.

107

Service brake, checking pressure This is part of other procedure Op. no. Tools: 11666051 Pressure gauge 14290266 Hose E1708, see 080, E 1708, Checking point.

WARNING Beware of any remaining pressure in the brake system.

Checking pressure

1

2

3

1

Release the pressure in the brake system by depressing the brake pedal several times.

2

Disconnect one of the brake hoses from the rear axle.

3

Fit E1708 and connect the brake hose.

4

Fit the hose and the pressure gauge. 11666051 Pressure gauge 14290266 Hose

5

Start the engine and run the engine at low idle speed.

6

Press the brake pedal to the stop. Check the service brake pressure against specification, see 500, Service brake, specification.

7

Stop the engine.

8

Remove the checking equipment and reconnect the brake hose.

9

Repeat steps 2–8 for the other brake.

V1024325

Fig.128 Checking service brake pressure 1 Brake hose 2 E1708 3 Hose (tool 14290266)

108

Bleeding brakes 10

Lock the brake pedals together.

11

Start the engine.

12

Depress the pedals and hold them in applied position.

13

Place a suitable container under the brake bleed screw of the rear axle, to collect draining oil.

NOTICE The following two steps must be performed by a second person.

WARNING Operator and technician should be fully aware of each other when working around a machine while it is running. 14

Open the bleed screws on the rear axle.


1 1

V1049843

Fig.129 brake system, bleeding 1 bleed screws

15

Close the bleed screws until no more air is coming from the system.

16

Release the brake pedals.

17

Stop the engine.

18

Repeat steps 11–16 until no more air is coming from the system.

109

Seat belt, replace This is part of other procedure Op. no.

NOTICE The seatbelt must be replaced every 3 years! 1

Loosen the retaining screw and remove it together with the washer and the seatbelt buckle.

2

Loosen the retaining screw and remove it together with the washers and the seatbelt.

3

Assemble the new seatbelt together with the washers and the retaining screw.

4

Fasten the retaining screw, see 800, Cab, tightening torques for recommended torque.

5

Assemble the new seatbelt buckle together with the washer and the retaining screw.

6

Fasten the retaining screw, see 800, Cab, tightening torques for recommended torque.

7

Check the extension and retraction of the seatbelt and the functionality of the seatbelt buckle.

Fig.130 Seatbelt buckle 1 Seatbelt buckle 2 Retaining screw, washer

1

V1096433

4 Fig.131 Seatbelt 1 Seatbelt 2 Retaining screw 3 Washer 4 Washer

110

3

2

Service journal (included in Operator's manual), fill in Op. no. This is part of other procedure 1

Fill in the Service journal that is included in the Operator's Manual.

111

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From

Volvo Construction Equipment AB Customer Support Division Dept. 45110, RLA 0301 SE-631 85 Eskilstuna Sweden e-mail: [email protected]

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Concerns publication:.......................................................................................................................................... Ref no: ............................................................................................................................................................................. Page no: .............................................................................................................................................................................

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Date: ............................................................. Name:............................................................

Ref. no. PUB 20026861-B 2011.09 Volvo, Konz

English CST

Service Manual Backhoe Loader B-Series, 1 Service and Maintenance

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