Professional Documents
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Service manual
BL60B/BL61B/BL70B/BL71B
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.
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
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
SAE 5W-30
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-50
V1038303
Fig.1
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
WB101
V1097344
Fig.3
COOLING
SYSTEM
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
-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 hardness
< 9.5 dH
Chlorine
< 40 ppm
Sulfate
pH value
5.59
Silicate
< 20 mg SiO2/litre
Iron
Manganese
< 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.
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
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.
Lift up the loader boom and secure it with the loader safety
strut. See 191, Loader boom, safety strut.
5
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.
10
10
11
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
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.
10
11
11
Service position 3
Op. no. 191-025
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.
V1083373
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.
12
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.
13
Service points
11
12
18 17
10
13
16
14
15
V1095272
10
11
Air cleaner
12
13
14
15
16
Battery/batteries
17
18
14
173 Maintenance
Maintenance service, first 100 hours
Op. no. 173-036
1
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
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
10
11
12
13
14
15
16
17
18
19
20
21
22
23
15
24
25
26
V1094146
NOTICE
Before checking the hydraulic oil filter for leakage, the machine
must be warmed up.
16
27
28
29
Stop the engine and turn off the battery disconnect switch.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Hammer (if installed), tool retaining pin and the tool, check
See Operators Manual of the hammer
59
60
61
17
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
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
V1094146
NOTICE
Before draining the engine oil and checking the hydraulic oil filter
for leakage, the machine must be warmed up.
31
32
33
Stop the engine and turn off the battery disconnect switch.
34
35
36
37
38
39
40
41
42
NOTICE
Replace the transmission suction filter before refilling
transmission oil.
43
44
NOTICE
The check has to be carried out between 5 and 10 minutes
after the engine has been stopped with engine on working
temperature.
45
46
47
48
49
50
51
52
53
54
55
56
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
20
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
Hammer (if installed), tool retaining pin and the tool, check
See Operators Manual of the hammer
79
80
81
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
Hammer (if installed), tool retaining pin and the tool, check
See Operators Manual of the hammer
21
NOTICE
Following maintenance services are included in this procedure:
Maintenance service, daily
Op. no. 173-004
1
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
22
10
11
12
13
14
15
Hammer (if installed), tool retaining pin and the tool, check
See Operators Manual of the hammer
16
NOTICE
Following maintenance services are included in this procedure:
Maintenance service, daily
Maintenance service, every 50 hours
Op. no. 173-007
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.
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
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
24
25
26
Hammer (if installed), tool retaining pin and the tool, check
See Operators Manual of the hammer
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
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.
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.
4
10
11
12
13
14
15
16
25
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
Stop the engine and turn off the battery disconnect switch.
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
Hammer (if installed), tool retaining pin and the tool, check
See Operators Manual of the hammer
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
10
11
12
13
14
15
16
17
18
19
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
Stop the engine and turn off the battery disconnect switch.
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
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
30
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
Hammer (if installed), tool retaining pin and the tool, check
See Operators Manual of the hammer
78
79
80
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
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.
2
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
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
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.
2
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
33
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.
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
V1088102
Max.
Min.
V1090437
34
35
Check the hose from air filter to turbocharger for leakage and
porosity.
Op. no.
This is part of other procedure
1
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
37
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.
V1071109
CAUTION
Always handle oils and other environmentally hazardous
fluids in an environmentally safe manner.
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.
38
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
Remove the hose (see fig. step 1) from the air filter and
remove the air filter.
39
40
10
11
12
13
41
14
15
16
17
V1044254
42
18
19
V1044255
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
4
V1022560
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
43
4
V1022563
21
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.
V1044256
22
NOTICE
Take care not to turn the adjustment screw.
V1060095
23
V1060096
44
24
V1060097
NOTICE
26
27
28
29
Fit the cylinder head cover and tighten the screws alternately
to 13 Nm (9.6 lbf ft).
30
31
32
33
34
35
45
36
37
38
Fasten the coolant hose on the fan guard by use of two cable
ties (2).
39
NOTICE
Tighten the screws by hand, so that the exhaust pipe cant
be moved.
46
40
41
42
43
44
45
Assemble the clamp to the hose and air filter (see fig. step
43). Tighten the clamp.
46
47
Start the engine and check for leaks and proper operation.
47
Check that the cable terminals and pole studs are clean, well
tightened and coated with petroleum jelly or similar.
Check the charging status for all battery cells with an acid
tester.
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
Loosen the catches on either side of the radiator, pull the oil
cooler and condenser to the front.
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
Place the oil cooler and condenser back in position and lock
them with the catches.
49
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.
50
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.
NOTICE
Check that all hose and pipe connections from the air
cleaner to the engine induction manifold are tight.
51
52
Remove the filter cover and the primary filter. See Air cleaner
primary filter, changing page 51.
Mount the primary filter and the filter housing. See Air
cleaner primary filter, changing page 51.
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
Install a new filter onto the filter head. When installing the
filter, it should be tightened by hand.
NOTICE
The filter is top filled with fuel. Observe when changing the fuel
filter.
6
53
54
Fill the new filter with fuel, lubricate the seal and hand tighten
plus 3/4 turn.
Fill the fuel tank with fuel, leaving room for expansion.
CAUTION
Always handle oils and other environmentally hazardous
fluids in an environmentally safe manner.
5
55
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
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
Loosen the locking devices (1, 4) and remove the plate (3).
NOTICE
If cleaning is required:
Shake the filters carefully without damaging them. Avoid
using compressed air, vacuum cleaner or water.
1
V1094339
57
V1090584
Front axle
1
NOTICE
Standard 2WD front axle does not contain any oil.
Loosen the front axle breather (4) to release internal
pressure.
Rear axle
58
The oil should be up to the hole. Fill with oil if necessary. For
oil specifications, see Recommended lubricants,
oils page 7.
V1049382
V1049383
NOTICE
Take care of waste oil and liquids in an environmentally safe way.
59
NOTICE
Standard 2WD front axle does not contain any oil.
1
WARNING
Only use lifting devices with adequate capacity.
NOTICE
See your Operators 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
Rotate the wheel hub so that the oil level marking (1) is
horizontal.
Clean the area around the drain plug (2). Place a suitable
container under the drain plug.
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
CAUTION
Always handle oils and other environmentally hazardous
fluids in an environmentally safe manner.
6
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
V1092389
Fig.63 Wheel
61
62
NOTICE
Standard 2WD front axle does not contain any oil.
Place a suitable container under the drain plug.
Clean the area around the oil drain plug and the oil filling and
level plug.
Remove the oil drain plug and the oil filling plug. Drain the
oil.
CAUTION
Take care of filters, oils and liquids in an environmentally
safe way.
Re-fit the oil drain plug after the oil has been drained.
See section 461, Front axle, tightening torque for correct
tightening torque.
Re-fit the oil filling plug. See section 461, Front axle,
tightening torque for correct tightening torque.
V1019818
Clean the area around the oil drain plug and filling plug.
Remove the drain plug and the oil filling plug. Drain the oil.
CAUTION
Take care of filters, oils and liquids in an environmentally
safe way.
10
Re-fit the drain plug after the oil has been drained.
See section 463, Rear axle, tightening torques for correct
tightening torque.
11
12
V1049370
63
NOTICE
Standard 2WD front axle does not contain any oil.
1
WARNING
Only use lifting devices with adequate capacity.
NOTICE
See your Operators 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
Clean the area around the drain plug (2). Place a suitable
container under the drain plug.
Remove the drain plug (2) and drain the oil in the container.
CAUTION
Always handle oils and other environmentally hazardous
fluids in an environmentally safe manner.
V1092556
V1092557
64
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.
10
Screw on a new filter until the gasket just touches the sealing
surface. Then tightening a further half of a turn by hand.
V1019812
V1050632
1
Fig.70
1 Transmission breather filter
65
CAUTION
Always handle oils and other environmentally hazardous
fluids in an environmentally safe manner.
V1061302
Fig.71
1 Drain plug
2 Hydraulic oil filter
66
Fill the new filter with hydraulic oil and apply oil to the gasket.
For oil specifications, see Recommended lubricants,
oils page 7.
Screw on the filter until the gasket just touches the sealing
surface. Then tighten a further half turn by hand.
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.
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
CAUTION
Always handle oils and other environmentally hazardous
fluids in an environmentally safe manner.
4
V1090867
67
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.
Assemble the new engine oil filter until the rubber seal just
touches the filter head, then tighten by hand a further 3/4
turn.
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.
Max.
Min.
V1090437
68
NOTICE
The transmission oil should be warm before draining.
1
V1088102
CAUTION
Always handle oils and other environmentally hazardous
fluids in an environmentally safe manner.
1
V1049277
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.
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
70
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
71
Op. no.
This is part of other procedure
Draining
NOTICE
The hydraulic system is drained by removing the suction line
from the hydraulic oil pump.
2
CAUTION
Take care of filters, oils and liquids in an environmentally
safe way.
3
V1093286
Filling
72
Fill the hydraulic oil pump through the inlet from the suction
line.
For oil specifications, see Recommended lubricants,
oils page 7.
Fill the hydraulic system with oil through the filler neck.
For oil specifications, see Recommended lubricants,
oils page 7.
10
Operate the control levers for the loader boom and backhoe
cylinders to their end positions smoothly.
11
12
Check the hydraulic oil level through the oil level glass. Top
up with oil when required.
13
73
Op. no.
This is part of other procedure
Draining
1
NOTICE
The drain plug is located under the machine on the bottom
of the lower hydraulic tank.
2
CAUTION
Take care of filters, oils and liquids in an environmentally
safe way.
3
Filling
4
Fill the hydraulic system with oil through the filler neck.
For oil specifications, see Recommended lubricants,
oils page 7.
V1093164
NOTICE
Check the bleed plug of the pump. When oil is coming out,
refit the bleed plug on top of the hydraulic pump.
74
Operate the control levers for the loader boom and backhoe
cylinders to their end positions smoothly.
10
11
Check the hydraulic oil level through the oil level glass. Top
up with oil when required.
12
75
WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in
severe personal injuries
CAUTION
Do the work in an environmentally safe manner.
NOTICE
The check ports are located on the backhoe control valve
mounting bracket.
2
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
NOTICE
Do not activate any hydraulic function while checking the
pressure.
76
NOTICE
The check ports are located on the backhoe control valve
mounting bracket.
10
11
12
13
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
NOTICE
The check ports are located on the backhoe control valve
mounting bracket.
18
19
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
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.
22
23
NOTICE
Screw out to decrease the pressure.
NOTICE
Screw in to increase the pressure.
24
25
26
V1093563
NOTICE
The check ports are located on the backhoe control valve
mounting bracket.
78
28
29
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
33
WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in
severe personal injuries
CAUTION
Do the work in an environmentally safe manner.
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.
NOTICE
Screw out to decrease the pressure.
NOTICE
Screw in to increase the pressure.
6
79
NOTICE
The check ports are located on the main control valve
mounting bracket.
10
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
13
NOTICE
Do not activate any hydraulic function while checking the
pressure.
14
15
NOTICE
The check ports are located on the main control valve
mounting bracket.
17
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
20
NOTICE
p 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 p:
p = HP pressure LS pressure
See 910, Hydraulic system, specification for correct p
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 FRvalve (1) and loosen the
lock nut.
Adjust the adjusting screw on the FRvalve.
NOTICE
Screw out to decrease the pressure.
NOTICE
Screw in to increase the pressure.
23
24
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
NOTICE
Before fitting the nipple to the LR-valve, the thread length of
the nipple must be shortened by approx. 5mm.
28
Remove the cover and place the hose down into the
hydraulic oil tank as shown in the figure.
29
30
31
Raise one stabilizer leg, keep the joystick activated when the
stabilizer leg is in end position and read off the HP pressure.
32
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
Screw out to decrease the pressure.
NOTICE
82
35
36
37
NOTICE
The check ports are located on the main control valve
mounting bracket.
39
40
41
Raise one stabilizer leg, keep the joystick activated when the
stabilizer leg is in end position and read off the HP pressure.
42
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.
NOTICE
Screw out to decrease the pressure.
NOTICE
Screw in to increase the pressure.
44
45
83
NOTICE
The check ports are located on the main control valve
mounting bracket.
84
47
48
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
52
V1020198
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
V1093853
86
Remove the plug and fit the testing nipple (part no. 936440)
to the forward clutch pressure check port.
Remove the plug and fit the testing nipple (part no.936440)
to the reverse clutch pressure check port.
10
11
12
13
14
Remove the plug and fit the testing nipple (part no.936440)
to the lubrication pressure check port.
16
17
18
19
20
21
87
23
24
25
26
27
28
29
30
31
32
33
3
V1094071
V1093905
Remove the plug and fit the testing nipple (part no. 936440)
to the forward clutch pressure check port.
89
Remove the plug and fit the testing nipple (part no. 936440)
to the reverse clutch pressure check port.
10
11
12
13
14
Remove the plug and fit the testing nipple (part no. 936440)
to the lubrication pressure check port.
16
17
18
19
20
21
90
22
Remove the plug and fit the testing nipple (part no. 936440)
to the 4WD pressure check port.
23
24
25
26
27
28
30
31
32
33
34
35
36
37
38
39
40
3
V1094071
91
92
Remove the plug and fit the testing nipple (part no. 936440)
to the forward clutch pressure check port.
Turn off the engine and shift the forward/reverse lever into
position N.
Remove the plug and fit the testing nipple (part no. 936440)
to the reverse clutch pressure check port.
11
12
13
14
15
16
17
Turn off the engine and shift the forward/reverse lever into
position N.
18
Remove the plug and fit the testing nipple (part no. 936440)
to the lubrication pressure check port.
20
21
22
23
24
25
26
27
93
29
30
31
32
33
34
35
36
37
38
39
3
V1094071
94
40
41
Fit the nipple (part no. 935331) to the brake pressure port
fitting.
42
43
44
45
46
47
48
49
Turn off the engine and shift the forward/reverse lever into
position N.
50
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
53
54
55
56
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
96
58
Turn off the engine and shift the forward/reverse lever into
position N.
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
97
Op. no.
This is part of other procedure
Check the functionality of the sideshift mechanism locking
cylinders.
1
98
Op. no.
This is part of other procedure
99
Op. no.
This is part of other procedure
1
100
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 Operators Manual.
6
101
NOTICE
The hydraulic oil pressure in the accumulators must first have
been released.
NOTICE
When checking and reducing the accumulator precharging
pressure, there is no need for the gas cylinder to be connected.
2
1
L65759A
1
2
102
NOTICE
L65760A
Fig.123
1 Gas valve
2 Unloading valve
3 Non-return valve
Carefully open unloading valve (2). Gas flows out of the tool.
NOTICE
Gradually adjust the pressure, so as not to overload gas
valve 1.
10
11
Restoring system
12
13
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
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.
NOTICE
The check should be carried out when the oil is cold and has had
time to run down to the oil pan.
1
Max.
Min.
V1090437
104
Instruments
Lights
Direction indicators
Hazards flashers
Wipers
Washers
Horn
Reversing alarm
10
Steering System
11
Gear positions
12
Differential lock
13
14
15
16
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.
106
Press the brake pedal, release the throttle pedal and put the
forward/reverse lever in neutral position.
10
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
NOTICE
Repeat the parking brake test/adjustment until the machine
doesnt move anymore during testing.
NOTICE
V1096693
107
WARNING
Beware of any remaining pressure in the brake system.
Checking pressure
Start the engine and run the engine at low idle speed.
Press the brake pedal to the stop. Check the service brake
pressure against specification, see 500, Service brake,
specification.
V1024325
108
Bleeding brakes
10
11
12
13
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
CAUTION
Take care of filters, oils and liquids in an environmentally
safe way.
1
1
V1049843
15
Close the bleed screws until no more air is coming from the
system.
16
17
18
109
NOTICE
The seatbelt must be replaced every 3 years!
1
V1096433
4
Fig.131 Seatbelt
1 Seatbelt
2 Retaining screw
3 Washer
4 Washer
110
111
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