Volvo BL60B Backhoe Loader Service Repair Manual Instant Download

Service Information Document Title: Engine, description Function Group: 200 Information Type: Service Information Date: 2014/3/14 Profile: BHL, BL60B [GB] Engine, description The engine is a four-cylinder, four-stroke, in-line diesel engine with direct injection, exhaust turbocharger, liquid cooling and internal, unregulated exhaust gas recirculation (EGR). To comply with exhaust gas limit values, the turbocharger is equipped with unregulated, internal exhaust gas recirculation (IEGR), which returns the exhaust gas within the cylinder head to the combustion air. The oxygen content of this exhaust is low. A lower oxygen content reduces the temperature spike during combustion and thereby reduces nitrogen oxide (NO?). The camshaft has an extra cam - the trailing cam. This causes the inlet valve to briefly open during the exhaust stroke so that exhaust gas also enters the engine intake system. In the subsequent induction stroke, this exhaust is sucked back in. There is no regulation of exhaust gas quantity. Engine data plate The engine data plate specifies model, engine number and power data. The engine number is also stamped into the crankcase. Model and engine number must be specified when ordering spare parts. The direction of rotation is found on the flywheel, anticlockwise. Firing order: 1-3-4-2 (cylinder no. 1 on the flywheel side). IMPORTANT! Adjustments to the regulator may only be performed by trained staff in an authorized central repair workshop. Figure 1 Engine data plate A. B. C. D. E. F. Engine type Spare part number Engine number Capacity Rated speed Timing setting Components, servicing view

Figure 2 Components, servicing view 1. 2. 3. 4. 5. 6. 7. 8. 9. Attachment for power take-off Cylinder head Oil cooler Coolant supply Coolant pump Fuel pump Vibration damper Engine mounting Oil filter Fuel filter Oil sump 10. 11. Components, exhaust view

Figure 3 Components, exhaust view 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine fan Inlet manifold Exhaust manifold Transport device Crankcase ventilation Speed (rpm) sensor Flywheel Starter motor Turbocharger

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Service Information Document Title: Engine, removing Function Group: 210 Information Type: Service Information Date: 2014/3/14 Profile: BHL, BL60B [GB] Engine, removing Op nbr 210-070 885530 Rotation tool Lifting chains, min. 1000 kg (2200 lb) two chain tensions WARNING Hot liquids and machine parts can cause burns. Allow the machine to cool before beginning any work. NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. NOTE! In general, all cable ties that secure hoses and electrical cables must be removed. All disconnected hoses and open connections must be plugged. 191 Service position 1 1. Place the machine in Service position 1, see . 2. Disconnect the main battery switch. 311 Batteries, replacing 3. Remove the battery/batteries, see . 173 Coolant, change 4. Drain the coolant, see . 173 Transmission, changing oil 5. Drain the transmission oil, see . 821 Engine hood, removal 6. Disassemble the engine hood, see . 7. Loosen the retaining clamp of the exhaust pipe (2). Remove the exhaust pipe together with it s sealing.

Figure 1 exhaust assembly, disassembly 1. 2. 3. retaining screws filler neck assembly exhaust pipe with retaining clamp retaining screws exhaust assembly bracket 8. Loosen and remove the retaining screws (1) of the oil filler neck assembly. 9. Loosen the retaining screws and disconnect the flexible exhaust tube from the turbocharger. WARNING The parts are heavy. Take appropriate safety cautions when handling them. 10. Use a slop to attach the exhaust assembly to a suitable lifting device. 11. Loosen and remove the retaining screws (3) of the exhaust assembly bracket. 12. Remove the exhaust assembly from the machine. 13. Loosen the retaining clamps (4, 5) from the upper radiator hose (1) and remove the hose.

Figure 2 radiator hose and air inlet, disassembly 1. 2. 3. 4. 5. upper radiator hose air inlet retaining clamp retaining clamp retaining clamp 14. Loosen the retaining clamp (3) from the air inlet (2) and remove it from the air filter assembly. 15. Loosen and remove the hoses (4, 5) connecting the expansion tank (3) with the coolant pump (6). NOTE! Loosen the retaining clamps on the pump side, so the hoses can be removed with the tank. Figure 3 radiator with attached parts 1. 2. radiator hose

3. 4. 5. 6. expansion tank hose hose coolant pump 16. Loosen and remove the hose (2) connecting the expansion tank (3) to the radiator (1). NOTE! Loosen the retaining clamp on the radiator side, so the hose can be removed with the tank. 17. Loosen the retaining screws connecting the expansion tank s attachment bracket to the machine frame. 18. Remove the expansion tank with the attachment bracket. 19. Disconnect the two pressure sensor connectors from the air filter (2). Figure 4 air filter, disassembly 1. 2. 3. 4. attachment bracket air filter hose turbocharger 20. Loosen the retaining clamp connecting the air filter hose (3) to the turbocharger (4). 21. Remove the hose from the turbocharger. 22. Loosen and remove the retaining screws connecting the air filter to the engine (4 pcs). 23. Remove the complete air filter assembly. 24. Loosen and remove the retaining screws of the fan guard. Figure 5 fan, disassembly

1. 2. 3. 4. fan fan adapter V-belt pulley retaining screws 25. Remove the fan guard. 26. Loosen and remove the retaining screws (4) of the fan (1). 27. Slightly turn the fan, to remove it from the fan adapter (2). NOTE! Leave the fan inside the fan shroud. 28. Loosen and remove the retaining screws (4) together with the fan adapter. 29. Loosen and remove the retaining screws of the fan shroud. 30. Remove the fan shroud together with the fan. 31. Disassemble the transmission oil filler pipe from the engine. 32. Remove the coolant pump (1) connection of the lower coolant hose (2). Figure 6 coolant hose, disassembly 1. 2. coolant pump lower coolant hose 33. Remove the two battery connection cables from the starter motor. 34. Remove all electrical connectors and cables from the engine. Make notes to which component the connectors and cables have to be attached. 35. Loosen the hose (1) from the engine oil cooler.

Figure 7 hoses, disassembly 1. 2. hose to engine oil cooler hose to coolant pump 36. Loosen the hose (2) from the coolant pump. 37. Loosen and remove the hose (1) from the main fuel filter (3). Figure 8 main fuel filter, disassembly 1. 2. 3. hose (tank connection) attachment bracket fuel filter 38. Loosen and remove the fuel filter from the attachment bracket (2). Fasten the filter to the engine (cable tie). 39. Loosen and remove the filter's attachment bracket from the machine. 40. Loosen the adjusting nuts (1) of the throttle cable.

Figure 9 throttle cable, disassembly 1. adjusting nuts 41. Loosen and remove the retaining nut. Remove the throttle cable from the lever (1). Figure 10 throttle cable, disassembly 1. accelerator lever 42. Secure all disconnected hoses and cables, so they can t be catched when removing the engine. 43. Remove the plate on the engine to access the screws connecting engine to turbocharger.

Figure 11 engine, retaining screws torque converter 1. 2. 3. engine retaining screws, torque converter transmission 44. Loosen the connection screws from engine to torque converter (4 pcs). To turn the engine and screws in the right position, use special tool. Special tool: 885530 Rotation tool WARNING The parts are heavy. Take appropriate safety precautions. 45. Place a suitable support under transmission and hydraulic pump to avoid overturning when engine is disconnected. 46. Attach the engine with a suitable chain and two chain tensions to a crane. The chain tensions are used to align the engine while removing from machine. Figure 12 engine, attached to lifting device 1. Additional lifting eye must be attached for the 2nd chain tension Engine weight (dry): 520 kg (1146.2 lb) 47. Loosen the connection screws from engine to transmission. 48. Loosen the connection screws from the engine to the engine mounts (3) (on the left and right of the machine front).

Figure 13 engine mounts, disassembly 1. 2. 3. spacer spacer engine mounting 49. Disassemble the engine mounts from the frame. NOTE! Take care not to loose the spacers. WARNING Risk of crushing injuries 50. Use the crane and the chain tensions to remove the engine from the transmission shaft. WARNING Heavy lift. Make sure that everybody stands well back from the engine when it is lifted. 51. Carefully lift the engine out of the machine and place the engine on suitable stable surface. NOTE! Take care not to catch any hoses or cables when removing.

Service Information Document Title: Engine, installing Function Group: 210 Information Type: Service Information Date: 2014/3/14 Profile: BHL, BL60B [GB] Engine, installing Op nbr 210-072 885530 Rotation tool Lifting chains, min. 1000 kg (2200 lb) two chain tensions NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. NOTE! In general, all cable ties that have been removed must be replaced. Hoses and cables must be fastened, so that they cannot move. WARNING The parts are heavy. Take appropriate safety precautions. 1. Attach the engine with a suitable chain and two chain tensions to a crane. The chain tensions are needed to align the engine while installing to machine. Engine weight (dry): 520 kg (1146.2 lb)

Figure 1 engine, attached to lifting device 1. Additional lifting eye must be attached for the 2nd chain tension 2. Assemble the left engine mount (3) to the engine. Figure 2 engine mounts, assembly 1. 2. 3. spacer spacer engine mounting WARNING Heavy lift. Make sure that everybody stands well back from the engine when it is lifted. 3. Carefully lift the engine in the machine. NOTE! Take care not to crush any hoses or cables when installing. WARNING Risk of crushing injuries 4. Use the crane and the chain tensions to assemble the engine to the transmission shaft. NOTE! Take care not to crush any hoses or cables when installing. 5. Assemble the engine with two screws to the transmission. NOTE! Don t fasten the screws completely. The engine must be free for aligning it to other parts. 6. Assemble the right side engine mount to the engine.

Figure 3 engine mounts, assembly 1. 2. 3. 4. 5. 6. frame washer washer lock nut washer washer 7. Assemble the engine mounts to the machine frame. NOTE! Take care to install all washers in the right order. 200 Engine, tightening torque 8. Fasten all screws of the engine mounts. See for recommended tightening torques. 9. Assemble the remaining screws for connecting engine to transmission. 030 VOLVO standard tightening torques 10. Fasten retaining screws to transmission, see torque. for recommended tightening 11. Assemble the retaining screws to connect the engine to the torque converter (4 pcs). To turn the engine in the right position, use special tool. Special tool: 885530 Rotation tool Figure 4 engine, retaining screws torque converter 1. 2. 3. engine retaining screws, torque converter transmission 030 VOLVO standard tightening torques 12. Fasten the screws, see for recommended tightening torque. 13. Assemble the plate to the engine. 14. Remove the support from the transmission and the hydraulic pump. 15. Assemble the throttle cable to the lever (1), assemble and fasten the nut.

Figure 5 throttle cable, assembly 1. accelerator lever 16. Insert the cable into the bracket and lock the adjusting nuts (1). Figure 6 throttle cable, assembly 1. adjusting nuts 17. Assemble the attachment bracket (2) of the main fuel filter (1) to the engine and fasten the retaining screws. Figure 7 main fuel filter, assembly

1. 2. 3. hose (tank connection) attachment bracket fuel filter 18. Assemble the fuel filter to the attachment bracket and fasten the retaining screws. 19. Assemble the hose (1) to the fuel filter and fasten it. 20. Assemble the hose (1) to the engine oil cooler and fasten the retaining clamp. Figure 8 hoses, assembly 1. 2. hose to engine oil cooler hose to coolant pump 21. Assemble the hose (2) to the coolant pump and fasten the retaining clamp. 22. Assemble all electrical connectors and cables to the engine components according to the notes done while disassembly. NOTE! Secure the connectors and cables against moving. Use cable ties. 23. Assemble the two battery connections to the starter motor. 260 Cooling system, tightening torques 24. Assemble the lower coolant (2) hose to the coolant pump (1). See recommended tightening torque. for

Figure 9 coolant hose, assembly 1. 2. coolant pump hose to coolant pump 25. Assemble the transmission oil filler pipe to the engine. 26. Place the fan (1) in the fan shroud and assemble the fan shroud. Figure 10 fan, assembly 1. 2. 3. 4. fan fan adapter V-belt pulley retaining screws 260 Cooling system, tightening torques 27. Fasten the retaining screws of the fan shroud. See tightening torque. for recommended 260 Cooling system, tightening torques 28. Assemble the fan adapter (2) and fasten the retaining screws. See recommended tightening torque. for 29. Assemble the fan on the fan adapter and fasten the retaining screws. See 260 Cooling system, tightening torques for recommended tightening torque. 260 Cooling system, tightening torques 30. Assemble the fan guard and fasten the retaining screws. See recommended tightening torque. for 31. Assemble the air filter assembly (2) to the engine and fasten the retaining screws of the attachment bracket (1). Figure 11 air filter, assembly

1. 2. 3. attachment bracket air filter turbocharger 32. Assemble the hose (3) to the turbocharger (4) and fasten the retaining clamp. 33. Assemble the pressure sensor connectors to the air filter. 34. Assemble the expansion tank (3) and the attachment bracket to the machine frame. Figure 12 radiator with attached parts 1. 2. 3. 4. 5. 6. radiator hose expansion tank hose hose coolant pump 260 Cooling system, tightening torques 35. Fasten the retaining screws of the attachment bracket. See recommended tightening torque. for 36. Assemble 260 Cooling system, tightening torques the hose (2) to the for recommended tightening torque. radiator (1) and fasten the retaining clamp. See 37. Assemble the two hoses (4, 5) to the coolant pump (6) and fasten the retaining clamps. See for recommended tightening torque. 260 Cooling system, tightening torques 38. Assemble the air inlet (2) to the air filter and fasten the retaining clamp (3).

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Figure 13 radiator hose and air inlet, assembly 1. 2. 3. 4. 5. upper coolant hose air inlet retaining clamp retaining clamp retaining clamp 39. Assemble 260 Cooling system, tightening torques the upper coolant hose for recommended tightening torque. (1). Tighten the retaining clamps (4, 5). See WARNING The parts are heavy. Take appropriate safety cautions when handling them. 40. Use a slop to attach the exhaust assembly to a suitable lifting device.

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