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Service and Maintenance Machine Serial Number Test Procedure B L60

Backhoe Lubrication Loader Lubrication Stabilizer Lubrication Front Axle Lubrication Drive Shaft Lubrication Cab Ventilation Filter Extendible Dipper Wear Pads (Option) Stabilizer Wear Pads

Volvo Construction Equipment Customer Support

1

Machine Serial Number Volvo Construction Equipment Volvo Compact Equipment S.A.S. F-01303 Belley, France.

Model/Type

BL 71

Product Identification Number

BL71D10021

Engine net power kW

8600 kg 70 kW

Manufacturing year

2003

Delivery year

2003

Made in Poland

11883332

Machine mass kg

BL71 D 10021 Machine Serial Number

Model Diesel Volvo Construction Equipment Customer Support

xxx

Test Procedure B L60

Test Procedure of BL60/BL61

Test Procedure of BL70/BL71

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Test Procedure of BL60/BL61

1/8

Tests 1. Engine RPM Check Points

2. delta p Open Center 3. Checking loader relief valve 4. Checking backhoe relief valve 5. Checking steering unit relief valve 6. Hammer Valve settings 7. Optional hand held tool setting 8. Max. pump flow 9. Stall tests

Note: for all tests the Backhoe has to be warm, all fluid levels must be ok.

1. Engine RPM Test conditions: - warm Engine - Engine oil-level must be ok - Engine speed is read on the tachometer on the right side console in the cabin

Test Tested Engine rpm

Expected Engine rpm

Low idle

.......................rpm

900 rpm –0 / +50

High idle

.......................rpm

2350 rpm –0 / +40

ML 12/03

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Check Points

2/8

Pressure check points at the Backhoe Valve

3

2

1

1 2 3

Checking point for HP-pressure Checking point for LS-pressure Adjusting point Backhoe relief valve

Adjusting point Loader relief valve

1

1

Adjusting point Loader relief valve ML 12/03

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Test Procedure of BL60/BL61

3/8

2. Checking delta p open centre Test conditions: - Hyd.- Oil temperature ca. 50 °C (+/- 5°C) - delta p Pressure is calculated: Hp – Ls = delta p - HP pressure is checked at the HP pressure check port (1) at the inlet element of the Backhoe valve with digital pressure check tool - LS pressure is checked at LS pressure check port (2) at the inlet element of the Backhoe valve with digital pressure check tool - Start the engine (2200 rpm) and read off delta p: Check value (HP - LS): 1,9 ± 0,1 MPa (19 bar ± 1 bar), (276 ± 15 psi) Test Engine RPM

Tested Pressure

2200 rpm

.........bar

Expected Pressure 19 bar ± 1 bar

3. Checking loader relief valve (loader, max. pressure) Test conditions: - Hyd Oil temperature p ca. 50° C (+/- 5°C) - HP pressure is checked at the HP pressure check port (1) at the inlet element of the Backhoe valve with digital pressure check tool - LS pressure is checked at the LS pressure check port (2) at the inlet element of the Backhoe valve with digital pressure check tool - engine speed is read on the tachometer on the right side console in the cabin - checked under load; tilt out the loader bucket to end position, hold and read off the HP pressure (loader) Test Engine RPM

Tested Pressure Hp

ca. 2350 rpm

....bar

Expected Pressure

Ls ....bar

Hp 220 bar ± 5 bar

Ls (HP - 19) bar

ML 12/03

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Test Procedure of BL60/BL61

4/8

4. Checking backhoe relief valve (backhoe, max. pressure) Test conditions: - Hyd. oil temperature ca. 50° C (+/- 5°C) - HP pressure is checked at the HP pressure check port (1) at the inlet element of the Backhoe valve with digital pressure check tool - LS pressure is checked at the LS pressure check port (2) at the inlet element of the Backhoe valve with digital pressure check tool - engine speed is read on the tachometer on the right side console in the cabin - checked under load, one function (stabilizer for example) end of stroke - adjust backhoe relief valve if necessary Test Engine RPM

Tested Pressure Hp

ca. 2350 rpm

....bar

Expected Pressure

Ls ....bar

Hp

Ls

250 bar ± 5 bar

(HP - 19) bar

5. Checking steering unit relief valve Test conditions: - Hyd. oil temperature ca. 50° C (+/- 5°C) - HP pressure is checked at the HP pressure check port (1) at the inlet element of the Backhoe valve with digital pressure check tool - engine speed is read on the tachometer on the right side console in the cabin - turn the steering wheel to the right or left to full lock and read off the HP pressure Test Engine RPM

Tested Pressure Hp

ca. 2350 rpm

....bar

Expected Pressure Hp 175 bar ± 5 bar

Attention: The relief valve in the Orbitrol is setted at the 175 bar, but the pressure is checked at the valve and there because of pressure loose in the pipes and connectors nearly 10 bar higher. The relief valve is pre-setted and can not be adjusted.

ML 12/03

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Test Procedure of BL60/BL61

5/8

6. Hammer valve settings Test conditions:

- Hyd. oil temperature ca 50° C (+/- 5°C) Procedure Hammer relief valve - fit a flow meter with adjustable restrictor and pressure sensor on the hammer quickcouplers - one function (stabilizer for example) must be permanently end of stroke - press enable switch and the hammer button on the floor mat - adjust the restrictor to the max. pressure and read of the pressure in the hammer line - Engine speed is read on the tachometer on the right side console in the cabin Test Hammer relief valve Engine Speed

Tested pressure in hammer line

Ca 2350 rpm

........... bar

Expected Pressure 210 bar

Procedure Hammer flow - fit a flow meter with adjustable restrictor and pressure sensor on the hammer quick couplers - one function (stabilizer for example) must be permanently end of stroke - press hammer button on the flor mat - adjust the restrictor to the spec. pressure and read of the flow in the hammer line - Engine speed is read on the tachometer on the right side console in the cabin

Test Hammer flow Engine Speed Ca 2350 rpm

spec. Pressure in hammer line

Tested flow in hammer line

170 bar

........... l/min

Expected flow in hammer line 85 l/min

ML 12/03

Volvo Construction Equipment Customer Support

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Test Procedure of BL60/BL61

6/8

7. Optional hand held tool setting Test conditions:

- Hyd. oil temperature ca 50° C (+/- 5°C) Procedure hand held tool - fit a flow meter with adjustable restrictor and pressure sensor on the hand held tool quickcouplers - one function (stabilizer for example) must be permanently end of stroke - activate hand held tool - adjust the restrictor to the max. pressure and read off the pressure in the hand held tool line - Engine speed is read on the tachometer on the right side console in the cabin Test optional hand held tool Engine Speed

Tested pressure in hammer line

Ca 2350 rpm

........... bar

Expected Pressure 210 bar

Procedure hand held tool flow - fit a flow meter with adjustable restrictor and pressure sensor on the hand held tool quickcouplers - one function (stabilizer for example) must be permanently end of stroke - activate hand held tool - adjust the restrictor to the spec. pressure and read of the flow in the hand held tool line - Engine speed is read on the tachometer on the right side console in the cabin Test Hammer flow Engine Speed Ca 2350 rpm

spec. Pressure in hammer line

Tested flow in hammer line

140 bar

........... l/min

Expected flow in hammer line 40 l/min

ML 12/03

Volvo Construction Equipment Customer Support

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Test Procedure of BL60/BL61

7/8

Note: Before doing flow checks, please check the cycle times. It proves that flows (apart from max pump flow) are correct without opening the hydraulic circuit. 8. Max. pump flow-check

n

Test conditions: - Hyd Oil temperature ca. 50° C (+/- 5°C)

o

Procedure

i

Step 1

c

t

- disconnect hammer supply line on the pump to avoid leakage through the hammer valve (2,8 l/min) and close with plugs

u

Step 2 Flow meter with temperature sensor

d

- disconnect hose coming from the main pump and going to the main control valve and connect to flow meter

Step 3 Adjustable restrictor

o

- connect outgoing hose from flowmeter to the main control valve

(smaller hoses than

r

- disconnect hose of boom rod side and close cylinder with plug

piston side)

p

- disconnect hose of dipper rod side and close cylinder with plug - fit the hoses to the inlet side of the adjustable restrictor - For return line use hammer return line

e

r

- Hp-Pressure is checked at Hp pressure check port near the main pump with digital pressure check tool - Engine speed is read on the tachometer on the right side console in the cabin

d

- fully open dipper cylinder and boom cylinder valve

n

- adjust the restrictor to the specified pressure and read of the flow

u

Test Engine Speed Ca 2350 rpm

spec. Pressure Hp 100 bar

Tested Flow

Expected Flow

........... l/min

162 l/min –0/+5

ML 12/03

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Test Procedure of BL60/BL61

8/8

11. Stall tests

Tested hyd. Stall speed

Ca 2350 rpm

........ rpm

Expected hyd. Stall speed

t

Engine RPM

i

o

- Hyd Oil temperature ca. 50° C (+/- 5°C) - warm Engine and transmission - max Engine RPM, 2350 rpm - curl loader bucket to end of stroke - Engine RPM is read on the tachometer on the right side console in the cabin

n

Test

c

2250 rpm +/- 50

d

- warm Engine and transmission

u

Test conditions Torque Converter stall: - Hyd Oil temperature ca. 50° C (+/- 5°C)

o

- select parking brake on, engage gear lever into forth, max. Engine RPM, engage forward/reverse lever into forward

r

- Engine speed is read on the tachometer on the right side console in the cabin Tested T. C. Stall speed

Ca 2350 rpm

........ rpm

p

Engine RPM

e

r

Test conditions Combined stall: - Hyd Oil temperature

Expected T. C. Stall speed 2100 rpm +/- 50

ca. 50° C (+/- 5°C)

- warm Engine and transmission

d

- select parking brake on, engage gear lever into forth, max. Engine RPM, curl loader bucket to end of stroke, engage forward/reverse lever into forward

n

- Engine speed is read on the tachometer on the right side console in the cabin

u

Engine RPM

Ca 2350 rpm

Tested combined Stall speed

Expected combined Stall speed

......... rpm

1800 rpm +/- 50

Note: The engine can have different results during the run in period. The tachometer has a tolerance about +/- 50 rpm.

ML 12/03

Volvo Construction Equipment Customer Support

XXX

Test Procedure of BL70/BL71

1/10

Tests 1. Engine RPM Check Points

2. Servo Pressure 3. Stand by situation 4. delta p Pressure, setting of the spring in the FR-valve 5. Power regulation, setting of the spring in the LR-valve 6. Max. Hp Pressure, setting of the relief-valve in the LS-line 7. Setting of the pressure limitation of the steering unit 8. Max. Pump flow-check 9. Pump power regulation-check 10. Hammer valve settings 11. Stall tests

Note: for all tests the Backhoe has to be warm, all fluid levels must be ok.

1. Engine RPM Test conditions: - warm Engine - Engine oil-level must be ok - Engine speed is read on the tachometer on the right side console in the cabin

Test Tested Engine rpm

Expected Engine rpm

Low idle

.......................rpm

900 rpm –0 / +50

High idle

.......................rpm

2350 rpm –0 / +40

Volvo Construction Equipment Customer Support

XXX

Check Points

2/10

Pressure check points at the pump

2 3

1 1 2 3

Checking point for HP-pressure Checking point for LS-pressure Checking point for servo pressure

Plug, to check the setting of the spring in the LR-valve

1

1 Volvo Construction Equipment Customer Support

Plug at LR Valve XXX

Test Procedure of BL70/BL71

3/10

2. Servo Pressure Test conditions: - Hyd.- Oil temperature

ca. 50° C (+/- 5°C)

- Pressure is checked at servo pressure check port near the servo pump - Engine RPM is read on the tachometer on the right side console in the cabin Test Engine Speed

Tested Pressure

2200 rpm

Expected Pressure

.........bar

37.5 bar –0 / +5

3. Stand by situation Test conditions: - Hyd Oil temperature

ca. 50° C (+/- 5°C)

- delta p Pressure is calculated: Hp – Ls = delta p - Hp-Pressure is checked at Hp pressure check port near the main pump with digital pressure check tool - LS-Pressure is checked at Ls pressure check port near the main pump with digital pressure check tool - Engine speed is read on the tachometer on the right side console in the cabin - Checked in stand by situation, no function is in use Test Engine RPM

Ca 900 rpm

Tested Pressure

Expected Pressure

Hp

Ls

delta p

....bar

....bar

.....bar

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Hp ~30 bar

Ls

delta p

~7 bar

~23 bar

Test Procedure of BL70/BL71

4/10

4. delta p Pressure, setting of the spring in the FR-valve Test conditions: - Hyd Oil temperature

ca. 50° C (+/- 5°C)

- delta p Pressure is calculated: Hp – Ls = delta p - Hp-Pressure is checked at Hp pressure check port near the main pump with digital pressure check tool - LS-Pressure is checked at Ls pressure check port near the main pump with digital pressure check tool - Engine speed is read on the tachometer on the right side console in the cabin - Hp pressure must be below 115 bar to avoid beeing involved in power regulation of the pump

- delta p is checked while moving one function with a slow and constant speed Attention: Speed must be absolutly constant! Test Engine RPM

Tested Pressure, delta p

Ca 2350 rpm

........bar

Expected Pressure, delta p 21 bar +/- 1 bar

Note: Some denominations have changed as shown below LR

to

FR1

Flow and Power regulation Valve, commands the Pump to reduce the flow to stay below the max. hyd. Power

FR

to

FR2

Flow regulation Valve, commands the pump to give the requested flow

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Test Procedure of BL70/BL71

5/10

5. Power regulation, setting of the spring in the LR-valve Test conditions: - Hyd Oil temperature

ca. 50° C (+/- 5°C)

- Disconnect plug at LR Valve and fit a hose which goes pressureless into the hyd.-tank - one function (stabilizer for example) must be permanently end of stroke - Hp-Pressure is checked at Hp pressure check port near the main pump with digital pressure check tool - Engine RPM is read on the tachometer on the right side console in the cabin Test Engine Speed

Tested Pressure, Hp

Ca 2350 rpm

Expected Pressure, Hp

........bar

20 bar +/- 3 bar

6. Max. Hp Pressure, setting of the relief-valve in the LS-line Test conditions: - Hyd Oil temperature

ca. 50° C (+/- 5°C)

- Hp-Pressure is checked at Hp pressure check port near the main pump with digital pressure check tool - LS-Pressure is checked at Ls pressure check port near the main pump with digital pressure check tool - Engine speed is read on the tachometer on the right side console in the cabin - Checked under load, one function (stabilizer for example) end of stroke Test Engine Speed

Ca 2350 rpm

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Tested Pressure

Expected Pressure

Hp

Ls

Hp

Ls

.......bar

.......bar

250 bar +/-5

(Hp – 21) bar

XXX

Test Procedure of BL70/BL71

6/10

7. Setting of the pressure limitation of the steering unit Test conditions: - Hyd Oil temperature

ca. 50° C (+/- 5°C)

- Hp-Pressure is checked at Hp pressure check port near the main pump with digital pressure check tool - LS-Pressure is checked at Ls pressure check port near the main pump with digital pressure check tool - Engine speed is read on the tachometer on the right side console in the cabin - Checked with steering cylinder permanently end of stroke

Test Engine RPM Ca 2350 rpm

Tested Pressure Hp Ls

Expected Pressure Hp

Ls

..... bar

175 bar +0/-5

(Hp – 21)bar

..... bar

Attention: The relief valve in the Orbitrol is setted at 175 bar, but the pressure is checked at the pump and there because of pressure loose in the pipes and connectors nearly 10 bar higher. The relief valve is pre-setted and can not be adjusted.

Volvo Construction Equipment Customer Support

XXX

Test Procedure of BL70/BL71

7/10

Note: Before doing flow checks, please check the cycle times. It proves that flows (apart from max pump flow) are correct without opening the hydraulic circuit. 8. Max. Pump flow-check Test conditions: - Hyd Oil temperature

ca. 50° C (+/- 5°C)

Procedure Step 1 - disconnect hammer supply line on the pump to avoid leakage through the hammer valve (2,8 l/min) and close with plugs Step 2 Flow meter with temperature sensor - disconnect hose coming from the main pump and going to the main control valve and connect to flow meter - connect outgoing hose from flowmeter to the main control valve Step 3 Adjustable restrictor - disconnect hose of boom rod side and close cylinder with plug

(smaller hoses than

- disconnect hose of dipper rod side and close cylinder with plug

piston side)

- fit the hoses to the inlet side of the adjustable restrictor - For return line use hammer return line - Hp-Pressure is checked at Hp pressure check port near the main pump with digital pressure check tool - Engine speed is read on the tachometer on the right side console in the cabin - fully open dipper cylinder and boom cylinder valve - adjust the restrictor to the specified pressure and read of the flow Test Engine Speed Ca 2350 rpm

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spec. Pressure Hp 100 bar

XXX

Tested Flow

Expected Flow

........... l/min

162 l/min –0/+5

Test Procedure of BL70/BL71

8/10

Note: Before doing flow checks, please check the cycle times. It proves that flows (apart from max pump flow) are correct without opening the hydraulic circuit. 9. Pump power regulation-check Same conditions and procedure like 8, but: !!adjust the restrictor to the specified flow and read of the pressure!! Loader mode ( 1. no gear selected on right hand gear lever, 2. forward/reverse lever engaged into forward) Engine RPM

spec. Flow

Tested Pressure Hp

Expected Pressure Hp

Ca 2350 rpm

130 l/min

........... bar

115 bar +/-5

Ca 2350 rpm

84 l/min

........... bar

195 bar +/-10

Excavator mode ( 1. no gear selected on right hand gear lever, 2. forward/reverse lever in neutral position) Engine RPM

spec. Flow

Tested Pressure Hp

Ca 2350 rpm

140 l/min

........... bar

185 bar +5/-15

Ca 2350 rpm

107 l/min

........... bar

227 bar +15/-10

Note: Both modes are related together.

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Expected Pressure Hp

Test Procedure of BL70/BL71

9/10

10. Hammer valve settings Test conditions: - Hyd Oil temperature

ca. 50° C (+/- 5°C)

Procedure Hammer relief valve - fit a flow meter with adjustable restrictor and pressure sensor on the hammer quickcouplers - one function (stabilizer for example) must be permanently end of stroke - press hammer button on the flor mat - adjust the restrictor to the max. pressure and read of the pressure in the hammer line - Engine speed is read on the tachometer on the right side console in the cabin Test Hammer relief valve Engine Speed

Tested pressure in hammer line

Ca 2350 rpm

........... bar

Expected Pressure 210 bar

Procedure Hammer flow - fit a flow meter with adjustable restrictor and pressure sensor on the hammer quick couplers - one function (stabilizer for example) must be permanently end of stroke - press hammer button on the flor mat - adjust the restrictor to the spec. pressure and read of the flow in the hammer line - Engine speed is read on the tachometer on the right side console in the cabin Test Hammer flow Engine Speed Ca 2350 rpm

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spec. Pressure in hammer line

Tested flow in hammer line

170 bar

........... l/min

XXX

Expected flow in hammer line 110 l/min

Test Procedure of BL70/BL71

10/10

11. Stall tests Test conditions hydraulic stall: - Hyd Oil temperature ca. 50° C (+/- 5°C) - warm Engine and transmission - max Engine RPM, 2350 rpm - curl loader bucket to end of stroke - Engine RPM is read on the tachometer on the right side console in the cabin Engine RPM

Tested hyd. Stall speed

Ca 2350 rpm

........ rpm

Expected hyd. Stall speed 2250 rpm +/- 50

Test conditions Torque Converter stall: - Hyd Oil temperature ca. 50° C (+/- 5°C) - warm Engine and transmission - select parking brake on, engage gear lever into forth, max. Engine RPM, engage forward/reverse lever into forward - Engine speed is read on the tachometer on the right side console in the cabin Engine RPM

Tested T. C. Stall speed

Ca 2350 rpm

........ rpm

Test conditions Combined stall: - Hyd Oil temperature

Expected T. C. Stall speed 2100 rpm +/- 50

ca. 50° C (+/- 5°C)

- warm Engine and transmission - select parking brake on, engage gear lever into forth, max. Engine RPM, curl loader bucket to end of stroke, engage forward/reverse lever into forward - Engine speed is read on the tachometer on the right side console in the cabin Engine RPM Ca 2350 rpm

Tested combined Stall speed

Expected combined Stall speed

......... rpm

1800 rpm +/- 50

Note: The engine can have different results during the run in period. The tachometer has a tolerance about +/- 50 rpm.

Volvo Construction Equipment Customer Support

XXX

Backhoe Lubrication

1/2

1 3

7 1

5

4

6 4

2

2 3 7 points

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4 points

xxx

Backhoe Lubrication

2/2

9 8 10 12

11 7

6 5

12 points 1

3 2

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4

Loader Lubrication

11

1/2

10 12 9 13, 14 1 8 2 5

7 6

15

15 points 4

3 Volvo Construction Equipment Customer Support

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Loader Lubrication

2/2

2 1

3

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2 x 3 points

Stabilizer Lubrication B L60

Stabilizer Lubrication BL60/BL70

Stabilizer Lubrication BL61/BL71

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X

Stabilizer Lubrication BL60/BL70

1 2

3, 4

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2 x 4 points

Stabilizer Lubrication BL61/BL71

2 points

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Front Axle Lubrication

2 + 3 points

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Drive Shaft Lubrication

6 points Volvo Construction Equipment Customer Support

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Cab Ventilation Filter

B

A

L68993A

A Filter cover B Filter lockings

Volvo Construction Equipment Customer Support

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Extendible Dipper Wear Pads (Option)

1002947

1002971

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Stabilizer Wear Pads BL 61/BL71

A B

Volvo Construction Equipment Customer Support

C

xxx