Volvo BL 71 2 Engine With Mounting and Equipment

Service Information
Document Title: Function Group: Information Type: Date:

Engine, description 200 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
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Engine, description
Numbering of cylinders
Figure 1
A = flywheel
Starter motor side

Figure 2
1. Turbocharger
2. Lifting eye
3. Engine revolution governor
4. Direction of rotation
5. Flywheel housing
6. Flywheel
7. Starter motor
8. Outlet pipe, coolant
NOTICE
The governor's settings may only be adjusted by trained personnel at a central overhaul workshop.
Engine revolution governor (Heinzmann).

The engine revolution governor on the D4D engine is of the centrifugal type.
Engine type, serial number and rated speed (rpm) must always be stated when ordering a governor as spare part.
Each regulator for the above mentioned engines has been especially made for a particular engine. This means that a
governor cannot be moved from one engine to another.
NOTE!
An incorrectly adjusted governor may cause the engine not to meet the applicable regulations for emissions and
performance.
Service side
Figure 3
1. Oil filling point
2. Inlet pipe, coolant
3. Coolant pump
4. Alternator
5. Crankshaft belt pulley
6. Fuel pump
7. Fuel filter
8. Lubricating oil filter
9. Oil pan
10. Oli dipstick
11. Lubricating oil cooler
12. Power take-off for, for example, hydraulic pump, air compressor etc.
13. Cylinder head
Service Information

Engine, description 200 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [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. Engine type
B. Spare part number
C. Engine number
D. Capacity
E. Rated speed
F. Timing setting
Components, servicing view

Figure 2
Components, servicing view
1. Oil filler pipe

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

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

Engine, removal 210 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Engine, removal
Op nbr 21070-1
14360000 Vacuum pump

Lifting chains, min. 1000 kg (2200 lb)
WARNING
To avoid severe burns, DO NOT attempt the next procedure when the engine is HOT. Wait for the engine, silencer
and tailpipe to cool before proceeding.
NOTE!
In general, all strip clamps that secure hoses and electrical cables must be removed. All disconnected hoses and open
connections must be plugged.
1. Remove the engine hood, see 821 Engine hood, removal.
2. Detach cable from the bracket.
Figure 1
1. Cable
3. Remove the grille and the front plate.

Figure 2
1. Grille
2. Front plate
4. Remove the clamps from both sides of the cooler.
Figure 3
1. Clamp
5. Connect the vacuum pump, see 900 Vacuum pump, connection.
6. Open the locking device and let down the hydraulic oil cooler.
Disconnect the hoses (4 hoses) from the hydraulic oil cooler.
Turn off the vacuum pump after the hoses have been plugged.
Figure 4
1. Locking device
2. Hoses
7. Connect a drain hose to the valve and place the drain hose down into a container. Open the valve and drain the
coolant into the container.
Figure 5
1. Valve
2. Drain hose
8. Disconnect the radiator hoses and the lower hose (hidden).

Remove the screws radiator-radiator casting.
Figure 6
1. Hose
2. Hose
3. Hose
4. Hose
5. Screws
9. Remove the screws from both sides and lift out the hydraulic oil cooler and the radiator.
Figure 7
1. Screw
10. Remove the fan guard and the radiator casting.
Figure 8
1. Fan guard
2. Radiator casting
11. Remove the fan.
Figure 9
1. Fan
12. Remove the attaching screws (4 attaching screws, 2 underneath).
Remove the nuts and remove the silencer.
Figure 10
1. Attaching screws
2. Nuts
13. Loosen the hose clamp. Remove the screws and remove the air cleaner. Remove the screws (3 pcs) and remove the
bracket.
Figure 11
1. Screws
2. Hose clamp
3. Screws
4. Air cleaner
14. Disconnect hose from the engine.
Figure 12
1. Hose
15. Disconnect the hoses (2 hoses, one hidden) from the engine and release the fuel filter/pump from the hydraulic
tank.
Figure 13
1. Hoses
16. Detach the seat , move the seat back, and lift up the rubber mat from the floor against the seat.
Figure 14
1. Seat
2. Rubber mat
17. Remove the plate.

Figure 15
1. Plate
18. Remove the shift lever.
Figure 16
19. Disconnect the hoses from the gearbox.
Figure 17
1. Hose
2. Hose
20. Disconnect the hoses from the gearbox.

Figure 18
1. Hose
2. Hose
3. Hose
21. Disconnect the hose from the gearbox.
Figure 19
1. Hose
22. Disconnect ground cables from the gearbox.
Figure 20
1. Ground cable
2. Ground cable
23. Turn off the electric power with the battery disconnect switch and disconnect the ground cable.
Figure 21
1. Battery disconnect switch

2. Ground cable
24. Disconnect the electrical cables from the starter motor.
Figure 22
1. Electrical cable
25. Disconnect the fuel hoses from the fuel filter. Remove the fuel filter from the hydraulic tank.
26. Unscrew the nuts and remove the throttle control cable from the engine.
Figure 23
1. Nut
27. Disconnect the front propeller shaft from the gearbox unit.
Figure 24
1. Propeller shaft
28. Disconnect the rear propeller shaft from the gearbox unit.
Figure 25
1. Propeller shaft
29. Disconnect the connector from the working pump.

Figure 26
1. Connector
30. Remove the screws (2 screws) gearbox unit - working pump.
Figure 27
1. Screw
31. Arrange a strap around the working pump and tighten the string using a pinch-bar.
Pull the working pump away from the gearbox.
Figure 28
1. Strap
2. Iron-bar lever
32. Remove the attaching screws for the engine.
Figure 29
1. Attaching screw
2. Attaching screw
33. Remove the attaching screw from both sides of the gearbox.
Figure 30
1. Attaching screw
34. Connect a lifting chain between the lifting eyes and a lifting device.
Carefully lift and balance the engine/gearbox unit when the unit is lifted out.
Figure 31
1. Lifting eye
2. Lifting eye
35. Place the engine on stable supports.

Make sure that the gearbox unit is dismountable.
See .Gearbox, removal in Section 4
Figure 32
Service Information

Engine, removing 210 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Engine, removing
Op nbr 210-070
885530 Rotation tool

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.
1. Place the machine in Service position 1, see 191 Service positions.
2. Disconnect the main battery switch.
3. Remove the battery/batteries, see 310 Battery, changing.
4. Drain the coolant, see 173 Coolant, change.
5. Drain the transmission oil, see 173 Transmission, changing oil.
6. Disassemble the engine hood, see 821 Engine hood, removal.
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. retaining screws filler neck assembly

2. exhaust pipe with retaining clamp
3. 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.
10. WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
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. upper radiator hose

2. air inlet
3. retaining clamp
4. retaining clamp
5. 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. radiator
2. hose
3. expansion tank
4. hose
5. hose
6. 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. attachment bracket
2. air filter
3. hose
4. 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. fan
2. fan adapter
3. V-belt pulley
4. 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. coolant pump
2. 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. hose to engine oil cooler

2. 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. hose (tank connection)

3. 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. engine
2. retaining screws, torque converter
3. 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:
45. WARNING
The parts are heavy. Take appropriate safety precautions.
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. spacer
2. spacer
3. engine mounting
49. Disassemble the engine mounts from the frame.

NOTE!
Take care not to loose the spacers.
50. WARNING
Risk of crushing injuries
Use the crane and the chain tensions to remove the engine from the transmission shaft.
51. WARNING
Heavy lift. Make sure that everybody stands well back from the engine when it is lifted.
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

Engine, installation 210 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Engine, installation
Op nbr 21072-1

Lifting chains, min 1000 kg (220 lb)
NOTE!
In general, all strip clamps that have been removed must be replaced.
1. Install the gearbox, see Gearbox, installation in Section 4.
2. Transfer the bracket to the engine.
3. Transfer the hose connections.

Transfer the electrical cables.
Transfer the front right and left engine mounting.
Tightening torque:140 ± 15 Nm (103 ± 11 lbf ft)
4. Connect a lifting chain between the lifting eyes and to a lifting device.
Carefully lift and balance the engine-gearbox unit when the unit is lifted into the machine.
Figure 1
1. Lifting eye
2. Lifting eye
5. Remove the rubber cushion from the mounting bracket for the gearbox, and lower the gearbox onto the mounting
bracket.
Place a jack under the gearbox and lift it up and install the rubber cushion and the washer on the mounting
bracket. Lower the gearbox and install the attaching screws 1 on both sides.
Tightening torque: 173 ± 15 Nm (127 ± 11 lbf ft)
Figure 2
1. Screw
6. Install the attaching screws for the engine.

Tightening torque: 173 ± 15 Nm (127 ± 11 lbf ft)
Figure 3
1. Attaching screw
2. Attaching screw
7. Apply some grease to the o-ring and place it on the working pump.
Move the working pump carefully into the gearbox.
Remove the strap and the pinchbar.
Figure 4
1. Strap
2. Pinchbar
8. Install the screws (2 screws) gearbox unit–working pump.
Figure 5
1. Screw
9. Connect the connector to the work pump.
Figure 6
1. Connector
10. Connect the ground cables to the gearbox.

Figure 7
1. Ground cable
2. Ground cable
11. Connect the hose to the gearbox.
Figure 8
1. Hose
12. Connect the hoses to the gearbox.
Figure 9
1. Hose
2. Hose
3. Hose (hidden)
13. Connect the hoses to the gearbox.
Figure 10
1. Hose
2. Hose
14. Install the shift lever.
Figure 11
1. Shift lever
15. Install the plate.

Figure 12
1. Plate
16. Place rubber mat on the floor and install the seat.
Figure 13
1. Seat
2. Rubber mat
17. Connect the rear propeller shaft 1 to the gearbox.

Tightening torque: 31–41 Nm (23–30 lbf ft)
Figure 14
1. Propeller shaft
18. Connect the front propeller shaft 1 to the gearbox unit.

Tightening torque: 31–41 Nm (23–30 lbf ft)
Figure 15
1. Propeller shaft
19. Connect the electrical cables to the starter motor.
Figure 16
1. Electrical cable
20. Install the throttle control cable and tighten the nuts.
Figure 17
1. Nut
21. Connect the fuel filter to the hydraulic tank.

Connect the fuel hoses to the fuel filter.
22. Connect the hoses (2 hoses, one hidden) to the engine and fit the fuel filter/pump on the hydraulic tank.
Figure 18
1. Hoses
23. Connect the hose to the engine.
Figure 19
1. Hose
24. Install the bracket with the screws (3 pcs). Install the air cleaner with the screws. Tighten the hose clamp.
Figure 20
1. Screws
2. Hose clamp
3. Screws
4. Air cleaner
25. Install the silencer and the nuts for the turbocharger.
Install the attaching screws (4 attaching screws, 2 underneath).
Figure 21
1. Attaching screws
2. Nuts
26. Install the fan.
Figure 22
1. Fan
27. Install the radiator casing and the fan guard.
Figure 23
1. Fan guard
2. Radiator casting
28. Lift in the hydraulic oil cooler/radiator and install the screws on both sides.
Figure 24
1. Screw
29. Install the screws radiator and radiator casing (4 screws). Connect the radiator hoses and the lower hose (hidden).
Figure 25
1. Hose
2. Hose
3. Hose
4. Hose
5. Screws
30. Connect the ground cable and turn on the electric power with the battery disconnect switch.
Figure 26
1. Battery disconnect switch

2. Ground cable
31. Connect the vacuum pump, see Vacuum pump, connection in section 9.
32. Lock the hydraulic oil cooler with the locking device. Connect the hoses (4 hoses) to the hydraulic oil cooler.
Figure 27
1. Locking device
2. Hoses
33. Turn off the vacuum pump.
34. Install the clamps on both sides on the cooler.

Figure 28
1. Clamp
35. Install the front plate and the grille.
Figure 29
1. Grille
2. Front plate
36. Connect the cable to the bracket.
Figure 30
Cable
37. Remove the cap and fill coolant in the radiator.

Figure 31
1. Cap
38. Start the engine.
39. Check for leaks and repair if needed.
40. Check the coolant level and top up, if needed.
41. Install the hood, see 821 Engine hood, installation.

Service Information

Engine, installing 210 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Engine, installing
Op nbr 210-072

two chain tensions
NOTICE
NOTE!
In general, all cable ties that have been removed must be replaced. Hoses and cables must be fastened, so that they cannot
move.
1. WARNING
The parts are heavy. Take appropriate safety precautions.
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. spacer
2. spacer
3. engine mounting
3. WARNING
Heavy lift. Make sure that everybody stands well back from the engine when it is lifted.
Carefully lift the engine in the machine.

NOTE!
Take care not to crush any hoses or cables when installing.
4. WARNING
Risk of crushing injuries
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. frame
2. washer
3. washer
4. lock nut
5. washer
6. washer
7. Assemble the engine mounts to the machine frame.

NOTE!
Take care to install all washers in the right order.
8. Fasten all screws of the engine mounts. See 200 Engine, tightening torque for recommended tightening torques.
9. Assemble the remaining screws for connecting engine to transmission.
10. Fasten retaining screws to transmission, see 030 VOLVO standard tightening torques for recommended tightening
torque.
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:
Figure 4
engine, retaining screws torque converter
1. engine
2. retaining screws, torque converter
3. transmission
12. Fasten the screws, see 030 VOLVO standard tightening torques 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. hose (tank connection)

3. 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. hose to engine oil cooler

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.
24. Assemble the lower coolant (2) hose to the coolant pump (1). See 260 Cooling system, tightening torques for
recommended tightening torque.
Figure 9
coolant hose, assembly
1. 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. fan
2. fan adapter
3. V-belt pulley
4. retaining screws
27. Fasten the retaining screws of the fan shroud. See 260 Cooling system, tightening torques for recommended
tightening torque.
28. Assemble the fan adapter (2) and fasten the retaining screws. See 260 Cooling system, tightening torques for
29. Assemble the fan on the fan adapter and fasten the retaining screws. See 260 Cooling system, tightening torques
for recommended tightening torque.
30. Assemble the fan guard and fasten the retaining screws. See 260 Cooling system, tightening torques 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
2. air filter
3. 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. radiator
2. hose
3. expansion tank
4. hose
5. hose
6. coolant pump
35. Fasten the retaining screws of the attachment bracket. See 260 Cooling system, tightening torques for
36. Assemble the hose (2) to the radiator (1) and fasten the retaining clamp. See
260 Cooling system, tightening torques for recommended tightening torque.
37. Assemble the two hoses (4, 5) to the coolant pump (6) and fasten the retaining clamps. See
38. Assemble the air inlet (2) to the air filter and fasten the retaining clamp (3).
Figure 13
radiator hose and air inlet, assembly
1. upper coolant hose

2. air inlet
3. retaining clamp
4. retaining clamp
5. retaining clamp
39. Assemble the upper coolant hose (1). Tighten the retaining clamps (4, 5). See
40. WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
Use a slop to attach the exhaust assembly to a suitable lifting device.
Figure 14
exhaust assembly, assembly
1. retaining screws filler neck assembly

2. exhaust pipe with retaining clamp
3. retaining screws exhaust assembly bracket
41. Place the exhaust assembly in mounting position.
42. Assemble and fasten the retaining screws (3) of the exhaust assembly.
43. Assemble the flexible exhaust tube to the turbocharger. Fasten the retaining screws.
44. Assemble the oil filler neck assembly and fasten the retaining screws (1).
45. Assemble the exhaust pipe (2) with the sealing.
46. Fasten the retaining clamp of the exhaust pipe.

47. Assemble the engine hood, see 821 Engine hood, installation.
48. Assemble the battery/batteries, see 310 Battery, changing.
49. Fill the transmission with oil, see 173 Transmission, changing oil.
50. Fill the cooling system with coolant, see 173 Coolant, change.
51. Close the engine hood.
52. Connect the main battery switch.

Service Information

Valves, description 214 Service Information 2014/3/18
Profile:
BHL, BL61 PLUS, BL71 PLUS, BL71, BL70, BL61, BL60 [GB]
Valves, description
The engines are equipped with one inlet and one exhaust valve per cylinder.
The upper area of the valve guide (on the valve stem) houses an O-ring (A). This O-ring seal should prevent a large level of
oil consumption and reduce the amount of hydrocarbons in the exhaust.
Valve rotation is achieved through the eccentric position of the rocker arm.
The valve springs have a prescribed direction of installation. The closely wound end of the valve spring must point toward
the cylinder head.
Rocker arm lubrication is a component of the centralized lubricating system. The oil is supplied via the tappets and push
rods.
Figure 1
Figure 2
Valve system
1. Counter nut
2. Adjustment screw
3. Rocker arm
4. washer
5. Snap ring
6. Spring disc
7. Valve
8. Push rod
Service Information

Valves, adjusting 214 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Valves, adjusting
Op nbr 214-012
1. Place the machine in service position 1.
WARNING
To avoid severe burns, DO NOT attempt the next procedure when the engine is HOT. Wait for the engine,
silencer and tailpipe to cool before proceeding.
2. Disconnect the two wires to the inlet air pressure sensor.
3. Remove the inlet air cleaner together with the bracket.
Figure 1
1. Flange screws
2. Hose clamp
3. Flange screws
4. Air cleaner
4. Remove the two allen bolts holding the crank case ventilation housing to the valve cover. Pull out the housing from
the valve cover.
Figure 2
Crank case ventilation housing and valve cover
5. Remove the engine valve cover.
Figure 3
1. Exhaust valves: 1, 3, 5, 7
2. Inlet valves: 2, 4, 6, 8
NOTICE
Valve adjustment with the engine running is not allowed since the valves may strike the piston, causing
severe damage.
Valve adjustment shall be done on cold engine.
6. Turn the engine until the valves on cylinder 1 is "overlapping" (rocking). It should not be possible to turn the push
rods for this cylinder at this time. Use the rotation tool, 885530, attached to the lower belt pulley, at the front end
of the engine.
Figure 4
7. Adjust the valves marked black in illustration.

Inlet valve: 0.3 mm (0.0118 in)
Exhaust valve: 0.5 mm (0.0197 in)
NOTE!
In case where the cylinder head gasket has been replaced, increase Valve clearance by 0.1 mm (0.0040 in) !
Figure 5
8. Tighten the lock nut 20 Nm (15 lbf ft). Check the valve play again with the feeler gauge.
Figure 6
9. Turn the engine again one turn until the valves on cylinder 4 is "overlapping" (rocking). Adjust the valve play on
valves marked black in illustration.
Inlet valve: 0,3 mm (0.0118 in)
Exhaust valve: 0,5 mm (0.0197 in)
Figure 7
10. Refit the valve cover gasket, change if necessary.
11. Fit the engine valve cover.

NOTE!
Make sure that the rubber seals for the fuel pipes end up at the right position when assembling. Tightening torque:
11Nm (8.1 lbf ft)
Figure 8
1. Valve cover gasket

2. Rubber seal
12. Fit the crank case ventilation housing to the valve cover with the two Allen bolts.
Figure 9
Crank case ventilation housing and valve cover
13. Refit the inlet air cleaner bracket with the air cleaner.
Figure 10
1. Flange screws
2. Hose clamp
3. Flange screws
4. Air cleaner
14. Refit the two wires to the inlet air pressure sensor.
15. Return the machine back to service.

Service Information

Valves, adjusting 214 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Valves, adjusting
Op nbr 214-012

885812 Timing tool
NOTE!
Only adjust the valve clearance with cold engine.
1.
Figure 1
1. Pressure sensor connector

2. Clamp
3. Plastic pipe
Set the machine in service position 1, see 191 Service positions.
2. Unplug both pressure sensor connectors.
3. Undo the bolt and slide the clamp to the right.

4.
Figure 2
1. retaining bolts
Loosen and remove the two air filter retaining bolts.
5. Detach the plastic pipe (see fig. 1) from the air filter and remove the air filter.
6.
Figure 3
1. Clamp
2. Exhaust pipe
Loosen the bolt for the clamp.

7.
Figure 4
Undo the retaining bolts. Remove the bolts and exhaust pipe.
8. Unscrew the bolts (1) and remove crankcase ventilation (2).
Figure 5
Crankcase ventilation channel
9. Remove the cover plate (1) with wiring.
Figure 6
10. Unscrew the cylinder head cover bolts and remove with gasket.
NOTICE
Valve adjustment with the engine running is not allowed since the valves may strike the piston, causing
severe damage.
Figure 7
1. Exhaust valves: (EX) 1, 3, 5, 7

2. Inlet valves: (IN) 2, 4, 6, 8
11. Rotate the engine until the valves on cylinder no. 1 stand at "valve overlap".
NOTE!
Valve overlap means: exhaust valve not yet closed, inlet valve begins to open.
Figure 8
IN = inlet vavle
EX = outlet valve
Adjust valve clearance in accordance with the black mark on the adjustment chart for each cylinder.
Inlet valve: (IN) 90°
Figure 9
Adjust inlet valve clearance
12. Undo the lock nut (1) and screw in the adjustment screw (2) until it makes contact.
Figure 10
NOTE!
The rocker arm must make contact (no gap) with the thrust washer (arrow) of the spring disc.
13. 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.
Figure 11
NOTE!
Take care not to turn the adjustment screw.
14. Turn the adjustment screw anticlockwise 90°.
Figure 12
15. Counterhold the adjustment screw and tighten the lock nut to 20 ± 2 Nm (14.8 ± 1.5 lbf ft). Remove the rotation
angle disc.
Figure 13
Adjust exhaust valve clearance
16. 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°
NOTE!
Follow steps 6 to 9 for adjusting exhaust valve clearance.
Figure 14
17. Clean the sealing surfaces of the cylinder head.
18. Fit a new gasket to the cylinder head cover.
19. Fit the cylinder head cover and tighten the bolts alternately to 13 Nm (9.6 lbf ft).
20. Fit the cover plate (1) with wiring.
21. Fit the crankcase ventilation. Tighten the bolts to 20 ± 2 Nm (14.8 ± 1.5 lbf ft.
22. Fit the exhaust pipe with flange to the turbocharger.
23. Fit the retaining bolts. Tighten by hand until the pipe can no longer be moved.
24. Fit the exhaust pipe to the manifold.
25. Position the clamp and tighten the bolt.
26. Tighten the turbocharger retaining bolts.

27.
Figure 15
1. Connector
2. Clamp
3. Plastic pipe
Fit the plastic pipe to the air filter.
28. Fit the air filter to the brake with the retaining bolts. Tighten the bolts.
29. Pull the clamp over the plastic pipe and air filter. Tighten the retaining bolt.
30. Plug in both pressure sensor connectors.
31. Start the engine and check for leaks and proper operation.
Service Information

Lubrication system, 220 Service Information 2014/3/18
description
Profile:
BHL, BL71 PLUS [GB]
Lubrication system, description

Lubrication system
Figure 1
1. return flow from turbocharger to oil pan

2. turbocharger
3. oil line to turbocharger
4. plunger with lubrication to rocker arm
5. push rod, oil supply for rocker arm lubrication
6. rocker arm
7. return flow to oil pan
8. piston cooling nozzle
9. oil-conveying line to cooling nozzle
10. camshaft bearing
11. main oil pipe
12. oil pressure switch
13. lubrication oil cooler
14. oil pump
15. by-pass valve oil cooler
16. control valve
17. lubrication oil filter with by-pass valve
18. oil suction pipe
19. crankshaft bearing
20. con-rod bearing
21. oil pan
Service Information

Lubrication system, 220 Service Information 2014/3/18
description
Profile:
BHL, BL71 PLUS [GB]
Lubrication system, description

Lubrication system
Figure 1
1. return flow from turbocharger to oil pan

2. turbocharger
3. oil line to turbocharger
4. oil pressure sensor
5. plunger with lubrication to rocker arm
6. push rod, oil supply for rocker arm lubrication
7. rocker arm
9. piston cooling nozzle
10. oil-conveying line to cooling nozzle
11. camshaft bearing
12. main oil pipe
13. lubrication oil cooler
14. oil pump
15. safety relief valve
16. control valve
17. lubrication oil filter with by-pass valve
18. oil suction pipe
19. crankshaft bearing
20. con-rod bearing
21. oil pan
Service Information

Lubrication oil pressure, 221 Service Information 2014/3/18
check
Profile:
BHL, BL71 PLUS [GB]
Lubrication oil pressure, check

Op nbr 221-021
14360064 Digital pressure gauge
1. Remove the oil pressure sensor and fit the connection.
Figure 1
1. Oil pressure sensor

2. Connection (M14 x 1,5) part no. 14211659
2. Reset the digital pressure gauge to zero. Connect a pressure sensor (6,0 Mpa (60 bar) (870 psi) between the
checking point for oil pressure and the connection on the test instrument.
Figure 2
1. Pressure sensor
3. Start the engine and warm up the engine until the temperature gauge shows normal operating temperature as in
illustration.
Figure 3
Instrument panel
1. Temperature gauge
4. Check value at 2000 rpm. Engine speed can be read on instrument panel.
Pressure value, see: 220 Lubrication system, specification.
Figure 4
Digital pressure gauge
5. Remove the measuring equipment and fit the oil pressure sensor.
Service Information

Fuel system, description 230 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel system, description

Fuel system
Figure 1
1. Fuel tank
2. Fuel pump
3. Fuel filter
4. Line to injection pumps
5. Injection pump
6. Delivery pipe to injector
7. Injectors
8. Fuel return line
9. Overflow valve
10. Fuel pipe[ 1] 
11. Primary filter, water separating
[ 1]NOTE: Smallest distance 300 mm (11.8 in)

Service Information

Fuel system, description 230 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel system, description

The fuel flows from the tank via the primary filter to the fuel feed pump and then travel through the secondary filter to the
inlet duct of the injection pump. From the injection pump, the fuel travels via the delivery pipes to the injectors.
The fuel feed pump has a high displacement. The surplus fuel serves to cool the injection pump.
A pressure control valve is located at the end of the inlet duct. The valve maintains a constant pressure of 5 bar (72 psi) for
the injection pump.
The surplus fuel is led back to the tank via the return line.
Figure 1
Fuel system diagram
1. Fuel tank
2. Primary filter (fuel pre-filter/water separator)
3. Fuel pump
4. Secondary filter (fuel filter)
5. Fuel line from secondary filter to the injection pump.
6. Injection pump
7. Line to injector
8. Injector
9. Pressure retention valve
10. Fuel return pipe
Service Information

Fuel filter, description 230 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel filter, description

The fuel system consists of a primary filter with integrated water trap and a secondary filter. Both filters are positioned on
the right side of the machine under the engine hood.
Service Information

Fuel feed pump, removal 233 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel feed pump, removal

Op nbr 23311-1
Engine Service Manual
WARNING
1. Turn off the electric power with the battery disconnect switch.
2. Open the engine hood.
Figure 1
1. Fan guard
4. Remove the fan belt from the belt pulley, see 263 Fan belt, replacement.
Disconnect the fuel lines.
Figure 2
1. Belt pulley
2. Fuel line
3. Fuel line
5. Remove the fuel feed pump according to the Engine Service Manual
Figure 3
1. Fuel feed pump

Service Information

Fuel pump, removal 233 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel pump, removal

Op nbr 233-011
WARNING
Figure 1
1. Fan guard
4. Remove the fan belt from the belt pulley, see 263 Fan belt, replacement.
Disconnect the fuel lines.
Figure 2
1. Belt pulley
2. Fuel line
3. Fuel line
5. Remove the fuel feed pump according to the Engine Service Manual
Figure 3
1. Fuel feed pump

Service Information

Fuel pump, removal 233 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel pump, removal

Op nbr 233-011
WARNING
1. Place the machine in service position one, see 173 Service positions.
3.
Figure 1
1. fan guard
2. fuel lines
Remove the fan belt and the fan guard, see 263 Fan belt, replacement.
4. Place a suitable container under the fuel pump to collect draining fuel.
5. Disconnect the fuel lines.
6. Loosen and remove the three retaining screws.

Figure 2
1. fuel pump
2. retaining screws
7. Disassemble the fuel pump.

Service Information

Fuel feed pump, 233 Service Information 2014/3/18
installation
Profile:
BHL, BL71 PLUS [GB]
Fuel feed pump, installation

Op nbr 23312-1
1. Install the fuel feed pump according to the Engine Service Manual
Figure 1
1. Fuel pump
2. Install the fan belt on the belt pulley, see 263 Fan belt, replacement.
Connect fuel lines.
Figure 2
1. Belt pulley
2. Fuel line
3. Install the fan guard.
Figure 3
1. Fan guard
4. Bleed the fuel system if necessary, see 233 Fuel system, bleeding.
5. Turn on the electric power with the battery disconnect switch.

Service Information

Fuel pump, installation 233 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel pump, installation

Op nbr 233-012
1. Install the fuel feed pump according to the Engine Service Manual.
Figure 1
1. Fuel pump
2. Install the fan belt on the belt pulley, see 263 Fan belt, replacement.
Connect fuel lines.
Figure 2
1. Belt pulley
2. Fuel line
3. Fuel line
Figure 3
1. Fan guard
4. Bleed the fuel system if necessary, see 233 Fuel system, bleeding.

Service Information

Fuel pump, installation 233 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel pump, installation

Op nbr 233-012
1. Assemble the fuel pump to the engine.
Figure 1
1. fuel pump
2. retaining screws
2. Assemble and fasten the retaining screws.
3. Install the fan belt, see 263 Fan belt, replacement.

NOTE!
Do not assemble the fan guard before connecting the fuel lines.
Figure 2
1. fan guard
2. fuel lines
4. Assemble the fuel lines. Start with the plastic pipe.
6. Bleed the fuel system, see 233 Fuel system, bleeding.

Service Information

Fuel system, bleeding 233 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel system, bleeding

Op nbr 233-001
WARNING
Smoking or open flames near the machine are absolutely forbidden during refuelling or when the fuel system is
open to contact with the air.
1. Loosen the plug on the fuel filter and pump on the fuel priming pump (on the hydraulic tank) until fuel without air
comes out from the plug hole.
Tighten the plug.
Figure 1
1. Plug
Service Information

Fuel system, bleeding 233 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel system, bleeding

Op nbr 233-001
Do not bleed the system when the engine is warm.
Place the machine in service position one, see 173 Service positions.
1. Fill the fuel tank with fuel, leaving room for expansion.
2.
Figure 1
1. draining nipple
2. water trap
3. primary fuel filter
4. hand pump
Loosen the drain plug, so that fuel can leak out.
NOTICE
3. Pump the hand pump until fuel, free from air bubbles flows out.
4. Screw in and tighten the drain plug.

Service Information

Fuel filter, replacing 233 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel filter, replacing

Op nbr 23314-2
2. Remove the fuel filter from the filter housing, and fit a new fuel filter to the filter housing.
Figure 1
1. Fuel filter
3. Bleed the fuel system, see 233 Fuel system, bleeding.

Service Information

Feed pump, checking feed 233 Service Information 2014/3/18
pressure
Profile:
BHL, BL71 PLUS [GB]
Feed pump, checking feed pressure

Op nbr 233-004
14360064 Digital pressure gauge
1. Remove the plug and fit the connection.
Figure 1
1. Plug
2. Connection (M12 x 1,5) part no. 14212998
2. Reset the digital pressure gauge to zero. Connect a pressure sensor 6.0 MPa (60 bar) (870 psi) between the
checking point for fuel pressure and connection on the test instrument.
Figure 2
1. Pressure sensor
3. Start the engine and warm up the engine to normal operating temperature. See gauge on instrument panel.
Figure 3
Instrument panel
1. Temperature gauge
4. Check value at high and low idle, see 230 Fuel system, specifications.
Figure 4
1. Digital pressure gauge
5. Remove the measuring equipment and fit the plug on the fuel filter.
Service Information

Fuel tank, removing 234 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel tank, removing

Op nbr 234-011
Container (clean)
WARNING
Smoking or open flames near the machine are absolutely forbidden during refuelling or when the fuel system is
open to contact with the air.
2. Remove the plug from the bottom of the tank and drain the fuel into a container.
Re-install the plug after draining.
3. Remove the side panel.
Figure 1
1. Side panel
4. Disconnect the fuel hoses.

Disconnect the cable from the level sensor connector.
Figure 2
1. Fuel hoses
2. Level sensor connector
5. Place a pallet on a jack underneath the fuel tank. Remove the attaching screws (4 attaching screws) and remove the
fuel tank from the machine.
Figure 3
1. Pallet
2. Jack
Service Information

Fuel tank, installing 234 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fuel tank, installing

Op nbr 234-012
1. Transfer the level sensor, the step and the fuel cap from the old tank to the new.
Figure 1
1. Pallet
2. Jack
2. Place a pallet on a jack underneath the fuel tank and lift up the fuel tank.
Install the attaching screws (4 attaching screws).
3. Connect the fuel hoses and the cable to the level sensor connector.
Figure 2
1. Fuel hose
2. Cable
4. Ensure that the tank contains fuel and bleed the fuel system, see 233 Fuel system, bleeding.
5. Install the side panel.
Figure 3
1. Side panel

Service Information

Silencer, replacing 252 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Silencer, replacing
Op nbr 252-020
WARNING
2. Remove the attaching screws (4 attaching screws, 2 underneath). Remove the nuts for the turbocharger.
Figure 1
1. Attaching screws
2. Nuts
3. Pull off the pipe from the screw studs, angle the silencer and remove it.
Figure 2
1. Silencer
4. Install the silencer pipe on the turbocharger with the nuts .
Figure 3
1. Attaching screws
2. Nuts
5. Install the silencer to the bracket with the attaching screws (4 attaching screws, 2 underneath). Ensure the bellows
are not under tension after re-assembly.

Service Information

Silencer, replacing 252 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Silencer, replacing
Op nbr 252-020
WARNING
Disassembly
1. Place machine in service position 1, see 173 Service positions.
3. Remove the engine hood, see 821 Engine hood, removal.
4. Loosen and remove the retaining screws (1, 2 pcs) of the oil filler neck.
Figure 1
oil filler neck, disassembly
1. retaining screws filler neck

2. exhaust pipe
3. retaining screws exhaust bracket
5. Loosen the retaining clamp (3) of the exhaust pipe (4).
Figure 2
silencer, disassembly
1. retaining bracket
2. exhaust bracket
3. retaining clamp
4. exhaust pipe
6. flexible exhaust tube
7. retaining clamp
8. silencer
6. Remove the exhaust pipe, sealing ring and the retaining clamp.
7. Loosen the retaining clamp (7) and remove the flexible exhaust tube (6) from the silencer.
8. Attach the silencer (8) to a suitable lifting device.
9. Loosen and remove the retaining screws (4pcs) of the exhaust bracket (2).
10. Remove the silencer and the bracket with a suitable lifting device. Place it on a suitable surface.
NOTE!
Lift away the oil filler assembly while removing the silencer with the bracket.
11. Loosen the retaining brackets (1, 5) of the silencer.
12. Remove the exhaust bracket.
Assembly
13. Mount the silencer (8) with the retaining brackets (1, 5) on the exhaust bracket (2). Tighten the retaining brackets.
Figure 3
silencer, disassembly
2. exhaust bracket
3. retaining clamp
4. exhaust pipe
6. flexible exhaust tube
7. retaining clamp
8. silencer
14. Lift the exhaust bracket and the silencer in mounting position. Use a suitable lifting device.
15. Align the exhaust bracket. Assemble and fasten the retaining screws. See
030 Inlet and exhaust system, tightening torques for recommended tightening torque.
16. Assemble the retaining clamp (7) and the flexible exhaust tube (6) to the silencer.
17. Tighten the retaining clamp at the silencer intake. See 030 Inlet and exhaust system, tightening torques for
18. Mount the exhaust pipe (4) together with the sealing. Fasten the retaining clamp (3). See
030 Inlet and exhaust system, tightening torques for recommended tightening torque.
19. Assemble the oil filler neck to the exhaust bracket.

Figure 4
oil filler neck, disassembly
1. retaining screws filler neck

2. exhaust pipe
3. retaining screws exhaust bracket
20. Fasten the retaining screws (1).
21. Mount the engine hood. See 821 Engine hood, installation.

Service Information

Turbocharger, description 255 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Turbocharger, description
The turbocharger is driven by the exhaust gases as they pass through the turbine housing.
The exhaust gas flow causes the turbine rotor in the turbine housing to rotate. The compressor rotor is positioned on the
same shaft as the turbine rotor. The compressor rotor is positioned in a housing which is connected between the air cleaner
and the engine induction manifold.
When the compressor rotor rotates, air is drawn from the air cleaner. The air is compressed and forced into the engine
cylinders, after it first has been cooled down while passing through the intercooler.
Figure 1
Turbocharger, principle diagram
A. Supply of lubricating oil

B. Exhaust gases from engine into turbocharger
C. Exhaust gases out from turbocharger
D. Air via air filter
E. Air to inlet manifold
Service Information

Cooling system, description 260 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Cooling system, description

Cooling system
Figure 1
1. Coolant connection, inlet

2. Thermostat housing
3. Coolant pump
4. Lubricating oil cooler
5. Cylinder cooling
6. Cylinder head cooling
7. Coolant connection, outlet
Service Information

Cooling system, description 260 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Cooling system, description

The cooling system has a closed cooling circuit, with externally operated fans. The coolant pump (1) is operated via the V-
belt, delivering coolant to the cylinder block via the oil cooler (2). In the cylinder block, the coolant flows around the cylinder
liner (3) and up to the cylinder head grooving (4).
The thermostat (5) starts to open at 86°C (187°F) and is completely open at 102°C (216°F). If the temperature is higher than
86°C (187°F), the coolant flows to the heat exchanger (7) via the feed line (6) and then through the thermostat housing to
the engine via the return line (8).
The expansion tank (9) has an expansion line (10) to the thermostat housing and a bleed line (11) for the cylinder head.
The cab heating feed line (12) is connected to the oil cooler (2). The return line connection is on the thermostat housing.
Figure 1
Cooling system
Service Information

Radiator, removal 261 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Radiator, removal
Op nbr 26111-1
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.
Figure 1
1. Cable

Figure 2
1. Grille
2. Front plate
Figure 3
1. Clamp
Figure 4
1. Locking device
2. Hoses
7. Connect a drain hose to the valve and place the drain hose down into a container.
Open the valve and drain the coolant into the container.
Figure 5
1. Valve
2. Drain hose

Remove the screws radiator–radiator casting (4 screws).
Figure 6
1. Hose
2. Hose
3. Hose
4. Hose
5. Screws
9. Remove the screws from both sides and lift out the hydraulic oil cooler/radiator.
Figure 7
1. Screw
Service Information

Radiator, removal 261 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Radiator, removal
Op nbr 26111-1
WARNING
cause severe burns.
Figure 1
1. Cable

Figure 2
1. Grille
2. Front plate
Figure 3
1. Clamp
Figure 4
1. Locking device
2. Hoses
Figure 5
1. Valve
2. Drain hose

Remove the screws radiator–radiator casting (4 screws).
Figure 6
1. Hose
2. Hose
3. Hose
4. Hose
5. Screws
9. Remove the screws from both sides and lift out the hydraulic oil cooler/radiator.
Figure 7
1. Screw
Service Information

Radiator, installation 261 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Radiator, installation
Op nbr 26113-1
If a new radiator is to be installed, transfer the hydraulic oil cooler to the radiator and transfer the expansion tank.
Figure 1
1. Screw
2. Install the screws radiator–radiator casting (4 screws). Connect the radiator hoses and the lower hose (hidden).
Figure 2
1. Hose
2. Hose
3. Hose
4. Hose
5. Screws
4. Lock the bracket of the hydraulic oil cooler. Connect the hoses (4 hoses) to the hydraulic oil cooler.
Figure 3
1. Locking device
2. Hoses
Figure 4
1. Clamp

Figure 5
1. Grille
2. Front plate
Figure 6
1. Cable
Figure 7
1. Cap


Service Information

Radiator, installation 261 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Radiator, installation
Op nbr 26113-1
If a new radiator is to be installed, transfer the hydraulic oil cooler to the radiator and transfer the expansion tank.
Figure 1
1. Screw
2. Install the screws radiator–radiator casting (4 screws). Connect the radiator hoses and the lower hose (hidden).
Figure 2
1. Hose
2. Hose
3. Hose
4. Hose
5. Screws
4. Lock the bracket of the hydraulic oil cooler. Connect the hoses (4 hoses) to the hydraulic oil cooler.
Figure 3
1. Locking device
2. Hoses
Figure 4
1. Clamp

Figure 5
1. Grille
2. Front plate
Figure 6
1. Cable
Figure 7
1. Cap


Service Information

Expansion tank, replacing 261 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Expansion tank, replacing

Op nbr 261-018
WARNING
cause severe burns.
2. Remove the grille.
Figure 1
1. Grille
Figure 2
1. Valve
2. Drain hose
4. Disconnect the hoses 1, 2 and 4. Remove the hose 3.
Figure 3
1. Hose
2. Hose
3. Hose
4. Hose
5. Remove attaching screws (2 pcs) and remove the expansion tank.
Figure 4
1. Attaching screw
6. Install a new expansion tank.
7. Connect hoses.
Figure 5
1. Hose
2. Hose
3. Hose
4. Hose
8. Remove the cap and fill coolant in the radiator.
Figure 6
1. Cap
12. Install the grille.

Figure 7
1. Grille
Service Information

Expansion tank, replacing 261 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Expansion tank, replacing

Op nbr 261-018
WARNING
cause severe burns.
Place the machine in service position two, see 173 Service positions.
1.
Figure 1
1. filling cap
2. hose with retaining clip
3. hose with retaining clip
Drain the coolant until the expansion tank is completely empty, see 173 Coolant, change.
NOTICE
2. Disconnect the two hoses from the expansion tank.

3.
Figure 2
1. retaining screws
Loosen and remove the retaining screws.
4. Exchange the expansion tank.
5. Assemble and fasten the retaining screws.
6. Connect the two hoses to the expansion tank and tighten the clips.
7. Remove the filling cap, fill the radiator and the expansion tank with coolant until the filling mark is reached.
8. Check for leaks.
10. Check the coolant level and top up if needed.
11. Assemble the grille.

Service Information

Radiator, hose upper, 261 Service Information 2014/3/18
replacement
Profile:
BHL, BL71 PLUS [GB]
Radiator, hose upper, replacement

Op nbr 26112-2
WARNING
cause severe burns.
Figure 1
1. Grille
NOTE!
Drain until the coolant level is below the upper hose.
Figure 2
1. Valve
2. Drain Hose
5. Remove the radiator hose and fit a new one.

Tighten the hose clips.
Figure 3
1. Hose clip
2. Radiator hose
3. Hose clip
6. Remove the cap and fill coolant in the expansion tank.
Figure 4
1. Cap
Figure 5
1. Grille
Service Information

Radiator hose upper, 261 Service Information 2014/3/18
replacing
Profile:
BHL, BL71 PLUS [GB]
Radiator hose upper, replacing

Op nbr 261-012
WARNING
cause severe burns.
Place the machine in service position two, see 173 Service positions.
1.
Figure 1
1. hose
2. hose clips
Drain the coolant until the coolant level is below the upper hose, see 173 Coolant, change.
NOTICE
2. Remove the radiator hose and fit a new one. Tighten the hose clips.
3. Refill coolant and check for leakage, see 173 Coolant, change.
Service Information

Radiator, hose lower, 261 Service Information 2014/3/18
replacement
Profile:
BHL, BL71 PLUS [GB]
Radiator, hose lower, replacement

Op nbr 26114-2
WARNING
cause severe burns.
Figure 1
1. Grille
Figure 2
1. Valve
2. Drain hose
5. Release the hose clip and disconnect the radiator hose.
Figure 3
1. Radiator hose
2. Hose clip
6. Remove the radiator hose from the radiator and fit a new one.
Tighten the hose clamps.
Install the radiator hose on the engine and tighten the hose clamp.
Figure 4
1. Hose clamp
2. Radiator hose
7. Remove the cap and fill coolant in the expansion tank.

Figure 5
1. Cap
Figure 6
1. Grille
Service Information

Fan shroud, replacing 263 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fan shroud, replacing

Op nbr 263-084
Disassembly
1.
Figure 1
1. hoses expansion tank

2. retaining screws bracket
Place the machine in service position 1, see 191 Service positions.
2. Disassemble the grille and drain the coolant, see 173 Coolant, change or the operator´s manual.
3. Loosen and remove the hoses from the expansion tank.
4. Loosen and remove the retaining screws of the attachment bracket. Remove the bracket together with the
expansion tank.
5.
Figure 2
1. clip connecting hose to radiator

2. clip connecting air inlet to filter
3. clip connecting hose to turbocharger
Loosen the clip connecting the upper hose to the radiator and remove the hose from the radiator.
6. Slightly loosen the clip on the turbocharger so that the upper hose can be turned away.
7. Loosen the clip connecting the air inlet to the air filter and remove the air inlet.
8. Loosen and remove the retaining screws of the fan guard.
10.
Figure 3
1. fan
2. fan adapter
3. V-belt pulley
4. retaining screws
Loosen and remove the retaining screws of the fan.
11. Slightly turn the fan so that it can be removed from the fan adapter.
NOTE!
Leave the fan inside the fan shroud.
12. Loosen and remove the retaining screws together with the fan adapter.
13. Loosen and remove the retaining screws of the fan shroud.
14. Remove the fan shroud together with the fan.
Assembly
15. Insert the fan into the new fan shroud and assemble the fan shroud with the retaining screws. See
260 Cooling system, tightening torques for tightening torque.
16. Assemble the fan adapter and the retaining screws. See 260 Cooling system, tightening torques for tightening
torque.
17. Assemble the fan to the fan adapter, assemble the retaining screws. See 260 Cooling system, tightening torques for
tightening torque.
18. Assemble the fan guard and the retaining screws. See 260 Cooling system, tightening torques for tightening
torque.
19. Assemble the air intake on the filter and fasten the clip.
20. Bring the upper hose into position and assemble it. Fasten the clip. See 260 Cooling system, tightening torques for
tightening torque.
21. Assemble the attachment bracket together with the expansion tank and the retaining screws. See
22. Assemble the hoses to the expansion tank. See 260 Cooling system, tightening torques for tightening torque.
23. Assemble the grille and fill in coolant, see 173 Coolant, change or the operator´s manual.
Service Information

Fan shroud, additional 263 Service Information 2014/3/18
sheet, installing
Profile:
BHL, BL71 PLUS [GB]
Fan shroud, additional sheet, installing

Op nbr 263-085
Tool:
Hand riveter
Disassembly
1.
Figure 1
1. hoses expansion tank

2. retaining screws bracket
Place the machine in service position 1, see 191 Service positions.
2. Disassemble the grille and drain the coolant, see 173 Coolant, change or the operator´s manual.
3. Loosen and remove the hoses from the expansion tank.
4. Loosen and remove the retaining screws of the attachment bracket. Remove the bracket together with the
expansion tank.
5.
Figure 2
1. clip connecting hose to radiator

2. clip connecting air inlet to filter
3. clip connecting hose to turbocharger
Loosen the clip connecting the upper hose to the radiator and remove the hose from the radiator.
6. Loosen the clip connecting the air inlet to the air filter and remove the air inlet.
7. Remove the fan shroud sealing.

NOTE!
To remove the sealing the retaining screws of the shroud have to be loosened first.
Installing sheet
8.
Figure 3
1. blind rivets
2. additional sheet
Position the additional sheet at the fan shroud and mark the drills on the fan shroud.
9. Drill the holes into the fan shroud.
10. Place the additional sheet in position and preassemble the blind rivets in their holes.
11. Fasten the blind rivets with a hand riveter.

Assembly
12. Assemble the fan shroud sealing.

NOTE!
To assemble the sealing the retaining screws of the shroud have to be loosened first.
13. Assemble the air intake on the filter and fasten the clip.
14. Assemble the attachment bracket together with the expansion tank and the retaining screws. See
15. Assemble the hoses to the expansion tank. See 260 Cooling system, tightening torques for tightening torque.
16. Assemble the grille and fill in coolant, see 173 Coolant, change or the operator´s manual.
Service Information

Fan belt, replacement 263 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Fan belt, replacement

Op nbr 26312-2
1. Remove the ignition key and turn off the electric power with the battery disconnect switch.
Figure 1
1. Fan guard
4. Put an open-ended wrench (22 mm) on the belt tensioner and press down.
Figure 2
1. Open-ended wrench
2. Belt tensioner
5. Remove the fan belt from the belt pulleys and over the fan blades.
Figure 3
1. Fan belt
6. Install the new fan belt over the fan blades, press down the belt tensioner and install the fan belt on the belt
pulleys.

Service Information

Fan belt and/or alternator 263 Service Information 2014/3/18
belt, replacing
Profile:
BHL, BL71 PLUS [GB]
Fan belt and/or alternator belt, replacing

Op nbr 263-012
Disassembly
1. Place the machine in service position one, see 173 Service positions
2.
Figure 1
1. Fan guard
Remove the ignition key and turn off the electric power with the battery disconnect switch.
3. Loosen and displace the fan guard.

4.
Figure 2
1. belt
2. belt tensioner
Put an open-ended wrench (½ inch) on the belt tensioner and lift off the tensioner. Insert a pin (ø6 mm) to ensure.
5. Remove the belt from the belt pulleys and over the fan blades.
Assembly
6. Install the new belt over the fan blades, the belt tensioner and on the belt pulleys.
7. Release the belt tensioner and remove the pin.

Service Information

Accelerator control cable, 271 Service Information 2014/3/18
changing
Profile:
BHL, BL71 PLUS [GB]
Accelerator control cable, changing

Op nbr 272-010
Disassembly
3. Release the fuel filter (1) from the bracket (2).
Figure 1
fuel filter, disassembly
1. Fuel filter
2. Bracket
4. Loosen the adjusting nuts (1).

Figure 2
adjusting nuts, disassembly
1. adjusting nuts
5. Loosen the nut and turn off the pin from the lever.
Figure 3
lever, disassembly
1. lever
6. Remove the screws (1, 6 pcs).
Figure 4
plate, disassembly
1. retaining screws
7. Tilt the steering column backward.
8. Loosen the front console and separate the instrument panel by pushing from behind.
Figure 5
instrument panel, disassembly
9. Pull off the connectors from the instrument panel.
10. Remove the front console.
11. Loosen the screws (1).
Figure 6
retaining screws, disassembly
1. retaining screws
12. Remove the screws (1), then pull and lift the bracket for accelerator pedal off the screws (underneath) and move it
backward.
Figure 7
bracket, disassembly
1. retaining screws
13. Loosen the nuts (2) and remove the locking device (1).
Figure 8
accelerator cable, disassembly
1. locking device
2. nuts
14. Remove the accelerator control cable.
Assembly
15. Transfer the clevis and spring to the new cable. Tighten the nuts.
NOTE!
Screw on to the half length of the thread.
16. Install the lever (1) and tighten the nut.
Figure 9
lever, assembly
1. lever
17. Insert the cable into the bracket and lock the adjusting (1) nuts.
NOTE!
Adjust the cable with the nuts into the centre position.
Figure 10
adjusting nuts, assembly
1. adjusting nuts
18. Guide the accelerator control cable into the cab.
19. Install the accelerator control cable with the locking device (1) and tighten the nuts (2).
NOTE!
Figure 11
accelerator cable, assembly
1. locking device
2. nuts
20. Lift the bracket for the accelerator pedal onto the screws (underneath) and install the screws (1).
Figure 12
bracket, assembly
1. retaining screws
21. Tighten the screws (1).
Figure 13
retaining screws, assembly
1. retaining screws, assembly
22. Install the front console.
23. Plug in the connectors to the instrument panel.
24. Fit the instrument panel into the hole.
Figure 14
instrument panel, assembly
25. Install the screws (1) (6 pcs).
Figure 15
plate, assembly
1. retaining screws
26. Adjust the idle speed of the engine by changing the mounting position of the cable. Tighten the nuts (1).
Figure 16
1. adjusting nuts
27. Fit the fuel filter (1) to the bracket (2).
Figure 17
fuel filter, assembly
1. Fuel filter
2. Bracket
Service Information

changing
Profile:
BHL, BL71 PLUS [GB]

Op nbr 272-010
Disassembly
3. Release the bracket with the fuel filter (1).
Figure 1
fuel filter, disassembly
4. Loosen the adjusting nuts (1).
Figure 2
adjusting nuts, disassembly
1. adjusting nuts
5. Loosen the nut and turn off the pin from the lever.
Figure 3
lever, disassembly
6. Remove the screws (1, 6 pcs).
Figure 4
plate, disassembly
1. retaining screws
8. Loosen the front console and separate the instrument panel by pushing from behind.
Figure 5
instrument panel, disassembly

11. Loosen the screws (1).
Figure 6
retaining screws, disassembly
1. retaining screws
12. Remove the retaining screws (1), then pull and lift the bracket for accelerator pedal off the screws (underneath) and
move it backward.
Figure 7
bracket, disassembly
1. retaining screws
13. Loosen the nuts (2) and remove the locking device (1).
Figure 8
accelerator cable, disassembly
1. locking device
2. nuts
14. Remove the accelerator control cable.
Assembly
15. Transfer the clevis and spring to the new cable. Tighten the nuts.
NOTE!
Screw on to the half length of the thread.
16. Install the pin and tighten the nut.
Figure 9
lever, assembly
17. Insert the cable into the bracket and lock the adjusting nuts (1).
NOTE!
Figure 10
1. adjusting nuts
18. Guide the accelerator control cable into the cab.
19. Install the accelerator control cable with the locking device (1) and tighten the nuts (2).
NOTE!
Figure 11
accelerator control cable, assembly
1. locking device
2. nuts
20. Lift the bracket for the accelerator pedal onto the screws (underneath) and install the screws (1).
Figure 12
bracket, assembly
1. retaining screws
21. Tighten the screws (1).
Figure 13
retaining screws, assembly
1. retaining screws
24. Fit the instrument panel into the hole.
Figure 14
instrument panel, assembly
25. Install the screws (1) (6 pcs).
Figure 15
plate, assembly
1. retaining screws
26. Adjust the idle speed of the engine by changing the mounting position of the cable. Tighten the nuts (1).
Figure 16
1. adjusting nuts
27. Fit the fuel filter to the bracket.
Figure 17
fuel filter, assembly
1. fuel filter

Service Information

replacement
Profile:
BHL, BL71 PLUS [GB]
Accelerator control cable, replacement

Op nbr 27210-2
1. Release the fuel filter/pump from the bracket.
Figure 1
1. Fuel filter/pump
2. Bracket
2. Loosen the nuts.
Figure 2
1. Nut
3. Disconnect the spring from the pin.

Figure 3
1. Spring
4. Remove the screws (6 screws).

Tilt the steering wheel backward, see the arrow.
Figure 4
1. Screw
5. Loosen the front console and separate the instrument panel from the console by pushing from behind.
Remove the console.
Figure 5
6. Secure the instrument panel in a suitable position with, for example, a cable tie.
7. Remove the cover and loosen the screws.
Figure 6
1. Cover
2. Screw
8. Remove the screws and pull and lift the bracket for accelerator pedal off the screws underneath and move it
backward.
Figure 7
1. Screw
9. Loosen the nuts and remove the locking device. Remove the accelerator control cable.
Transfer the clevis attachment and spring to the new cable.
Install the new accelerator control cable with the locking device and tighten the nuts.
Figure 8
1. Locking device
2. Nut
10. Install the spring on the pin and tighten the nuts.
NOTE!
Check through the hole for the cover plate that the spring is in the groove on the pin.
Figure 9
1. Spring
11. Lift the bracket for the accelerator pedal onto the screws (underneath) and install the screws.
Figure 10
1. Screw
12. Tighten the screws and install the cover.
Figure 11
1. Cover
2. Screw
13. Install the front console, then pull out the instrument panel from the back and fit it in the hole.
Figure 12
14. Install the screws (6 screws).

Figure 13
1. Screw
15. Fit the fuel filter/pump to the bracket.
Figure 14
1. Fuel filter/pump
2. Bracket
Service Information

changing
Profile:
BHL, BL71 PLUS [GB]

Op nbr 272-010
1. Place machine in service position 2, see 173 Service positions
Disassembly
2. Remove the floor mat.
3. Dismantle the cover of the stabiliser control.
4. Remove the fastening screws of the stabiliser control bracket.
5. If installed,remove the fastening screws of the pilot control bracket.
6. Remove both cover in the floor panel.
7. Remove the side panel, see 851 Side panel, removal
8. Remove the cab filter.
9. Remove the fastening screw of the hand control.
10.
Figure 1
Disassemble the hand control and release the cable.
11. Unscrew the control cable from the housing.

12.
Figure 2
Remove the screws (6 pce).
14.
Figure 3
Loosen the front console and separate the instrument panel by pushing from behind.
17.
Figure 4
Remove the cover 1 and loosen the screws (2).

18.
Figure 5
Remove the screws, then pull and lift the bracket for accelerator pedal off the screws (underneath) and move it
backward.
19. Remove the nuts 1, see figure below.
20.
Figure 6
Loosen the nuts 2.
21. Remove the clamps and pull out the control cable.
NOTE!
Attach a pull in tool at the end of the cable to assemble the new control cable.
Assembly
22.
Figure 7
Pedal bracket
Pull in the new control cable. Guide the cable to the bottom side cabin and hand control.
23.
Figure 8
Insert the cable into the bracket and lock the nuts 2. Mount the nuts 1
24. Secure the control cable with the clamp and cable ties.
NOTE!
Check that the control cable is well fitted.
25.
Figure 9
Mount the cable at the hand control.
26. Hook up the cable and assemble the hand control.
27. Mount the hand control at the console.
28. Attach the cab filter.
29. Install the side panel, see 851 Side panel, installation
30. If installed,fit the pilot control bracket and tighten the fastening screws.
31.
Figure 10
Lift the bracket for the accelerator pedal onto the screws (underneath) and tighten the screws 1.
32. Bring the hand control into idle speed position and adjust the control cable. Shift the nuts in there position to avoid
clearance. Tighten the nuts after adjusting.
33.
Figure 11
Install the cover 1 and tighten the screws 2

36.
Figure 12
Fit the instrument panel into the hole.
37.
Figure 13
Install the screws 1 (6 pce).
38. Install the covers in the floor panel.
39. Mount the stabiliser control bracket.
40. Attach the cover of the stabiliser control.
41. Install the floor mat.

Thank you for your purchase.
Have a nice day.
file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/3/18 16:14:50]

Volvo BL 71 2 Engine With Mounting and Equipment

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Volvo BL 71 2 Engine With Mounting and Equipment

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Service Information

Document Title: Function Group: Information Type: Date:

Go back to Index Page

Starter motor side

Engine revolution governor (Heinzmann).

Document Title: Function Group: Information Type: Date:

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Components, servicing view

1. Oil filler pipe

Components, exhaust view

Document Title: Function Group: Information Type: Date:

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14360000 Vacuum pump

1. Remove the engine hood, see 821 Engine hood, removal.

2. Detach cable from the bracket.

3. Remove the grille and the front plate.

4. Remove the clamps from both sides of the cooler.

5. Connect the vacuum pump, see 900 Vacuum pump, connection.

8. Disconnect the radiator hoses and the lower hose (hidden).

10. Remove the fan guard and the radiator casting.

11. Remove the fan.

14. Disconnect hose from the engine.

17. Remove the plate.

18. Remove the shift lever.

19. Disconnect the hoses from the gearbox.

20. Disconnect the hoses from the gearbox.

21. Disconnect the hose from the gearbox.

22. Disconnect ground cables from the gearbox.

1. Battery disconnect switch

24. Disconnect the electrical cables from the starter motor.

29. Disconnect the connector from the working pump.

30. Remove the screws (2 screws) gearbox unit - working pump.

32. Remove the attaching screws for the engine.

35. Place the engine on stable supports.

Document Title: Function Group: Information Type: Date:

Go back to Index Page

885530 Rotation tool

Lifting chains, min. 1000 kg (2200 lb)

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

2. Disconnect the main battery switch.

3. Remove the battery/batteries, see 310 Battery, changing.

4. Drain the coolant, see 173 Coolant, change.

5. Drain the transmission oil, see 173 Transmission, changing oil.

6. Disassemble the engine hood, see 821 Engine hood, removal.

1. retaining screws filler neck assembly

Use a slop to attach the exhaust assembly to a suitable lifting device.

12. Remove the exhaust assembly from the machine.

1. upper radiator hose

18. Remove the expansion tank with the attachment bracket.

21. Remove the hose from the turbocharger.

23. Remove the complete air filter assembly.

25. Remove the fan guard.

30. Remove the fan shroud together with the fan.

1. hose to engine oil cooler

36. Loosen the hose (2) from the coolant pump.

1. hose (tank connection)

40. Loosen the adjusting nuts (1) of the throttle cable.

Engine weight (dry): 520 kg (1146.2 lb)

47. Loosen the connection screws from engine to transmission.

49. Disassemble the engine mounts from the frame.

Document Title: Function Group: Information Type: Date:

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14360000 Vacuum pump