Volvo BL 71 4 Power Transmission

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

Power transmission, 400 Service Information 2014/3/18
description
Profile:
BHL, BL71 PLUS [GB]
Power transmission, description

Gearbox
The gearbox is a four forward, four reverse power shuttle gearbox with torque converter, hydraulic shuttle control and
column mounted electro–hydraulic direction control. The transmission has switchable four wheel drive. The torque converter
is a fluid clutch.
Front axle
Drive is provided to the front axle by a propeller shaft direct from the transmission.
The front axle consists of a beam casing, housing the differential in the middle and a wheel hub unit at each end. The
differential, of "open" type, is supported by two bearings.
The wheel hubs containing the epicyclic reduction gears are supported by two tapered roller bearings and are powered by a
hydraulically–operated steering valve.
Rear axle
The rear axle features permanent drive, via a propeller shaft direct from the transmission. The axle features spiral crown and
pinion driving through epicyclic hubs, differential lock and inboard oil–immersed brakes.
The rear axle consists of a beam casing, housing the differential in the middle and a wheel hub unit at each end. The
differential, type "mechanical lock", is supported by two bearings.
The wheel hubs containing the epicyclic reduction gears are supported by two tapered roller bearings.
Furthermore, the rear axle has a braking system, that provides braking force to both the service brake and the parking brake.
Figure 1
Power transmission
1. Torque converter
2. Gearbox
3. Front axle
4. Propeller shaft, front
5. Propeller shaft, rear
6. Rear axle
Service Information

Powershift transmission, 400 Service Information 2014/3/18
description
Profile:
BHL, BL71 PLUS [GB]
Powershift transmission, description

The Power Shift transmission is a fully automatic transmission with torque converter. The transmission has four forward
gears and four reverse gears and operator controlled 4WD/2WD. Gear shifting is controlled by the position of the gear
selector, SW4, and an electronic control unit, T-ECU. Engagement of gears is controlled by the electro-hydraulic control
system. The engine output torque is transmitted and reinforced by the torque converter to the transmission.
The transmission is supplied with hydraulic pressure from a pump driven by the input shaft from the engine.
Gears are selected by using the gear selector, SW4, placed on the steering column.
Engagement of gears is controlled by the transmission control unit after impulses from the speed sensor, SE5. Clutches in
the transmission are activated by solenoid valves on the transmission control system.
The four wheel drive, is operated by a spring applied clutch in the transmission. When supplied with hydraulic pressure from
the control valve, the four wheel drive is disengaged.
Figure 1
Power Shift transmission
Figure 2
Power shift transmission, cut view
Service Information

Power transmission, 400 Service Information 2014/3/18
troubleshooting
Profile:
BHL, BL71 PLUS [GB]
Power transmission, troubleshooting

Problem Cause Action
Machine does not move Faulty supply to solenoid valves Check/Replace
Damaged wiring connections between Repair/Replace
transmission and machine
Oxidised contacts in electrical wiring Clean
Break in electric cable Replace
Damaged solenoids Replace
Damaged sensors Replace
Short circuits or false contacts Check/Replace fuses
Incorrect oil level Top up
Check for leaks Repair/Top up
Blocked intake filter Clean
Damaged oil pump Replace
Damaged oil pump relief valve Replace oil pump
Blocked/Damaged transmission filter Replace
Damaged/Jammed control valve Replace
Damaged converter Replace
Oil temperature below 0 °C (32 °F) Carefully warm up the machine and all
subsystems until the oil has reached working
temperature
Damaged rotary seals Replace
Damaged synchronisers Replace
Blocked reverser lever Repair
Worn clutch unit Replace/Repair clutch unit
No drive transmission (broken gears, shafts, Check/Repair/Replace
bearings, etc.)
Machine has reduced Incorrect oil temperature Wait for oil to reach working temperature (stall
power transmission test)
Transmission oil overheating Restore acceptable temperature values
Incorrect operating pressure Check hydraulic circuit and replace (oil pump,
filters, control valve)
Worn clutch unit Replace/Repair
4WD clutch failure Repair/Replace 4WD shaft group
Overheating solenoids Replace
Damaged transmission and machine wiring Repair/Replace
connections
Damaged sensors Replace
Overheating Damaged hydraulic cooling system Repair
Dirty heat exchanger Clean
Parking brake inadvertently activated Release
Excessive dirt on axle wheel hubs Clean
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Braking force outside transmission: irregular Check/Repair axle
axle operation
Clutch plate drag Repair/Replace
Damaged oil thermostat Replace
Worn oil pump Replace
Wheels rotate when Clutch plate drag Repair/Replace
machine is raised Low oil temperature (high oil viscosity) Wait for oil to reach working temperature (stall
test)
Incorrect oil specifications Replace oil and filters
Damaged control valve Replace
Faulty reverser locking Repair/Replace
Noise Damaged converter Replace
Damaged oil pump Replace
Aeration/Cavitation Check oil level/Check oil specifications
Seizing (broken gears, shafts, bearings, etc.) Check/Repair/Replace
Worn clutch plates Replace
Worn synchroniser actuation unit Replace
Worn 4WD clutch Replace
Irregular actuation Damaged control valve Replace
Electrical system fault Repair/Replace
Worn clutch plates Replace
Low oil temperature (high oil viscosity) Wait for oil to reach working temperature (stall
test)
Overheating See "Overheating"
Damaged hydraulic system Repair/Replace
Gear remains engaged Damaged/Jammed shuttleshaft lever Repair/Replace
Damaged hydraulic system Repair/Replace
Damaged clutch unit Repair/Replace
Damaged gear lever rod Replace
No 4WD power Damaged 4WD clutch Replace
transmission Hydraulic system fault Repair/Replace
Faulty brake sensor Check/Replace
Gear shift won't engage Damaged shifter Replace
Service Information

Torque converter, 414 Service Information 2014/3/18
description
Profile:
BHL, BL61 PLUS, BL71 PLUS [GB]
Torque converter, description

The engine output torque is transmitted and amplified by the torque converter.
The torque converter consists of an oil filled outer housing, an impeller, a turbine and a stator.
The oil pump inside a torque converter is a type of centrifugal pump. As oil is flung to the outside, a partial vacuum is
created that draws more oil in at the center.
The impeller driving member produces oil movement inside the torque converter whenever the engine is running. The
turbine, a driven fan splined to the input shaft of the gear box, is not fastened to the impeller, but is free to turn
independently. Oil is the only connection between the two. The stator, designed to improve oil circulation inside the torque
converter, increases efficiency and torque by causing the oil to swirl around the inside of the housing.
The primary action of the torque converter results from the action of the impeller passing oil at an angle into the blades of
the turbine.
The oil pushes against the faces of the turbine vanes, causing the turbine to rotate in the same direction as the impeller.
With the engine idling, the impeller rotates slowly. Only a small amount of oil is thrown into the stator and turbine. Not
enough force is developed inside the torque converter to rotate the turbine. The machine remains stationary with the
gearbox in gear.
During acceleration, the engine crankshaft, the converter housing, and the impeller begin to rotate faster. More oil is thrown
out by centrifugal force, turning the turbine. As a result, the gearbox input shaft begins to rotate and the machine starts to
move, but with some slippage. At speed, the impeller and turbine rotate at almost the same speed with very little slippage.
The stator is located in the very center of the torque converter, between the impeller and the turbine, and is mounted on a
one way clutch that allows it to rotate clockwise, but not counter–clockwise. The purpose of the stator is to redirect the oil
returning from the turbine and change its rotation back to that of the impeller, before it hits the pump (impeller) again.
Stator action is only needed when the impeller and turbine are turning at different speeds.
The one–way clutch locks the stator when the impeller is turning faster than the turbine. This causes the stator to route oil
flow over the impeller vanes properly. Then, when turbine speed almost equals impeller speed, the stator can freewheel in its
shaft so as not to obstruct flow.
Figure 1
Torque converter, sectional view
1 Torque converter 3 Flexplate 5 Flywheel

2 Gear box 4 Flexplate 6 Engine
Service Information

Torque converter, removal 414 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Torque converter, removal

Op nbr 41404-1
NOTE!
Oil that is being drained from the engine/transmission unit must be collected in a container.
1. Remove the engine/transmission unit, see 210 Engine, removal.
2. Block and support the engine/transmission unit in a safe and stable manner.
NOTE!
Make sure that it is possible to remove the transmission.
Figure 1
Supporting of engine/transmission unit
3. Remove the oil plug and drain the transmission oil (approx. 23 liters) into a clean container.
Figure 2
Draining transmission
1. Plug
4. Remove the filler pipe and the dipstick tube.
Figure 3
Transmission
1. Filler pipe
2. Dipstick tube
5. Remove the plate on the flywheel housing.
Figure 4
Underside of flywheel housing
1. Plate
6. Remove the bolt.
Figure 5
1. Bolt
7. Rotate the engine by hand and remove the remaining bolts (3 pcs), through the plate opening under the flywheel
housing.
Figure 6
Rotating the engine
8. Loop a sling around the transmission and tighten the sling using a lifting device. Remove the bolts (12 pcs).
9. Move the transmission backwards from the engine and lift it away carefully.
NOTE!
Make sure that the torque converter does not fall off the gear box shaft.
Figure 7
Removing transmission
1. Bolt
10. Lift away the torque converter.

NOTE!
Ensure that the transmission oil seal is not damaged in the process.
Figure 8
Removing torque converter
1. Torque converter
Service Information

Torque converter, 414 Service Information 2014/3/18
installation
Profile:
BHL, BL71 PLUS [GB]
Torque converter, installation

Op nbr 41405-1
NOTE!
The flexplates should be transferred to the new torque converter before installing.
NOTE!
When installing the torque converter, the bolt heads must be inserted in the bolt holes.
Figure 1
Before installing
1. Bolt head
2. Bolt hole
1. Measure the distance between the flywheel and the flywheel housing.
Figure 2
Check measurement
1. Flywheel
2. Flywheel housing
2. Carefully lift the torque converter into place.

NOTE!
Ensure that the transmission oil seal is not damaged in the process.
Measure the distance between the flexplate and the transmission housing. Check that the result agrees with the
result in step 1.
Figure 3
Check measurement
1. Flexplate
2. Transmission housing
3. Carefully lift the transmission into place.

NOTE!
Make sure that the torque converter does not fall off the gear box shaft.
4. Fit the bolt without tightening it.

Figure 4
1. Bolt
5. Fit the bolts (12 pcs)
Figure 5
Installing transmission
1. Bolt
6. Rotate the engine by hand and fit the remaining bolts (3 pcs) without tightening them, through the plate opening
under the flywheel housing.
Figure 6
Rotating engine
7. Tighten the bolts (4 pcs). Rotate the engine once more and make sure that all four bolts are tight.
8. Fit the plate on the flywheel housing.
9. Clean the contact surface where the filler pipe is to be installed.
10. Apply sealing compound on the filler pipe flange and to the bolt threads.
11. Fit the filler pipe and the dipstick tube.
Figure 7
Transmission
1. Filler pipe
2. Dipstick tube
12. Fill the transmission with oil, see Operator's Manual
13. Fit the engine/transmission unit, see 210 Engine, installation.

Service Information

Transmission control unit 420 Service Information 2014/3/18
T-ECU, description
Profile:
BHL, BL71 PLUS [GB]
Transmission control unit T-ECU, description

The Power Shift transmission is controlled via a Transmission Control Unit, T–ECU. The T–ECU is located close to the Vehicle
Control Unit, V–ECU, inside the side panel.
The T–ECU controls gear shifting depending in which position the gear selector SW4 has. If SW4 is in 4:th gear position the
transmission is in fully automatic gear shifting and the machine starts in 2nd gear.
Figure 1
Location T-ECU
1. Side dash panel

2. Transmission control unit, T-ECU
3. Vehicle control unit, V-ECU
T–ECU, pin assignment

Figure 2
Connector A, X 21
Pin no. Input/output Designation

1 GND Ground
2 Digital output 1:st gear solenoid
3 Digital input Forward gear selected on gear selector SW4
4 Digital input Kick–down
5 Frequency input Speed sensor
6 Digital input 1:st gear selected on gear selector SW4
7 Digital input 2:nd gear selected on gear selector SW4
8 Digital input 3:rd gear selected on gear selector SW4
9 Digital input Reverse gear selected on gear selector SW4
10 Digital output
11 Digital output 3:rd/4:th gear signal
12 Power supply +12V Power supply
Connector B, X 22
Pin no. Input/output Designation

1 Digital output 4:th gear solenoid
2 PWM output Reverse +
3 PWM output Forward +
4 RxD
5 TxD
6 Analog input Reverse feedback
7 Digital input Disconnect
8 Analog input Forward feedback
9 Digital output 2:nd gear solenoid
10 Digital output 3:rd gear solenoid
11 Power supply Supply to solenoids
12 Analog input
Service Information

Electrical troubleshooting, 420 Service Information 2014/3/18
Powershift transmission
Profile:
BHL, BL71 PLUS [GB]
Electrical troubleshooting, Powershift transmission

When having problems with the Power Shift transmission, and the problems are judged to be electrical, perform the
following tests.
420 Solenoids, testing
420 Wires, testing
420 Gear selector switch, testing
Service Information

Solenoids, testing 420 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Solenoids, testing
Op nbr
1. Disconnect the battery disconnect switch.
2. Fold away the floor mat and remove the front floor plate.
3. Remove the electrical connection from the solenoid.
4. Measure the electrical resistance between the two poles of the solenoid. The resistance should be approximately 7
to 8 Ω.
5. Refit the electrical connection.
6. Repeat step 3–5 on all solenoids.
7. Refit the floor plate and floor mat.

Service Information

Wires, testing 420 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Wires, testing
Op nbr
2. Fold away the floor mat and remove the front floor plate.
3. Remove the side panel, see 851 Side panel, removal.
4. Measure the resistance between both ends of each wire from solenoid to Transmission Control Unit. Each wire
should have an electrical resistance of approximately 0 Ω.
5. Measure resistance between wires. There should be no electrical connection between wires.
6. Refit the side panel, see 851 Side panel, installation.
7. Refit the floor plate and floor mat.

Service Information

Gear selector switch, 420 Service Information 2014/3/18
testing
Profile:
BHL, BL71 PLUS [GB]
Gear selector switch, testing

Op nbr
2. Remove the front panel, see 851 Front panel, removal.
3. Disconnect the connector, (X47), from the Gear selector switch, SW4.
4. Check the electrical resistance in the connector according to illustration. X indicates approximately 0 Ω between
pins. Change the position of the switch as necessary.
Figure 1
5. Install the front panel, see 851 Front panel, installing.

Service Information

Transmission, replacing 420 Service Information 2014/3/18
solenoid
Profile:
BHL, BL71 PLUS [GB]
Transmission, replacing solenoid

Op nbr 421-025
NOTE!
For the correct tightening torques of the valves see 030 Transmission, tightening torques.
1.
Figure 1
V1050662
1. Rev
2. Fwd
3. HDL
4. 4WD
Place the machine in service position two, see 173 Service positions .
2. Remove the floor mat.
3. Remove the front floor plate inside the cab.
4. Remove the electrical connection to the solenoid.
5. Remove the two screws holding the solenoid in place.
6. Pull the solenoid valve straight out from the valve block.
7. Push the new solenoid valve into place.
8. Fit the two screws.

9. Fit the electrical connection.
10. Fit the floor plate and floor mat.

Service Information

Transmission, check oil 420 Service Information 2014/3/18
pressure
Profile:
BHL, BL71 PLUS [GB]
Transmission, check oil pressure

Op nbr 421-002
936446 Testing nipple

14290266 Hose
14290262 Adapter
11666018 Pressure gauge
General rules for pressure checking:
 Transmission oil temperature: 80 °C (176 °F)

 The values must always be checked against the latest issued service bulletin.
A way of quickly warming up the transmission oil to the correct temperature is to have the parking brake on, service (foot)
brake on, start the engine and keep it ticking over at low idle speed (900 rpm), select the 4th gear and move the forward/
reverse lever to forward. Rev the engine for short periods to a maximum of 1500-1700 rpm, to bring the oil up to working
temperature.
NOTE!
Do not exceed a maximum duration of 30 seconds each time. After this 30 second period, put the forward/reverse lever in
neutral for 15 seconds, then repeat the procedure.
1.
Figure 1
1. Gear pressure
2. Control valve supply pressure
3. HDL pressure
4. Lubrication pressure
5. Forward clutch pressure
6. Reverse clutch pressure
Place the machine in service position 2, see 173 Service positions.
2. Remove the floor mat.
3. Remove the front floor plate.
Forward clutch pressure
4. Remove the plug and connect the test nipple 936446 on the forward clutch test port. Connect the pressure gauge
to the test nipple.
5. Start the engine.
6. Apply the service brakes.
7. Shift the forward/reverse lever into position F
8. Increase the engine speed to high idle (see 030 Powershift transmission, specifications for required idle). Read off
the oil pressure. See 030 Powershift transmission, specifications for check value.
9. Turn off the engine.
10. Shift the forward/reverse lever into position N
11. Remove the test nipple and refit the plug.
Reverse clutch pressure
12. Remove the plug and connect the test nipple 936446 on the reverse clutch test port. Connect the pressure gauge
to the test nipple.
15. Shift the forward/reverse lever into position R
the oil pressure. See030 Powershift transmission, specifications for check value.
Lubrication oil pressure
20. Remove the plug and connect the test nipple 936446 on the lubrication oil test port. Connect the pressure gauge
to the test nipple.

the oil pressure. See 030 Powershift transmission, specifications for check value.
HDL pressure
27. Remove the hose, close it with a plug and then connect the test nipple 936446 on the HDL pressure test port.
Connect the pressure gauge to the test nipple.
30. Increase the engine speed to high idle (see 030 Powershift transmission, specifications for required idle), depress
the differential lock button and read off the oil pressure. See 030 Powershift transmission, specifications for check
value.
32. Remove the test nipple and connect the hose to the valve.
Control valve supply pressure
33. Remove the plug and connect the test nipple 936446 on the control valve supply pressure test port. Connect the
pressure gauge to the test nipple.
the control valve supply oil pressure. See 030 Powershift transmission, specifications for check value.
Gear clutch pressure
40. Remove the plug and connect the test nipple 936446 on the gear clutch pressure test port. Connect the pressure
gauge to the test nipple.
43. Select a gear and shift the forward/reverse lever into position F
the gear clutch pressure. See 030 Powershift transmission, specifications for check value. Change gear and repeat
on all gears. Abort test if transmission oil temperature is getting to high (indicated by high temperature warning
light), and allow the transmission to cool down to normal operating temperature before resuming tests. Repeat the
procedure with reverse selected on the gear selector.
47. Fit the front floor plate and the floor mat.
Service Information

Hydraulic diagram, 420 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Hydraulic diagram, Powershift transmission
Figure 1
Hydraulic diagram, Power Shift transmission
1 Oil filter relief valve 12 Reverse clutch pressure check 23 Torque converter
2.3–2.6 MPa (23–26 bar) (334–377 port
psi)
2 Spin on filter 13 Reverse clutch 24 Transmission oil pump
(10µm)
3 Oil filter by–pass 14 4WD engagement/ 25 Suction filter
(Opens at 0.345 Mpa (3.45 bar) (50 disengagement (250 µm)
psi)
4 Oil flow divider/pressure regulator 15 Hydraulic diff. lock, 26 Air breather
valve engagement/ disengagement
5 Transmission control valve unit 16 Ramp valve 27 Torque converter pressure relief
valve
0.55 MPa (5.5 bar) (80 psi)
6 Supply pressure check port 17 Supply clutch pressure check 28 Transport lock oil, return port to
port sump
7 Oil cooler back temperature check 18 1st gear clutch 29 Brake oil, return port to sump
port
8 Oil outlet port to brakes 19 2nd gear clutch 30 Output shafts lubrication
(Axis C/E)
9 Oil outlet port to boom lock 20 3rd gear clutch 31 Primary shaft lubrication
(Axis B)
10 Forward clutch pressure check 21 4th gear clutch 32 Input shaft lubrication
port (Axis A)
11 Forward clutch 22 Oil cooler
Service Information

Gearbox 4WD, description 431 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Gearbox 4WD, description

The gearbox is an hydro–mechanical, manual four speed power shuttle gearbox with torque converter, two gear shafts and
spring applied four wheel drive.
Drive is transmitted from the engine to the gearbox via a flywheel onto which is mounted a single stage torque converter.
The gearbox has four forward and four reverse fully synchronised gears, featuring multi–plate hydraulically modulated clutch
packs for smooth directional changes under full power.
The forward and reverse clutch packs are operated by a forward/reverse lever and a hydro–electrical gear selector valve.
All four gears have syncromesh for on the move changes and are operated by a gear shift lever. The gear shift lever also has
a thumb operated dump button for de–clutching, which must be used when changing gear.
The differential lock, used when operating on slippery ground, is operated by a foot switch and a hydro–electrical solenoid
valve.
The four wheel drive clutch contains a multi–plate pack, operated hydro–electrically via a switch mounted on the side
console, for four wheel drive engagement and disengagement.
Figure 1
Gearbox, split
1. Rear cover
2. Solenoid valve block
3. 4WD solenoid valve
4. Filter by-pass valve
5. Spin-on filter
6. Suction filter
7. Oil pump
8. Flexplate
Figure 2
Gearbox, components
1. Spin-on filter
2. Flexplate
3. Mounting front axle drive
4. Gear selector lever
5. Radiator return
6. Mounting rear axle drive
7. Drain plug
8. Cover suction filter
9. 3rd-4th gear sensor
10. Outlet to radiator
11. Solenoid valve block
12. Breather
13. Temperature sensor
Figure 3
Gearbox, sectional view
1. Forward clutch pack

2. Reverse idler
3. Reverse clutch pack
4. Forward/reverse shaft
5. Pump drive shaft
6. Shaft
7. Gear shaft
8. 3rd gear
9. 4th gear
10. 4WD gear
11. 4WD clutch
12. 2nd gear
13. 1st gear
14. Oil pump
Service Information

Gearbox, removing 431 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Gearbox, removing
When removing gearbox, refer to 414 Torque converter, removal.
Service Information

Gearbox, installing 431 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Gearbox, installing
When installing gearbox, refer to 414 Torque converter, installation.
Service Information

Gearbox 4WD, checking oil 431 Service Information 2014/3/18
pressure
Profile:
BHL, BL71 PLUS [GB]
Go back to Index Page
Gearbox 4WD, checking oil pressure

Op nbr 42102-2
935635 Test nipple

935651 Plug
13933936 T-nipple
14360064 Digital pressure checking kit
 Transmission oil temperature: 70–80 °C (158–176 °F)

A way of quickly warming up the transmission oil to the correct temperature is to have the parking brake on, service (foot)
brake on, start the engine and keep it ticking over at low idle speed (900 rpm), select the 4th gear and move the forward/
reverse lever to forward. Rev the engine for short periods to a maximum of 1500-1700 rpm, to bring the oil up to working
temperature.
NOTE!
Figure 1
Checking points for pressure
1 Forward pressure 3 4WD pressure 5 Torque converter pressure, not

used
2 Reverse pressure 4 Lubrication pressure
1. Fold up the floor mat in the cab and remove the plate on the floor.
Checking forward pressure
2. Remove the plug and fit the testing nipple (part no. 14341365).
3. Reset the digital pressure gauge to zero, see special instruction. Connect a pressure sensor (6.0 MPa (60 bar) (870
psi)) between the checking point for forward pressure and the connection on the checking instrument.
Figure 2
1. Checking point for forward pressure
4. Start the engine and warm up the transmission.
5. Increase the engine speed to high idle (2350 rpm), select forward and read off the forward pressure. Check value:
1.1–1.3 MPa (11–13 bar) (160–189 psi).
7. Remove the checking equipment.
Checking reverse pressure
psi)) between the checking point for reverse pressure and the connection on the checking instrument.
Figure 3
1. Checking point for reverse pressure
11. Increase the engine speed to high idle (2350 rpm), select reverse and read off the reverse pressure. Check value:
1.1–1.3 MPa (11–13 bar) (160–189 psi).

Checking 4WD pressure
NOTE!
Do not tighten to hard – aluminium connection.
psi)) between the checking point for 4WD pressure and the connection on the checking instrument.
Figure 4
1. Checking point for 4WD pressure
17. Set the engine speed to low idle (900 rpm), select forward or reverse, engage four wheel drive and read off the
4WD pressure. Check value: 1.3–1.4 MPa (13–14 bar) (189–203 psi).
18. Increase the engine speed to 2200 rpm, select forward or reverse, engage four wheel drive and read off the 4WD
pressure. Check value: 1.3–1.55 MPa (13–15.5 bar) (189–225 psi).
Checking lubrication pressure
psi)) between the checking point for lubrication pressure and the connection on the checking instrument.
Figure 5
1. Checking point for lubrication pressure
24. Increase the engine speed to high idle (2350 rpm), select forward or reverse and read off the lubrication pressure.
Check value: 0.05–0.35 MPa (0.5–3.5 bar) (7.3–50.8 psi).
Checking diff.lock pressure
27. Disconnect the hose.
Figure 6
1. Hose
28. Fit the T–nipple (1), plug (2), test nipple (3) and testing nipple (4). Reset the digital pressure gauge to zero, see
special instruction. Connect a pressure sensor (6.0 MPa (60 bar) (870 psi)) between the checking point for diff.lock
pressure and the connection on the checking instrument.
Figure 7
1. T-nipple (part no. 13933936)

2. Plug (part no. 935651)
3. Test nipple (part no. 935635)
4. Testing nipple (part no. 14211659)
5. Checking point for diff.lock pressure
30. Increase the engine speed to high idle (2350 rpm), select forward or reverse, engage differential lock and read off
the diff.lock pressure. Check value: 1.1–1.3 MPa (11–13 bar) (160–189 psi).
33. Fit the plate on the floor and put the floor mat in the cab back in place.
Service Information

Gearbox 4WD, checking oil 431 Service Information 2014/3/18
pressure
Profile:
BHL, BL71 PLUS [GB]
Gearbox 4WD, checking oil pressure

Op nbr 42102-2
935635 Test nipple

935651 Plug
13933936 T-nipple
14360064 Digital pressure checking kit
11666051 Pressure gauge
 Transmission oil temperature: 70–80 °C (158–176 °F)

A way of quickly warming up the transmission oil to the correct temperature is to have the parking brake off, as the clutch is
not pressurized. Be sure that the service (foot) brake is on, start the engine and keep it ticking over at low idle speed (900
rpm), select the 4th gear and move the forward/reverse lever to forward. Rev the engine for short periods to a maximum of
1500-1700 rpm, to bring the oil up to working temperature.
NOTE!
Figure 1
Gearbox pressure check points
1. Lubrication pressure check point

2. Reverse clutch pressure check point
3. Forward clutch pressure check point
4. Converter pressure check point
5. Forward/reverse clutch pressure check port
6. Forward clutch pressure check port
7. Reverse clutch pressure check port
8. Differential lock pressure check port
1. Fold up the floor mat in the cab and remove the plate on the floor.
psi)) between the checking point for forward pressure and the connection on the checking instrument.
5. Increase the engine speed to high idle (2350 rpm), select forward and read off the forward pressure. Check value:
1.1–1.3 MPa (11–13 bar) (160–189 psi).
psi)) between the checking point for reverse pressure and the connection on the checking instrument.
11. Increase the engine speed to high idle (2350 rpm), select reverse and read off the reverse pressure. Check value:
1.1–1.3 MPa (11–13 bar) (160–189 psi).
NOTE!
Do not tighten to hard – aluminium connection.
psi)) between the checking point for 4WD pressure and the connection on the checking instrument.
17. Set the engine speed to low idle (900 rpm), select forward or reverse, engage four wheel drive and read off the
4WD pressure. Check value: 1.3–1.4 MPa (13–14 bar) (189–203 psi).
18. Increase the engine speed to 2200 rpm, select forward or reverse, engage four wheel drive and read off the 4WD
pressure. Check value: 1.3–1.55 MPa (13–15.5 bar) (189–225 psi).
psi)) between the checking point for lubrication pressure and the connection on the checking instrument.
24. Increase the engine speed to high idle (2350 rpm), select forward or reverse and read off the lubrication pressure.
Check value: 0.05–0.35 MPa (0.5–3.5 bar) (7.3–50.8 psi).
Checking differential lock pressure
27. Disconnect the hose.
28. Fit the T–nipple (1), plug (2), test nipple (3) and testing nipple (4). Reset the digital pressure gauge to zero, see
special instruction. Connect a pressure sensor (6.0 MPa (60 bar) (870 psi)) between the checking point for
differential lock pressure and the connection on the checking instrument.
30. Increase the engine speed to high idle (2350 rpm), select forward or reverse, engage differential lock and read off
the differential lock pressure. Check value: 1.1–1.3 MPa (11–13 bar) (160–189 psi).

33. Fit the plate on the floor and put the floor mat in the cab back in place.
Service Information

Transmission mounts, 436 Service Information 2014/3/18
changing
Profile:
BHL, BL71 PLUS [GB]
Transmission mounts, changing

Op nbr
Removal
1. Place the machine in service position one, see 173 Service positions.
2. Remove the service panel from the floor of the cab to access the transmission.
3. NOTE!
Keep the flange screw stationary.
Remove the lock nut, washer and vibration damper from the lower side of both transmission mounts, attached to
the frame. Do not remove the two flange screws.
4. WARNING
Only use lifting devices with adequate capacity.
Using a lifting jack, lift up the transmission 12 mm (1/2 in.).

Installation
5. Remove the flange screw, washers and vibration dampers.

NOTE!
Change one side at the time.
Figure 1
Left side transmission mount
1. Bracket
2. Vibration damper
3. Washer
4. Flange screw
5. Lock nut
6. Flange screw
6. Loosen the flange screws and change the bracket.
7. NOTE!
There is an extra spacer on the right side.
Repeat the above steps on the other side.
Figure 2
Right side transmission mount
1. Flange screw
2. Spacer
3. Washer
4. Vibration damper
5. Lock nut
6. Bracket
7. Flange screw
8. Tighten the screws attached to the transmission.

Tightening torque: 85 N·m (63 lbf·ft)
9. After installing the flange screws attached to the transmission on both sides, carefully remove the lifting jack.
10. Tighten the screws attached to the frame.

Tightening torque: 175 N·m (130 lbf·ft)
11. Place the machine back in service.

Service Information

Front axle, removing 461 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Front axle, removing

Op nbr
1. Place the machine in service position one, see 173 Service positions on firm level ground.
2. Remove the counterweight, see 716 Counterweight, removing.
3. Lift the front of the machine with a jack. Place the machine on stands. See illustration.
4. Remove the front wheels.
5. Remove the hydraulic hoses from the steering cylinder. Plug all connections.
6. Remove the prop shaft from the front axle.
7. Remove the screw and nut that is locking the pivot pin.
8. Support the front axle. Tap out the pin and lower the axle. Remove the axle.
Service Information

Axle suspension, adjusting 461 Service Information 2014/3/18
axial clearance
Profile:
BHL, BL71 PLUS [GB]
Axle suspension, adjusting axial clearance

Op nbr 460-002
Measure front axle play
1. Park vehicle on flat ground, service position 1, see chapter 173 Service positions.
WARNING
Place the machine on a horizontal and solid surface and block the wheels securely so that there's no risk of
the machine starting to roll.
2. Raise the machine on the jack and secure with suitable supports. Place the jack centrally below the axle.
WARNING
Never work under/on machines without using recommended support equipment.
3. Measure play via the feeler gauge between the axle suspension and axle. If the play is too large, this must be
reduced by shims (see table).
Determine the necessary thickness of the shims
Measured clearance Quantity Thickness of shims

> 1 mm 0
< 1.5 mm; > 2 mm (< 0.04 in; > 0.08 1 1 mm (0.0394 in)
in.)
< 2 mm; > 3 mm (< 0.08 in; > 0.12 1 2 mm (0.0788 in)
in)
< 3 mm; > 4mm (< 0.12 in; > 0.16 1 3 mm (0.1181 in)
in)
< 4 mm; > 5 mm (< 0.16 in; > 0.20 1 3 mm (0.1181 in)
in) 1 1 mm (0.0394 in)
< 5 mm; > 6 mm (< 0.20 in; > 0.24 1 3 mm (0.1181 in)
in) 1 2 mm (0.0788 in)
< 6 mm; > 7 mm (< 0.24 in; > 0.28 1 3 mm (0.1181 in)
in) 1 3 mm (0.1181 in)
4. Remove the counterweight and radiator grille, see chapter 716 Counterweight, removing
5. Place jack centrally below the axle and raise slightly. This takes the pressure off the axle suspension.
6. Remove the lock bolt from the main journal.
7. Screw an M16 eyelet into the main journal. Drive out the main journal by levering until the axle is free.
8. Place shims, to the thickness determined in the table, between the axle and frame and refit main journal.
9. Lower jack again and check play again.

NOTE!
the play should be less than 2 mm (0.0788 in). Otherwise repeat procedure. Ensure that the entire play is on one
side.
10. Remove eyelet from main journal and refit lock bolt.
11. Lubricate main journal.
12. Refit counterweight, see chapter 716 Counterweight, installation

Service Information

Axle, removing 463 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Axle, removing
Op nbr 463-002
1. Park vehicle on flat ground, service position 2, see chapter 173 Service positions.
WARNING
Place the machine on a horizontal and solid surface and block the wheels securely so that there's no risk of
the machine starting to roll.
2. Loosen the wheel nuts on the rear wheels.
3. Raise the rear axle using the rear jacking feet and provide additional security (below chassis).
WARNING
4. Remove drive shaft, see chapter 4614 Drive axles
5. Remove rear wheels.
6. Remove handbrake cable from fixing on rear axle.
7. Release the brake line connections and seal with a plug.
8. Release the hydraulic line connection at the differential lock and seal with a plug.
9. Remove brake assembly cable.
10. Remove line holder bolts on the rear axle.
11. Separate brake light switch wire at plug connection to wiring harness, and protect from damage.
12. Secure the axle with a jack.
13. Remove axle mounting bolts.
14. Carefully lower the axle using the jack, and withdraw.
Service Information

Axle, installing 463 Service Information 2014/3/18
Profile:
BHL, BL71 PLUS [GB]
Axle, installing
Op nbr 463-003
WARNING
Place the machine on a horizontal and solid surface and block the wheels securely so that there's no risk of the
machine starting to roll.
1. Top up axle and brake cylinder with oil. For capacity and oil grades, see chapter 030 Rear axle, capacities
WARNING
2. Using the jack, bring the axle into position.
3. Insert axle fixing bolts and loosely tighten.
4. Check installation position. To do this release the load on the jack slightly and tighten the bolts. For bolt tightening
torques see 030 Rear axle, specification
NOTE!
The axle position is achieved during tightening by guiding the bolts for fixing the axle.
5. Attach line holder to axle.
6. Connect brake light switch wire to wiring harness using the plug connection.
7. Fit brake assembly cable.
8. Fit hydraulic line to differential lock and check for leaks.
9. Install brake lines and check for leaks.
10. Insert handbrake cable in the axle mounting lever and attach.
11. Install drive shaft, see chapter 4634 drive shafts
12. Fit wheels.
13. Lower safety supports and remove. Then lower the vehicle.
14. Check function.
NOTICE
Air must be bled after repairs to the hydraulic system and after oil change.
Service Information

gearbox 4WD
Profile:
BHL, BL71 PLUS [GB]
Hydraulic diagram, gearbox 4WD

1 Suction filter (250 micron) 12 Flow divider 23 FWD/REV main pressure check
port
2 Transmission oil pump 13 FWD/REV modulating valve 24 Forward pressure check port
3 Spin-on filter (15 micron) 14 Modulation relief valve 25 Reverse pressure check port
4 Pressure regulator 15 FWD/REV selection valve 26 Diff. lock eng./disengagement
5 Oil filter relief valve 16 Forward clutch 27 Diff. lock solenoid valve
6 4WD solenoid valve 17 Reverse clutch 28 Air breather
7 4WD clutch 18 FWD/REV shaft lubrication 29 4WD shaft lubrication
8 Torque converter relief valve 19 1st, 2nd, 3rd, 4th gear shaft 30 Boom lock oil return
lubrication
9 Torque converter 20 4WD pressure check port 31 Brake system oil return
10 Transmission oil cooler 21 Torque converter pressure check 32 Oil outlet port to brake system
port and boom lock
11 Temperature sensor, high 22 Lubrication pressure check port
(warning at 115 °C (239 °F))
Figure 1
Service Information

Profile:
BHL, BL71 PLUS [GB]
Hydraulic diagram, Powershift transmission

1 Suction filter 12 FWD clutch 23 2nd gear clutch (related
solenoid valve above)
2 Transmission oil pump 13 Rev clutch 24 3rd gear clutch (related solenoid
valve above)
3 Pressure relief valve 14 4WD 25 4th gear clutch (related solenoid
valve above)
4 Filter with filter by-pass valve 15 modulating valve 26 Shaft lubrication
5 Torque converter 16 Shaft lubrication 27 Shaft lubrication
6 Radiator 17 Shaft lubrication 28 Outlet to brakes
7 Torque converter pressure relief 18 Shaft lubrication 29 Gear pressure check port
valve
8 Flow divider 19 Outlet (not used)
9 Breather 20 Outlet boom lock (not used)
10 FWD clutch pressure check port 21 Differential lock
11 Rev clutch pressure check port 22 1st gear clutch (related solenoid
valve above)
Figure 1
Thank you for your purchase.
Have a nice day.
file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/3/18 16:51:54]

Volvo BL 71 4 Power Transmission

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Service Information

Document Title: Function Group: Information Type: Date:

Power transmission, description

Document Title: Function Group: Information Type: Date:

Powershift transmission, description

Document Title: Function Group: Information Type: Date:

Power transmission, troubleshooting

Document Title: Function Group: Information Type: Date:

Torque converter, description

1 Torque converter 3 Flexplate 5 Flywheel

Document Title: Function Group: Information Type: Date:

Torque converter, removal

1. Remove the engine/transmission unit, see 210 Engine, removal.

4. Remove the filler pipe and the dipstick tube.

5. Remove the plate on the flywheel housing.

6. Remove the bolt.

10. Lift away the torque converter.

Document Title: Function Group: Information Type: Date:

Torque converter, installation

2. Carefully lift the torque converter into place.

3. Carefully lift the transmission into place.

4. Fit the bolt without tightening it.

5. Fit the bolts (12 pcs)

8. Fit the plate on the flywheel housing.

9. Clean the contact surface where the filler pipe is to be installed.

11. Fit the filler pipe and the dipstick tube.

12. Fill the transmission with oil, see Operator's Manual

13. Fit the engine/transmission unit, see 210 Engine, installation.

Document Title: Function Group: Information Type: Date:

Transmission control unit T-ECU, description

1. Side dash panel

T–ECU, pin assignment

Pin no. Input/output Designation

Pin no. Input/output Designation

Document Title: Function Group: Information Type: Date:

Electrical troubleshooting, Powershift transmission

Document Title: Function Group: Information Type: Date:

1. Disconnect the battery disconnect switch.

3. Remove the electrical connection from the solenoid.

5. Refit the electrical connection.

6. Repeat step 3–5 on all solenoids.

7. Refit the floor plate and floor mat.

Document Title: Function Group: Information Type: Date:

1. Disconnect the battery disconnect switch.

3. Remove the side panel, see 851 Side panel, removal.

6. Refit the side panel, see 851 Side panel, installation.

7. Refit the floor plate and floor mat.

Document Title: Function Group: Information Type: Date:

Gear selector switch, testing

1. Disconnect the battery disconnect switch.

2. Remove the front panel, see 851 Front panel, removal.

5. Install the front panel, see 851 Front panel, installing.

Document Title: Function Group: Information Type: Date:

Transmission, replacing solenoid

2. Remove the floor mat.

3. Remove the front floor plate inside the cab.

4. Remove the electrical connection to the solenoid.

5. Remove the two screws holding the solenoid in place.

7. Push the new solenoid valve into place.

8. Fit the two screws.

10. Fit the floor plate and floor mat.

Document Title: Function Group: Information Type: Date:

Transmission, check oil pressure