VOLVO L110H WHEEL LOADER SERVICE REPAIR MANUAL PDF – 2568 PAGES

The Volvo L110H Wheel Loader Service Repair Manual is a comprehensive workshop reference designed to support the inspection, maintenance, troubleshooting, adjustment, and repair of the Volvo L110H wheel loader.

With 2,568 pages of technical documentation and information updated in 2020, this PDF manual covers the machine's engine, exhaust aftertreatment equipment, electronic control systems, power transmission, drive axles, braking system, steering, operator cab, and working hydraulics.

The documentation combines technical system descriptions with repair procedures, electrical wiring diagrams, hydraulic circuit diagrams, diagnostic information, equipment installation instructions, safety precautions, and detailed service specifications.

Among its notable features are extensive references to Volvo Co-Pilot, Load Assist, CareTrack, Comfort Drive Control (CDC), Boom Suspension System (BSS), and Volvo Tech Tool diagnostics.

The manual also provides service procedures for AdBlue/DEF equipment, the Diesel Particulate Filter (DPF), Exhaust Gas Recirculation (EGR), Selective Catalytic Reduction (SCR), electronic control modules, and hydraulic pump systems.

Whether you are investigating an electronic fault, replacing an engine component, calibrating hydraulic functions, or servicing the transmission, this manual provides model-specific technical information to support professional workshop operations.

MANUAL DETAILS

• Manufacturer: Volvo Construction Equipment
• Machine Model: Volvo L110H Wheel Loader
• Publication Type: Service Repair / Workshop Manual
• Document Format: PDF
• Total Pages: 2,568
• Information Updated: 2020
• Delivery Method: Digital Download

COMPLETE MANUAL CONTENTS

The documentation is divided into technical descriptions, wiring and hydraulic diagrams, installation instructions, repair procedures, safety information, and specifications.

1. GENERAL WORKSHOP INFORMATION

The general section provides workshop references and technical information used during service operations.

Included topics:

• Leak detector 951 1207
• General service instructions
• Special workshop equipment
• Checking points and service tools
• E-tool references
• Infrared thermometer
• Additional work operation numbers

2. ENGINE OPERATION AND TECHNICAL DESCRIPTION

This section explains the operation of the Volvo L110H engine and its associated systems.

ENGINE SYSTEMS

• Engine descriptions
• Engine reference values
• Engine fuel system
• Engine lubrication system
• Cooling system operation
• Cooling fan motor
• Reversible cooling fan
• Crankcase ventilation
• Air intake and exhaust system
• ECO accelerator pedal
• Auxiliary engine braking

EXHAUST AFTERTREATMENT

• Exhaust Aftertreatment System
• AdBlue/DEF pump unit diagnostics
• Exhaust Gas Recirculation (EGR)
• Regeneration process
• Aftertreatment-related engine functions

ENGINE DIAGNOSTICS

• Volvo Tech Tool operations
• Engine reference values
• Diagnostic information

3. ENGINE REMOVAL, INSTALLATION AND MECHANICAL REPAIR

The repair section provides procedures for major engine service operations.

ENGINE MECHANICAL SERVICE

• Engine removal
• Engine installation
• Complete engine replacement
• Rear engine mounting replacement
• Cylinder compression testing
• Engine belt replacement
• Valve adjustment
• Engine stall speed testing

FUEL SYSTEM REPAIR

• Fuel system bleeding
• Fuel feed pump pressure testing
• High-pressure fuel pump replacement
• High-pressure fuel pipe replacement
• Fuel rail replacement
• Fuel rail pressure sensor replacement
• Fuel Control Valve (FCV) replacement
• Pressure Relief Valve (PRV) replacement
• Fuel injector replacement
• Injector sleeve replacement

COOLING AND LUBRICATION

• Cooling system pressure testing
• Coolant pump replacement
• Coolant valve replacement
• Radiator replacement
• Thermostat replacement
• Engine oil pressure testing
• Engine oil consumption checks
• Carbon dioxide checks in the cooling and fuel systems

AIR INTAKE AND EXHAUST

• Turbocharger replacement
• Wastegate inspection
• Inlet throttle replacement
• Flexible exhaust pipe replacement

4. ADBLUE/DEF, DPF, EGR AND SCR REPAIR PROCEDURES

The manual includes dedicated procedures for servicing the engine exhaust aftertreatment system.

ADBLUE/DEF EQUIPMENT

• AdBlue/DEF pump unit replacement
• AdBlue/DEF pump filter replacement
• AdBlue/DEF pump flushing
• Pump inlet nipple replacement
• AdBlue/DEF dosing injector replacement
• AdBlue/DEF hose replacement
• AdBlue/DEF fluid quality checks
• AdBlue/DEF crystallization checks
• AdBlue/DEF tank cleaning
• AdBlue/DEF tank replacement
• Tank armature cleaning and replacement
• Tank armature suction filter replacement
• AdBlue/DEF draining

EXHAUST AFTERTREATMENT COMPONENTS

• Diesel Oxidation Catalyst (DOC) replacement
• Diesel Particulate Filter (DPF) inspection and cleaning
• EGR cooler replacement
• EGR valve replacement
• EGR reed valve replacement
• EGR venturi tube replacement
• SCR dosing system inspection
• SCR muffler replacement
• Regeneration log checks

ELECTRONIC ENGINE CONTROLS

• Engine Control Module (ECM) replacement
• Aftertreatment Control Module (ACM) replacement
• Procedures for pre-programmed and non-programmed modules

5. ELECTRICAL SYSTEM AND ELECTRONIC CONTROL MODULES

The electrical section covers the machine's electrical architecture, control units, instrumentation, and diagnostic functions.

ELECTRICAL EQUIPMENT

• Battery and charging system
• Alternator
• Starter motor
• Battery disconnector switch
• Electrical system voltage
• Cable and component identification
• Electrical symbols
• Connector overview
• Chassis connections
• Electrical system work instructions

ELECTRONIC CONTROL UNITS

• Engine Control Module (ECM)
• Aftertreatment Control Module (ACM)
• Climate Control Module (CCM)
• GPMECU1
• GPMECU2
• GPMECU3
• HMICU
• W-ECU

The manual includes input and output lists for several control modules.

DIAGNOSTIC AND MONITORING FUNCTIONS

• Electronic control system descriptions
• General fault diagnosis information
• Troubleshooting strategies
• Troubleshooting tools
• Lead and connector checks
• Software parameters
• Information display
• Service display mode
• Limp-home function
• Volvo Tech Tool operations

6. VOLVO CO-PILOT AND CARETRACK

The documentation contains dedicated information for selected electronic assistance and connectivity systems.

VOLVO CO-PILOT

• Volvo Co-Pilot system descriptions
• Volvo Co-Pilot replacement
• Software updating
• Online Android software updates (OTA)
• SIM card installation
• Volvo Co-Pilot technical specifications

CARETRACK

• CareTrack W-ECU descriptions
• CareTrack installation instructions
• W-ECU replacement
• Pre-programmed and non-programmed W-ECU procedures

7. ELECTRICAL WIRING DIAGRAMS

A significant part of this manual is its collection of electrical wiring diagrams.

SYSTEM-SPECIFIC DIAGRAMS

• Exhaust aftertreatment
• Brake system
• Boom Suspension System (BSS)
• Comfort Drive Control (CDC)
• Electrically controlled battery disconnector
• Emergency stop configurations
• Gear control
• Starting system

NUMBERED WIRING DIAGRAMS

The documentation includes numerous numbered electrical diagrams, such as:

• WD201–WD202
• WD260–WD270 (selected numbers)
• WD301–WD337 (selected numbers)
• WD350–WD376 (selected numbers)
• WD401–WD406
• WD501
• WD601, WD602 and WD604
• WD801–WD831 (selected numbers)
• WD901–WD915 (selected numbers)

Several wiring diagrams include alternative versions for different equipment configurations.

These diagrams provide technical references for tracing electrical circuits, identifying components, and investigating electrical system faults.

8. HYDRAULIC TRANSMISSION AND POWERTRAIN

The power transmission section explains the operation and servicing of the hydraulic transmission.

TRANSMISSION OPERATION

• Hydraulic transmission descriptions
• Transmission calibration
• Transmission hydraulic diagram
• Transmission function checks
• Transmission warm-up procedures
• Transmission oil pressure testing
• Volvo Tech Tool operations

TRANSMISSION REPAIR

• Transmission removal
• Transmission installation
• Gear selector valve solenoid replacement
• Lock-up valve replacement
• Transmission heat exchanger replacement
• Front output shaft seal replacement
• Rear output shaft seal replacement
• Transmission calibration error codes

9. DRIVE AXLES AND DIFFERENTIALS

The manual provides technical information for the front and rear drive axles.

DRIVELINE COMPONENTS

• Front axle
• Rear axle
• Rear axle mounting
• Propeller shaft
• Differential lock
• Automatic differential brake
• Limited-slip differential
• Hub reduction assemblies

AXLE SERVICE PROCEDURES

• Axle removal
• Axle installation
• Differential lock adjustment
• Differential lock function testing
• Axle suspension bushing and seal replacement
• Hub reduction removal and installation
• Hub seal replacement

10. BRAKE SYSTEM SERVICE AND REPAIR

The brake section includes descriptions, functional checks, and repair procedures.

BRAKING SYSTEM COMPONENTS

• Service braking system
• Automatic brake valve
• Foot brake valve
• Brake accumulators
• Parking brake
• Axle oil cooler

BRAKE SERVICE PROCEDURES

• Brake accumulator pressure testing
• Brake accumulator removal and installation
• Brake accumulator inspection
• Brake disc wear measurement
• Brake disc replacement
• Brake piston seal replacement
• Brake system charging checks
• Brake circuit pressure testing and adjustment
• Brake system bleeding
• Brake retardation function testing
• Automatic brake function testing
• Parking brake adjustment
• Parking brake pad replacement
• Parking brake disc and seal replacement
• Parking brake disassembly and assembly
• Manual parking brake release

11. STEERING SYSTEM AND COMFORT DRIVE CONTROL

The steering section covers conventional steering, secondary steering, and CDC lever steering.

STEERING SYSTEM

• Steering system operation
• Steering control valve
• Steering cylinders
• Steering pressure monitoring
• Secondary steering
• Steering shift valve
• Steering hydraulic pressure testing

COMFORT DRIVE CONTROL (CDC)

• CDC system descriptions
• CDC calibration
• CDC lever steering valve
• CDC joystick replacement
• CDC angle sensor replacement
• CDC solenoid valve replacement
• CDC servo pressure checks
• CDC functional testing

STEERING SERVICE

• Left steering cylinder removal and installation
• Right steering cylinder removal and installation
• Steering cylinder reconditioning
• Steering accumulator inspection
• Steering accumulator removal and installation
• Secondary steering pump pressure testing and adjustment
• Steering working pressure testing and adjustment

12. FRAME, WHEELS AND STRUCTURAL COMPONENTS

This section provides procedures for selected structural components.

Included topics:

• Frame descriptions
• Frame joint
• Frame joint bearing replacement
• Front wheel removal and installation
• Rear wheel removal and installation

13. OPERATOR CAB AND CLIMATE CONTROL

The cab section provides information for the operator environment, climate control, and selected exterior components.

CAB COMPONENTS

• Cab descriptions
• Driver seat
• Electric door opener
• Viscous cab suspension
• Engine hood
• Cab removal and installation
• Door lock cylinder replacement
• Windscreen replacement
• Side window replacement
• Window installation
• Plastic hood repair

AIR CONDITIONING AND HEATING

• Climate control system
• Air conditioning operation
• Air conditioning performance testing
• Air conditioning troubleshooting
• Climate Control Module (CCM) replacement
• Climate unit removal and installation
• Air conditioning compressor replacement
• Condenser replacement
• Evaporator replacement
• Expansion valve replacement
• Heater core replacement
• Heat control valve replacement
• Fan motor replacement
• Refrigerant draining
• Refrigerant filling and vacuum pumping
• Cooling unit leak detection

14. WORKING HYDRAULIC SYSTEM

The hydraulic section provides technical descriptions, diagnostic information, and repair procedures for the working hydraulic equipment.

HYDRAULIC SYSTEM COMPONENTS

• Hydraulic oil tank
• Hydraulic pumps
• Hydraulic pump flow regulation
• Central hydraulic valve
• Main hydraulic control valve
• Servo hydraulic system
• Hydraulic pressure monitoring
• Lift cylinders
• Tilt cylinders

HYDRAULIC PUMP SERVICE

• Hydraulic pump P1 removal and installation
• Hydraulic pump P2 removal and installation
• Hydraulic pump P3 inspection
• Hydraulic pump P3 removal and installation
• Hydraulic standby pressure testing
• Hydraulic working pressure testing and adjustment
• Load-sensing pressure checks
• Servo pressure testing and adjustment

HYDRAULIC SYSTEM SERVICE

• Hydraulic system bleeding
• Hydraulic system warm-up
• Hydraulic coupling information
• Hydraulic oil tank vacuum-pumping procedures
• Hydraulic back-up valve inspection and adjustment

15. LIFT AND TILT HYDRAULIC FUNCTIONS

The manual contains service procedures for lifting and tilting equipment.

LIFT AND LOWER SYSTEM

• Lift cylinder seal replacement in the machine
• Lift and lower function testing
• Lift and lower angle sensor replacement
• Lift solenoid valve replacement
• Lower solenoid valve replacement

TILT SYSTEM

• Tilt cylinder seal replacement in the machine
• Tilt function testing
• Tilt angle sensor replacement
• Tilt-in solenoid valve replacement
• Tilt-out solenoid valve replacement

ADDITIONAL HYDRAULIC COMPONENTS

• Lift function shock valve checks
• Tilt function shock valve checks
• Hydraulic pressure testing
• Hydraulic system testing

16. BOOM SUSPENSION SYSTEM (BSS)

The documentation includes detailed information for the Boom Suspension System.

Included topics:

• Boom Suspension System description
• BSS component descriptions
• Boom suspension accumulator inspection
• Accumulator pressure testing and adjustment
• Accumulator reconditioning
• Left accumulator removal and installation
• Right accumulator removal and installation
• Hydraulic accumulator depressurization
• Boom suspension safety valve testing and adjustment
• Boom Suspension System functional checks

17. THIRD AND FOURTH HYDRAULIC FUNCTIONS

The manual includes information for additional hydraulic functions and attachment controls.

Included topics:

• Third hydraulic function
• Fourth hydraulic function
• Hydraulic function calibration
• Hydraulic pressure testing and adjustment
• Shock valve inspection
• Hydraulic solenoid valve replacement
• Hydraulic function testing
• Hydraulic attachment locking
• Attachment locking functional checks

18. LOAD ASSIST SYSTEM AND SENSOR CALIBRATION

The Volvo L110H manual contains dedicated documentation for Load Assist.

LOAD ASSIST SYSTEM

• Load Assist descriptions
• Load Assist reference values
• Software parameter settings
• Diagnostic information

LOAD ASSIST CALIBRATION

• Front frame position sensor calibration
• GDF-linkage position sensor calibration
• Lifting arm position sensor calibration

LOAD ASSIST COMPONENT REPAIR

• Front frame position sensor bracket replacement
• GDF-linkage position sensor bracket replacement
• Lifting arm position sensor bracket replacement
• Position sensor replacement
• Lift and lower pressure sensor replacement

19. CENTRAL LUBRICATION AND FIRE SUPPRESSION

The manual contains technical documentation for selected auxiliary systems.

CENTRAL LUBRICATION

• Central lubrication system operation
• Lubrication points
• Lubricant filling
• Lubrication interval adjustment
• Automatic lubrication pump reconditioning
• Automatic lubrication system updates

FIRE SUPPRESSION

• Fire suppression system descriptions
• Fire suppression components
• Procedures following automatic activation
• Procedures following manual activation

20. HYDRAULIC CIRCUIT DIAGRAMS

The documentation includes hydraulic circuit diagrams for major machine systems.

Included diagrams:

• Hydraulic transmission diagram
• Basic machine hydraulic diagram
• Complete working hydraulic system diagram
• Hydraulic diagram explanations

These diagrams support the identification of hydraulic components, pressure circuits, and system connections.

21. OPTIONAL EQUIPMENT INSTALLATION INSTRUCTIONS

The manual includes installation procedures for selected equipment and accessories.

HYDRAULIC EQUIPMENT

• Third hydraulic function installation
• Hydraulic attachment locking installation
• Boom Suspension System installation
• Axle oil cooler installation
• Multi-lever hydraulic controls
• Single-lever hydraulic controls

ELECTRICAL AND ELECTRONIC EQUIPMENT

• CareTrack installation
• Forward-view camera installation
• Reverse warning system installation
• Emergency stop installation
• LED working lights
• Rotating warning beacon
• Flashing strobe warning beacon
• Radio installation
• Seat belt LED beacon

ADDITIONAL EQUIPMENT

• Engine heater installation
• Hand throttle installation
• Reversible fan installation
• High-sulphur fuel conversion kit
• Cyclone-type air pre-cleaner
• Oil-bath air pre-cleaner
• Turbo-type air pre-cleaner
• Radiator grille guard
• Windscreen guard
• Rear-view mirror installation
• Cab air pre-cleaner
• Illuminated cab entrance

22. SAFETY AND WORKSHOP PROCEDURES

The manual includes a dedicated section covering service safety and environmental precautions.

Included topics:

• General service safety rules
• Machine handling precautions
• Safe lifting and supporting
• Working under a raised boom
• Hydraulic system safety
• Battery safety
• Electrical system safety
• Air conditioning refrigerant precautions
• Fuel and oil handling
• Tyre handling
• Fire prevention
• Fire and heat exposure inspections
• Environmental protection
• Hazardous fluid handling
• Waste disposal
• Machine towing
• Booster battery starting
• Service positions

23. TECHNICAL SPECIFICATIONS AND SERVICE DATA

The specifications section contains technical reference values for major machine systems.

ENGINE SPECIFICATIONS

• Engine specifications
• Engine capacities
• Fuel system specifications
• Cooling system specifications
• Lubrication system specifications
• Cooling fan speed references
• Valve mechanism specifications
• Engine tightening torques

ELECTRICAL SPECIFICATIONS

• Battery specifications
• Alternator specifications
• Starter motor specifications
• Lighting specifications
• Volvo Co-Pilot specifications

POWER TRANSMISSION SPECIFICATIONS

• Transmission specifications
• Transmission capacities
• Front and rear axle specifications
• Axle oil volumes
• Transmission tightening torques

BRAKE AND STEERING SPECIFICATIONS

• Brake system specifications
• Brake accumulator specifications
• Parking brake specifications
• Steering system specifications
• CDC calibration specifications
• Secondary steering pump specifications

HYDRAULIC SPECIFICATIONS

• Hydraulic pump P1 specifications
• Hydraulic pump P2 specifications
• Hydraulic pump P3 specifications
• Hydraulic system volume
• Control valve specifications
• Servo system specifications
• Boom Suspension System specifications
• Working hydraulic calibration specifications

GENERAL TECHNICAL REFERENCES

• Recommended lubricants
• Coolant specifications
• AdBlue/DEF specifications
• Alternative fuels
• Conversion tables
• Standard tightening torques

DIAGNOSTICS AND TROUBLESHOOTING

The Volvo L110H manual provides technical references for investigating problems involving:

• Engine operation and fuel delivery
• AdBlue/DEF pump operation
• DPF regeneration
• EGR and SCR equipment
• Electronic control modules
• Electrical wiring and connections
• Transmission calibration
• Brake pressure and operation
• Steering and CDC calibration
• Hydraulic pump performance
• Lift and tilt functions
• Boom Suspension System
• Load Assist sensor calibration
• Air conditioning
• Automatic lubrication

The documentation also includes Volvo Tech Tool operations for selected machine systems.

WHY THIS MANUAL IS USEFUL

The Volvo L110H Service Repair Manual brings together mechanical repair information and modern electronic diagnostic references in one technical publication.

It can help technicians:

• Identify relevant service and repair procedures
• Inspect and maintain engine components
• Diagnose fuel and exhaust aftertreatment problems
• Work with electronic control modules
• Trace circuits using electrical wiring diagrams
• Perform transmission and hydraulic system checks
• Inspect and repair brakes and steering equipment
• Service Comfort Drive Control components
• Check hydraulic pressures and control valves
• Calibrate Load Assist position sensors
• Maintain Boom Suspension System components
• Replace selected electrical and hydraulic components
• Consult technical specifications and tightening torques

WHO SHOULD USE THIS MANUAL?

This publication is suitable for:

• Professional Volvo construction equipment mechanics
• Heavy equipment service technicians
• Construction machinery repair workshops
• Fleet maintenance departments
• Equipment maintenance companies
• Volvo L110H owners responsible for servicing and repairs

IMPORTANT COMPATIBILITY INFORMATION

This manual is identified for the Volvo L110H Wheel Loader.

The documentation includes references to different electronic systems, machine configurations, and optional equipment.

Before purchasing, verify the machine model, serial number, and installed equipment.

Some procedures, electrical diagrams, and hydraulic diagrams may apply only to particular machine configurations or optional systems.

The 2020 information update refers to the supplied documentation and does not necessarily indicate the machine's manufacturing year.

DIGITAL PDF DOWNLOAD

This product is supplied as a digital PDF service repair manual.

What you receive:

• 2,568 pages of technical documentation
• Engine descriptions and repair procedures
• AdBlue/DEF, DPF, EGR, and SCR service information
• Electronic control module documentation
• Electrical wiring diagrams
• Volvo Co-Pilot and CareTrack information
• Transmission and axle service procedures
• Brake and steering system repairs
• Comfort Drive Control documentation
• Cab and air conditioning service information
• Working hydraulic system repair procedures
• Hydraulic circuit diagrams
• Boom Suspension System documentation
• Load Assist calibration information
• Optional equipment installation instructions
• Safety and workshop procedures
• Technical specifications and tightening torque references
• Digital delivery – no printed book will be shipped

A compatible PDF reader is required to access the document.

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Detailed contents:

DESCRIPTIONS
(0) GENERAL
Leak detector 951 1207, description
(1) STANDARD PARTS, SERVICE
Service
(2) ENGINE WITH MOUNTING AND EQUIPMENT
AdBlue® DEF pump unit diagnostics, description
Auxiliary brake (engine braking), description
Coolant with anti-freeze and corrosion protection, recommendation
Cooling fan motor, description
Cooling fan, description
Cooling system, description
Crankcase ventilation, description
ECO – accelerator pedal
Engine, description (1)
Engine, description
Engine, reference values
Exhaust Aftertreatment System, description
Exhaust Gas Recirculation (EGR), description
Fuel system, description
Inlet and exhaust system, description
Lubricating system, description
Regeneration process, description
Reversible cooling fan, description
Tech Tool, operations (2)
Tech Tool, operations
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
ACM, I O list
Alternator 80 A, description
Alternator, description
Battery disconnector switch, description
Battery, charging
Battery, description
Booting sequence
Cable and component designations
Cable and component marking explanations
CareTrack W-ECU, description
CCM, I O list
Chassis connection
Collection of basic data
Components list
Conditions when checking
Connectors, overview
ECM (Engine Control Module), I O list
Electrical symbols and designations
Electrical system, description
Electrical system, work instructions
Electronic control system, description
General fault diagnosis information
GPMECU1, I O list
GPMECU2, I O list
GPMECU3, I O list
HMICU, I O list
Hood opening
Information display, general
Information display, service mode
Intermittent wiper and washer
Key feed
Lead and connector checks
Limp home function, description
Preheating, description
Rear vision system
Reverse warning system, description
Software parameters, description
Starter motor, description
System voltage
Tech Tool, operations
Troubleshooting strategy
Troubleshooting tools
Volvo Co-Pilot, description (2)
Volvo Co-Pilot, description
W-ECU, I O list
(4) POWRER TRANSMISSION
Automatic differential brake, Limited Slip , description
Differential lock, description (2)
Differential lock, description
Drive axles, description
Front axle, component description
Hydraulic transmission calibration, description
Hydraulic transmission, description (2)
Hydraulic transmission, description (3)
Hydraulic transmission, description (4)
Hydraulic transmission, description
Propeller shaft, component description
Rear axle mounting, component description
Rear axle, component description
Tech Tool, operations
(5) BRAKE
Automatic brake valve, description
Axle oil cooler, description
Brake accumulator, description
Braking system, description (2)
Braking system, description
Foot brake valve, description
Parking brake, component description (2)
Parking brake, component description
Parking brake, function description (2)
Parking brake, function description
Tech Tool, operations
Tightening torque
(6) STEERING
Calibration of Comfort Drive Control (CDC), function description
CDC valve, lever steering, description
Comfort Drive Control (CDC), description (2)
Comfort Drive Control (CDC), description
Pressure monitor, description
Secondary steering, description (2)
Secondary steering, description
Shift valve, description
Steering cylinder, description (2)
Steering cylinder, description
Steering system, description (2)
Steering system, description (3)
Steering valve, description
Tech Tool, operations
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Frame joint, description
Frame, description
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, function description
Air conditioning, tightening torques (2)
Air conditioning, tightening torques
Cab, description
Climate control system, description
Driver seat, component description (2)
Driver seat, component description (3)
Driver seat, component description
Electric door opener, description
Pause heater, description
Tech Tool, operations
Viscous cab suspension, description
Windows, general, gluing
Windows, general
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
3rd, or 3rd 4th hydraulic function, description (2)
3rd, or 3rd 4th hydraulic function, description
Boom Suspension System, component description
Boom Suspension System, description
Calibration of 3rd 4th hydraulic function, description
Calibration of lift lower function, description
Calibration of tilt in out function, description
Central lubrication system, description
Central valve, description
Change of lubrication interval
Control valve, description
Diagnostic tools, description
Dosage valves, description
Filling lubricant
Fire suppression system, component description
Fire suppression system, functional description
Hydraulic attachment locking, description
Hydraulic components, cleanliness when handling
Hydraulic oil tank, description
Hydraulic pump flow regulation, description
Hydraulic pumps, description
Lever control, electric servo, description
Lifting cylinder, description
Load Assist, description (2)
Load Assist, description (3)
Load Assist, description
Load Assist, reference values
Lubrication points, central lubrication
Parameter settings
Pressure monitor, description
Pump unit, description
Servo system, description (2)
Servo system, description
Shift valve, description
Software, parameter settings and read-outs
Tech Tool, operations
Tilt cylinder, description
TP-Linkage’s bearing points
Working hydraulic system, description (2)
Working hydraulic system, description
DIAGRAMS
(3) ELEC. SYSTEM, WARNING SYSTEM, INFORMATION SYSTEM, INSTRUMENTS
Table of contents, wiring diagrams
Wiring diagram – Aftertreatment (2)
Wiring diagram – Aftertreatment
Wiring diagram – Brake
Wiring diagram – BSS
Wiring diagram – CDC
Wiring diagram – Electrically controlled battery disconnector – Key operated, with emergency stop
Wiring diagram – Electrically controlled battery disconnector – Manual, with emergency stop
Wiring diagram – Electrically controlled battery disconnector – Manual, without emergency stop
Wiring diagram – Gear
Wiring diagram – Start
Wiring diagram WD201
Wiring diagram WD202
Wiring diagram WD260
Wiring diagram WD261
Wiring diagram WD262
Wiring diagram WD263
Wiring diagram WD264
Wiring diagram WD265
Wiring diagram WD266
Wiring diagram WD268
Wiring diagram WD269
Wiring diagram WD270
Wiring diagram WD301
Wiring diagram WD302
Wiring diagram WD303
Wiring diagram WD304 (2)
Wiring diagram WD304
Wiring diagram WD305
Wiring diagram WD306 (2)
Wiring diagram WD306
Wiring diagram WD320 (2)
Wiring diagram WD320 (3)
Wiring diagram WD320
Wiring diagram WD321 (2)
Wiring diagram WD321
Wiring diagram WD322 (2)
Wiring diagram WD322 (3)
Wiring diagram WD322
Wiring diagram WD324 (2)
Wiring diagram WD324
Wiring diagram WD325
Wiring diagram WD326
Wiring diagram WD327
Wiring diagram WD330
Wiring diagram WD331
Wiring diagram WD333
Wiring diagram WD334
Wiring diagram WD335
Wiring diagram WD337
Wiring diagram WD350
Wiring diagram WD351
Wiring diagram WD352
Wiring diagram WD360 (2)
Wiring diagram WD360 (3)
Wiring diagram WD360
Wiring diagram WD361
Wiring diagram WD362
Wiring diagram WD363
Wiring diagram WD371
Wiring diagram WD372
Wiring diagram WD373 (2)
Wiring diagram WD373
Wiring diagram WD374 (2)
Wiring diagram WD374
Wiring diagram WD375
Wiring diagram WD376
Wiring diagram WD401
Wiring diagram WD402
Wiring diagram WD403
Wiring diagram WD404
Wiring diagram WD405
Wiring diagram WD406
Wiring diagram WD501
Wiring diagram WD601
Wiring diagram WD602
Wiring diagram WD604
Wiring diagram WD801
Wiring diagram WD802 (2)
Wiring diagram WD802 (3)
Wiring diagram WD802
Wiring diagram WD804
Wiring diagram WD805
Wiring diagram WD806
Wiring diagram WD807 (2)
Wiring diagram WD807
Wiring diagram WD808
Wiring diagram WD831
Wiring diagram WD901
Wiring diagram WD902
Wiring diagram WD903
Wiring diagram WD904
Wiring diagram WD908
Wiring diagram WD909
Wiring diagram WD910
Wiring diagram WD911
Wiring diagram WD912
Wiring diagram WD913
Wiring diagram WD915
(4) POWER TRANSMISSION
Hydraulic diagram transmission
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC EQUIP
Explanations to hydraulic diagram
Hydraulic diagram, basic machine
Hydraulic diagram, complete
Installation Instruction
3rd hydraulic function, installing new
Attachment locking, installing new
Axle oil cooler, installing new (2)
Axle oil cooler, installing new
Back up alarm, installing new
Boom suspension system, installing new
Cab front work light LED, installing new
Cab illuminated entrance LED, installing new
Cab rear work light LED, installing new
Cab side work light LED, installing new
Cab, air pre cleaner, installing new
Care Track
CareTrack, installing new
Decal set, installing new
Emergency stop, installing new
Engine heater, installing new (2)
Engine heater, installing new
Forward view camera, installing new
Front work light LED, installing new
Grill work light LED, installing new
Hand throttle, installing new
High Sulphur Fuel Conversion kit, installing new
LED beacon for seat belt, installing new
Lever steering (CDC), electric, installing new (2)
Lever steering (CDC), electric, installing new
Multi lever control, 3rd hydraulic function, installing new
Multi lever control, 4th hydraulic function, installing new
Pre-cleaner cyclone type, installing new (2)
Pre-cleaner cyclone type, installing new
Pre-cleaner oil bath type, installing new
Pre-cleaner turbo type, installing new
Radiator grille guard, installing new
Radio, installing new
Rear view mirror, installing new
Reverse warning system, installing new
Reversible fan, installing new (2)
Reversible fan, installing new
Rotating beacon, installing new
Single lever control, 2nd hydraulic function, installing new
Single lever control, 3rd hydraulic function, installing new
Single lever control, 4th hydraulic function, installing new
Warning beacon flashing strobe light, installing new
Wind shield guard, installing new
REPAIR
(0) GENERAL
88830557 User Instruction
E 1708, Checking point
E1711
E-2001
E-2005
E-2010
E-2014
E-2015
E-2017
E-2019
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
AdBlue® DEF pump unit filter, replacing
Hydraulic pressure, checking
Parking brake, manually releasing (2)
Parking brake, manually releasing
(2) ENGINE WITH MOUNTING AND EQUIPMENT
ACM (Aftertreatment control module) non-programmed, replacing
ACM (Aftertreatment control module) pre-programmed, replacing
AdBlue® DEF dosing injector, replacing
AdBlue® DEF hoses, replacing
AdBlue® DEF pump unit, filter, replacing
AdBlue® DEF pump unit, flushing
AdBlue® DEF pump unit, inlet nipple, replacing
AdBlue® DEF pump unit, replacing
AdBlue® DEF quality, checking
AdBlue® DEF tank armature suction filter, replacing
AdBlue® DEF tank armature, cleaning
AdBlue® DEF tank armature, replacing
AdBlue® DEF tank, cleaning
AdBlue® DEF tank, replacing
AdBlue® DEF, draining
AdBlue®DEF tank, replacing
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, checking
Coolant pump, replacing
Coolant valve, replacing
Cooling system pressure, checking
Crystallization of AdBlue® DEF, checking
Cylinder compression, testing
DOC (Diesel oxidation catalyst), replacing
DPF (Diesel particulate filter), checking and cleaning
EGR cooler, replacing
EGR reed valve, replacing
EGR valve, replacing
EGR venturi tube, replacing
Engine belts, replacing
Engine control module (ECM), replacing non-programmed
Engine control module (ECM), replacing pre-programmed
Engine mounting rear, changing
Engine, installing
Engine, removing
Engine, replacing (2)
Engine, replacing
Exhaust pipe flexible tube, replacing
Feed pump pressure, checking
Fuel control valve (FCV), replacing
Fuel rail pressure sensor, replacing
Fuel rail, replacing
Fuel system, bleeding
High pressure fuel pipes, replacing
High pressure fuel pump, replacing
Injector sleeves, replacing
Injectors, replacing
Inlet throttle, replacing
Lubrication oil consumption, checking
Lubrication oil pressure, checking with pressure gauge
Pressure relief valve (PRV), replacing
Radiator, replacing
Regeneration log, checking
SCR (Selective catalytic reduction) dosing system, checking
SCR (Selective catalytic reduction) muffler, replacing
Stall speed, checking
Thermostat, replacing
Turbocharger, replacing
Valves, adjusting
Wastegate, checking
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Batteries, replacing
Battery condition, checking
GPMECU1 non-programmed, replacing
GPMECU1 pre-programmed, replacing
GPMECU2 non-programmed, replacing
GPMECU2 pre-programmed, replacing
GPMECU3 non-programmed, replacing
GPMECU3 pre-programmed, replacing
HMICU non-programmed, replacing
HMICU pre-programmed, replacing
Starter lock, replacing
Starter motor, replacing
Tech Tool, operations
Volvo Co-Pilot Android software, updating online (OtA) (2)
Volvo Co-Pilot Android software, updating online (OtA)
Volvo Co-Pilot SIM card, installing (2)
Volvo Co-Pilot SIM card, installing
Volvo Co-Pilot, replacing
Volvo Co-Pilot, software updating
W-ECU, replacing, non-programmed
W-ECU, replacing, pre-programmed
(4) POWER TRANSMISSION
Axle suspension bushes and seals, replacing
Axle, installing
Axle, removing
Differential lock, adjusting
Differential lock, function check
Error codes when calibrating
Gear selector valve, replacing one solenoid (2)
Gear selector valve, replacing one solenoid
Heat exchanger, replacing
Hub reduction, installing (2)
Hub reduction, installing
Hub reduction, removing (2)
Hub reduction, removing
Hub seal, replacing
Hydraulic transmission, warming up
Lock up valve, replacing
Seal for front output shaft, replacing (2)
Seal for front output shaft, replacing
Seal for rear output shaft, replacing
Tech Tool, operations
Transmission oil pressure, checking (2)
Transmission oil pressure, checking (3)
Transmission oil pressure, checking (4)
Transmission oil pressure, checking
Transmission, function check (2)
Transmission, function check
Transmission, installing (2)
Transmission, installing
Transmission, removing (2)
Transmission, removing
(5) BRAKE
Accumulator (removed) charging pressure, checking
Accumulator, discarding
Accumulator, installing
Accumulator, removing
Accumulators, checking in machine
Automatic brake function, checking
Brake disc, replacing
Brake discs, measuring wear
Brake discs, replacing
Brake piston seals, replacing (2)
Brake piston seals, replacing
Brake system charging, checking
Brake system circuit pressure, checking and adjusting
Brake system retardation function, checking
Brake system, bleeding
Parking brake assembly, removing
Parking brake brake pads, replacing
Parking brake discs and seals, replacing
Parking brake function, checking
Parking brake, adjusting
Parking brake, assembling
Parking brake, disassembling
Parking brake, installing
(6) STEERING
Accumulator, discarding
Comfort drive control (CDC) angle sensor, changing
Comfort Drive Control (CDC) joystick, changing
Comfort drive control (CDC) solenoid valve, changing
Comfort Drive Control, servo pressure, checking
Left steering cylinder, installing (2)
Left steering cylinder, installing
Left steering cylinder, removing (2)
Left steering cylinder, removing
Lever steering (CDC) function, checking
Right steering cylinder, installing (2)
Right steering cylinder, installing
Right steering cylinder, removing (2)
Right steering cylinder, removing
Secondary steering pump working pressure, checking and adjusting
Steering accumulator removed, checking
Steering accumulator, installing
Steering accumulator, removing
Steering cylinder removed, reconditioning excl replacing bearings (2)
Steering cylinder removed, reconditioning excl replacing bearings
Steering system function, checking
Steering system working pressure, checking and adjusting
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEELTRACK UNIT
Frame joint, replacing bearings
Front wheel, installing
Front wheel, removing
Rear wheel, installing
Rear wheel, removing
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Actuator, replacing
Air conditioning, checking performance
Air mix door actuator, replacing
Cab, installing
Cab, removing
CCM, replacing
Climate unit, installing
Climate unit, removing
Compressor, replacing
Condenser, replacing
Cooling unit, leak detection
Door lock cylinder, replacing (1)
Door lock cylinder, replacing
Drying filter, replacing
Electric door opener, control unit, replacing
Electric door opener, locking motor, replacing
Electric door opener, opening support motor, replacing
Electric door opener, rotor switch, replacing
Engine hood, raising and securing
Evaporator, replacing
Expansion valve, replacing
Fan motor, replacing
Heat control valve, replacing
Heater core, replacing
Operator’s seat, securing
Plastic hood, repairing
Refrigerant, draining
Refrigerant, filling incl vacuum pumping
Side window, replacing
Troubleshooting, air conditioning unit (AC)
Viscous cab suspension, changing one unit
Window pane, installing
Windscreen, replacing
(9) HYDRAULIC SYSTEM; DIGGINGHANDLINGGRADING EQUIPM; MISC. EQUIP
3rd 4th hydraulic function, pressure, checking and adjusting
3rd 4th hydraulic function, shock valve, checking
3rd 4th hydraulic function, solenoid valve, replacing
3rd 4th hydraulic, functional check
Accumulator removed, checking
Accumulator, boom suspension system, discarding
Accumulator, discarding (2)
Accumulator, discarding
Attachment locking, checking
Automatic lubrication pump unit, reconditioning
Back-up valve, checking and adjusting
Bleeding air
Boom suspension accumulator, checking and adjusting
Boom suspension accumulator, reconditioning
Boom suspension system, checking
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom suspension system, left accumulator, installing
Boom suspension system, left accumulator, removing
Boom suspension system, pressure reduction, safety valve, checking and adjusting
Boom suspension system, right accumulator, installing
Boom suspension system, right accumulator, removing
Calibration of Load Assist, front frame position sensor
Calibration of Load Assist, GDF-linkage position sensor
Calibration of Load Assist, lifting arm position sensor
Error codes when calibrating
Fire suppression system, actions after activation
Fire suppression system, actions after manual activation
Hydraulic couplings
Hydraulic cylinder, piston’s lock brace, installing
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic pump P1, installing
Hydraulic pump P1, removing
Hydraulic pump P2, installing
Hydraulic pump P2, removing
Hydraulic pump P3, checking
Hydraulic pump P3, installing
Hydraulic pump P3, removing
Hydraulic pump, standby pressure and working pressure, checking and adjusting
Hydraulic system, bleeding
Hydraulic system, warming up
Lift cylinder, repacking in machine
Lift lower function, checking
Lift lower, angle sensor, changing (2)
Lift lower, angle sensor, changing
Lift, solenoid valve, changing
Load Assist, front frame position sensor bracket, replacing
Load Assist, GDF linkage position sensor bracket, replacing
Load Assist, lifting arm position sensor, bracket, replacing
Load Assist, position sensors, replacing (2)
Load Assist, position sensors, replacing
Load Assist, pressure sensor, lift- and lower function, replacing (2)
Load Assist, pressure sensor, lift- and lower function, replacing
Lower, solenoid valve, changing
LS (load sense) pressure, checking
Pressure back-up valve, replacing
Servo accumulator, installing
Servo accumulator, removing
Servo pressure, checking and adjusting
Shock valve lift function, checking
Shock valve, tilt function, checking
System test
Tilt cylinder, repacking in machine
Tilt in out, angle sensor, changing (1)
Tilt in out, angle sensor, changing
Tilt in, solenoid valve, changing
Tilt out, solenoid valve, changing
Tilt, checking
Update of automatic lubrication system
Safety
(1) STANDARD PARTS, SERVICE
CE-marking, EMC-directive
Checking function
Checklist after a fire or heat exposure
Decontamination
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Fire prevention measures
Health hazards with paint, plastics and rubber
Safety concerns everybody!
Safety rules when servicing
Safety when handling oils and fuel
Safety when handling the machine
Safety when lifting and supporting complete machine
Safety when working on hydraulic systems
Safety when working with air conditioning refrigerant
Safety when working with batteries
Service position 1
Service position 2
Some simple rules regarding tyre handling
Starting with booster batteries
Towing
Waste handling
Working in environmentally contaminated areas
Working on the electrical system of the machine
Working under raised boom
Specification
(0) GENERAL
Conversion tables
Tightening torques
(1) STANDARD PARTS, SERVICE
AdBlue®DEF
Alternative fuels
Coolant
Recommended lubricants (2)
Recommended lubricants
(2) ENGINE WITH MOUNTING AND EQUIPMENT
AdBlue®DEF
Cooling fan rpm, specifications
Cooling fan, tightening torques
Cooling system, specifications
Cooling system, tightening torques
EGR system, tightening torques
Engine, capacities
Engine, specifications
Engine, tightening torques
Fuel system, specifications
Fuel system, tightening torques
Inlet and exhaust system, specification
Inlet and exhaust system, tightening torques
Lubrication system, specifications
Lubrication system, tightening torques
Temperature limits for cooling fan speed, specifications
Valve mechanism, specifications
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMEN
Alternator 80 A, specification
Battery, specifications
Battery, weight
Electrical system, specifications
Electrical system, tightening torques
Lighting, specifications
Preheating, specifications
Starter motor, specifications
Starter motor, tightening torques
Volvo Co-Pilot, specifications
Volvo Co-Pilot, tightening torques
(4) POWRER TRANSMISSION
Axle suspension, tightening torque
Front and rear axles, specifications
Front and rear axles, tightening torque
Front and rear axles, volume
Hydraulic transmission, capacity (2)
Hydraulic transmission, capacity
Propeller shaft, tightening torque
Rear axle mounting, volume
Transmission, specifications (2)
Transmission, specifications (3)
Transmission, specifications (4)
Transmission, specifications (5)
Transmission, specifications (6)
Transmission, specifications (7)
Transmission, specifications (8)
Transmission, specifications
Transmission, tightening torques (2)
Transmission, tightening torques (3)
Transmission, tightening torques (4)
Transmission, tightening torques (5)
Transmission, tightening torques (6)
Transmission, tightening torques
(5) BRAKE
Brake accumulator, specifications
Brake system, specifications
Parking brake, specifications (2)
Parking brake, specifications
Wheel brake, specification
(6) STEERING
Calibration of Comfort Drive Control (CDC), specification
Lever steering (CDC), specifications
Lever steering CDC, tightening torques
Secondary steering pump, specifications (2)
Secondary steering pump, specifications
Steering cylinder, tightening torque (2)
Steering cylinder, tightening torque
Steering, specifications (2)
Steering, specifications
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Counterweight, tightening torques
Counterweight, weight
Frame joint, tightening torques
Wheel, tightening torque
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, refrigerant, weight
Air conditioning, specifications
Cabin, tightening torques
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
3rd 4th hydraulic function, specifications
3rd4th hydraulic function, tightening torques
Automatic lubrication system, specifications
Boom Suspension System, specifications
Boom Suspension System, tightening torques
Calibration of working hydraulics, specifications
Control valve, specifications
Control valve, tightening torques
Fire suppression system, specification
Function times, specifications
Hydraulic connections, tightening torques
Hydraulic pump (P1), specifications
Hydraulic pump (P2), specifications
Hydraulic pump (P3), specifications
Hydraulic pumps, tightening torques
Hydraulic system, volume
Lift cylinder, tightening torques
Recommended lubricants
Servo system, specifications
Tilt cylinder, tightening torques