VOLVO L150H WHEEL LOADER SERVICE REPAIR MANUAL PDF – 3217 PAGES

The Volvo L150H Wheel Loader Service Repair Manual is an extensive technical reference covering the inspection, diagnosis, maintenance, adjustment, servicing, and repair of the Volvo L150H wheel loader.

This comprehensive 3,217-page PDF manual, with information updated in 2020, provides detailed documentation for the engine, exhaust aftertreatment equipment, electrical and electronic systems, power transmission, drive axles, brakes, steering, frame, operator cab, and working hydraulics.

The manual contains technical system descriptions, service and repair procedures, electrical wiring diagrams, hydraulic circuit diagrams, diagnostic references, component removal and installation instructions, equipment installation procedures, safety information, and technical specifications.

It also covers advanced machine systems, including Volvo Co-Pilot, Load Assist, CareTrack, Comfort Drive Control (CDC), Boom Suspension System (BSS), AdBlue/DEF, Diesel Particulate Filter (DPF), Exhaust Gas Recirculation (EGR), and Selective Catalytic Reduction (SCR).

The documentation is intended for professional heavy equipment mechanics, Volvo construction equipment technicians, repair workshops, fleet maintenance departments, and machine owners responsible for servicing their equipment.

MANUAL DETAILS

• Manufacturer: Volvo Construction Equipment
• Equipment Model: L150H Wheel Loader
• Manual Type: Service Repair Manual
• File Format: PDF
• Number of Pages: 3,217
• Information Update: 2020
• Delivery: Digital Download

WHAT IS INCLUDED IN THIS SERVICE REPAIR MANUAL?

The documentation is organized into several major sections, including technical descriptions, electrical and hydraulic diagrams, installation instructions, repair procedures, safety information, and specifications.

1. GENERAL SERVICE INFORMATION

The general section provides introductory service references and technical information for the Volvo L150H.

Included topics:

• General service information
• Special service equipment references
• Leak detector information
• Checking points and service tools
• Additional work operation numbers
• Infrared thermometer
• General workshop procedures

2. ENGINE SYSTEM DESCRIPTION AND TECHNICAL INFORMATION

The engine section explains the operation of major engine systems and associated equipment.

ENGINE OPERATING SYSTEMS

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

EXHAUST AFTERTREATMENT SYSTEM

• Exhaust Aftertreatment System operation
• AdBlue/DEF pump diagnostics
• Exhaust aftertreatment fuel system diagnostics
• Exhaust Gas Recirculation (EGR)
• Internal Exhaust Gas Recirculation (IEGR)
• Regeneration process
• Fuel injector checks

DIAGNOSTIC REFERENCES

• Volvo Tech Tool operations
• Engine system reference values
• Diagnostic descriptions

3. ENGINE SERVICE AND REPAIR

The repair section contains procedures for servicing major engine components.

ENGINE MECHANICAL REPAIRS

• Engine removal and installation
• Engine mounting replacement
• Camshaft timing checks
• Camshaft replacement
• Crankshaft oil seal replacement
• Cylinder compression testing
• Rocker arm replacement
• Valve adjustment
• Engine belt replacement
• Engine speed sensor replacement

FUEL SYSTEM SERVICE

• Fuel system air checks
• Fuel system bleeding
• Fuel feed pump pressure testing
• Fuel feed pump replacement
• Fuel feed pump reconditioning
• Fuel tank replacement
• Fuel injector replacement
• Injector sleeve replacement
• Injector yoke inspection
• Fuel system hand pump replacement

LUBRICATION AND COOLING

• Engine oil pressure testing
• Engine oil consumption checks
• Oil cooler leak testing
• Oil cooler replacement
• Engine oil level sensor replacement
• Cooling system pressure testing
• Radiator replacement
• Fan control valve seal replacement

AIR INTAKE AND EXHAUST

• Turbocharger inspection
• Turbocharger replacement
• Inlet throttle replacement
• Exhaust flexible pipe replacement
• Muffler removal and installation
• Silencer removal and installation

4. ADBLUE/DEF, DPF, EGR AND SCR SERVICE

The manual provides extensive servicing information for the Volvo L150H exhaust aftertreatment equipment.

ADBLUE/DEF SYSTEM

• AdBlue/DEF pump unit replacement
• AdBlue/DEF pump component replacement
• AdBlue/DEF nozzle replacement
• AdBlue/DEF hose replacement
• AdBlue/DEF tank replacement
• AdBlue/DEF tank cleaning
• AdBlue/DEF tank armature cleaning
• AdBlue/DEF tank armature replacement
• AdBlue/DEF suction filter replacement
• AdBlue/DEF quality checks
• AdBlue/DEF draining

EXHAUST AFTERTREATMENT COMPONENTS

• Diesel Particulate Filter (DPF) inspection and cleaning
• EGR cooler pressure testing
• EGR cooler replacement
• EGR valve replacement
• Internal EGR valve replacement
• EGR venturi tube cleaning and replacement
• SCR dosing system checks
• Aftertreatment fuel dosing unit replacement
• Aftertreatment fuel nozzle cleaning and replacement
• Aftertreatment fuel flow checks
• NOx sensor replacement

ELECTRONIC CONTROL MODULES

• Engine Control Module (ECM) replacement
• Aftertreatment Control Module (ACM) replacement
• Pre-programmed and non-programmed module replacement procedures

5. ELECTRICAL AND ELECTRONIC CONTROL SYSTEMS

The electrical section contains detailed information about the Volvo L150H electrical architecture and electronic control equipment.

ELECTRICAL SYSTEM INFORMATION

• Electrical system descriptions
• Electrical symbols and designations
• Cable and component identification
• Connector overview
• Electrical component lists
• Chassis connections
• System voltage
• Battery and alternator information
• Starter motor operation
• 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 documentation includes input and output lists for several electronic control modules.

ELECTRONIC DIAGNOSTICS

• Electronic control system operation
• General fault diagnosis information
• Troubleshooting strategy
• Troubleshooting tools
• Software parameter information
• Service display functions
• Limp-home operation
• Volvo Tech Tool operations

6. ELECTRICAL WIRING DIAGRAMS

The manual includes an extensive collection of electrical wiring diagrams for the Volvo L150H.

SYSTEM-SPECIFIC WIRING DIAGRAMS

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

NUMBERED ELECTRICAL DIAGRAMS

The documentation includes numerous numbered wiring diagrams, including:

• WD201–WD224 series
• WD275
• WD301–WD337 series
• WD350–WD376 series
• WD401–WD406 series
• WD501
• WD601–WD604 series
• WD801–WD831 series
• WD901–WD915 series

Some diagrams have multiple versions for different configurations.

These references are useful for electrical troubleshooting, circuit identification, and understanding the connections between machine components.

7. POWER TRANSMISSION AND DRIVE AXLES

The power transmission section provides technical descriptions, hydraulic diagrams, repair procedures, and adjustment information.

TRANSMISSION SYSTEM

• Hydraulic transmission operation
• Transmission calibration
• Transmission hydraulic diagram
• Transmission removal and installation
• Transmission oil pressure testing
• Transmission function checks
• Transmission warm-up procedures
• Gear selector solenoid replacement
• Lock-up valve replacement
• Transmission heat exchanger replacement
• Transmission calibration error codes

DRIVELINE AND AXLES

• Drive axle descriptions
• Front axle components
• Rear axle components
• Rear axle mounting
• Propeller shaft components
• Differential lock operation
• Differential lock adjustment
• Differential lock function checks
• Limited-slip differential operation
• Axle suspension bush and seal replacement
• Hub reduction removal and installation
• Hub seal replacement
• Transmission output shaft seal replacement

8. BRAKE SYSTEM SERVICE AND REPAIR

The braking system section includes descriptions, functional checks, hydraulic pressure testing, and component repair procedures.

BRAKE SYSTEM COMPONENTS

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

BRAKE SERVICE PROCEDURES

• Brake accumulator pressure testing
• Brake accumulator removal and installation
• 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 checks
• Automatic brake function testing
• Parking brake adjustment
• Parking brake pad replacement
• Parking brake disc and seal replacement
• Parking brake disassembly and assembly

9. STEERING SYSTEM AND COMFORT DRIVE CONTROL

The steering section covers conventional steering equipment, secondary steering, and Comfort Drive Control (CDC).

STEERING SYSTEM

• Steering system operation
• Steering control valve
• Steering cylinders
• Steering pressure monitoring
• Secondary steering system
• Steering accumulator
• Steering hydraulic pressure testing
• Steering system function checks

COMFORT DRIVE CONTROL (CDC)

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

STEERING REPAIRS

• Steering cylinder removal and installation
• Steering accumulator inspection
• Steering accumulator removal and installation
• Secondary steering pump pressure testing and adjustment

10. FRAME, WHEELS AND STRUCTURAL COMPONENTS

The manual contains service information for selected structural components.

Included topics:

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

11. OPERATOR CAB AND AIR CONDITIONING

The cab section provides technical descriptions and repair procedures for the operator environment.

CAB COMPONENTS

• Cab descriptions
• Operator seat information
• Viscous cab suspension
• Electric door opener
• Cab positioning procedures
• Cab tilt cylinder replacement
• Engine hood securing
• Door lock cylinder replacement
• Windscreen replacement
• Side window replacement
• Window installation

HEATING AND AIR CONDITIONING

• Climate control system operation
• Air conditioning performance testing
• Air conditioning troubleshooting
• Climate Control Module (CCM) replacement
• 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

12. HYDRAULIC SYSTEM AND WORKING EQUIPMENT

The hydraulic section provides descriptions, repair procedures, pressure testing information, and calibration references.

HYDRAULIC SYSTEM COMPONENTS

• Hydraulic oil tank
• Hydraulic pumps
• Hydraulic pump flow regulation
• Central hydraulic valve
• Hydraulic control valves
• Servo hydraulic system
• Hydraulic pressure monitoring
• Load-sensing hydraulic system
• Hydraulic lift and 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

LIFT AND TILT EQUIPMENT

• Lift cylinder seal replacement in the machine
• Tilt cylinder seal replacement in the machine
• Lift and lower function testing
• Tilt function testing
• Lift and lower angle sensor replacement
• Tilt angle sensor replacement
• Lift and tilt solenoid valve replacement
• Lift and tilt shock valve testing
• Load-sensing disconnecting solenoid valve replacement
• TP-linkage bearing points

13. BOOM SUSPENSION SYSTEM (BSS)

The manual contains dedicated information for the Boom Suspension System.

Included topics:

• Boom Suspension System operation
• Boom suspension components
• Boom suspension accumulator inspection
• Accumulator pressure 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 function checks

14. THIRD AND FOURTH HYDRAULIC FUNCTIONS

The manual includes documentation for additional hydraulic functions.

Included topics:

• Third hydraulic function
• Fourth hydraulic function
• Hydraulic pressure testing and adjustment
• Hydraulic shock valve checks
• Hydraulic solenoid valve replacement
• Hydraulic function testing
• Calibration procedures
• Hydraulic attachment locking
• Attachment locking function checks

15. VOLVO CO-PILOT AND LOAD ASSIST

The documentation includes technical information for Volvo Co-Pilot and Load Assist equipment.

VOLVO CO-PILOT

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

LOAD ASSIST

• Load Assist system descriptions
• Load Assist reference values
• Front frame position sensor calibration
• GDF-linkage position sensor calibration
• Lifting arm position sensor calibration
• Load Assist position sensor replacement
• Lift and lower pressure sensor replacement
• Sensor bracket replacement

16. CENTRAL LUBRICATION AND FIRE SUPPRESSION

The manual contains documentation for selected auxiliary systems.

AUTOMATIC 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

17. HYDRAULIC CIRCUIT DIAGRAMS

The manual includes hydraulic diagrams for the power transmission and working hydraulic equipment.

TRANSMISSION

• Hydraulic transmission diagram

WORKING HYDRAULICS

• Basic machine hydraulic diagrams
• Complete hydraulic diagrams
• Explanations of hydraulic diagram symbols and references
• Multiple hydraulic diagram versions

These diagrams help technicians understand hydraulic system connections, pressure circuits, and component operation.

18. EQUIPMENT INSTALLATION INSTRUCTIONS

An important part of this publication is the collection of installation instructions for selected machine accessories and optional equipment.

Included topics:

• Third hydraulic function installation
• Hydraulic attachment locking installation
• Axle oil cooler installation
• Boom Suspension System installation
• CareTrack installation
• Forward-view camera installation
• Rear-view camera installation
• Reverse warning system installation
• Emergency stop installation
• Engine heater installation
• Additional fuel filter installation
• Reversible fan installation
• Comfort Drive Control installation
• Single-lever and multi-lever hydraulic controls
• LED working lights
• Rotating warning beacons
• Radio installation
• Windscreen guard installation
• Radiator grille guard installation
• Engine air pre-cleaner installation
• Hand throttle installation
• High-sulphur fuel conversion kit installation
• Seat belt warning beacon installation

19. SAFETY AND WORKSHOP PROCEDURES

The manual contains a dedicated safety section.

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

20. TECHNICAL SPECIFICATIONS AND SERVICE DATA

The specifications section provides reference information for major machine systems.

ENGINE

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

ELECTRICAL

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

TRANSMISSION AND BRAKES

• Transmission specifications
• Transmission capacities
• Axle specifications
• Axle oil volumes
• Brake system specifications
• Brake accumulator specifications
• Parking brake specifications

STEERING AND HYDRAULICS

• Steering system specifications
• CDC calibration specifications
• Hydraulic pump specifications
• Hydraulic system volume
• Control valve specifications
• Servo system specifications
• Boom Suspension System specifications
• Working hydraulic calibration specifications

GENERAL REFERENCE INFORMATION

• Recommended lubricants
• Coolant recommendations
• Alternative fuels
• Conversion tables
• Standard tightening torques
• Component tightening torques

DIAGNOSTICS AND TROUBLESHOOTING

The Volvo L150H manual provides technical references for investigating problems involving:

• Engine operation
• Fuel injection
• Exhaust aftertreatment
• AdBlue/DEF system
• DPF and EGR components
• Electronic control modules
• Electrical wiring and connections
• Transmission operation and calibration
• Brake pressure and function
• Steering pressure and CDC
• Hydraulic pumps and control valves
• Load Assist calibration
• Lift and tilt equipment
• Air conditioning
• Automatic lubrication

The documentation also contains Volvo Tech Tool operations for several machine systems.

BENEFITS OF THIS SERVICE REPAIR MANUAL

This publication can help users:

• Access detailed Volvo L150H technical documentation
• Perform engine inspection and repair procedures
• Maintain AdBlue/DEF, DPF, EGR, and SCR systems
• Diagnose electrical and electronic control systems
• Consult extensive electrical wiring diagrams
• Service the transmission and drive axles
• Inspect and repair brake and steering systems
• Maintain Comfort Drive Control equipment
• Test hydraulic pressures and repair hydraulic components
• Service Boom Suspension System equipment
• Consult Volvo Co-Pilot and Load Assist information
• Install selected optional equipment
• Follow workshop safety procedures
• Consult technical specifications and tightening torques

WHO IS THIS MANUAL FOR?

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 L150H wheel loader owners responsible for servicing and repairs

IMPORTANT COMPATIBILITY INFORMATION

This manual is identified for the Volvo L150H Wheel Loader.

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

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

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

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:

• 3,217 pages of technical documentation
• Engine descriptions and repair procedures
• AdBlue/DEF, DPF, EGR, and SCR service information
• Electrical and electronic control system documentation
• Extensive electrical wiring diagrams
• Transmission and axle repair procedures
• Brake and steering system servicing
• Comfort Drive Control documentation
• Operator cab and air conditioning repair procedures
• Working hydraulic system repair information
• Hydraulic circuit diagrams
• Boom Suspension System documentation
• Volvo Co-Pilot and Load Assist information
• CareTrack-related installation information
• 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:

COVER
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 (2)
Cooling fan, description
Cooling system, description (2)
Cooling system, description
Crankcase ventilation, description (2)
Crankcase ventilation, description
ECO – accelerator pedal
Engine, reference values
Exhaust aftertreatment fuel system diagnostics, description
Exhaust Aftertreatment System, description
Exhaust Gas Recirculation (EGR), description
Fuel system, description (2)
Fuel system, description
Injectors, checking
Inlet and exhaust system, description (2)
Inlet and exhaust system, description (3)
Inlet and exhaust system, description
Internal Exhaust Gas Recirculation (IEGR), description
Lubrication system, description (2)
Lubrication system, description (3)
Lubrication system, description
Regeneration process, description
Reversible cooling fan, description (2)
Reversible cooling fan, description
Tech Tool, operations (2)
Tech Tool, operations (3)
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 (2)
Components list (3)
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 (2)
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) POWER 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
Propeller shaft, component description
Rear axle mounting, component description
Rear axle, component description
(5) BRAKE
Automatic brake valve, description
Axle oil cooler, description (2)
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
Shift valve, 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
Steering cylinder, description
Steering system, description (2)
Steering system, description
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 HANDLING GRADING EQUIPM; MISC. EQUIP
3rd, or 3rd 4th hydraulic function, description
3rd, or 3rd4th hydraulic function, description (2)
3rd, or 3rd4th hydraulic function, description (3)
3rd, or 3rd4th hydraulic function, description
Boom Suspension System, component description
Boom Suspension System, description (2)
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 (2)
Central valve, description
Change of lubrication interval
Control valve, description (2)
Control valve, description (3)
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 (2)
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 (3)
Servo system, description
Shift valve, description
Software, parameter settings and read-outs
Tech Tool, operations (2)
Tech Tool, operations
Tilt cylinder, description
TP-Linkage’s bearing points
Working hydraulic system, description (2)
Working hydraulic system, description (3)
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 WD208
Wiring diagram WD210
Wiring diagram WD211
Wiring diagram WD212
Wiring diagram WD214 (2)
Wiring diagram WD214 (3)
Wiring diagram WD214 (4)
Wiring diagram WD214
Wiring diagram WD220
Wiring diagram WD221 2
Wiring diagram WD221
Wiring diagram WD223
Wiring diagram WD224
Wiring diagram WD275
Wiring diagram WD301 (2)
Wiring diagram WD301 (3)
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
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 2
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 (2)
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 (2)
Wiring diagram WD403
Wiring diagram WD404
Wiring diagram WD405
Wiring diagram WD406
Wiring diagram WD501
Wiring diagram WD601 (2)
Wiring diagram WD601
Wiring diagram WD602 (2)
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 (2)
Wiring diagram WD904
Wiring diagram WD908
Wiring diagram WD909 (2)
Wiring diagram WD909
Wiring diagram WD910
Wiring diagram WD911 (2)
Wiring diagram WD911
Wiring diagram WD912 (2)
Wiring diagram WD912 (3)
Wiring diagram WD912
Wiring diagram WD913 (2)
Wiring diagram WD913 (3)
Wiring diagram WD913
Wiring diagram WD915 2
Wiring diagram WD915
(4) POWRER TRANSMISSION
Hydraulic diagram transmission
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
Explanations to hydraulic diagram
Hydraulic diagram, basic machine (2)
Hydraulic diagram, basic machine (3)
Hydraulic diagram, basic machine
Hydraulic diagram, complete (2)
Hydraulic diagram, complete (3)
Hydraulic diagram, complete (4)
Hydraulic diagram, complete (5)
Hydraulic diagram, complete
INSTALLATION INSTRUCTION
3rd hydraulic function, installing new (2)
3rd hydraulic function, installing new
After market engine, transfer of components
Attachment locking, installing new
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
Fuel filter extra, 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 (2)
Pre-cleaner oil bath type, installing new
Pre-cleaner turbo type, installing new (2)
Pre-cleaner turbo type, installing new
Radiator grille guard, installing new
Radio, installing new
Rear view camera, installing new
Rear view mirror, installing new
Reverse warning system, installing new
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
E1680, Holder
E1711
E-2001
E-2005
E-2007
E-2014
E-2015
E-2016
E-2017
E-2018
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
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 tank, replacing
AdBlue® DEF tank armature, cleaning
AdBlue® DEF tank armature, replacing
AdBlue® DEF, draining
AdBlue®DEF hoses, replacing
AdBlue®DEF nozzle, replacing
AdBlue®DEF pump unit, components, replacing
AdBlue®DEF pump unit, replacing
AdBlue®DEF quality, checking
AdBlue®DEF tank armature suction filter, replacing
AdBlue®DEF tank, cleaning
Aftertreatment fuel dosing unit, replacing
Aftertreatment fuel nozzle, cleaning
Aftertreatment fuel nozzle, replacing
Air in fuel system, checking
Cable harness O-ring, replacing
Camshaft setting, checking 2
Camshaft setting, checking
Camshaft, replacing 2
Camshaft, replacing
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, checking
Compressor, replacing
Cooling system pressure, checking
Crankcase ventilation separator, replacing
Crankshaft front oil seal, replacing 2
Crankshaft front oil seal, replacing
Crankshaft rear oil seal, replacing
Cylinder compression, testing
DPF (Diesel particulate filter), checking and cleaning
EGR cooler pressure, testing
EGR cooler, replacing
EGR valve (internal), replacing
EGR valve, replacing
EGR venturi tube, cleaning
EGR venturi tube, replacing
Engine belts, replacing
Engine control module (ECM), replacing non-programmed 2
Engine control module (ECM), replacing non-programmed
Engine control module (ECM), replacing pre-programmed 2
Engine control module (ECM), replacing pre-programmed
Engine mount rubber cushion, replacing 2
Engine mount rubber cushion, replacing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor (crank shaft), replacing
Engine, installing 2
Engine, installing
Engine, removing (2)
Engine, removing
Exhaust aftertreatment system fuel flow, checking
Exhaust pipe flexible tube, replacing 2
Exhaust pipe flexible tube, replacing
Fan control valve, seal replacing
Feed pump pressure, checking
Feed pump removed, reconditioning
Feed pump, replacing
Fuel system hand pump, replacing
Fuel system, bleeding
Fuel tank, replacing 2
Fuel tank, replacing
High pressure air system pressure, checking
Injector sleeves, replacing 2
Injector sleeves, replacing
Injectors, replacing 2
Injectors, replacing 3
Injectors, replacing
Inlet throttle, replacing
Lubrication oil consumption, checking
Lubrication oil pressure, checking with pressure gauge
Muffler with console, installing
Muffler with console, removing
Muffler, replacing
NOx sensor, replacing
Oil cooler, leakage check
Oil cooler, replacing 2
Oil cooler, replacing
Oil level sensor, replacing
Radiator, replacing
Rocker arms, replacing
SCR (Selective catalytic reduction) dosing system, checking
Silencer, installing
Silencer, removing
Stall speed, checking
Turbocharger, inspecting 2
Turbocharger, inspecting
Turbocharger, replacing 2
Turbocharger, replacing
Valves, adjusting 2
Valves, adjusting
Yoke, injector, checking
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Batteries, replacing
Battery condition, checking
Brake discs, replacing
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 2
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 (2)
Hub seal, replacing
Hydraulic transmission, warming up
Lock up valve, replacing (2)
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
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
Left steering cylinder, removing
Lever steering (CDC) function, checking
Right steering cylinder, installing
Right steering cylinder, removing
Secondary steering pump working pressure, checking and adjusting
Steering accumulator removed, checking
Steering accumulator, installing 2
Steering accumulator, installing
Steering accumulator, removing 2
Steering accumulator, removing
Steering system function, checking
Steering system working pressure, checking and adjusting
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Counterweight, installing
Counterweight, removing
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 tilt cylinder, replacing
Cab, position 1, restoring
Cab, position 1
Cab, position 2, restoring
Cab, position 2
CCM, replacing
Climate unit, installing
Climate unit, removing
Compressor, replacing
Condenser, replacing
Cooling unit, leak detection
Door lock cylinder, replacing (2)
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
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; DIGGING HANDLING GRADING 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 (2)
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, solenoid valve, changing (2)
Lift, solenoid valve, changing (3)
Lift, solenoid valve, changing
Liftlower function, checking (2)
Liftlower function, checking
Liftlower, angle sensor, changing (2)
Liftlower, angle sensor, changing
Liftlower, LS-disconnecting, solenoid valve, replacing (2)
Liftlower, LS-disconnecting, solenoid valve, replacing
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
Lower, solenoid valve, changing (2)
Lower, solenoid valve, changing (3)
Lower, solenoid valve, changing
LS (load sense) pressure, checking
Pressure back-up valve, replacing (2)
Pressure back-up valve, replacing (3)
Pressure back-up valve, replacing
Servo accumulator, installing
Servo accumulator, removing
Servo pressure, at the spool in control valve, checking (2)
Servo pressure, at the spool in control valve, checking
Servo pressure, checking and adjusting
Shock valve lift function, checking (2)
Shock valve lift function, checking (3)
Shock valve lift function, checking
Shock valve, tilt function, checking (2)
Shock valve, tilt function, checking (3)
Shock valve, tilt function, checking
System test
Tilt cylinder, repacking in machine
Tilt in out, angle sensor, changing (2)
Tilt in out, angle sensor, changing
Tilt in, solenoid valve, changing (2)
Tilt in, solenoid valve, changing (3)
Tilt in, solenoid valve, changing
Tilt out, solenoid valve, changing (2)
Tilt out, solenoid valve, changing (3)
Tilt out, solenoid valve, changing
Tilt, checking (2)
Tilt, checking
Tilt, LS-disconnecting, solenoid valve, replacing (2)
Tilt, LS-disconnecting, solenoid valve, replacing
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 3
Recommended lubricants 4
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 2
Engine, capacities
Engine, specifications
Engine, tightening torques
Fuel system, specifications
Fuel system, tightening torques
Inlet and exhaust system, specification 2
Inlet and exhaust system, specification
Inlet and exhaust system, tightening torques 2
Inlet and exhaust system, tightening torques
Lubrication system, specifications
Lubrication system, tightening torques
Reversible cooling fan, tightening torques
Temperature limits for cooling fan speed, specifications 2
Temperature limits for cooling fan speed, specifications
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
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 2
Propeller shaft, tightening torque
Rear axle mounting, volume
Transmission, specifications 2
Transmission, specifications 3
Transmission, specifications 4
Transmission, specifications
Transmission, tightening torques 2
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
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 2
3rd 4th hydraulic function, specifications
3rd 4th hydraulic function, tightening torques 2
3rd 4th 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 2
Control valve, specifications 3
Control valve, specifications
Control valve, tightening torques 2
Control valve, tightening torques
Fire suppression system, specification
Function times, specifications
Hydraulic connections, tightening torques
Hydraulic pump (P1), specifications 2
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