VOLVO L180H HL WHEEL LOADER SERVICE REPAIR MANUAL PDF – 2071 PAGES

Workshop Documentation for AdBlue/DEF, SCR, DPF, IQAN Electronics, Transmission, Grapple, Rotator and Hydraulic Repairs

The Volvo L180H HL Wheel Loader Service Repair Manual is a comprehensive 2,071-page technical publication covering system descriptions, diagnostic procedures, mechanical repairs, electrical troubleshooting, hydraulic testing, component replacement, installation instructions, safety information, and technical specifications for the Volvo L180H HL wheel loader.

With technical information updated in 2020, this digital PDF manual provides extensive documentation for the engine, exhaust aftertreatment system, electronic controls, transmission, braking system, steering, operator cab, working hydraulics, and specialized handling equipment.

A major feature of this manual is its detailed coverage of the AdBlue/DEF system, Selective Catalytic Reduction (SCR), Diesel Particulate Filter (DPF), Exhaust Gas Recirculation (EGR), NOx sensor, and exhaust aftertreatment regeneration system.

The electrical section includes documentation for IQAN, ECM, ACM, CCM, HMICU, GPMECU1, GPMECU2, GPMECU3, and CareTrack W-ECU, together with input/output lists, troubleshooting procedures, wiring diagrams, and Tech Tool service operations.

The drivetrain section covers the hydraulic transmission, Lock-Up valve, differential locks, drive axles, hub reductions, and transmission pressure checks.

The hydraulic section provides detailed information about hydraulic pumps P1, P2 and P3, Boom Suspension System (BSS), servo controls, load-sensing pressure, central lubrication, and fire suppression equipment.

A particularly valuable feature is the inclusion of specialized procedures for grapple removal and installation, rotator inspection and adjustment, rotator pin replacement, log mover checking, and hydraulic control valve servicing.

The manual also contains an extensive collection of electrical wiring diagrams, including dedicated diagrams for aftertreatment, braking, BSS, CDC, gear selection, and starting systems.

This publication is intended for professional Volvo equipment technicians, heavy machinery repair workshops, fleet maintenance departments, and experienced equipment owners.

MANUAL INFORMATION

• Manufacturer: Volvo Construction Equipment
• Equipment Model: Volvo L180H HL Wheel Loader
• Manual Type: Service Repair / Workshop Manual
• Format: PDF
• Total Pages: 2,071
• Technical Information Updated: 2020
• Delivery: Digital Download
• Language: English

WHAT DOES THIS VOLVO L180H HL MANUAL COVER?

The publication is organized into six principal categories:

1. Descriptions
2. Diagrams
3. Installation Instructions
4. Repair Procedures
5. Safety Information
6. Technical Specifications

These sections cover the machine's mechanical components, electronic systems, exhaust aftertreatment, transmission, brakes, steering, hydraulic equipment, and specialized handling functions.

1. GENERAL SERVICE AND WORKSHOP INFORMATION

The manual contains general technical references and workshop information.

Included topics:

• General machine service information
• Leak detector 951 1207
• Special workshop tools
• Infrared thermometer
• Tool references and user instructions
• Additional workshop operation numbers
• General tightening torques
• Conversion tables
• Recommended lubricants
• Coolant recommendations
• AdBlue/DEF specifications
• Alternative fuels

2. ENGINE MECHANICAL COMPONENTS

The engine section includes descriptions and repair procedures for major engine components.

ENGINE SYSTEM INFORMATION

• Engine general description
• Engine reference values
• Crankcase ventilation
• Lubrication system
• Fuel system
• Engine cooling system
• Inlet and exhaust system
• Engine auxiliary braking
• ECO accelerator pedal

ENGINE REPAIR PROCEDURES

• Engine removal
• Engine installation
• Cylinder compression testing
• Camshaft setting checking
• Camshaft replacement
• Rocker arm replacement
• Valve adjustment
• Crankshaft front oil seal replacement
• Crankshaft rear oil seal replacement
• Engine mount rubber cushion replacement
• Engine belt replacement
• Engine stall speed checking

3. EXHAUST AFTERTREATMENT SYSTEM

A distinctive feature of this manual is its extensive coverage of the exhaust aftertreatment equipment.

AFTERTREATMENT SYSTEMS

• Exhaust Aftertreatment System
• Aftertreatment Control Module (ACM)
• AdBlue/DEF supply system
• SCR dosing system
• Diesel Particulate Filter (DPF)
• Exhaust aftertreatment fuel system
• Regeneration process
• NOx sensor

AFTERTREATMENT REPAIR PROCEDURES

• ACM replacement, pre-programmed
• ACM replacement, non-programmed
• Aftertreatment fuel dosing unit replacement
• Aftertreatment fuel nozzle cleaning
• Aftertreatment fuel nozzle replacement
• Exhaust aftertreatment fuel flow checking
• High-pressure air system pressure checking
• NOx sensor replacement
• Exhaust pipe flexible tube replacement

4. ADBLUE/DEF SYSTEM

The manual provides extensive repair information for the AdBlue/DEF system.

ADBLUE/DEF COMPONENTS

• AdBlue/DEF pump unit
• AdBlue/DEF tank
• AdBlue/DEF tank armature
• AdBlue/DEF hoses
• AdBlue/DEF nozzle
• AdBlue/DEF dosing components

ADBLUE/DEF SERVICE PROCEDURES

• AdBlue/DEF quality checking
• AdBlue/DEF draining
• AdBlue/DEF tank cleaning
• AdBlue/DEF tank replacement
• AdBlue/DEF tank armature cleaning
• AdBlue/DEF tank armature replacement
• AdBlue/DEF hose replacement
• AdBlue/DEF nozzle replacement
• AdBlue/DEF pump unit replacement
• AdBlue/DEF pump unit component replacement
• AdBlue/DEF pump unit diagnostics

5. SELECTIVE CATALYTIC REDUCTION (SCR)

The manual includes service information for the SCR dosing system.

Included topics:

• SCR dosing system checking
• AdBlue/DEF dosing components
• Aftertreatment control functions
• NOx sensor replacement
• Exhaust aftertreatment diagnostics
• Related technical specifications

6. DIESEL PARTICULATE FILTER (DPF)

The publication includes procedures for inspecting and servicing the particulate filter.

Included topics:

• DPF checking
• DPF cleaning
• Regeneration process description
• Exhaust aftertreatment operating information
• Aftertreatment system diagnostics

7. EXHAUST GAS RECIRCULATION (EGR)

The manual covers both Exhaust Gas Recirculation and Internal Exhaust Gas Recirculation systems.

EGR COMPONENTS

• EGR valve
• Internal EGR valve
• EGR cooler
• EGR venturi tube
• Related exhaust system components

EGR REPAIR PROCEDURES

• EGR cooler pressure testing
• EGR cooler replacement
• EGR valve replacement
• Internal EGR valve replacement
• EGR venturi tube cleaning
• EGR venturi tube replacement

8. FUEL SYSTEM AND INJECTORS

The fuel system section contains descriptions and workshop procedures.

FUEL SYSTEM COMPONENTS

• Fuel feed pump
• Fuel injectors
• Injector sleeves
• Fuel system hand pump
• Fuel tank
• Fuel supply components

FUEL SYSTEM REPAIR PROCEDURES

• Fuel system bleeding
• Air in fuel system checking
• Feed pump pressure checking
• Feed pump reconditioning
• Feed pump replacement
• Fuel system hand pump replacement
• Fuel tank replacement
• Injector checking
• Injector replacement
• Injector sleeve replacement
• Injector yoke checking
• Carbon dioxide checking in the fuel system

9. TURBOCHARGER AND AIR INTAKE SYSTEM

The manual includes descriptions and repair procedures for the engine air intake and turbocharger system.

Included topics:

• Inlet and exhaust system description
• Turbocharger inspection
• Turbocharger replacement
• Variable turbocharger actuator replacement
• Inlet throttle replacement
• Exhaust system component servicing
• Inlet and exhaust system specifications
• Inlet and exhaust tightening torques

10. ENGINE COOLING SYSTEM

The cooling system section includes descriptions, technical specifications, and repair procedures.

COOLING COMPONENTS

• Cooling system
• Radiator
• Cooling fan
• Cooling fan motor
• Reversible cooling fan
• Fan control valve
• Coolant system components

COOLING SYSTEM SERVICE PROCEDURES

• Cooling system pressure checking
• Carbon dioxide checking in coolant
• Radiator replacement
• Fan control valve seal replacement
• Cooling fan speed specifications
• Cooling system tightening torques

11. ENGINE LUBRICATION SYSTEM

The lubrication section includes descriptions and service procedures for engine lubrication components.

Included topics:

• Engine lubrication system description
• Lubrication oil pressure checking with pressure gauge
• Lubrication oil consumption checking
• Oil cooler leakage checking
• Oil cooler replacement
• Oil level sensor replacement
• Crankcase ventilation separator replacement
• Lubrication system specifications
• Lubrication system tightening torques

12. ELECTRONIC CONTROL SYSTEMS

The electrical section includes descriptions of the machine's electronic control architecture.

CONTROL MODULES AND SYSTEMS

• Engine Control Module (ECM)
• Aftertreatment Control Module (ACM)
• Climate Control Module (CCM)
• Human-Machine Interface Control Unit (HMICU)
• GPMECU1
• GPMECU2
• GPMECU3
• CareTrack W-ECU
• IQAN electronic control system

ELECTRONIC CONTROL INFORMATION

• Electronic control system description
• Control unit input/output lists
• Software parameter descriptions
• Booting sequence
• Electrical component identification
• Electrical connector information
• Chassis connections
• System voltage
• Key feed
• Electronic troubleshooting

13. IQAN ELECTRONIC CONTROL SYSTEM

A notable feature of this publication is its coverage of the IQAN system.

Included topics:

• IQAN system description
• Electronic control functions
• Software parameter settings
• Control unit communication
• Electronic troubleshooting references
• Input/output signal information

14. GPMECU1, GPMECU2 AND GPMECU3

The manual includes documentation for the three GPMECU control units.

CONTROL UNIT INFORMATION

• GPMECU1 input/output list
• GPMECU2 input/output list
• GPMECU3 input/output list

CONTROL UNIT REPLACEMENT

• GPMECU1 pre-programmed replacement
• GPMECU1 non-programmed replacement
• GPMECU2 pre-programmed replacement
• GPMECU2 non-programmed replacement
• GPMECU3 pre-programmed replacement
• GPMECU3 non-programmed replacement

15. TECH TOOL DIAGNOSTICS

The manual includes references to Volvo Tech Tool diagnostic operations.

DIAGNOSTIC INFORMATION

• Tech Tool operations
• General fault diagnosis
• Troubleshooting strategy
• Troubleshooting tools
• Electrical lead checking
• Connector checking
• Software parameter references
• Electronic control unit input/output information

CONTROL MODULE REPLACEMENT

• ECM pre-programmed replacement
• ECM non-programmed replacement
• ACM pre-programmed replacement
• ACM non-programmed replacement
• HMICU pre-programmed replacement
• HMICU non-programmed replacement
• GPMECU replacement
• W-ECU replacement

16. INSTRUMENT PANEL AND INFORMATION DISPLAY

The manual includes information about the operator information display and electronic monitoring functions.

Included topics:

• Information display general description
• Service mode
• Electronic booting sequence
• System voltage monitoring
• Software parameters
• Electronic control signals
• Troubleshooting information
• Limp-home function

17. ELECTRICAL SYSTEM COMPONENTS

The electrical documentation includes descriptions and service procedures for major electrical components.

ELECTRICAL COMPONENTS

• Alternator
• 80 A alternator
• Batteries
• Battery disconnector switch
• Starter motor
• Starter lock
• Electrical connectors
• Wiring harnesses
• Rear vision system
• Reverse warning system
• Intermittent wiper and washer

ELECTRICAL SERVICE PROCEDURES

• Battery condition checking
• Battery replacement
• Starter motor replacement
• Starter lock replacement
• Electronic control unit replacement
• Electrical troubleshooting

18. HYDRAULIC TRANSMISSION

The power transmission section provides descriptions and repair procedures for the drivetrain.

TRANSMISSION COMPONENTS

• Hydraulic transmission
• Gear selector valve
• Lock-Up valve
• Transmission heat exchanger
• Transmission output shafts
• Transmission control system

TRANSMISSION REPAIR PROCEDURES

• Transmission removal
• Transmission installation
• Transmission functional checking
• Transmission oil pressure checking
• Transmission warm-up procedure
• Gear selector valve solenoid replacement
• Lock-Up valve replacement
• Heat exchanger replacement
• Front output shaft seal replacement
• Rear output shaft seal replacement

19. TRANSMISSION CALIBRATION

The manual includes technical information related to transmission calibration.

Included topics:

• Hydraulic transmission calibration description
• Transmission calibration error codes
• Tech Tool transmission operations
• Transmission functional checking
• Transmission hydraulic diagram

20. DRIVE AXLES, DIFFERENTIALS AND HUB REDUCTIONS

The drivetrain section includes descriptions and repair procedures for axle components.

DRIVETRAIN COMPONENTS

• Front axle
• Rear axle
• Rear axle mounting
• Propeller shaft
• Differential lock
• Automatic differential brake
• Limited Slip differential
• Hub reductions

REPAIR PROCEDURES

• Axle removal
• Axle installation
• Differential lock adjustment
• Differential lock functional checking
• Hub reduction removal
• Hub reduction installation
• Hub seal replacement
• Axle suspension bushing replacement
• Axle suspension seal replacement

21. HYDRAULIC BRAKING SYSTEM

The brake section contains descriptions and repair procedures for the service brake system.

BRAKE COMPONENTS

• Brake accumulators
• Foot brake valve
• Automatic brake valve
• Wheel brakes
• Brake discs
• Brake pistons
• Axle oil cooler

BRAKE REPAIR PROCEDURES

• Brake accumulator checking in the machine
• Removed accumulator charging pressure checking
• Brake accumulator removal
• Brake accumulator installation
• Brake system charging checking
• Brake circuit pressure checking
• Brake circuit pressure adjustment
• Brake system bleeding
• Brake disc wear measurement
• Brake disc replacement
• Brake piston seal replacement
• Brake retardation functional checking
• Automatic brake function checking

22. PARKING BRAKE SYSTEM

The manual includes detailed procedures for servicing the parking brake.

Included operations:

• Manual parking brake release
• Parking brake functional checking
• Parking brake adjustment
• Parking brake assembly removal
• Parking brake installation
• Parking brake disassembly
• Parking brake assembly
• Parking brake pad replacement
• Parking brake disc replacement
• Parking brake seal replacement

23. STEERING SYSTEM

The steering section contains descriptions and workshop repair procedures for the hydraulic steering system.

STEERING COMPONENTS

• Steering valve
• Steering cylinders
• Steering pressure monitor
• Steering shift valve
• Secondary steering
• Steering accumulator

STEERING REPAIR PROCEDURES

• Steering system functional checking
• Steering working pressure checking
• Steering working pressure adjustment
• Left steering cylinder removal
• Left steering cylinder installation
• Right steering cylinder removal
• Right steering cylinder installation
• Steering accumulator checking
• Steering accumulator removal
• Steering accumulator installation

24. COMFORT DRIVE CONTROL (CDC)

The manual provides descriptions and service procedures for the Comfort Drive Control lever steering system.

CDC COMPONENTS

• CDC valve
• CDC joystick
• CDC angle sensor
• CDC solenoid valve
• CDC servo pressure circuit

CDC REPAIR PROCEDURES

• CDC calibration function description
• CDC angle sensor replacement
• CDC joystick replacement
• CDC solenoid valve replacement
• CDC servo pressure checking
• CDC lever steering functional checking

25. SECONDARY STEERING SYSTEM

The manual includes technical information and pressure adjustment procedures for the secondary steering system.

Included topics:

• Secondary steering description
• Secondary steering pump working pressure checking
• Secondary steering pump pressure adjustment
• Steering system functional checking
• Secondary steering pump specifications

26. FRAME, WHEELS AND COUNTERWEIGHT

The frame section includes descriptions and repair procedures for structural components.

Included topics:

• Machine frame
• Frame joint
• Counterweight removal
• Counterweight installation
• Front wheel removal
• Front wheel installation
• Rear wheel removal
• Rear wheel installation
• Counterweight specifications
• Frame joint tightening torques
• Wheel tightening torques

27. OPERATOR CAB AND CLIMATE CONTROL

The cab section includes descriptions and service procedures for the operator environment.

CAB COMPONENTS

• Operator cab
• Driver seat
• Viscous cab suspension
• Climate control system
• Air conditioning system
• Electric door opener
• Pause heater
• Windows and windscreen

CAB REPAIR PROCEDURES

• Cab positioning
• Cab restoration from service positions
• Cab suspension replacement
• Operator seat securing
• Engine hood raising and securing
• Plastic hood repair
• Window installation
• Windscreen replacement

28. AIR CONDITIONING SYSTEM

The manual contains repair procedures and technical information for the air conditioning equipment.

AIR CONDITIONING SERVICE PROCEDURES

• Air conditioning performance checking
• Air conditioning troubleshooting
• Climate unit removal
• Climate unit installation
• Compressor replacement
• Condenser replacement
• Evaporator replacement
• Expansion valve replacement
• Drying filter replacement
• Heater core replacement
• Fan motor replacement
• Heat control valve replacement
• Air mix door actuator replacement
• Refrigerant draining
• Refrigerant filling
• Vacuum pumping
• Cooling unit leak detection

29. ELECTRIC DOOR OPENER

The manual includes detailed procedures for servicing the electric door opening mechanism.

Included operations:

• Electric door opener control unit replacement
• Electric door opener locking motor replacement
• Electric door opener opening support motor replacement
• Electric door opener rotor switch replacement
• Door lock cylinder replacement

30. WORKING HYDRAULIC SYSTEM

The hydraulic section provides extensive technical information and repair procedures for the machine's hydraulic equipment.

HYDRAULIC COMPONENTS

• Hydraulic oil tank
• Hydraulic pumps
• Central valve
• Main control valve 1
• Main control valve 2
• Hydraulic servo system
• Hydraulic pressure monitor
• Hydraulic shift valve
• Electric servo lever control
• Hydraulic pump flow regulation

HYDRAULIC SERVICE PROCEDURES

• Hydraulic system bleeding
• Hydraulic system warming up
• Hydraulic system testing
• Hydraulic oil tank vacuum pumping
• Hydraulic coupling servicing
• Hydraulic pressure checking
• Hydraulic pressure adjustment

31. HYDRAULIC PUMPS P1, P2 AND P3

The manual includes repair procedures for the three hydraulic pumps.

HYDRAULIC PUMP P1

• Pump P1 removal
• Pump P1 installation
• Pump P1 specifications

HYDRAULIC PUMP P2

• Pump P2 removal
• Pump P2 installation
• Pump P2 specifications

HYDRAULIC PUMP P3

• Pump P3 checking
• Pump P3 removal
• Pump P3 installation
• Pump P3 specifications

ADDITIONAL PUMP TESTING

• Hydraulic pump standby pressure checking
• Hydraulic pump standby pressure adjustment
• Hydraulic pump working pressure checking
• Hydraulic pump working pressure adjustment
• Load-sensing pressure checking

32. HYDRAULIC SERVO SYSTEM

The manual includes procedures for checking and adjusting hydraulic servo functions.

Included topics:

• Servo system description
• Electric servo lever control
• Servo accumulator removal
• Servo accumulator installation
• Servo pressure checking
• Servo pressure adjustment
• Servo pressure checking at the control valve spool
• Servo pressure checking at control valve 2

33. BOOM SUSPENSION SYSTEM (BSS)

The manual includes technical descriptions and repair procedures for the Boom Suspension System.

BSS COMPONENTS

• Boom suspension accumulators
• Pressure reduction valve
• Safety valve
• Hydraulic suspension circuits

BSS REPAIR PROCEDURES

• Boom Suspension System functional checking
• Boom suspension accumulator checking
• Boom suspension accumulator pressure adjustment
• Hydraulic accumulator depressurization
• Pressure reduction valve checking
• Pressure reduction valve adjustment
• Safety valve checking
• Safety valve adjustment

34. GRAPPLE AND LOG HANDLING EQUIPMENT

A particularly important feature of this manual is its coverage of specialized grapple and log handling equipment.

GRAPPLE REPAIR PROCEDURES

• Complete grapple removal
• Complete grapple installation
• Grapple functional checking
• Grapple tilt shock valve checking
• Grapple tightening torques

LOG HANDLING FUNCTIONS

• Log mover checking
• Grapple hydraulic control references
• Specialized handling equipment service information

These procedures distinguish the L180H HL documentation from manuals focused primarily on conventional wheel loader bucket functions.

35. ROTATOR AND ROTATOR PIN REPAIRS

The manual includes specific procedures for the rotator assembly.

ROTATOR SERVICE PROCEDURES

• Rotator checking
• Rotator adjustment
• Rotator pin replacement
• Vertical rotator pin bushing replacement
• Rotator-related hydraulic system checking

36. LIFTING ARM AND HYDRAULIC FUNCTIONS

The manual includes repair procedures for the lifting arm and associated hydraulic controls.

Included topics:

• Lifting arm removal
• Lifting arm installation
• Lift/lower function checking
• Tilt function checking
• Lift shock valve checking
• Tilt shock valve checking
• Hydraulic control valve 2 shock valve checking
• Hydraulic system functional testing

37. CENTRAL LUBRICATION SYSTEM

The manual includes technical descriptions and repair procedures for the automatic lubrication system.

Included topics:

• Central lubrication system description
• Lubrication pump unit
• Dosage valves
• Lubrication points
• Lubrication interval adjustment
• Lubricant filling
• Automatic lubrication pump reconditioning
• Automatic lubrication system updating
• Lubrication system parameter settings

38. FIRE SUPPRESSION SYSTEM

The manual contains technical information about the machine's fire suppression equipment.

Included topics:

• Fire suppression system component description
• Fire suppression system functional description
• Actions after fire suppression system activation
• Actions after manual activation
• Fire suppression system specifications

39. ELECTRICAL WIRING DIAGRAMS

The manual contains an extensive collection of electrical wiring diagrams.

SPECIALIZED WIRING DIAGRAMS

• Aftertreatment wiring diagram
• Brake wiring diagram
• Boom Suspension System wiring diagram
• Comfort Drive Control wiring diagram
• Electrically controlled battery disconnector diagrams
• Gear system wiring diagram
• Starting system wiring diagram

INCLUDED WIRING DIAGRAM GROUPS

• WD201, WD202, WD208
• WD210, WD211, WD214
• WD220, WD221, WD223, WD224
• WD275
• WD301–WD306
• WD320–WD322
• WD324–WD326
• WD330–WD335, WD337
• WD350–WD352
• WD360–WD363
• WD371–WD377
• WD401–WD406
• WD501
• WD601, WD602, WD604
• WD801, WD802, WD804–WD808
• WD831
• WD901–WD904
• WD908, WD913, WD915
• WD930
• WD951–WD955

The diagrams provide circuit references for the electrical and electronic systems documented in the publication.

40. HYDRAULIC CIRCUIT DIAGRAMS

The manual includes hydraulic diagrams for the major machine systems.

Included diagrams:

• Complete hydraulic system diagram
• Transmission hydraulic diagram
• Hydraulic diagram explanations

41. OPTIONAL EQUIPMENT INSTALLATION INSTRUCTIONS

The installation section includes procedures for selected equipment and components.

Included instructions:

• Aftermarket engine component transfer
• CareTrack
• Emergency stop installation
• Extra fuel filter installation
• High Sulphur Conversion Kit installation
• Cyclone-type pre-cleaner installation
• Oil-bath-type pre-cleaner installation
• Turbo-type pre-cleaner installation
• Rear-view mirror installation

42. WORKSHOP SAFETY INFORMATION

The manual includes safety instructions for servicing heavy construction equipment.

Included topics:

• General workshop safety
• CE marking and EMC directive
• Machine service positions
• Safe lifting and supporting
• Hydraulic system safety
• Battery safety
• Electrical system servicing
• Fuel and oil handling
• Air conditioning refrigerant safety
• Tyre handling
• Fire prevention
• Checks after fire or heat exposure
• Decontamination
• Environmental handling
• Waste disposal
• Working in contaminated areas
• Towing
• Working under a raised boom
• Booster battery starting

43. TECHNICAL SPECIFICATIONS

The specifications section provides reference data for the machine's major systems.

ENGINE AND AFTERTREATMENT

• Engine specifications
• Engine capacities
• Engine tightening torques
• Fuel system specifications
• Fuel system tightening torques
• EGR system tightening torques
• AdBlue/DEF specifications
• Cooling system specifications
• Cooling fan speed specifications
• Lubrication system specifications
• Inlet and exhaust system specifications

ELECTRICAL SYSTEM

• 80 A alternator specifications
• Battery specifications
• Battery weight
• Electrical system specifications
• Lighting specifications
• Preheating specifications
• Starter motor specifications

TRANSMISSION AND AXLES

• Transmission specifications
• Transmission capacity
• Transmission tightening torques
• Front and rear axle specifications
• Axle oil volumes
• Rear axle mounting volumes
• Propeller shaft tightening torques

BRAKES AND STEERING

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

FRAME AND CAB

• Counterweight weight
• Counterweight tightening torques
• Frame joint tightening torques
• Wheel tightening torques
• Air conditioning specifications
• Air conditioning refrigerant weight
• Cab tightening torques

HYDRAULIC SYSTEM

• Hydraulic pump P1 specifications
• Hydraulic pump P2 specifications
• Hydraulic pump P3 specifications
• Hydraulic system specifications
• Hydraulic system volume
• Control valve specifications
• Servo system specifications
• Boom Suspension System specifications
• Automatic lubrication system specifications
• Fire suppression system specifications
• Grapple tightening torques
• Lift cylinder tightening torques
• Lifting arm tightening torques
• Tilt cylinder tightening torques
• Hydraulic function times

PRACTICAL WORKSHOP APPLICATIONS

This manual can assist with operations such as:

• Checking AdBlue/DEF quality
• Diagnosing AdBlue/DEF pump unit problems
• Cleaning and replacing AdBlue/DEF components
• Checking SCR dosing system operation
• Inspecting and cleaning the DPF
• Testing EGR cooler pressure
• Replacing EGR valves
• Diagnosing NOx sensor-related issues
• Checking engine compression
• Servicing fuel injectors
• Replacing turbocharger components
• Using Tech Tool diagnostic references
• Replacing ECM, ACM, HMICU and GPMECU modules
• Checking transmission oil pressure
• Replacing the Lock-Up valve
• Servicing hub reductions
• Checking brake accumulator pressure
• Replacing brake discs and piston seals
• Servicing the parking brake
• Checking CDC lever steering
• Adjusting secondary steering pressure
• Testing hydraulic pumps P1, P2 and P3
• Checking load-sensing pressure
• Servicing Boom Suspension System accumulators
• Removing and installing grapple assemblies
• Checking and adjusting the rotator
• Replacing rotator pins and bushings
• Checking log mover functions
• Servicing central lubrication equipment
• Reviewing fire suppression system procedures
• Consulting electrical wiring diagrams
• Reviewing hydraulic circuit diagrams

WHO IS THIS MANUAL FOR?

This technical publication is suitable for:

• Professional Volvo wheel loader technicians
• Heavy equipment repair workshops
• Construction machinery fleet maintenance departments
• Diesel engine and exhaust aftertreatment technicians
• Electronic diagnostics specialists
• Transmission and drivetrain repair technicians
• Hydraulic system technicians
• Grapple and log handling equipment maintenance teams
• Experienced Volvo L180H HL owners

IMPORTANT COMPATIBILITY INFORMATION

This manual is identified for the Volvo L180H HL Wheel Loader.

Some procedures, electrical diagrams, hydraulic arrangements, exhaust aftertreatment components, and specialized handling equipment instructions may apply only to specific machine configurations.

Before purchasing, verify your machine model, serial number, and installed equipment to determine whether the relevant documentation applies to your machine.

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

DIGITAL PDF DELIVERY

This product is supplied as a digital PDF workshop manual.

The publication includes:

• 2,071 pages of technical documentation
• Engine mechanical repair procedures
• AdBlue/DEF diagnostics and repairs
• SCR dosing system checking
• DPF checking and cleaning
• EGR and Internal EGR repair information
• Turbocharger and fuel system servicing
• IQAN electronic control information
• ECM, ACM, HMICU and GPMECU documentation
• Tech Tool diagnostic references
• Transmission and Lock-Up valve repairs
• Axle and hub reduction servicing
• Brake and parking brake repairs
• CDC and secondary steering procedures
• Hydraulic pump P1, P2 and P3 service information
• Boom Suspension System procedures
• Grapple and rotator repair instructions
• Log mover checking procedures
• Central lubrication system documentation
• Fire suppression system information
• Extensive electrical wiring diagrams
• Complete hydraulic diagrams
• Optional equipment installation instructions
• Workshop safety information
• Technical specifications and tightening torques

Digital product only. No printed manual will be shipped.

A compatible PDF reader is required to view the document.

IMPORTANT DOWNLOAD INFORMATION

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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
Engine, reference values
Exhaust aftertreatment fuel system diagnostics, description
Exhaust Aftertreatment System, description
Exhaust Gas Recirculation (EGR), description
Fuel system, description
Injectors, checking
Inlet and exhaust system, description
Internal Exhaust Gas Recirculation (IEGR), description
Lubrication system, description
Regeneration process, description
Reversible cooling fan, description
Tech Tool, operations
(3) ELEC. SYSTEM, WARNING SYSTEM, INFORMATION SYSTEN, INSTRUMENTS
ACM, IO 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, IO list
Chassis connection
Collection of basic data
Components list
Conditions when checking
Connectors, overview
ECM (Engine Control Module), IO list
Electrical symbols and designations
Electrical system, description
Electrical system, work instructions
Electronic control system, description
General fault diagnosis information
GPMECU1, IO list
GPMECU2, IO list
GPMECU3, IO list
HMICU, IO list
Hood opening
Information display, general
Information display, service mode
Intermittent wiper and washer
IQAN, description
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
W-ECU, IO list
(4) POWER TRANSMISSION
Automatic differential brake, Limited Slip, description
Differential lock, description
Drive axles, description
Front axle, component description
Hydraulic transmission calibration, description
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
Brake accumulator, description
Braking system, description
Foot brake valve, description
Parking brake, component description
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
Pressure monitor, description
Secondary steering, description
Shift valve, description
Steering cylinder, description
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
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
Boom Suspension System, component description
Boom Suspension System, description
Central lubrication system, description
Central valve, description
Change of lubrication interval
Diagnostic tools, description
Dosage valves, description
Filling lubricant
Fire suppression system, component description
Fire suppression system, functional description
Hydraulic components, cleanliness when handling
Hydraulic oil tank, description
Hydraulic pump flow regulation, description
Hydraulic pumps, description
Lever control, electric servo, description
Lubrication points, central lubrication
Main control valve 1, description
Main control valve 2, description
Parameter settings
Pressure monitor, description
Pump unit, description
Servo system, description
Shift valve, description
Software, parameter settings and read-outs
Tech Tool, operations
TP-Linkage’s bearing points
Working hydraulic system, description
DIAGRAMS
(3) ELEC. SYSTEM, WARNING SYSTEM, INFORMATION SYSTEM, INSTRUMENTS
Table of contents, wiring diagrams
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 WD214 (2)
Wiring diagram WD214
Wiring diagram WD220
Wiring diagram WD221
Wiring diagram WD223
Wiring diagram WD224
Wiring diagram WD275
Wiring diagram WD301
Wiring diagram WD302
Wiring diagram WD303
Wiring diagram WD304
Wiring diagram WD305
Wiring diagram WD306
Wiring diagram WD320
Wiring diagram WD321
Wiring diagram WD322
Wiring diagram WD324
Wiring diagram WD325
Wiring diagram WD326
Wiring diagram WD330
Wiring diagram WD331
Wiring diagram WD332
Wiring diagram WD333
Wiring diagram WD334
Wiring diagram WD335
Wiring diagram WD337
Wiring diagram WD350
Wiring diagram WD351
Wiring diagram WD352
Wiring diagram WD360
Wiring diagram WD361
Wiring diagram WD362
Wiring diagram WD363
Wiring diagram WD371
Wiring diagram WD372
Wiring diagram WD373
Wiring diagram WD374
Wiring diagram WD375
Wiring diagram WD376
Wiring diagram WD377
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
Wiring diagram WD804
Wiring diagram WD805
Wiring diagram WD806
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 WD913
Wiring diagram WD915
Wiring diagram WD930
Wiring diagram WD951
Wiring diagram WD952
Wiring diagram WD953
Wiring diagram WD954
Wiring diagram WD955
(4) POWER TRANSMISSION
Hydraulic diagram transmission
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
Explanations to hydraulic diagram
Hydraulic diagram, complete
INSTALLATION INSTRUCTION
After market engine, transfer of components
CARE TRACK
Emergency stop, installing new
Fuel filter extra, installing new
HIGH SULPHUR CONVERSION KIT, INSTALLING NEW
Pre-cleaner cyclone type, installing new
Pre-cleaner oil bath type, installing new
Pre-cleaner turbo type, installing new
Rear view mirror, installing new
REPAIR
(0) GENERAL
88830557 User Instruction
E 1708, Checking point
E1680, Holder
E-2001
E-2005
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 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, cleaning
AdBlue®DEF tank armature, replacing
AdBlue®DEF tank, cleaning
AdBlue®DEF tank, replacing
AdBlue®DEF, draining
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
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
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
Engine control module (ECM), replacing pre-programmed
Engine mount rubber cushion, replacing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor (crank shaft), replacing
Engine, installing
Engine, removing
Exhaust aftertreatment system fuel flow, checking
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
High pressure air system pressure, checking
Injector sleeves, replacing
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
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
Turbocharger, replacing
Valves, adjusting
Variable turbocharger actuator, replacing
Yoke, injector, 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
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
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
Seal for front output shaft, replacing
Seal for rear output shaft, replacing
Tech Tool, operations
Transmission oil pressure, checking
Transmission, function check
Transmission, installing
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
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
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, 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
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
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
Accumulator removed, checking
Accumulator, boom suspension system, discarding
Accumulator, discarding (2)
Accumulator, discarding
Automatic lubrication pump unit, reconditioning
Bleeding air
Boom suspension accumulator, checking and adjusting
Boom suspension system, checking
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom suspension system, pressure reduction, safety valve, checking and adjusting
Fire suppression system, actions after activation
Fire suppression system, actions after manual activation
Grapple complete, installing
Grapple complete, removing
Grapple, checking
Hydraulic couplings
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
Lifting arm, installing
Lifting arm, removing
Liftlower function, checking
Log mover, checking
LS (load sense) pressure, checking
Rotator pin (vertical) bushing, replacing
Rotator pin, replacing
Rotator, checking and adjusting
Rotator, checking
Servo accumulator, installing
Servo accumulator, removing
Servo pressure, at the spool in control valve 2, checking
Servo pressure, at the spool in control valve, checking
Servo pressure, checking and adjusting
Shock valve lift function, checking
Shock valve removed (Control valve 2), checking
Shock valve, tilt function, checking
Shock valves grapple tilt (Control valve 2), checking
System test
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 (2)
Service position 1
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
SPECIFICATIONS
(0) GENERAL
Conversion tables
Tightening torques
(1) STANDARD PARTS, SERVICE
AdBlue®DEF
Alternative fuels
Coolant
Recommended lubricants
(2) ENGINE WITH MOUNTING AND EQUIPMENT
AdBlue®DEF
Cooling fan rpm, specifications
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
(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
(4) POWER TRANSMISSION
Axle suspension, tightening torque
Front and rear axles, specifications
Front and rear axles, tightening torque
Front and rear axles, volume
Hydraulic transmission, capacity
Propeller shaft, tightening torque
Rear axle mounting, volume (2)
Rear axle mounting, volume
Transmission, specifications (2)
Transmission, specifications
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, tightening torques
Secondary steering pump, specifications
Steering cylinder, tightening torque
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, HANDLING, GRADING EQUIPM, MISC. EQUIP
Automatic lubrication system, specifications
Boom Suspension System, specifications
Boom Suspension System, tightening torques
Channel properties, specifications
Control valve, specifications
Control valve, tightening torques
Fire suppression system, specification
Function times, specifications
Grapple, tightening torques
Hydraulic connections, tightening torques
Hydraulic pump (P1), specifications
Hydraulic pump (P2), specifications
Hydraulic pump (P3), specifications
Hydraulic pumps, tightening torques
Hydraulic system, specification
Hydraulic system, volume
Lift cylinder, tightening torques
Lifting arm, tightening torques
Recommended lubricants
Servo system, specifications
Tilt cylinder, tightening torques