VOLVO L180H WHEEL LOADER SERVICE REPAIR MANUAL PDF – 3007 PAGES

The Volvo L180H Wheel Loader Service Repair Manual provides comprehensive technical documentation for the inspection, diagnosis, maintenance, servicing, and repair of the Volvo L180H wheel loader.

This extensive 3,007-page English-language PDF manual covers major machine systems, including the engine, exhaust aftertreatment equipment, electrical and electronic control systems, power transmission, brakes, steering, operator cab, and hydraulic working equipment.

The publication includes technical descriptions, electrical wiring diagrams, hydraulic diagrams, installation instructions, detailed repair procedures, diagnostic information, safety guidance, and technical specifications.

With information updated in 2020, this manual is a valuable technical reference for professional mechanics, heavy equipment service technicians, construction machinery repair workshops, and Volvo L180H equipment owners.

MANUAL DETAILS

• Manufacturer: Volvo Construction Equipment
• Equipment Model: L180H Wheel Loader
• Manual Type: Service Repair Manual
• File Format: PDF
• Number of Pages: 3,007
• Language: English
• Information Update: 2020
• Delivery: Digital Download

WHAT IS INCLUDED IN THIS SERVICE REPAIR MANUAL?

The documentation is organized into six main sections: Technical Descriptions, Diagrams, Installation Instructions, Repair Procedures, Safety, and Specifications.

1. TECHNICAL DESCRIPTIONS

The manual explains the construction, functions, and operating principles of the Volvo L180H's major systems.

ENGINE AND EXHAUST AFTERTREATMENT

• Engine construction and operating principles
• Fuel injection and fuel supply systems
• Engine lubrication and cooling systems
• Crankcase ventilation
• Exhaust Gas Recirculation (EGR)
• Internal Exhaust Gas Recirculation (IEGR)
• Exhaust aftertreatment system
• Diesel particulate filter regeneration
• AdBlue/DEF pump unit diagnostics
• Reversible cooling fan
• Engine braking functions
• Volvo Tech Tool operations

ELECTRICAL AND ELECTRONIC SYSTEMS

• Electrical system architecture
• Engine Control Module (ECM)
• Aftertreatment Control Module (ACM)
• General Purpose Machine Electronic Control Units (GPMECU1, GPMECU2, and GPMECU3)
• Human Machine Interface Control Unit (HMICU)
• Climate Control Module (CCM)
• CareTrack communication equipment
• Sensors, connectors, and electrical components
• Information display and service mode
• Rear vision and reverse warning systems
• Volvo Co-Pilot
• Software parameters and diagnostic functions

POWER TRANSMISSION AND AXLES

• Hydraulic transmission
• Transmission calibration
• Drive axles and differential lock
• Front and rear axle components
• Propeller shaft
• Limited-slip differential functions

BRAKING AND STEERING SYSTEMS

• Service and parking brakes
• Brake accumulators and control valves
• Steering valves and cylinders
• Secondary steering system
• Comfort Drive Control (CDC)
• CDC calibration functions

HYDRAULIC SYSTEM AND WORKING EQUIPMENT

• Hydraulic pumps and flow regulation
• Hydraulic oil tank
• Main control valves
• Third and fourth hydraulic functions
• Hydraulic attachment locking
• Boom Suspension System
• Servo hydraulic system
• Load Assist
• Central lubrication system
• Fire suppression equipment
• Lift and tilt hydraulic systems

2. ELECTRICAL AND HYDRAULIC DIAGRAMS

The manual contains an extensive collection of technical diagrams for the Volvo L180H.

ELECTRICAL WIRING DIAGRAMS

• Engine and starting circuits
• Exhaust aftertreatment wiring
• Brake system wiring
• Boom Suspension System circuits
• Comfort Drive Control (CDC) wiring
• Gear and transmission control circuits
• Battery disconnector and emergency stop circuits
• Numerous numbered WD-series wiring diagrams

HYDRAULIC DIAGRAMS

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

Several diagram versions are included in the documentation.

These references help technicians understand electrical and hydraulic connections and investigate machine faults.

3. INSTALLATION INSTRUCTIONS

The installation section provides instructions for selected equipment and accessories, including:

• Third hydraulic function
• Hydraulic attachment locking
• Axle oil cooler
• Boom Suspension System
• CareTrack equipment
• Engine heaters
• High Sulphur Fuel Conversion Kit
• Comfort Drive Control (CDC) lever steering
• Additional hydraulic control levers
• Front and rear cameras
• LED working lights
• Emergency stop equipment
• Warning beacons and reversing alarms
• Cab air pre-cleaners
• Radiator grille protection
• Windscreen protection
• Additional cab and machine accessories

4. SERVICE AND REPAIR PROCEDURES

The manual provides detailed procedures for inspection, testing, adjustment, removal, installation, replacement, and servicing.

ENGINE SERVICE AND REPAIR

• Engine removal and installation
• Cylinder compression testing
• Camshaft timing checks and replacement
• Crankshaft oil seal replacement
• Engine valve adjustment
• Engine Control Module replacement
• Engine speed sensor replacement
• Fuel system pressure checks and bleeding
• Fuel injector and injector sleeve replacement
• Turbocharger inspection and replacement
• Variable turbocharger actuator replacement
• Cooling system pressure testing
• Radiator and oil cooler replacement
• Engine lubrication pressure testing

EXHAUST AFTERTREATMENT AND EMISSION CONTROL

• Diesel Particulate Filter (DPF) inspection and cleaning
• Exhaust Gas Recirculation (EGR) valve replacement
• EGR cooler pressure testing and replacement
• EGR venturi tube cleaning and replacement
• Selective Catalytic Reduction (SCR) dosing system checks
• AdBlue/DEF tank cleaning and replacement
• AdBlue/DEF pump unit servicing
• DEF hoses and dosing nozzle replacement
• DEF quality checks
• DEF suction filter replacement
• NOx sensor replacement
• Aftertreatment Control Module (ACM) replacement
• Aftertreatment fuel dosing equipment servicing

ELECTRICAL SYSTEM AND VOLVO CO-PILOT

• Battery inspection and replacement
• Starter motor replacement
• Electronic control unit replacement
• GPMECU module replacement
• HMICU module replacement
• Wireless ECU replacement
• Volvo Tech Tool service operations
• Volvo Co-Pilot replacement
• Volvo Co-Pilot SIM card installation
• Volvo Co-Pilot software updating
• Online Android software update procedures

TRANSMISSION AND AXLE REPAIR

• Transmission removal and installation
• Transmission function checks
• Transmission oil pressure testing
• Transmission warm-up procedures
• Differential lock inspection and adjustment
• Axle removal and installation
• Hub reduction gear servicing
• Hub seal replacement
• Gear selector valve servicing
• Lock-up valve replacement
• Transmission heat exchanger replacement

BRAKE SYSTEM REPAIR

• Brake disc wear measurement and replacement
• Brake accumulator pressure checks
• Brake hydraulic pressure testing
• Brake system bleeding
• Automatic brake function testing
• Brake retardation function testing
• Parking brake inspection and adjustment
• Parking brake disassembly and assembly
• Parking brake pad, disc, and seal replacement

STEERING SYSTEM REPAIR

• Steering pressure testing and adjustment
• Steering cylinder removal and installation
• Secondary steering pump pressure testing
• Steering accumulator servicing
• Comfort Drive Control (CDC) system testing
• CDC joystick replacement
• CDC angle sensor replacement
• CDC solenoid valve replacement

CAB AND AIR CONDITIONING REPAIR

• Cab positioning and service access
• Air conditioning performance checks
• Air conditioning troubleshooting
• Compressor and condenser replacement
• Evaporator and expansion valve replacement
• Refrigerant draining and filling
• Climate Control Module replacement
• Electric door opener servicing
• Heating system component replacement
• Cab suspension servicing
• Windscreen replacement

HYDRAULIC SYSTEM REPAIR

• Hydraulic pump P1, P2, and P3 servicing
• Hydraulic pressure testing and adjustment
• Load-sensing pressure checks
• Hydraulic system bleeding
• Servo pressure checks and adjustment
• Third and fourth hydraulic function testing
• Hydraulic attachment locking checks
• Boom Suspension System inspection
• Boom suspension accumulator servicing
• Hydraulic control valve testing
• Lift and tilt cylinder servicing
• Lift and tilt solenoid valve replacement
• Automatic lubrication system servicing

5. LOAD ASSIST AND WORKING HYDRAULICS CALIBRATION

The manual contains technical procedures associated with Volvo Load Assist and electronically controlled working hydraulics.

Topics include:

• Load Assist front frame position sensor calibration
• GDF-linkage position sensor calibration
• Lifting arm position sensor calibration
• Load Assist pressure sensor replacement
• Load Assist position sensor replacement
• Sensor mounting bracket replacement
• Calibration error code references
• Lift and lower function calibration
• Tilt function calibration
• Third and fourth hydraulic function calibration

These procedures are particularly useful for technicians servicing electronic hydraulic control and machine assistance systems.

6. DIAGNOSTICS AND TROUBLESHOOTING

The manual includes diagnostic and service information related to:

• Volvo Tech Tool operations
• Electronic control module replacement
• Engine and exhaust aftertreatment diagnostics
• Electronic control system functions
• Software parameters
• Transmission calibration error codes
• Load Assist calibration error codes
• Air conditioning troubleshooting
• Hydraulic pressure and function testing

These references support qualified technicians in investigating machine faults and selecting relevant service procedures.

7. SAFETY INFORMATION

The manual contains safety guidance covering:

• Safe handling of hydraulic systems
• Working beneath raised lifting equipment
• Machine lifting and support
• Battery and electrical system safety
• Fuel and oil handling
• Air conditioning refrigerant precautions
• Fire prevention
• Tyre handling precautions
• Environmental protection and waste management
• Safe machine servicing procedures

8. TECHNICAL SPECIFICATIONS

The specifications section provides technical reference information for:

• Engine specifications and capacities
• Fuel system specifications
• Exhaust aftertreatment and AdBlue/DEF
• Cooling system specifications
• Electrical system specifications
• Volvo Co-Pilot specifications
• Transmission and axle specifications
• Brake system specifications
• Steering system specifications
• Hydraulic pump specifications
• Hydraulic system volumes
• Boom Suspension System specifications
• Working hydraulics calibration specifications
• Recommended lubricants
• Component tightening torques

BENEFITS OF THIS SERVICE REPAIR MANUAL

This manual can help users:

• Understand the construction and operation of Volvo L180H systems
• Locate detailed repair and maintenance procedures
• Investigate electrical and hydraulic faults
• Consult wiring and hydraulic diagrams
• Perform specified pressure checks and component adjustments
• Service engine and exhaust aftertreatment equipment
• Maintain transmission, braking, and steering systems
• Consult Load Assist and working hydraulics calibration procedures
• Access technical specifications and tightening torque information

WHO IS THIS MANUAL FOR?

This publication is intended for:

• Professional Volvo construction equipment mechanics
• Heavy equipment service technicians
• Construction machinery repair workshops
• Fleet maintenance departments
• Equipment maintenance companies
• Volvo L180H wheel loader owners responsible for machine servicing

IMPORTANT COMPATIBILITY INFORMATION

This manual is identified for the Volvo L180H Wheel Loader.

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

Some procedures and specifications may apply only to particular machine versions or optional equipment.

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

DIGITAL PDF DOWNLOAD

This product is supplied as a digital PDF manual in English.

• 3,007 pages of technical documentation
• Detailed service and repair procedures
• Electrical wiring diagrams
• Hydraulic system diagrams
• Engine and exhaust aftertreatment documentation
• Volvo Co-Pilot and Load Assist references
• Diagnostic and calibration information
• Technical specifications and safety guidance
• Digital delivery – no printed book will be shipped

A compatible PDF reader is required to access the document.

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Detailed contents:

DESCRIPTIONS
(0) GENERAL
Leak detector 951 1207, description
(1) STANDARD PARTS, SERVICE
Service
(2) ENGINE WITH MOUNTING AND EQUIPMENT
AdBlue®DEF pump unit diagnostics, description
Auxiliary brake (engine braking), description
Coolant with anti-freeze and corrosion protection, recommendation
Cooling fan motor, description
Cooling fan, description
Cooling system, description
Crankcase ventilation, description (2)
Crankcase ventilation, description
ECO – accelerator pedal
Engine, description (2)
Engine, description (3)
Engine, description (4)
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 (2)
Tech Tool, operations
(3) ELEC. SYSTEM, WARNING SYSTEM, INFORMATION SYSTEM, 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
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 tools
Volvo Co-Pilot, description
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) STEERING
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 (2)
Secondary steering, description
Shift valve, description
Steering cylinder, description (2)
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
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 3rd4th hydraulic function, description
Boom Suspension System, component description
Calibration of 3rd4th hydraulic function, description
Calibration of lift lower function, description
Calibration of tilt inout function, description
Central lubrication system, description
Central valve, description
Change of lubrication interval
Control valve, description
Diagnostic tools, description
Dosage valves, description
Filling lubricant
Fire suppression system, component description
Fire suppression system, functional description
Hydraulic attachment locking, description
Hydraulic components, cleanliness when handling
Hydraulic oil tank, description
Hydraulic pump flow regulation, description
Hydraulic pumps, description
Lever control, electric servo, description
Lifting cylinder, description
Load Assist, description
Load Assist, reference values
Lubrication points, central lubrication
Parameter settings
Pressure monitor, description
Pump unit, description
Servo system, description
Shift valve, description
Software, parameter settings and read-outs
Tech Tool, operations
Tilt cylinder, description
TP-Linkage’s bearing points
Working hydraulic system, description
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 (2)
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 (2)
Wiring diagram WD321
Wiring diagram WD322 (2)
Wiring diagram WD322 (3)
Wiring diagram WD322
Wiring diagram WD324 (2)
Wiring diagram WD324
Wiring diagram WD325
Wiring diagram WD326
Wiring diagram WD327
Wiring diagram WD330
Wiring diagram WD331
Wiring diagram WD333
Wiring diagram WD334
Wiring diagram WD335 (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) POWER TRANSMISSION
Hydraulic diagram transmission
(9) HYDRAULIC SYSTEM; DIGGING, HANDING, GRADING 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 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 (2)
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
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 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 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 (2)
Camshaft setting, checking
Camshaft, replacing (2)
Camshaft, replacing (3)
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 (2)
Cylinder compression, testing (3)
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
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 (2)
Starter motor, replacing
Tech Tool, operations
Volvo Co-Pilot Android software, updating online (OtA)
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
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
Steering accumulator, removing (2)
Steering accumulator, removing
Steering system function, checking
Steering system working pressure, checking and adjusting
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEELTRACK 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
Plastic hood, repairing
Refrigerant, draining
Refrigerant, filling incl vacuum pumping
Side window, replacing
Troubleshooting, air conditioning unit (AC)
Viscous cab suspension, changing one unit
Window pane, installing
Windscreen, replacing
(9) HYDRAULIC SYSTEM; DIGGING, HANDING, GRADING EQUIPM.;MISC. EQUIP
3rd4th hydraulic function, pressure, checking and adjusting
3rd4th hydraulic function, shock valve, checking
3rd4th hydraulic function, solenoid valve, replacing
3rd4th 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 (2)
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, solenoid valve, changing (2)
Tilt in, solenoid valve, changing (3)
Tilt in, solenoid valve, changing
Tilt inout, angle sensor, changing (2)
Tilt inout, angle sensor, 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)
Update of automatic lubrication system
SAFETY
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
(2) ENGINE WITH MOUNTING AND EQUIPMENT
AdBlue®DEF (2)
AdBlue®DEF
Alternative fuels
Conversion tables
Coolant
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
Inlet and exhaust system, specification (2)
Inlet and exhaust system, specification
Lubrication system, specifications
Lubrication system, tightening torques (2)
Lubrication system, tightening torques
Recommended lubricants (2)
Recommended lubricants (3)
Recommended lubricants (4)
Recommended lubricants
Reversible cooling fan, tightening torques
Temperature limits for cooling fan speed, specifications (2)
Temperature limits for cooling fan speed, specifications
Tightening torques
(3) ELEC. SYSTEM, WARNING SYSTEM, INFORMATION SYSTEM, INSTRUMENTS
Alternator 80 A, specification
Battery, specifications
Battery, weight
EGR system, tightening torques
Electrical system, specifications
Lighting, specifications
Preheating, specifications
Starter motor, specifications
Starter motor, tightening torques
Volvo Co-Pilot, specifications
Volvo Co-Pilot, 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 (2)
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
(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 MISC. EQUIP
3rd4th hydraulic function, specifications (2)
3rd4th hydraulic function, specifications
3rd4th hydraulic function, tightening torques (2)
3rd4th hydraulic function, tightening torques
Automatic lubrication system, specifications
Boom Suspension System, specifications
Boom Suspension System, tightening torques
Calibration of working hydraulics, specifications
Control valve, specifications (2)
Control valve, specifications (3)
Control valve, specifications
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