VOLVO L90H WHEEL LOADER SERVICE REPAIR MANUAL PDF – 984 PAGES

The Volvo L90H Wheel Loader Service Repair Manual provides detailed technical procedures for the inspection, diagnosis, maintenance, servicing, and repair of the Volvo L90H wheel loader.

This 984-page PDF manual, with information updated in 2020, covers major mechanical, electrical, electronic, and hydraulic systems. It includes procedures for engine repairs, fuel system servicing, exhaust aftertreatment maintenance, transmission repairs, brake system adjustments, steering system servicing, cab repairs, and hydraulic equipment maintenance.

The documentation also includes diagnostic operations using Volvo Tech Tool, component replacement instructions, system pressure testing, calibration references, and specialized service procedures.

Designed for heavy equipment mechanics, construction machinery service workshops, fleet maintenance technicians, and Volvo wheel loader owners, this manual provides a practical technical reference for professional maintenance and repair work.

MANUAL DETAILS

• Manufacturer: Volvo Construction Equipment
• Equipment Model: L90H Wheel Loader
• Manual Type: Service Repair Manual
• File Format: PDF
• Number of Pages: 984
• Information Update: 2020
• Delivery: Digital Download

WHAT IS INCLUDED IN THIS SERVICE REPAIR MANUAL?

The manual is organized into ten numbered technical groups, covering general service information and the main machine systems.

1. GENERAL SERVICE INFORMATION

The introductory section contains technical references associated with specialized service equipment and additional repair operations.

Topics include:

• Service tool instructions
• Checking points and special equipment references
• Infrared thermometer applications
• Additional work operation numbers
• General service-related procedures

2. STANDARD SERVICE PROCEDURES

This section includes selected routine service and inspection operations.

Topics include:

• AdBlue/DEF pump unit filter replacement
• Hydraulic pressure checks
• Manual parking brake release

These procedures support essential maintenance and machine servicing operations.

3. ENGINE SERVICE AND REPAIR

The engine section contains extensive procedures for inspecting, testing, removing, installing, and replacing major engine components.

ENGINE INSPECTION AND MECHANICAL REPAIR

• Engine removal and installation
• Complete engine replacement
• Cylinder compression testing
• Engine valve adjustment
• Engine belt replacement
• Engine mounting replacement
• Valve cover removal and installation
• Turbocharger replacement
• Cooling system pressure testing
• Coolant pump replacement
• Thermostat replacement
• Radiator and charge air cooler removal and installation
• Lubrication oil pressure testing
• Engine oil consumption checks

FUEL INJECTION AND HIGH-PRESSURE FUEL SYSTEM

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

EXHAUST AFTERTREATMENT AND EMISSION CONTROL

• AdBlue/DEF dosing injector replacement
• AdBlue/DEF mixing tube replacement
• AdBlue/DEF pump unit replacement
• AdBlue/DEF pump flushing
• AdBlue/DEF pump filter replacement
• AdBlue/DEF tank cleaning and replacement
• AdBlue/DEF quality checks
• AdBlue/DEF crystallization checks
• AdBlue/DEF suction filter replacement
• Diesel Oxidation Catalyst (DOC) replacement
• Diesel Particulate Filter (DPF) inspection and cleaning
• Exhaust Gas Recirculation (EGR) valve replacement
• EGR cooler replacement
• EGR reed valve replacement
• EGR venturi tube cleaning and replacement
• Selective Catalytic Reduction (SCR) dosing system checks
• SCR muffler replacement
• Regeneration log checks
• Aftertreatment Control Module (ACM) replacement

ENGINE ELECTRONIC CONTROL

• Engine Control Module (ECM) replacement
• Replacement of programmed and non-programmed control modules
• Engine-related diagnostic and testing procedures

4. ELECTRICAL AND ELECTRONIC SYSTEM REPAIR

The electrical section covers the replacement and servicing of selected electronic components and control modules.

Included procedures:

• Battery condition testing
• Battery replacement
• Starter motor replacement
• Starter lock replacement
• GPMECU1 control module replacement
• GPMECU2 control module replacement
• GPMECU3 control module replacement
• HMICU control module replacement
• W-ECU replacement
• Volvo Tech Tool service operations

The manual includes procedures for both pre-programmed and non-programmed electronic control module replacements where specified.

5. POWER TRANSMISSION AND AXLE REPAIR

This section provides procedures for the transmission, drive axles, differential components, and associated mechanical systems.

Topics include:

• Transmission removal and installation
• Transmission function testing
• Transmission oil pressure checks
• Hydraulic transmission warm-up procedures
• Transmission calibration error code references
• Differential lock adjustment
• Differential lock function checks
• Axle removal and installation
• Axle suspension bush and seal replacement
• Hub reduction gear removal and installation
• Hub seal replacement
• Gear selector solenoid replacement
• Lock-up valve replacement
• Transmission heat exchanger replacement
• Front and rear output shaft seal replacement

6. BRAKE SYSTEM SERVICE AND REPAIR

The manual contains procedures for the inspection, testing, adjustment, and repair of the Volvo L90H braking system.

Included topics:

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

7. STEERING SYSTEM SERVICE AND REPAIR

The steering section includes procedures for both conventional steering components and Comfort Drive Control (CDC) equipment.

Topics include:

• Steering system function checks
• Steering hydraulic pressure testing and adjustment
• Left steering cylinder removal and installation
• Right steering cylinder removal and installation
• Steering cylinder reconditioning
• Steering accumulator servicing
• Secondary steering pump pressure testing
• Comfort Drive Control (CDC) joystick replacement
• CDC angle sensor replacement
• CDC solenoid valve replacement
• CDC servo pressure checks
• CDC lever steering function testing

8. FRAME, WHEELS AND STRUCTURAL COMPONENTS

This section provides procedures for servicing selected structural and wheel-related components.

Included topics:

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

9. CAB, CLIMATE CONTROL AND EXTERIOR COMPONENTS

The manual provides repair procedures for the operator cab, climate control equipment, and exterior machine components.

CAB AND EXTERIOR REPAIR

• Cab removal and installation
• Engine hood removal and installation
• Engine hood securing procedures
• Electric door opener servicing
• Door lock cylinder replacement
• Window installation
• Windscreen replacement
• Viscous cab suspension replacement
• Plastic hood repair

AIR CONDITIONING AND HEATING

• Air conditioning performance testing
• Air conditioning troubleshooting
• Climate control module replacement
• Climate unit removal and installation
• Condenser replacement
• Evaporator replacement
• Expansion valve replacement
• Refrigerant draining and filling
• Cooling system leak detection
• Heater core replacement
• Heat control valve replacement
• Fan motor replacement
• Air mix door actuator replacement

10. HYDRAULIC SYSTEM AND WORKING EQUIPMENT REPAIR

The hydraulic section contains procedures for pressure testing, adjustments, component replacement, and hydraulic system maintenance.

HYDRAULIC PUMPS AND PRESSURE TESTING

• Hydraulic pump P2 removal and installation
• Hydraulic pump P3 inspection
• Hydraulic pump P3 removal and installation
• Hydraulic standby pressure testing
• Hydraulic working pressure adjustment
• Load-sensing pressure checks
• Servo pressure testing and adjustment
• Hydraulic system bleeding
• Hydraulic system warm-up procedures

BOOM SUSPENSION SYSTEM

• Boom Suspension System function checks
• Boom suspension accumulator inspection
• Boom suspension accumulator pressure adjustment
• Boom suspension accumulator reconditioning
• Boom suspension solenoid valve replacement
• Boom suspension safety valve checks
• Hydraulic pressure release procedures

LIFT AND TILT HYDRAULICS

• Lift cylinder servicing
• Tilt cylinder servicing
• Lift and lower function testing
• Tilt function testing
• Lift angle sensor replacement
• Tilt angle sensor replacement
• Lift inductive sensor adjustment
• Tilt inductive sensor adjustment
• Hydraulic shock valve inspection

ADDITIONAL HYDRAULIC EQUIPMENT

• Third and fourth hydraulic function testing
• Third and fourth hydraulic pressure adjustment
• Hydraulic solenoid valve replacement
• Hydraulic attachment locking inspection
• Automatic lubrication pump reconditioning
• Automatic lubrication system updates
• Hydraulic accumulator servicing
• Hydraulic control valve pressure checks
• Fire suppression system procedures following activation

DIAGNOSTICS, TESTING AND CALIBRATION

The manual includes diagnostic and testing references associated with:

• Volvo Tech Tool operations
• Engine and fuel system testing
• AdBlue/DEF and exhaust aftertreatment checks
• Electronic control module servicing
• Transmission calibration error codes
• Hydraulic system calibration error codes
• Brake and steering pressure checks
• Hydraulic system function tests
• Air conditioning troubleshooting

These procedures help qualified technicians investigate machine faults and carry out the applicable service operations.

BENEFITS OF THIS SERVICE REPAIR MANUAL

This technical publication can help users:

• Access detailed Volvo L90H repair procedures
• Diagnose engine and fuel system problems
• Service high-pressure fuel injection components
• Maintain AdBlue/DEF, DPF, EGR, and SCR systems
• Inspect and repair transmission components
• Test and adjust brake and steering systems
• Service hydraulic pumps and working equipment
• Maintain cab heating and air conditioning equipment
• Consult Volvo Tech Tool diagnostic operations
• Identify relevant component removal and replacement procedures

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 L90H wheel loader owners responsible for machine servicing

IMPORTANT COMPATIBILITY INFORMATION

This manual is identified for the Volvo L90H Wheel Loader.

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

Some procedures 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 service repair manual.

• 984 pages of technical documentation
• Engine and high-pressure fuel system repair procedures
• AdBlue/DEF, DPF, EGR, and SCR servicing
• Transmission and axle repair procedures
• Brake and steering system maintenance
• Cab and climate control repair information
• Hydraulic system testing and servicing
• Volvo Tech Tool diagnostic 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:

(0) GENERAL
88830557 User Instruction
E 1708, Checking point
E1706
E1711
E-2001
E-2005
E-2014
E-2015
E-2017
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
AdBlue®DEF pump unit filter, replacing
Hydraulic pressure, checking
Parking brake, manually releasing
(2) ENGINE WITH MOUNTING AND EQUIPMENT
ACM (Aftertreatment control module) non-programmed, replacing
ACM (Aftertreatment control module) pre-programmed, replacing
AdBlue®DEF dosing injector, replacing
AdBlue®DEF hoses, replacing
AdBlue®DEF mixing tube, replacing
AdBlue®DEF pump unit, filter, replacing
AdBlue®DEF pump unit, flushing
AdBlue®DEF pump unit, inlet nipple, replacing
AdBlue®DEF pump unit, replacing
AdBlue®DEF quality, checking
AdBlue®DEF tank armature suction filter, replacing
AdBlue®DEF tank armature, cleaning
AdBlue®DEF tank armature, replacing
AdBlue®DEF tank, cleaning
AdBlue®DEF tank, replacing
AdBlue®DEF, draining
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, checking
Coolant pump, replacing
Coolant valve, replacing
Cooling system pressure, checking
Crystallization of AdBlue®DEF, checking
Cylinder compression, testing
DOC (Diesel oxidation catalyst), replacing
DPF (Diesel particulate filter), checking and cleaning
EGR cooler, replacing
EGR reed valve, replacing
EGR valve, replacing
EGR venturi tube, cleaning
EGR venturi tube, replacing
Engine belts, replacing
Engine control module (ECM), replacing non-programmed
Engine control module (ECM), replacing pre-programmed
Engine mounting rear, changing
Engine, installing
Engine, removing
Engine, replacing
Exhaust pipe flexible tube, replacing
Feed pump pressure, checking
Fuel control valve (FCV), replacing
Fuel rail pressure sensor, replacing
Fuel rail, replacing
Fuel system, bleeding
High pressure fuel pipes, replacing
High pressure fuel pump, replacing
Injector sleeves, replacing
Injectors, replacing
Inlet throttle, replacing
Lubrication oil consumption, checking
Lubrication oil pressure, checking with pressure gauge
Pressure relief valve (PRV), replacing
Radiator and charge air cooler, installling
Radiator and charge air cooler, removing
Regeneration log, checking
SCR (Selective catalytic reduction) dosing system, checking
SCR (Selective catalytic reduction) muffler, replacing
Stall speed, checking
Thermostat, replacing
Turbocharger, replacing
Valve cover, installing
Valve cover, removing
Valves, adjusting
(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
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
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 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 cylinder removed, reconditioning excl replacing bearings
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, installing
Cab, removing
CCM, replacing
Climate unit, installing
Climate unit, removing
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, installing
Engine hood, raising and securing
Engine hood, removing
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, HANDING, GRADING EQUIPM, MISC. EQIP
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
Back-up valve, replacing
Bleeding air
Boom suspension accumulator, checking and adjusting
Boom suspension accumulator, reconditioning
Boom suspension system, accumulator, installing
Boom suspension system, accumulator, removing
Boom suspension system, checking
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom suspension system, pressure reduction, safety valve, checking and adjusting
Boom suspension system, solenoid valve, replacing
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 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
Inductive sensor, lift, adjusting
Inductive sensor, tilt, adjusting
Lift cylinder, repacking in machine
Liftlower function, checking
Liftlower, angle sensor, changing
LS (load sense) pressure, checking
Servo accumulator, installing
Servo accumulator, removing
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
System test
Tech Tool, operations
Tilt cylinder, repacking in machine
Tilt inout, angle sensor, changing
Tilt, checking
Update of automatic lubrication system