Volvo L45F Compact Wheel Loader Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Construction L45F Compact Wheel Loader, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
L45F Volvo Compact Wheel Loaders workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,298 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
L45F Volvo Compact Wheel Loaders Service Manual.pdf
MAIN SECTIONS
0 - Foreword...2
0 - GENERAL...3
00 - DESCRIPTION; COMPLETE MACHINE...4
Description...5
Machine dimensions...6
Position of components...8
Product plates...11
03 - SPECIFICATIONS...13
Axles, tightening torques...14
Battery, specifications...15
Brakes, specifications...16
Cab mounts, tightening torques...18
Cooling system, capacity...19
Counterweight, tightening torques-...20
Counterweight, tightening torques...22
Electrical system, specifications...24
Engine, capacity...25
Engine, specifications...26
Engine, tightening torque...27
Engine, weights...29
Frame, weight...30
Front axle, capacity...31
Front axle, specification...32
Front axle, weight...33
Fuel tank, volume...34
Hydraulic system, specification...35
Hydraulic system, volume...36
Lever steering (CDC), specifications...37
Lights, specifications...38
Measurement conversion tables...39
Power transmission, specifications...44
Rear axle, capacity...45
Rear axle, specification...46
Rear axle, weight...47
Tire size...48
Volvo standard tightening torques...49
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...51
Transporting the machine...52
07 - STANDARD TIME...55
Operation numbers for additional work...56
08 - TOOL...58
E-2000...59
E-tool Cab support...61
1 - STANDARD PARTS, SERVICE...62
16 - LUBRICANT; FUEL; OTHER FLUID...63
Alternative fuels...64
Coolant with freezing and corrosion protection...67
Recommended lubricants...69
17 - SERVICE...71
Arrival Inspection, according to Inspection Programme...73
Axle oil, changing_{02-09-20}...74
Axle oil, changing_{02-09-47}...77
Axle oil, changing_{02-10-15}...80
Battery, checking...83
Brake pressure and function, checking...84
Cab main filter, replacing...89
Charging batteries...91
Cleanliness, braking and hydraulic system...92
Coolant freezing point, checking...93
Coolant level, checking...95
Coolant, changing...97
Delivery Inspection, according to Inspection Programme...99
Delivery Instructions, according to Inspection Programme...100
Electric welding...101
Engine air cleaner primary filter, replacing...102
Engine air cleaner secondary filter, replacing...104
Engine belt tension, checking...105
Engine oil and filter, changing...107
Engine oil level, checking...109
Fuel filters, replacing...110
Fuel tank breather filter, replacing...112
Hydraulic oil filters, replacing...114
Hydraulic oil level, checking...116
Hydraulic oil, changing...118
Hydraulic pressure, checking...120
Hydraulic tank sediment, draining...123
Leakage, checking...125
Lubrication...126
MATRIS and Tech Tool, reading...128
Maintenance of Stored Machines, according to Inspection Programme...129
Maintenance service, every 10 hours...130
Maintenance service, every 1000 hours...131
Maintenance service, every 1500 hours...133
Maintenance service, every 2000 hours...135
Maintenance service, every 3000 hours...137
Maintenance service, every 50 hours...139
Maintenance service, every 500 hours...140
Maintenance service, every 6000 hours...141
Parking brake pads, checking...142
Propeller shaft movement, checking...143
Radiator, cleaning...145
Service and maintenance...147
Service brake disc wear, checking...149
Service position 1_{02-24-21}...151
Service position 2_{02-24-48}...153
Service...155
Steering cylinders, locking of pivot pins, checking...156
Steering pressure, checking_{02-05-03}...158
Steering pressure, checking_{02-05-30}...161
Test running and checking...164
Towing...165
Transmission oil filter, replacing...166
Tyre wear and air pressure, checking...169
Valves, adjusting...170
Water separator, checking...175
Wheel nuts torque, checking...177
Work on the machine's electrical system...178
19 - GENERAL...179
CE-marking, EMC-directive...180
Checklist after a fire or heat exposure...184
Decontamination...185
Environmental handling for the future...187
Environmentally hazardous fluids...189
Environmentally safe handling...190
Fire prevention measures...192
Health hazards with paint, plastics and rubber...195
Loader boom, safety strut...197
Safety concerns everybody!...200
Safety rules when servicing...202
Safety when handling accumulators...205
Safety when handling oils and fuel...206
Safety when handling the machine...207
Safety when lifting and supporting complete machine...211
Safety when using lifting equipment...213
Safety when working on hydraulic systems...215
Safety when working with batteries...217
Safety when working with refrigerant...220
Service position 1_{01-56-44}...223
Service position 1_{01-57-52}...225
Service position 2_{01-57-11}...227
Service position 2_{01-58-20}...229
Some simple rules regarding tyre handling...231
Starting with booster batteries...233
Waste handling...235
Working in environmentally contaminated areas...236
Working under raised boom...237
2 - ENGINE WITH MOUNTING AND EQUIPMENT...239
20 - GENERAL...240
Component locations...241
Engine, description...243
Engine, weights...244
21 - ENGINE...245
Connecting rod, description...246
Crankshaft, description...248
Cylinder compression, testing...249
Cylinder head, description...251
Engine timing gears, description...253
Engine, installing...254
Engine, removing...264
Valves, adjusting...274
Valves, description...279
22 - LUBRICATING SYSTEM...281
Lubrication system, principle of operation...282
Oil cooler, replacing...284
Oil pump, description...288
23 - FUEL SYSTEM...289
Feed pump, replacing...290
Fuel feed pump, description...294
Fuel system, description...295
Fuel tank, installing...297
Fuel tank, removing...301
Idling speed, checking and adjusting...306
Injection valve, check...308
25 - INLET & EXHAUST SYSTEM...311
Turbocharger, description...312
26 - COOLING SYSTEM...314
Coolant pump, replacing...315
Cooling system, capacity...318
Cooling system, description...319
Radiator, installing...320
Radiator, removing...328
Thermostat, replacing...336
27 - ENGINE CONTROL...338
Accelerator Pedal...339
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...340
30 - GENERAL...341
Bus communication supervision...344
CU6601, description and measuring...346
Collection of basic data...350
Communication, vehicle electronics_{01-23-34}...352
Communication, vehicle electronics_{01-24-02}...354
Component descriptions...356
Conditions when checking...359
Electrical system, description...362
Electrical system, work instructions...364
Electronic control system, description_{01-22-26}...366
Electronic control system, description_{01-22-53}...368
Error codes, build-up...370
General fault diagnosis information...373
Information display, check ...375
Lead and connector checks...377
Limp home...381
MA2307, description and measuring...382
MA2602, description and measuring...384
MA4220, description and measuring...386
MA4221, description and measuring...388
MA4228, description and measuring...390
MA4603, description and measuring...392
MA4710, description and measuring...394
MA4720, description and measuring...396
MA9172, description and measuring...398
MA9173, description and measuring...400
MA9174, description and measuring...402
MO6401, description and measuring...404
Machine, Calibration...406
PWM2601, description and measuring...416
PWM4225, description and measuring...418
PWM4226, description and measuring...420
PWM4227, description and measuring...422
PWM6601, description and measuring...424
PWM6602, description and measuring...426
Parameter, setting...428
Power supply I-ECU, description and measuring...433
Power supply T-ECU, description and measuring...435
Power supply V-ECU, description and measuring...437
Power supply V2-ECU, description and measuring...439
R2701, description and measuring...441
RE02, description and measuring...443
RE06, description and measuring...445
RE09, description and measuring...447
RE10, description and measuring...449
RE15, description and measuring...451
RE2319, description and measuring...453
RE2501, description and measuring...455
RE6401, description and measuring...457
RE8701, description and measuring...459
SAE J1708_1587 Information link, description and measuring...461
SAE J1939_CAN1 Control link, description and measuring...464
SAE J1939_CAN2 Control link, description and measuring...467
SAE error codes, translation to error messages, general...470
SE2203, description and measuring...472
SE2303, description and measuring...474
SE2502, description and measuring...476
SE2603, description and measuring...478
SE2606, description and measuring...480
SE2701, description and measuring...482
SE2702, description and measuring...484
SE4201, description and measuring...486
SE4405, description and measuring...488
SE4406, description and measuring...490
SE4407, description and measuring...492
SE6401, description and measuring...494
SE6403, description and measuring...496
SE6404, description and measuring...498
SE6601, description and measuring...500
SE8503, description and measuring...502
SE8702, description and measuring...504
Software parameters, description...506
Special tools for troubleshooting...512
Transmission shutdown...513
Troubleshooting strategy...514
Troubleshooting tools...516
31 - BATTERY...517
Battery, charging...518
Battery, description...519
33 - STARTING SYSTEM...520
Booting sequence...521
35 - LIGHTING...522
Lighting, description...523
36 - OTHER ELECTRICAL EQUIPMENT...525
Connector I_O description ...526
Control units, changing...547
Electronic climate control unit ECC, description...548
I-ECU MID 140 non-programmed, replacing...549
I-ECU MID 140 pre-programmed, replacing...551
Instrument control unit I-ECU, functional description...553
Reduced computer communication...554
Vehicle control unit V-ECU, description...556
Vehicle control unit V2-ECU, description...558
37 - CABLE; FUSE; RELAY...559
Battery disconnect switch, description...561
Cable and component designations...562
Cable and component marking explanations...564
Component list Alternator, batteries, capacitors, electronic units, voltage outlet...565
Component list Fuses...567
Component list Heating coils, instruments, service socket...572
Component list Lights...574
Component list Relays...576
Component list Solenoid valves...579
Component list Switches...582
Component list, PWM valves...585
Component list, Sounders...587
Component list, motors...589
Component list, sensors...591
Connector I_O description...594
Electrical symbols and designations...615
Table of contents, wiring diagrams...618
Wiring diagram WD201_{09-05-40}...620
Wiring diagram WD201_{09-06-07}...622
Wiring diagram WD202...625
Wiring diagram WD203...627
Wiring diagram WD301...628
Wiring diagram WD302...631
Wiring diagram WD303...634
Wiring diagram WD304...639
Wiring diagram WD305...642
Wiring diagram WD306...645
Wiring diagram WD307...648
Wiring diagram WD308...649
Wiring diagram WD309...652
Wiring diagram WD310...655
Wiring diagram WD311...658
Wiring diagram WD312...660
Wiring diagram WD401...662
Wiring diagram WD402...665
Wiring diagram WD403...667
Wiring diagram WD404...669
Wiring diagram WD501...672
Wiring diagram WD601...675
Wiring diagram WD602...677
Wiring diagram WD603...680
Wiring diagram WD801...682
Wiring diagram WD802...685
Wiring diagram WD803...688
Wiring diagram WD901...691
Wiring diagram WD902...694
Wiring diagram WD903...695
Wiring diagram WD904...698
Wiring diagram WD905...700
Wiring diagram WD906...702
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...704
Central warning...705
Information display, axles _ brakes...706
Information display, check...707
Information display, electrical system...709
Information display, engine...710
Information display, general...712
Information display, hydraulics...715
Information display, operating display...716
Information display, service mode...717
Information display, settings...719
Information display, start lockout...720
Information display, transmission...722
Information display, vehicle info...723
Information display, vehicle messages...725
Instrument panels...726
Middle instrument panel with warning lights...728
39 - MISCELLANEOUS...730
CareTrack W-ECU, description...731
4 - POWER TRANSMISSION...735
40 - GENERAL...736
Power transmission, description...737
42 - TRANSMISSION; HYDRAULIC CONTROL...739
Hydrostatic transmission, description...740
Induction sensor for output shaft, replacing...742
Transmission circuit hydraulic schematic...745
Transmission sensor, replacing...747
Transmission solenoid, replacing...749
Transmission, disassembling...751
Transmission, function check_{08-31-59}...755
Transmission, function check_{08-32-35}...759
Transmission, installing...769
Transmission, removing...776
44 - HYDROSTATIC DRIVE...780
Hydraulic diagram transmission_{08-28-31}...781
Hydraulic diagram transmission_{08-28-59}...784
Hydraulic diagram transmission_{08-29-26}...787
Hydraulic motor, replacing...790
Hydraulic pump coupling, description...795
Hydrostatic pump charge pressure, checking and adjusting...797
Hydrostatic pump cut off valve, checking and adjusting...799
Hydrostatic pump high pressure valve, checking and adjusting...802
Hydrostatic pump mechanical zero position, checking and adjusting...805
Hydrostatic pump, description_{08-30-08}...808
Hydrostatic pump, description_{08-30-35}...811
Shaft seal replacing...814
Start hydraulic motor control, check and adjust...817
Start hydraulic pump control, checking and adjusting...820
Travel motor, description...822
45 - PROPELLER SHAFT...825
Propeller shaft, changing...826
46 - FRONT AXLE; REAR AXLE...829
Axle, installing...830
Axle, removing...835
Axles, tightening torques...840
Drive axles, description...841
Front axle, installing_{08-17-35}...845
Front axle, installing_{08-18-02}...848
Front axle, removing_{08-18-51}...851
Front axle, removing_{08-19-18}...854
Front axle, weight...857
Rear axle, capacity...858
5 - BRAKE...859
50 - GENERAL...860
Brakes, specifications...861
Description brake system_{07-16-35}...863
Description brake system_{07-16-58}...864
Hydraulic diagram, brake system...865
51 - WHEEL BRAKE...874
Brake linings, checking wear...875
52 - HYDRAULIC BRAKE SYSTEM...877
Accumulator (removed) charging pressure, checking...878
Accumulator, checking...880
Brake system hydraulic function, checking...882
Brake system, adjusting unloading pressure...887
Brake system, bleeding...890
Service brake pressure, checking...892
55 - PARKING BRAKE...894
Parking brake brake pads, replacing...895
Parking brake, replacing brake disc...900
Parking brake, replacing control cable-[0932]...903
Parking brake, replacing control cable-[0957]...909
Parking brake, replacing control cable...915
6 - STEERING...921
60 - GENERAL...922
Steering system, specifications_{08-15-02}...923
Steering system, specifications_{08-15-26}...924
Steering system, troubleshooting and elimination...925
64 - STEERING...928
Hydraulic diagram, steering...929
Secondary steering, description...931
Steering pressure, checking_{08-12-14}...932
Steering pressure, checking_{08-12-41}...935
Steering system working pressure, checking and adjusting_{08-11-06}...938
Steering system working pressure, checking and adjusting_{08-11-33}...941
Steering valve, reconditioning (removed)...944
Steering wheel, tightening torques...952
66 - LEVEL STEERING...954
Comfort Drive Control (CDC) control valve, removing...955
Comfort Drive Control (CDC), description...958
Comfort Drive Control, servo pressure, checking...962
Comfort drive control (CDC) angle sensor, changing...964
Comfort drive control (CDC) control valve, installing...970
Comfort drive control (CDC) solenoid valve, changing...973
Error codes when calibrating...976
Hydraulic diagram, steering incl. lever steering (CDC)...978
Lever steering (CDC) function, checking...981
Lever steering (CDC), specifications...982
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...983
70 - GENERAL...984
Frame and track unit, description...985
Frame, weight...987
71 - FRAME...988
Counterweight, installing...989
Counterweight, removing...991
Counterweight, tightening torques...994
74 - FRAME LINK...996
Frame joint, assembly of separated machine...997
Frame joint, replacing bearings...1009
Frame joint, separating machine...1013
75 - AXLE SUSPENSION...1024
Axle suspension, replacing bushes and seals...1025
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...1028
Wheel, tightening torque...1029
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...1030
80 - GENERAL...1031
Cab description...1032
81 - CAB, NAKED; CANOPY...1033
Cab mounts, tightening torques...1034
Cab, installing...1035
Cab, removing...1044
Repairs of minor damage on internal and external plastic parts (scratches, dents, breaks)...1054
Viscous cab suspension, description...1056
82 - ENGINE HOOD; MUDGUARD; FOOT STEP...1058
Engine hood, installing...1059
Engine hood, removing...1062
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...1065
Side window, replacing_{07-51-25}...1066
Windows, general...1075
Windscreen, replacing_{07-50-57}...1077
87 - AIR CONDITIONING UNIT...1086
Air conditioning unit, check function...1087
Air conditioning, capacity...1090
Climate control system, description...1091
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...1094
90 - GENERAL...1095
Accumulator, discarding...1096
Cleanliness when working on hydraulic components...1098
General information to note when working on the hydraulic system...1099
Hydraulic components, storing and transporting...1101
Hydraulic oil, storage and handling...1102
Hydraulic system, repair of hydraulic components in workshop...1103
Troubleshooting chart...1105
Vacuum pump, connection...1108
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...1110
Boom Suspension System, general description...1111
Hydraulic diagram, control valve_{07-42-09}...1113
Hydraulic diagram, control valve_{07-42-36}...1118
Hydraulic diagram, cooling fan_{07-35-09}...1122
Hydraulic diagram, cooling fan_{07-35-36}...1125
Hydraulic diagram, cooling fan_{07-36-03}...1127
Hydraulic diagram, cooling fan_{07-36-31}...1129
Hydraulic oil tank, description...1131
Hydraulic pump, description...1133
Hydraulic pump, max working pressure, checking and adjusting...1135
Hydraulic pump, standby pressure, checking and adjusting...1137
Hydraulic system, description...1140
Main control valve, description_{07-43-18}...1141
Main control valve, description_{07-43-47}...1147
Main control valve, installing...1153
Main control valve, removing...1157
Port relief valve pressure, checking and adjusting...1161
Servo valve, description...1166
92 - MECHANICAL EQUIPMENT_ATTACHMENT...1170
Attachment bracket cylinder, reconditioning...1171
Attachment locking hydraulic cylinder (vision-optimised bracket), replacing...1173
Boom suspension system, checking...1176
Hydraulic attachment bracket (quickfit), description...1181
Hydraulic diagram with option components...1182
Hydraulic diagram, Boom Suspension System...1186
Hydraulic diagram, working hydraulics, 3rd and 4th functions, attachment lock...1189
Implement attachment, repacking removed hydraulic cylinder...1191
99 - MISCELLANEOUS...1195
Automatic lubrication pump unit, reconditioning...1196
Automatic lubrication system, specifications...1218
Bleeding air...1220
Central lubrication system, description...1226
Change of lubrication interval...1231
Diagnostic tools, description...1233
Dosage valves, description...1235
Filling lubricant...1239
Hydraulic diagram with option components Image...1241
Hydraulic diagram with option components...1249
Hydraulic diagram, working hydraulic system_{07-27-48} Image...1265
Hydraulic diagram, working hydraulic system_{07-27-48}...1266
Hydraulic diagram, working hydraulic system_{07-28-15} Image...1268
Hydraulic diagram, working hydraulic system_{07-28-15}...1269
Hydraulic diagram, working hydraulic system_{07-28-43} Image...1271
Hydraulic diagram, working hydraulic system_{07-28-43}...1272
Hydraulic diagram, working hydraulic system_{07-29-10} Image...1274
Hydraulic diagram, working hydraulic system_{07-29-10}...1275
Parameter settings...1277
Pressure monitor, description...1279
Pump unit, description...1281
Recommended lubricants...1284
Shift valve, description...1286
Software, parameter settings and read-outs...1288
System test...1295
Update of automatic lubrication system...1297
