Volvo L25H Compact Wheel Loaders Service Repair Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo L25H Compact Wheel Loaders, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
Volvo Constructions L25H 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.
Volvo L25H Compact Wheel Loaders Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 964 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
MAIN SECTIONS
0 - Foreword......2
0 - GENERAL......3
00 - DESCRIPTION; COMPLETE MACHINE......4
Description......4
03 - SPECIFICATIONS......6
Measurement conversion tables......6
Volvo standard tightening torques......11
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION......13
Transporting the machine......13
07 - STANDARD TIME......15
Operation numbers for additional work......15
08 - TOOL......17
E-tool Cab support......17
E-tool Guide bolts......18
E-tool Sleeve......19
Infrared Thermometer......20
1 - STANDARD PARTS, SERVICE......24
16 - LUBRICANT; FUEL; OTHER FLUID......25
Alternative fuels......25
Coolant with freezing and corrosion protection......28
Fuel, recommendation......29
Lubricants and filling capacities......30
Recommended lubricants......32
17 - SERVICE......34
Arrival Inspection, according to Inspection Programme......34
Axle oil, changing......35
Battery, checking......38
Brake fluid level, checking......39
Cab main filter, replacing......40
Charging batteries......42
Cleanliness, braking and hydraulic system......43
Coolant freezing point, checking......44
Coolant level, checking......46
Coolant, changing......48
Crankcase ventilation separator element, replacing......51
Delivery Inspection, according to Inspection Programme......53
Delivery Instructions, according to Inspection Programme......54
EGR system, checking......55
Electric welding......64
Engine air cleaner primary filter, replacing......65
Engine air cleaner secondary filter, replacing......67
Engine belt tension, checking......68
Engine oil and filter, changing......70
Engine oil level, checking......72
Fuel filters, replacing......73
Fuel injectors, checking......75
Fuel tank breather filter, replacing......76
Hydraulic oil filters, replacing......77
Hydraulic oil level, checking......79
Hydraulic oil, changing......80
Hydraulic pressure, checking......82
Hydraulic tank sediment, draining......88
Leakage, checking......89
Lubrication......90
MATRIS and Tech Tool, reading......92
Maintenance of Stored Machines, according to Inspection Programme......93
Maintenance service, every 10 hours......94
Maintenance service, every 100 hours......95
Maintenance service, every 1000 hours......96
Maintenance service, every 1500 hours......98
Maintenance service, every 2000 hours......100
Maintenance service, every 3000 hours......102
Maintenance service, every 500 hours......104
Maintenance service, every 6000 hours......105
Radiator, cleaning......106
Service and maintenance......108
Service brake pads, checking......110
Service position 1......111
Service position 2......113
Service......115
Steering cylinders, locking of pivot pins, checking......116
Steering pressure, checking-[1548]......117
Tech Tool, operations-[3642]......119
Test running and checking......120
Towing a disabled machine......121
Turbocharger, checking......123
Tyre wear and air pressure, checking......124
Valves, adjusting-[2647]......125
Water separator, checking......130
Wheel nuts torque, checking......131
Work on the machine's electrical system......132
19 - GENERAL......133
CE-marking, EMC-directive......133
Checklist after a fire or heat exposure......137
Decontamination......138
Environmental handling for the future......140
Environmentally hazardous fluids......142
Environmentally safe handling......143
Fire prevention measures......145
Health hazards with paint, plastics and rubber......148
Loader boom, safety strut......150
Safety concerns everybody!......153
Safety rules when servicing......155
Safety when handling accumulators......158
Safety when handling oils and fuel......159
Safety when handling the machine......160
Safety when lifting and supporting complete machine......164
Safety when using lifting equipment......166
Safety when working on hydraulic systems......168
Safety when working with batteries......170
Safety when working with refrigerant......173
Service position 1_{10-07-58}......176
Service position 2_{10-08-26}......178
Some simple rules regarding tyre handling......180
Starting with booster batteries......182
Waste handling......184
Working in environmentally contaminated areas......185
2 - ENGINE WITH MOUNTING AND EQUIPMENT......186
20 - GENERAL......187
E-ECU MID 128 non-programmed, replacing......187
E-ECU MID 128 pre-programmed, replacing......189
Engine electric components, component locations......191
Engine refill capacities, specifications......193
Engine weight, specifications......194
Engine, component locations......195
Engine, description......198
Tech Tool, operations-[5534]......201
21 - ENGINE......202
Cylinder compression, testing......202
Engine, installing......204
Engine, removing......213
Engine, specifications......223
Valve cover, installing......224
Valve cover, removing......227
Valves, adjusting......230
22 - LUBRICATING SYSTEM......234
Lubricating system, description......234
Lubrication oil pressure, checking......238
Lubrication system, specifications......240
Lubrication system, tightening torques......241
Oil cooler, replacing......242
Oil pressure relief valve, replacing......244
23 - FUEL SYSTEM......247
Fuel cooler, replacing......247
Fuel pump unit, replacing......249
Fuel system, description......257
Fuel system, specifications......262
Fuel system, tightening torques......263
Fuel tank level sensor, replacing......264
Fuel tank, capacities......267
Fuel tank, replacing......268
Injectors, replacing......279
25 - INLET & EXHAUST SYSTEM......282
Charge air cooler, replacing......282
Exhaust Aftertreatment System, description......284
Inlet and exhaust system, component location......287
Inlet and exhaust system, description......289
26 - COOLING SYSTEM......293
Coolant pump, replacing......293
Cooling fan clutch, replacing......297
Cooling package, installing......300
Cooling package, removing......304
Cooling system, capacity......310
Cooling system, description......311
Fan belt and_or alternator belt, replacing......314
Thermostat, replacing......317
29 - MISCELLANEOUS......319
Exhaust Gas Recirculation (EGR), description......319
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS......323
30 - GENERAL......324
AL3201, description and measuring......324
Automatic engine shut down, description......326
Collection of basic data......328
Component descriptions......330
Conditions when checking......333
Electrical system, description......336
Electrical system, special instructions for servicing, electrical components, batteries......338
Electrical system, special instructions for servicing, electronic components......340
Electrical system, special instructions for servicing, general......341
Electrical system, specifications......343
FX1005, description and measuring......344
FX1052, description and measuring......347
FX1053, description and measuring......350
General fault diagnosis information......352
HE2501, description and measuring......354
Lead and connector checks......356
Limp Home......360
MA2301-MA2304, description and measuring......362
MA2310, description and measuring......364
MA4220, description and measuring......366
MA4221, description and measuring......368
MA4605, description and measuring......370
MA4710_MA4711, description and measuring......372
MA4720, description and measuring......375
RE01, description and measuring......378
RE04, description and measuring......380
RE05, description and measuring......382
RE2501, description and measuring......384
RE3301, description and measuring......386
RE3501, description and measuring......388
RE3502, description and measuring......390
RE8701, description and measuring......392
SAE J1939_CAN1 Control link, description and measuring......394
SAE J1939_CAN2 control link, description and measuring......396
SAE error codes, translation to error messages, general......398
SE2206, description and measuring......400
SE2303, description and measuring......402
SE2306, description and measuring......404
SE2309, description and measuring......406
SE2502, description and measuring......408
SE2507, description and measuring......410
SE2508, description and measuring......412
SE2606, description and measuring......415
SE2702, description and measuring......417
SE2709, description and measuring......419
SE2710, description and measuring......422
SE4307, description and measuring......425
SE9105, description and measuring......427
SE9106, description and measuring......429
SW4205_SW4206, description and measuring......431
Software parameters, description......433
Special tools for troubleshooting......437
Tech Tool, operations......438
Troubleshooting strategy......439
32 - ALTERNATOR; CHARGE REGULATOR......441
Alternator, replacing incl function checking......441
Alternator, testing......443
33 - STARTING SYSTEM......445
Glow plug, installing......445
Glow plug, removing......447
Glow plugs, testing......449
Preheating, specifications......450
Starter motor, replacing......451
Starter relay, replacing......453
36 - OTHER ELECTRICAL EQUIPMENT......454
Windscreen wiper front motor, replacing......454
37 - CABLE; FUSE; RELAY......460
Cable and component designations......460
Cable and component marking explanations......462
Component list Alternator, batteries, capacitors, electronic units, voltage outlet......464
Component list Fuses......466
Component list Heating coils, instruments, service socket......469
Component list Lights......470
Component list Relays......472
Component list Solenoid valves......474
Component list Switches......475
Component list, PWM valves......477
Component list, Sounders......478
Component list, motors......479
Component list, sensors......480
Component location 1......481
Component location 10......483
Component location 11......485
Component location 2......487
Component location 3......488
Component location 4......489
Component location 5......490
Component location 6......493
Component location 7......495
Component location 8......497
Component location 9......499
Component location......502
Connector I_O description......503
Electrical symbols and designations......521
Table of contents, wiring diagrams......525
Wiring diagram WD201 - Image......526
Wiring diagram WD201......527
Wiring diagram WD202 - Image......530
Wiring diagram WD202......531
Wiring diagram WD203 - Image......534
Wiring diagram WD203......535
Wiring diagram WD301 - Image......538
Wiring diagram WD301......539
Wiring diagram WD302 - Image......542
Wiring diagram WD302......543
Wiring diagram WD303 - Image......546
Wiring diagram WD303......547
Wiring diagram WD304 - Image......550
Wiring diagram WD304......551
Wiring diagram WD305 - Image......554
Wiring diagram WD305......555
Wiring diagram WD306 - Image......558
Wiring diagram WD306......559
Wiring diagram WD307 - Image......562
Wiring diagram WD307......563
Wiring diagram WD308 - Image......566
Wiring diagram WD308......567
Wiring diagram WD309 - Image......570
Wiring diagram WD309......571
Wiring diagram WD310 - Image......574
Wiring diagram WD310......575
Wiring diagram WD311 - Image......578
Wiring diagram WD311......579
Wiring diagram WD312 - Image......582
Wiring diagram WD312......583
Wiring diagram WD313 - Image......586
Wiring diagram WD313......587
Wiring diagram WD314 - Image......590
Wiring diagram WD314......591
Wiring diagram WD315 - Image......594
Wiring diagram WD315......595
Wiring diagram WD401 - Image......598
Wiring diagram WD401......599
Wiring diagram WD501 - Image......602
Wiring diagram WD501......603
Wiring diagram WD801 - Image......606
Wiring diagram WD801......607
Wiring diagram WD802 - Image......610
Wiring diagram WD802......611
Wiring diagram WD803 - Image......615
Wiring diagram WD803......616
Wiring diagram WD901 - Image......619
Wiring diagram WD901......620
Wiring diagram WD902 - Image......623
Wiring diagram WD902......624
Wiring diagram WD903 - Image......627
Wiring diagram WD903......628
Wiring diagram, electrical distribution box - Image......631
Wiring diagram, electrical distribution box......632
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM......635
Information display, general......635
Information display, start lockout......637
Service mode, description......639
39 - MISCELLANEOUS......646
CareTrack W-ECU, description......646
4 - POWER TRANSMISSION......650
40 - GENERAL......651
Power transmission, description......651
42 - TRANSMISSION; HYDRAULIC CONTROL......653
Induction sensor for output shaft, replacing......653
44 - HYDROSTATIC DRIVE......655
Hydraulic diagram transmission......655
Hydraulic motor, replacing......658
Hydraulic pump coupling, description......663
Hydraulic pump, replacing-[0142]......665
Hydrostatic pump charge pressure, checking and adjusting......671
Hydrostatic pump cut off valve, checking and adjusting......673
Hydrostatic pump mechanical zero position, checking and adjusting......676
Hydrostatic pump, description......679
Power transmission, specifications......682
Shaft seal replacing......683
Start hydraulic pump control, checking and adjusting......686
Travel motor, description......689
46 - FRONT AXLE; REAR AXLE......692
Axle, installing......692
Axle, removing......696
Axles and propeller shaft, tightening torque......700
Drive axles, description......701
Front axle, installing......702
Front axle, removing......705
Front axle, specifications......708
Rear axle, specifications......709
5 - BRAKE......710
50 - GENERAL......711
Brakes, specifications......711
Description brake system......712
Troubleshooting and actions to fix problems......714
51 - WHEEL BRAKE......716
Brake disc, replacing one......716
Brake pads, replacing......720
52 - HYDRAULIC BRAKE SYSTEM......727
Brake system, bleeding......727
Inching and brake pedal, adjusting......729
6 - STEERING......731
60 - GENERAL......732
Steering system, description......732
Steering unit, specification......734
Steering, tightening torques......735
64 - STEERING......736
Hydraulic diagram, steering......736
Steering pressure, checking......738
Steering valve solenoid, replacing......740
Steering wheel, tightening torques......744
Troubleshooting and actions to fix problems......746
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT......749
70 - GENERAL......750
Frame and track unit, description......750
Frame, weight......751
71 - FRAME......752
Counterweight, installing......752
Counterweight, removing......755
74 - FRAME LINK......758
Frame joint, Replacing the front pivot bearing with machine separated......758
Frame joint, assembly of separated machine......760
Frame joint, replacing the rear pivot bearing with machine separated......768
Frame joint, separating machine......770
Steering joint, tightening torques......779
77 - WHEELS; TRACKS; TYRE; HUB; DRUM......780
Tire size......780
Wheel, tightening torque......782
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE......783
80 - GENERAL......784
Cab description......784
81 - CAB, NAKED; CANOPY......785
Cab mounts, tightening torques......785
Cab, installing......786
Cab, removing......795
82 - ENGINE HOOD; MUDGUARD; FOOT STEP......805
Engine hood, installing......805
Engine hood, removing......807
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING......809
Rear window, replacing......809
Windows, general......812
Windscreen, replacing......813
87 - AIR CONDITIONING UNIT......816
Air conditioning unit, maintenance......816
Air conditioning, capacity......818
Combination sensor, check......819
Cooling unit, leak detection......821
Diesel heater, description......823
Diesel heater, principles......826
Diesel heater, specifications......827
Disassembly and assembly......829
Electrical schematic......834
Error code, troubleshooting......837
Fault mode diagnosis......840
Heating system, description......842
Refrigerant, draining......845
Refrigerant, filling incl vacuum pumping......847
Symptom_malfunction......850
Troubleshooting, air conditioning unit (AC)......852
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS......856
90 - GENERAL......857
Cleanliness when working on hydraulic components......857
General information to note when working on the hydraulic system......858
Hydraulic components, storing and transporting......860
Hydraulic oil, storage and handling......861
Hydraulic system, repair of hydraulic components in workshop......862
Troubleshooting chart......864
Vacuum pump, connection......867
91 - WORKING HYDRAULIC; SERVO HYDRAULICS......869
Boom Suspension System, general description......869
Hydraulic diagram, Boom Suspension System......872
Hydraulic diagram, control valve......874
Hydraulic oil cooler, replacing......876
Hydraulic oil tank, installing......878
Hydraulic oil tank, removing......881
Hydraulic pump, replacing......885
Hydraulic pumps, description......888
Hydraulic system, description......889
Hydraulic system, specification......890
Hydraulic system, volume......891
Main control valve, description......892
Main control valve, installing......894
Main control valve, removing......897
Primary pressure limiting valve, checking and adjusting......900
Secondary pressure limiting valve, checking and adjusting......904
Secondary pressure limiting valve, replacing......908
Working hydraulics, tightening torques......911
92 - MECHANICAL EQUIPMENT_ATTACHMENT......912
Implemental attachment hydraulic cylinder, replacing......912
94 - UNIT, LOAD HANDLING......916
Hydraulic cylinder creeping, checking......916
Lift cylinder, replacing......918
Tilt cylinder, replacing......923
Tilting and lifting cylinders......927
99 - MISCELLANEOUS......930
3rd hydraulic function - Image......930
3rd hydraulic function......931
Additional pump - Image......935
Additional pump......936
Flow control for 3rd hydraulic function - Image......939
Flow control for 3rd hydraulic function_{07-10-35}......941
Flow control for 3rd hydraulic function_{07-11-02}......945
Hydraulic diagram with option components - Image......949
Hydraulic diagram with option components......950
Hydraulic diagram, line rupture valves - Image......953
Hydraulic diagram, line rupture valves......954
Hydraulic diagram, working hydraulic system - Image......957
Hydraulic diagram, working hydraulic system......958
Hydraulic function, 4th switchable from 3rd - Image......961
Hydraulic function, 4th switchable from 3rd......962
Volvo L25H Compact Wheel Loaders Service Repair Manual
