Volvo L45G Compact Wheel Loader Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo L45G Compact Wheel Loaders, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
Volvo Constructions L45G 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 L45G Compact Wheel Loader Repair Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,484 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
0 - Foreword....2
0 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Description....4
Machine dimensions....5
03 - SPECIFICATIONS....8
Measurement conversion tables....8
Volvo standard tightening torques....13
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION....15
Transporting the machine....15
07 - STANDARD TIME....18
Operation numbers for additional work....18
08 - TOOL....20
E-2000....20
E-tool Cab support....22
Infrared Thermometer....23
1 - STANDARD PARTS, SERVICE....27
16 - LUBRICANT; FUEL; OTHER FLUID....28
Alternative fuels....28
Coolant with freezing and corrosion protection....31
Recommended lubricants ....33
17 - SERVICE....36
Arrival Inspection, according to Inspection Programme....36
Axle oil, changing_{01-08-45}....37
Axle oil, changing_{01-09-13}....40
Axle oil, changing_{01-09-41}....43
Battery, checking....46
Brake pressure and function, checking....47
Cab main filter, replacing....52
Charging batteries....54
Cleanliness, braking and hydraulic system....55
Coolant freezing point, checking....56
Coolant level, checking....58
Coolant, changing....60
Delivery Inspection, according to Inspection Programme....62
Delivery Instructions, according to Inspection Programme....63
Diesel particulate filter, checking and cleaning....64
Electric welding....68
Engine air cleaner primary filter, replacing....69
Engine air cleaner secondary filter, replacing....71
Engine belt tension, checking....72
Engine oil and filter, changing....74
Engine oil level, checking....76
Fuel filters, replacing....77
Fuel tank breather filter, replacing....79
Hydraulic oil filters, replacing....81
Hydraulic oil level, checking....83
Hydraulic oil, changing....85
Hydraulic pressure, checking....87
Hydraulic tank sediment, draining....90
Leakage, checking....92
Lubrication....93
MATRIS and Tech Tool, reading....95
Maintenance of Stored Machines, according to Inspection Programme....96
Maintenance service, every 10 hours....97
Maintenance service, every 1000 hours....98
Maintenance service, every 1500 hours....100
Maintenance service, every 2000 hours....102
Maintenance service, every 3000 hours....104
Maintenance service, every 4500 hours....106
Maintenance service, every 50 hours....107
Maintenance service, every 500 hours....108
Maintenance service, every 6000 hours....109
Parking brake pads, checking....110
Propeller shaft movement, checking....111
Radiator, cleaning....113
Service and maintenance....115
Service brake disc wear, checking....117
Service position 1_{01-26-14}....119
Service position 2_{01-26-43}....121
Service....123
Spark plugs, replacing....124
Steering cylinders, locking of pivot pins, checking....126
Steering pressure, checking ....128
Tech Tool, operations-[2856]....131
Test running and checking....132
Towing....133
Transmission oil filter, replacing....134
Tyre wear and air pressure, checking....137
Valves, adjusting-[1854]....138
Water separator, checking....144
Wheel nuts torque, checking....146
Work on the machine's electrical system....147
19 - GENERAL....148
CE-marking, EMC-directive....148
Checklist after a fire or heat exposure....152
Decontamination....153
Environmental handling for the future....155
Environmentally hazardous fluids....157
Environmentally safe handling....158
Fire prevention measures....160
Health hazards with paint, plastics and rubber....163
Loader boom, safety strut....165
Safety concerns everybody!....168
Safety rules when servicing....170
Safety when handling accumulators....173
Safety when handling oils and fuel....174
Safety when handling the machine....175
Safety when lifting and supporting complete machine....179
Safety when using lifting equipment....181
Safety when working on hydraulic systems....183
Safety when working with batteries....185
Safety when working with refrigerant....188
Service position 1_{12-53-02}....191
Service position 2_{12-53-30}....193
Some simple rules regarding tyre handling....195
Starting with booster batteries....197
Waste handling....199
Working in environmentally contaminated areas....200
Working under raised boom....201
2 - ENGINE WITH MOUNTING AND EQUIPMENT....203
20 - GENERAL....204
Component locations....204
Electric components location....206
Engine, capacity....210
Engine, description....211
Engine, weights....215
Tech Tool, operations-....216
21 - ENGINE....218
Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope....218
Crankcase ventilation, description....224
Engine mounting, tightening torque....225
Engine, installing....227
Engine, removing....236
Engine, specifications....246
Valve cover, installing....247
Valve cover, removing....251
Valves, adjusting....256
22 - LUBRICATING SYSTEM....262
Lubricating system, description....262
Lubrication oil pressure, checking....266
Lubrication system, specifications....268
23 - FUEL SYSTEM....269
Carbon dioxide in fuel system, checking....269
Fuel control valve (FCV), replacing....275
Fuel feed pump, description....279
Fuel pump, replacing....280
Fuel rail pressure sensor, replacing....282
Fuel system, bleeding....284
Fuel system, description....286
Fuel system, specifications....292
Fuel system, tightening torques....293
Fuel tank, installing....294
Fuel tank, removing....298
High pressure fuel pump, replacing....303
Injectors, replacing....306
25 - INLET & EXHAUST SYSTEM....312
ACM (Aftertreatment control module) non-programmed, replacing....312
ACM (Aftertreatment control module) pre-programmed, replacing....314
Air pump, replacing....316
Burner function, checking....320
Burner, replacing....325
DOC (Diesel oxidation catalyst), replacing....328
DPF (Diesel particulate filter), checking and cleaning....331
Exhaust Aftertreatment System, description....335
Exhaust aftertreatment system, specifications....346
Glow plug, replacing....349
Injector sleeves, replacing....351
Inlet and exhaust system, description....361
Inlet and exhaust system, tightening torques....365
Perform a service regeneration....367
Regeneration process, description....368
Spark plug cable, replacing....371
Spark plug control unit, replacing....373
Spark plug, inspecting....375
Spark plug, replacing....377
Turbocharger, description....379
Turbocharger, replacing....381
Wastegate, checking....385
26 - COOLING SYSTEM....387
Coolant pump, replacing....387
Cooling fan rpm, specifications....390
Cooling system pressure, checking....391
Cooling system, capacity....393
Cooling system, description....394
Fan belt and_or alternator belt, replacing....396
Thermostat, replacing....399
29 - MISCELLANEOUS....403
EGR actuator, replacing....403
EGR cooler, replacing....406
EGR reed valve, replacing....410
EGR system function, checking....414
EGR system, tightening torques....416
Exhaust Gas Recirculation (EGR), description....419
Exhaust gas recirculation (EGR), component location....423
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....425
30 - GENERAL....426
Automatic engine shut down, description....426
Bus communication supervision....428
CU2501, description and measuring....430
CU2503, description and measuring....432
CU6601, description and measuring....434
Collection of basic data....438
Communication with data buses-[5656]....440
Communication with data buses....442
Component descriptions....444
Conditions when checking....447
Electrical system, description....450
Electrical system, specifications....452
Electrical system, work instructions....453
Electronic control system, description....455
Error codes, build-up....460
FX1005, description and measuring....463
FX1007, description and measuring....466
FX1008, description and measuring....469
FX1031, description and measuring....472
General fault diagnosis information....475
HE2501, description and measuring....477
Information display, check ....479
Lead and connector checks....481
Limp home....485
MA2301-MA2304, description and measuring....486
MA2508, description and measuring....488
MA2509, description and measuring....490
MA2510, description and measuring....492
MA2512, description and measuring....494
MA2602, description and measuring....496
MA4220, description and measuring_{11-00-23}....498
MA4220, description and measuring_{11-02-54}....500
MA4221, description and measuring_{10-57-02}....502
MA4221, description and measuring_{10-59-01}....504
MA4228, description and measuring....506
MA4603, description and measuring....508
MA4710, description and measuring....510
MA4720, description and measuring....512
MA9172, description and measuring....514
MA9173, description and measuring....516
MA9174, description and measuring....518
MO2502, description and measuring....520
MO2505, description and measuring....523
MO3301, description and measuring....525
MO6401, description and measuring....527
Machine, Calibration....529
PPID 437 explanation....536
PWM2303, description and measuring....537
PWM2602, description and measuring....539
PWM4225, description and measuring....541
PWM4226, description and measuring....543
PWM4227, description and measuring....545
PWM6601, description and measuring....547
PWM6602, description and measuring....549
Power supply I-ECU, description and measuring....551
Power supply T-ECU, description and measuring....553
Power supply V-ECU, description and measuring....555
Power supply V2-ECU, description and measuring....557
Power supply, ACM (Aftertreatment Control Module), description and measuring....559
R2701, description and measuring....561
R4201, description and measuring....563
RE02, description and measuring....565
RE06, description and measuring....567
RE09, description and measuring....569
RE10, description and measuring....571
RE15, description and measuring....573
RE2501, description and measuring....575
RE6401, description and measuring....577
RE8712, description and measuring....579
SAE J1708_1587 Information link, description and measuring....581
SAE J1939_CAN1 Control link, description and measuring....584
SAE J1939_CAN2 control link, description and measuring....587
SAE error codes, translation to error messages, general....590
SAEJ1939_CAN7 Control link, description and measuring....592
SE2203, description and measuring....595
SE2301, description and measuring....597
SE2303, description and measuring....599
SE2309, description and measuring....601
SE2512, description and measuring....603
SE2519, description and measuring....605
SE2520, description and measuring....607
SE2521, description and measuring....609
SE2522, description and measuring....611
SE2523, description and measuring....613
SE2524, description and measuring....615
SE2525, description and measuring....617
SE2526, description and measuring....619
SE2603, description and measuring....621
SE2606, description and measuring....623
SE2701, description and measuring....625
SE2702, description and measuring....627
SE2703, description and measuring....629
SE4201, description and measuring....631
SE4405, description and measuring_{04-27-34}....633
SE4405, description and measuring_{04-28-38}....635
SE4406, description and measuring....637
SE4407, description and measuring....639
SE6403, description and measuring....641
SE6404, description and measuring....643
SE6601, description and measuring....645
SE8702, description and measuring....647
SE8705, description and measuring....649
SE8706, description and measuring....651
SE8708, description and measuring....653
SE8709, description and measuring....655
SE9105, description and measuring....657
SE9109, description and measuring....659
SW2506, description and measuring....661
SW4205_SW4206, description and measuring....663
SW4208, description and measuring....665
SW4217, description and measuring....667
SW8701, description and measuring....669
Semi-auto DPF regeneration....671
Software parameters, description....674
Special tools for troubleshooting....683
Tech Tool, operations....684
Transmission shutdown....685
Troubleshooting strategy....686
Troubleshooting tools....688
31 - BATTERY....689
Battery, charging....689
Battery, description....690
Battery, specifications....691
32 - ALTERNATOR; CHARGE REGULATOR....692
Alternator, replacing incl function checking....692
Alternator, testing....694
33 - STARTING SYSTEM....696
Booting sequence....696
Preheating, description ....697
Starter motor, replacing....699
35 - LIGHTING....704
Lighting, description....704
Lights, specifications....706
36 - OTHER ELECTRICAL EQUIPMENT....707
Connector I_O description ....707
Connectors, overview....735
Control units, changing....739
Engine control unit E-ECU, description....740
I-ECU MID 140 non-programmed, replacing....742
I-ECU MID 140 pre-programmed, replacing....745
Reduced computer communication....747
37 - CABLE; FUSE; RELAY....749
Battery disconnect switch, description....749
Cable and component designations....750
Cable and component marking explanations....752
Component list Alternator, batteries, capacitors, electronic units, voltage outlet....754
Component list Fuses....756
Component list Heating coils, instruments, service socket....759
Component list Lights....760
Component list Relays....762
Component list Solenoid valves....764
Component list Switches....766
Component list, PWM valves....768
Component list, Sounders....769
Component list, motors....770
Component list, sensors....771
Connector I_O description....773
Electrical symbols and designations....801
Table of contents, wiring diagrams....805
Wiring diagram WD201....807
Wiring diagram WD202....811
Wiring diagram WD203....814
Wiring diagram WD204....817
Wiring diagram WD205....821
Wiring diagram WD206....825
Wiring diagram WD301....829
Wiring diagram WD302....833
Wiring diagram WD303....837
Wiring diagram WD304....840
Wiring diagram WD305....844
Wiring diagram WD306....847
Wiring diagram WD307....850
Wiring diagram WD308....853
Wiring diagram WD309....856
Wiring diagram WD310....858
Wiring diagram WD311....862
Wiring diagram WD312....865
Wiring diagram WD313....867
Wiring diagram WD314....869
Wiring diagram WD315....871
Wiring diagram WD316....873
Wiring diagram WD317....875
Wiring diagram WD318....877
Wiring diagram WD401....879
Wiring diagram WD402....882
Wiring diagram WD403....885
Wiring diagram WD404....888
Wiring diagram WD501....891
Wiring diagram WD601....895
Wiring diagram WD602....898
Wiring diagram WD603....901
Wiring diagram WD801....904
Wiring diagram WD802....907
Wiring diagram WD803....910
Wiring diagram WD804....913
Wiring diagram WD901....916
Wiring diagram WD902....920
Wiring diagram WD903....922
Wiring diagram WD904....924
Wiring diagram WD905....926
Wiring diagram WD906....929
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....932
Central warning....932
Engine oil pressure sensor, replacing....933
Information display, axles _ brakes....935
Information display, check....936
Information display, electrical system....938
Information display, engine....939
Information display, general....941
Information display, hydraulics....944
Information display, operating display....945
Information display, service mode ....946
Information display, settings....948
Information display, start lockout....949
Information display, transmission....951
Information display, vehicle info....952
Information display, vehicle messages....954
Instrument panels....955
Middle instrument panel with warning lights....957
39 - MISCELLANEOUS....959
CareTrack W-ECU, description....959
4 - POWER TRANSMISSION....963
40 - GENERAL....964
Power transmission, description....964
42 - TRANSMISSION; HYDRAULIC CONTROL....966
Hydrostatic transmission, description....966
Induction sensor for output shaft, replacing....968
Transmission circuit hydraulic schematic - Image....971
Transmission circuit hydraulic schematic....972
Transmission sensor, replacing....974
Transmission solenoid, replacing....976
Transmission, disassembling....978
Transmission, function check....982
Transmission, installing....992
Transmission, removing....999
44 - HYDROSTATIC DRIVE....1003
Hydraulic diagram transmission - Image....1003
Hydraulic diagram transmission_{02-42-37}....1006
Hydraulic diagram transmission_{02-43-04}....1009
Hydraulic diagram transmission_{02-43-31}....1012
Hydraulic motor, replacing....1015
Hydraulic pump coupling, description....1020
Hydraulic pump, replacing ....1022
Hydrostatic pump charge pressure, checking and adjusting....1028
Hydrostatic pump cut off valve, checking and adjusting....1030
Hydrostatic pump high pressure valve, checking and adjusting....1033
Hydrostatic pump mechanical zero position, checking and adjusting....1036
Hydrostatic pump, description_{02-44-36}....1039
Hydrostatic pump, description_{02-45-03}....1042
Power transmission, specifications....1045
Shaft seal replacing....1046
Start hydraulic motor control, check and adjust....1049
Start hydraulic pump control, checking and adjusting....1052
Travel motor, description....1054
45 - PROPELLER SHAFT....1057
Propeller shaft, changing....1057
46 - FRONT AXLE; REAR AXLE....1060
Axle, installing....1060
Axle, removing....1065
Axles, tightening torques....1070
Drive axles, description....1071
Front axle, capacity....1075
Front axle, installing_{02-29-56}....1076
Front axle, installing_{02-30-23}....1079
Front axle, removing_{02-31-05}....1081
Front axle, removing_{02-31-32}....1084
Front axle, specification....1087
Front axle, weight....1088
Rear axle, capacity....1089
Rear axle, specification....1090
Rear axle, weight....1091
5 - BRAKE....1092
50 - GENERAL....1093
Brakes, specifications....1093
Description brake system....1095
Hydraulic diagram, brake system - Image....1096
Hydraulic diagram, brake system....1098
51 - WHEEL BRAKE....1103
Brake linings, checking wear....1103
52 - HYDRAULIC BRAKE SYSTEM....1105
Accumulator (removed) charging pressure, checking....1105
Accumulator, checking....1107
Brake system hydraulic function, checking....1109
Brake system, adjusting unloading pressure....1114
Brake system, bleeding....1118
Service brake pressure, checking....1120
55 - PARKING BRAKE....1122
Parking brake brake pads, replacing....1122
Parking brake, replacing brake disc....1127
Parking brake, replacing control cable....1130
6 - STEERING....1136
60 - GENERAL....1137
Steering system, description....1137
Steering system, specifications....1139
64 - STEERING....1140
Hydraulic diagram, steering - Image....1140
Hydraulic diagram, steering....1141
Secondary steering, description....1142
Steering pressure, checking....1143
Steering system working pressure, checking and adjusting....1146
Steering system, troubleshooting and elimination....1149
Steering wheel, tightening torques....1151
66 - LEVEL STEERING....1153
Comfort Drive Control (CDC) control valve, removing....1153
Comfort Drive Control (CDC), description....1156
Comfort Drive Control, servo pressure, checking....1160
Comfort drive control (CDC) angle sensor, changing....1162
Comfort drive control (CDC) control valve, installing....1168
Comfort drive control (CDC) solenoid valve, changing....1171
Error codes when calibrating....1174
Hydraulic diagram, steering incl. lever steering (CDC) - Image....1176
Hydraulic diagram, steering incl. lever steering (CDC)....1177
Lever steering (CDC) function, checking....1180
Lever steering (CDC), specifications....1181
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....1182
70 - GENERAL....1183
Frame and track unit, description....1183
Frame, weight....1185
71 - FRAME....1186
Counterweight, installing....1186
Counterweight, removing....1188
Counterweight, tightening torques....1191
74 - FRAME LINK....1193
Frame joint, assembly of separated machine....1193
Frame joint, replacing bearings....1205
Frame joint, separating machine....1209
75 - AXLE SUSPENSION....1220
Axle suspension, replacing bushes and seals....1220
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....1223
Tire size....1223
Wheel, tightening torque....1224
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....1225
80 - GENERAL....1226
Cab description....1226
81 - CAB, NAKED; CANOPY....1227
Cab mounts, tightening torques....1227
Cab, installing....1228
Cab, removing....1237
Viscous cab suspension, description....1247
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....1249
Engine hood, installing....1249
Engine hood, removing....1252
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....1255
Side window, replacing_{01-57-45}....1255
Sliding window, changing....1264
Windows, general....1266
Windscreen, replacing_{01-57-17}....1268
87 - AIR CONDITIONING UNIT....1277
Air conditioning unit, check function....1277
Air conditioning, capacity....1280
Cooling unit, leak detection....1281
Heating system, description....1283
Pause heater, description....1287
Refrigerant, draining....1288
Troubleshooting, air conditioning unit (AC)....1290
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....1294
90 - GENERAL....1295
Accumulator, discarding....1295
Cleanliness when working on hydraulic components....1297
General information to note when working on the hydraulic system....1298
Hydraulic components, storing and transporting....1300
Hydraulic oil, storage and handling....1301
Hydraulic system, repair of hydraulic components in workshop....1302
Troubleshooting chart....1304
Vacuum pump, connection....1307
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....1309
Boom Suspension System, general description....1309
Boom suspension system, checking....1311
Hydraulic diagram with option components - Image....1316
Hydraulic diagram with option components....1319
Hydraulic diagram, Boom Suspension System - Image....1323
Hydraulic diagram, Boom Suspension System....1324
Hydraulic diagram, control valve - Image....1327
Hydraulic diagram, control valve....1330
Hydraulic diagram, cooling fan - Image....1333
Hydraulic diagram, cooling fan_{01-39-40}....1336
Hydraulic diagram, cooling fan_{01-40-03}....1338
Hydraulic diagram, cooling fan_{01-40-26}....1340
Hydraulic diagram, working hydraulics, 3rd and 4th functions, attachment lock - Image....1342
Hydraulic diagram, working hydraulics, 3rd and 4th functions, attachment lock....1343
Hydraulic oil tank, description....1345
Hydraulic pump, description....1347
Hydraulic pump, max working pressure, checking and adjusting....1349
Hydraulic pump, replacing....1351
Hydraulic pump, standby pressure, checking and adjusting....1356
Hydraulic system, description....1359
Hydraulic system, specification....1360
Hydraulic system, volume....1362
Main control valve, description....1363
Main control valve, installing....1369
Main control valve, removing....1373
Port relief valve pressure, checking and adjusting....1377
Servo valve, description....1382
92 - MECHANICAL EQUIPMENT_ATTACHMENT....1386
Attachment bracket cylinder, reconditioning....1386
Attachment locking hydraulic cylinder (vision-optimised bracket), replacing....1388
Hydraulic attachment bracket (quickfit), description....1391
Implemental attachment hydraulic cylinder, replacing_{01-35-16}....1392
Implemental attachment hydraulic cylinder, replacing_{01-35-43}....1396
99 - MISCELLANEOUS....1400
Automatic lubrication pump unit, reconditioning....1400
Automatic lubrication system, specifications....1422
Bleeding air....1424
Central lubrication system, description....1430
Change of lubrication interval....1435
Diagnostic tools, description....1437
Dosage valves, description....1439
Filling lubricant....1443
Hydraulic diagram with option components - Image....1445
Hydraulic diagram with option components_{01-31-06}....1449
Hydraulic diagram with option components_{01-31-30}....1451
Hydraulic diagram with option components_{01-31-57}....1453
Hydraulic diagram with option components_{01-32-20}....1455
Hydraulic diagram, working hydraulic system - Image....1457
Hydraulic diagram, working hydraulic system_{01-32-58}....1459
Hydraulic diagram, working hydraulic system_{01-33-21}....1461
Parameter settings....1463
Pressure monitor, description....1465
Pump unit, description....1467
Recommended lubricants....1470
Shift valve, description....1472
Software, parameter settings and read-outs....1474
System test....1481
Update of automatic lubrication system....1483
Volvo L45G Compact Wheel Loader Repair Service Manual
