Volvo L50G Wheel Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for L50G Volvo Wheel Loaders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions L50G 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: 1,541 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
L50G Volvo Wheel Loaders Service Repair Manual.pdf
MAIN SECTIONS
000 - Foreword........2
000 - GENERAL........3
00 - DESCRIPTION; COMPLETE MACHINE........4
Description........5
Machine dimensions........6
03 - SPECIFICATIONS........9
Measurement conversion tables........10
Volvo standard tightening torques........15
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION........17
Transporting the machine........18
07 - STANDARD TIME........21
Operation numbers for additional work........22
09 - MISCELLANEOUS........24
E-2000........25
E-tool Cab support........27
Infrared Thermometer........28
001 - STANDARD PARTS; SERVICE........32
16 - LUBRICANT; FUEL; OTHER FLUID........33
Recommended lubricants........34
Coolant with freezing and corrosion protection........37
Alternative fuels........39
17 - SERVICE........42
Service........45
Service and maintenance........46
Work on the machine's electrical system........48
Cleanliness; braking and hydraulic system........49
Charging batteries........50
Electric welding........51
Tech Tool; operations-........52
Arrival Inspection; according to Inspection Programme........53
Delivery Inspection; according to Inspection Programme........54
Delivery Instructions; according to Inspection Programme........55
Maintenance of Stored Machines; according to Inspection Programme........56
Service position 2_{01-25-34}........57
Service position 1_{01-25-06}........59
Maintenance service; every 10 hours........61
Maintenance service; every 50 hours........62
Maintenance service; every 500 hours........63
Maintenance service; every 1000 hours........64
Maintenance service; every 1500 hours........66
Maintenance service; every 2000 hours........68
Maintenance service; every 3000 hours........70
Maintenance service; every 4500 hours........72
Maintenance service; every 6000 hours........73
Test running and checking........74
Leakage; checking........75
Lubrication........76
Engine belt tension; checking........78
Valves; adjusting-........80
Engine oil level; checking........86
Engine oil and filter; changing........87
Water separator; checking........89
Fuel filters; replacing........91
Fuel tank breather filter; replacing........93
Spark plugs; replacing........95
Diesel particulate filter; checking and cleaning........97
Engine air cleaner primary filter; replacing........101
Engine air cleaner secondary filter; replacing........103
Coolant level; checking........104
Coolant; changing........106
Coolant freezing point; checking........108
Radiator; cleaning........110
MATRIS and Tech Tool; reading........112
Battery; checking........113
Transmission oil filter; replacing........114
Propeller shaft movement; checking........117
Axle oil; changing_{01-06-53}........119
Axle oil; changing_{01-06-29}........122
Axle oil; changing_{01-06-06}........125
Service brake disc wear; checking........128
Brake pressure and function; checking........130
Parking brake pads; checking........135
Steering pressure; checking-........136
Steering cylinders; locking of pivot pins; checking........139
Tyre wear and air pressure; checking........141
Wheel nuts torque; checking........142
Cab main filter; replacing........143
Hydraulic oil level; checking........145
Hydraulic oil; changing........147
Hydraulic oil filters; replacing........149
Hydraulic tank sediment; draining........151
Hydraulic pressure; checking........153
Towing........156
19 - GENERAL........157
Safety concerns everybody!........158
CE-marking; EMC-directive........160
Safety when handling the machine........164
Safety rules when servicing........168
Service position 2_{12-54-22}........171
Service position 1_{12-53-53}........173
Loader boom; safety strut........175
Working under raised boom........178
Fire prevention measures........180
Some simple rules regarding tyre handling........183
Safety when lifting and supporting complete machine........185
Safety when using lifting equipment........187
Safety when working with batteries........189
Starting with booster batteries........192
Safety when handling oils and fuel........194
Safety when handling accumulators........195
Safety when working on hydraulic systems........196
Checklist after a fire or heat exposure........198
Health hazards with paint; plastics and rubber........199
Environmental handling for the future........201
Waste handling........203
Environmentally safe handling........204
Environmentally hazardous fluids........206
Safety when working with refrigerant........207
Working in environmentally contaminated areas........210
Decontamination........211
002 - ENGINE WITH MOUNTING AND EQUIPMENT........213
20 - GENERAL........214
Tech Tool; operations ........215
Component locations........217
Engine; description........219
Engine; capacity........223
Engine; weights........224
Electric components location........225
21 - ENGINE........229
Engine; specifications........230
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope........231
Engine; removing........237
Engine; installing........247
Crankcase ventilation; description........256
Valves; adjusting........257
Valve cover; removing........263
Valve cover; installing........268
Engine mounting; tightening torque........272
22 - LUBRICATING SYSTEM........274
Lubricating system; description........275
Lubrication system; specifications........279
Lubrication oil pressure; checking........280
23 - FUEL SYSTEM........282
Fuel system; description........283
Fuel system; specifications........289
Fuel system; tightening torques........290
Carbon dioxide in fuel system; checking........291
Fuel feed pump; description........297
Fuel system; bleeding........298
Fuel pump; replacing........300
Fuel tank; removing........302
Fuel tank; installing........307
Injectors; replacing........311
High pressure fuel pump; replacing........317
Fuel control valve (FCV); replacing........320
Fuel rail pressure sensor; replacing........324
Injector sleeves; replacing........326
25 - INLET & EXHAUST SYSTEM........336
Inlet and exhaust system; description........337
Inlet and exhaust system; tightening torques........341
Regeneration process; description........343
Air pump; replacing........346
Exhaust aftertreatment system; specifications........350
Exhaust Aftertreatment System; description........353
Perform a service regeneration........364
Spark plug; replacing........365
DPF (Diesel particulate filter); checking and cleaning........367
Spark plug control unit; replacing........371
ACM (Aftertreatment control module) non-programmed; replacing........373
ACM (Aftertreatment control module) pre-programmed; replacing........375
Glow plug; replacing........377
Spark plug; inspecting........379
Spark plug cable; replacing........381
Burner function; checking........383
Burner; replacing........388
DOC (Diesel oxidation catalyst); replacing........391
Turbocharger; replacing........394
Wastegate; checking........398
Turbocharger; description........400
26 - COOLING SYSTEM........402
Cooling system; description........403
Cooling system pressure; checking........405
Cooling system; capacity........407
Coolant pump; replacing........408
Thermostat; replacing........411
Cooling fan rpm; specifications........415
Fan belt and_or alternator belt; replacing........416
29 - MISCELLANEOUS........419
Exhaust gas recirculation (EGR); component location........420
EGR system; tightening torques........422
EGR reed valve; replacing........425
EGR cooler; replacing........429
Exhaust Gas Recirculation (EGR); description........433
EGR actuator; replacing........437
EGR system function; checking........440
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS........442
30 - GENERAL........443
Electrical system; work instructions........448
Electrical system; description........450
Electronic control system; description........452
Communication with data buses-........457
Electrical system; specifications........459
Automatic engine shut down; description........460
Machine; Calibration........462
Semi-auto DPF regeneration........469
Software parameters; description........472
General fault diagnosis information........481
Troubleshooting strategy........483
Collection of basic data........485
Information display; check-........487
Error codes; build-up........489
SAE error codes; translation to error messages; general........492
Communication with data buses........494
Bus communication supervision........496
Conditions when checking........498
Lead and connector checks........501
Troubleshooting tools........505
Special tools for troubleshooting........506
Tech Tool; operations........507
CU2501; description and measuring........508
CU2503; description and measuring........510
CU6601; description and measuring........512
FX1005; description and measuring........516
FX1007; description and measuring........519
FX1008; description and measuring........522
FX1031; description and measuring........525
HE2501; description and measuring........528
MA2301-MA2304; description and measuring........530
MA2508; description and measuring........532
MA2509; description and measuring........534
MA2510; description and measuring........536
MA2512; description and measuring........538
MA2602; description and measuring........540
MA4220; description and measuring_{10-46-17}........542
MA4220; description and measuring_{10-45-18}........544
MA4221; description and measuring_{10-43-52}........546
MA4221; description and measuring_{10-42-56}........548
MA4228; description and measuring........550
MA4603; description and measuring........552
MA4710; description and measuring........554
MA4720; description and measuring........556
MA9172; description and measuring........558
MA9173; description and measuring........560
MA9174; description and measuring........562
MO2502; description and measuring........564
MO2505; description and measuring........567
MO3301; description and measuring........569
MO6401; description and measuring........571
Power supply; ACM (Aftertreatment Control Module); description and measuring........573
Power supply I-ECU; description and measuring........575
Power supply T-ECU; description and measuring........577
Power supply V-ECU; description and measuring........579
Power supply V2-ECU; description and measuring........581
PWM2303; description and measuring........583
PWM2602; description and measuring........585
PWM4225; description and measuring........587
PWM4226; description and measuring........589
PWM4227; description and measuring........591
PWM6601; description and measuring........593
PWM6602; description and measuring........595
R2701; description and measuring........597
R4201; description and measuring........599
RE02; description and measuring........601
RE06; description and measuring........603
RE09; description and measuring........605
RE10; description and measuring........607
RE15; description and measuring........609
RE2501; description and measuring........611
RE6401; description and measuring........613
RE8712; description and measuring........615
SAE J1708_1587 Information link; description and measuring........617
SAE J1939_CAN1 Control link; description and measuring........620
SAE J1939_CAN2 control link; description and measuring........623
SAEJ1939_CAN7 Control link; description and measuring........626
SE2203; description and measuring........629
SE2301; description and measuring........631
SE2303; description and measuring........633
SE2309; description and measuring........635
SE2512; description and measuring........637
SE2519; description and measuring........639
SE2520; description and measuring........641
SE2521; description and measuring........643
SE2522; description and measuring........645
SE2523; description and measuring........647
SE2524; description and measuring........649
SE2525; description and measuring........651
SE2526; description and measuring........653
SE2603; description and measuring........655
SE2606; description and measuring........657
SE2701; description and measuring........659
SE2702; description and measuring........661
SE2703; description and measuring........663
SE4201; description and measuring........665
SE4405; description and measuring_{09-17-29}........667
SE4405; description and measuring_{09-16-37}........669
SE4406; description and measuring........671
SE4407; description and measuring........673
SE5205; description and measuring........675
SE6401; description and measuring........677
SE6403; description and measuring........679
SE6404; description and measuring........681
SE6601; description and measuring........683
SE8702; description and measuring-[0204]........685
SE8702; description and measuring........687
SE8705; description and measuring........689
SE8706; description and measuring........691
SE8708; description and measuring........693
SE8709; description and measuring-[5408]........695
SE8709; description and measuring........697
SE9105; description and measuring........699
SE9109; description and measuring........701
SW2506; description and measuring........703
SW4205_SW4206; description and measuring........705
SW4208; description and measuring........707
SW4217; description and measuring........709
SW8701; description and measuring........711
Component descriptions........713
Limp home........716
PPID 437 explanation........717
Transmission shutdown........718
31 - BATTERY........719
Battery; description........720
Battery; specifications........721
Battery; charging........722
32 - ALTERNATOR; CHARGE REGULATOR........723
Alternator; replacing incl function checking........724
Alternator; testing........726
33 - STARTING SYSTEM........728
Booting sequence........729
Starter motor; replacing........730
Preheating; description........735
35 - LIGHTING........737
Lighting; description........738
Lights; specifications........740
36 - OTHER ELECTRICAL EQUIPMENT........741
Reduced computer communication........742
Connectors; overview........744
Connector I_O description ........748
Engine control unit E-ECU; description........776
Control units; changing........778
I-ECU MID 140 non-programmed; replacing........779
I-ECU MID 140 pre-programmed; replacing........782
37 - CABLE; FUSE; RELAY........784
Electrical symbols and designations........786
Cable and component designations........790
Cable and component marking explanations........792
Component list Alternator; batteries; capacitors; electronic units; voltage outlet........794
Component list Fuses........796
Component list Heating coils; instruments; service socket........799
Component list Lights........800
Component list; motors........802
Component list; PWM valves........803
Component list Relays........804
Component list; sensors........806
Component list Solenoid valves........808
Component list; Sounders........810
Component list Switches........811
Connector I_O description........813
Table of contents; wiring diagrams........841
Wiring diagram WD201........843
Wiring diagram WD202........847
Wiring diagram WD203........850
Wiring diagram WD204........853
Wiring diagram WD205........857
Wiring diagram WD206........861
Wiring diagram WD301........865
Wiring diagram WD302........869
Wiring diagram WD303........873
Wiring diagram WD304........876
Wiring diagram WD305........880
Wiring diagram WD306........883
Wiring diagram WD307........886
Wiring diagram WD308........889
Wiring diagram WD309........892
Wiring diagram WD310........894
Wiring diagram WD311........898
Wiring diagram WD312........901
Wiring diagram WD313........903
Wiring diagram WD314........905
Wiring diagram WD315........907
Wiring diagram WD316........909
Wiring diagram WD317........911
Wiring diagram WD318........913
Wiring diagram WD401........915
Wiring diagram WD402........918
Wiring diagram WD403........921
Wiring diagram WD404........924
Wiring diagram WD501........927
Wiring diagram WD601........931
Wiring diagram WD602........934
Wiring diagram WD603........937
Wiring diagram WD801........940
Wiring diagram WD802........943
Wiring diagram WD803........946
Wiring diagram WD804........949
Wiring diagram WD901........952
Wiring diagram WD902........956
Wiring diagram WD903........958
Wiring diagram WD904........960
Wiring diagram WD905........962
Wiring diagram WD906........965
Battery disconnect switch; description........968
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM........969
Instrument panels........970
Middle instrument panel with warning lights........972
Engine oil pressure sensor; replacing........974
Information display; general........976
Information display; start lockout........979
Information display; operating display........981
Information display; engine........982
Information display; transmission........984
Information display; hydraulics........985
Information display; axles _ brakes........986
Information display; electrical system........987
Information display; vehicle info........988
Information display; vehicle messages........990
Information display; service mode........991
Information display; settings........993
Information display; check........994
Central warning........996
39 - MISCELLANEOUS........997
CareTrack W-ECU; description........998
004 - POWER TRANSMISSION........1002
40 - GENERAL........1003
Power transmission; description........1004
42 - TRANSMISSION; HYDRAULIC CONTROL........1006
Hydrostatic transmission; description........1007
Transmission circuit hydraulic schematic........1009
Transmission solenoid; replacing........1011
Transmission sensor; replacing........1013
Induction sensor for output shaft; replacing........1015
Transmission; removing........1018
Transmission; installing........1022
Transmission; disassembling........1029
Transmission; function check........1033
44 - HYDROSTATIC DRIVE........1043
Travel motor; description........1044
Hydrostatic pump; description_{07-37-51}........1047
Hydrostatic pump; description_{07-37-28}........1050
Power transmission; specifications........1053
Hydraulic diagram transmission_{07-36-35}........1054
Hydraulic diagram transmission_{07-36-13}........1057
Hydraulic diagram transmission_{07-35-50}........1060
Hydraulic motor; replacing........1063
Start hydraulic motor control; check and adjust........1068
Hydraulic pump coupling; description........1071
Hydraulic pump; replacing-........1073
Shaft seal replacing........1079
Hydrostatic pump charge pressure; checking and adjusting........1082
Start hydraulic pump control; checking and adjusting_{07-31-05}........1084
Start hydraulic pump control; checking and adjusting_{07-30-43}........1087
Hydrostatic pump cut off valve; checking and adjusting_{07-30-09}........1089
Hydrostatic pump cut off valve; checking and adjusting_{07-29-47}........1092
Hydrostatic pump high pressure valve; checking and adjusting_{07-29-13}........1095
Hydrostatic pump high pressure valve; checking and adjusting_{07-28-50}........1100
Hydrostatic pump mechanical zero position; checking and adjusting........1105
45 - PROPELLER SHAFT........1108
Propeller shaft; changing........1109
46 - FRONT AXLE; REAR AXLE........1112
Drive axles; description........1113
Front axle; specification........1117
Front axle; weight........1118
Front axle; capacity........1119
Rear axle; specification........1120
Rear axle; weight........1121
Rear axle; capacity........1122
Axles; tightening torques........1123
Front axle; removing_{07-22-38}........1124
Front axle; removing_{07-22-16}........1127
Front axle; installing_{07-21-42}........1130
Front axle; installing_{07-21-20}........1132
Axle; removing........1135
Axle; installing........1140
005 - BRAKE........1145
50 - GENERAL........1146
Description brake system........1147
Brakes; specifications........1148
Hydraulic diagram; brake system........1150
51 - WHEEL BRAKE........1155
Brake linings; checking wear........1156
52 - HYDRAULIC BRAKE SYSTEM........1158
Brake system hydraulic function; checking........1159
Service brake pressure; checking........1164
Brake system; adjusting unloading pressure........1166
Brake system; bleeding........1170
Accumulator; checking........1172
Accumulator (removed) charging pressure; checking........1174
55 - PARKING BRAKE........1176
Parking brake; replacing control cable........1177
Parking brake; replacing brake disc........1183
Parking brake brake pads; replacing........1186
006 - STEERING........1191
60 - GENERAL........1192
Steering system; description........1193
Steering system; specifications........1195
64 - STEERING........1196
Hydraulic diagram; steering - Image........1197
Hydraulic diagram; steering........1198
Secondary steering; description........1199
Steering pressure; checking........1200
Steering system working pressure; checking and adjusting........1203
Steering system; troubleshooting and elimination........1206
Steering wheel; tightening torques........1208
66 - LEVEL STEERING........1210
Hydraulic diagram; steering incl. lever steering (CDC) - Image........1211
Comfort Drive Control (CDC); description........1212
Lever steering (CDC); specifications........1216
Error codes when calibrating........1217
Hydraulic diagram; steering incl. lever steering (CDC)........1219
Comfort drive control (CDC) angle sensor; changing........1222
Comfort drive control (CDC) solenoid valve; changing........1228
Comfort Drive Control (CDC) control valve; removing........1231
Comfort drive control (CDC) control valve; installing........1234
Lever steering (CDC) function; checking........1237
Comfort Drive Control; servo pressure; checking........1238
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT........1240
70 - GENERAL........1241
Frame and track unit; description........1242
Frame; weight........1244
71 - FRAME........1245
Counterweight; tightening torques........1246
Counterweight; removing........1248
Counterweight; installing........1251
74 - FRAME LINK........1253
Frame joint; separating machine........1254
Frame joint; assembly of separated machine........1265
Frame joint; replacing bearings........1277
75 - AXLE SUSPENSION........1281
Axle suspension; replacing bushes and seals........1282
77 - WHEELS; TRACKS; TYRE; HUB; DRUM........1285
Wheel; tightening torque........1286
Tire size........1287
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE........1288
80 - GENERAL........1289
Cab description........1290
81 - CAB; NAKED; CANOPY........1291
Cab mounts; tightening torques........1292
Cab; installing........1293
Cab; removing........1302
Viscous cab suspension; description........1312
82 - ENGINE HOOD; MUDGUARD; FOOT STEP........1314
Engine hood; installing........1315
Engine hood; removing........1318
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING........1321
Side window; replacing_{06-45-50}........1322
Sliding window; changing........1331
Windows; general........1333
Windscreen; replacing_{06-45-24}........1335
87 - AIR CONDITIONING UNIT........1344
Air conditioning unit; check function........1345
Air conditioning; capacity........1348
Heating system; description........1349
Pause heater; description........1353
88 - INTERIOR EQUIPMENT........1354
Cooling unit; leak detection........1355
Refrigerant; draining........1357
Troubleshooting; air conditioning unit (AC)........1359
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS........1363
90 - GENERAL........1364
Accumulator; discarding........1365
Cleanliness when working on hydraulic components........1367
General information to note when working on the hydraulic system........1368
Hydraulic components; storing and transporting........1370
Hydraulic diagram with option components - Image........1371
Hydraulic diagram with option components........1378
Hydraulic diagram with option components_{006-37-35}........1382
Hydraulic diagram with option components_{006-37-57}........1384
Hydraulic diagram with option components_{006-38-20}........1386
Hydraulic diagram with option components_{006-38-42}........1388
Hydraulic diagram; Boom Suspension System - Image........1390
Hydraulic diagram; Boom Suspension System........1391
Hydraulic diagram; control valve - Image........1394
Hydraulic diagram; control valve........1397
Hydraulic diagram; cooling fan - Image........1400
Hydraulic diagram; cooling fan_{006-34-56}........1403
Hydraulic diagram; cooling fan_{006-35-18}........1405
Hydraulic diagram; cooling fan_{006-35-39}........1407
Hydraulic diagram; working hydraulic system - Image........1409
Hydraulic diagram; working hydraulic system_{006-36-40}........1411
Hydraulic diagram; working hydraulic system_{006-37-02}........1413
Hydraulic diagram; working hydraulics; 003rd and 4th functions; attachment lock........1415
Hydraulic diagram; working hydraulics; 3rd and 4th functions; attachment lock - Image........1417
Hydraulic oil; storage and handling........1418
Hydraulic system; repair of hydraulic components in workshop........1419
Troubleshooting chart........1421
Vacuum pump; connection........1424
91 - WORKING HYDRAULIC; SERVO HYDRAULICS........1426
Hydraulic system; description........1427
Hydraulic system; specification........1428
Hydraulic system; volume........1430
Hydraulic oil tank; description........1431
Main control valve; description........1433
Main control valve; removing........1439
Main control valve; installing........1443
Port relief valve pressure; checking and adjusting........1447
Hydraulic pump; description........1452
Hydraulic pump; standby pressure; checking and adjusting........1454
Hydraulic pump; max working pressure; checking and adjusting........1457
Hydraulic pump; replacing........1459
Servo valve; description........1464
Boom Suspension System; general description........1468
Boom suspension system; checking........1470
92 - MECHANICAL EQUIPMENT_ATTACHMENT........1475
Hydraulic attachment bracket (quickfit); description........1476
Attachment bracket cylinder; reconditioning........1477
Attachment locking hydraulic cylinder (vision-optimised bracket); replacing........1479
99 - MISCELLANEOUS........1482
Central lubrication system; description........1483
Pump unit; description........1488
Shift valve; description........1491
Pressure monitor; description........1493
Dosage valves; description........1495
Automatic lubrication system; specifications........1499
Recommended lubricants........1501
Diagnostic tools; description........1503
Parameter settings........1505
Software; parameter settings and read-outs........1507
Automatic lubrication pump unit; reconditioning........1514
Filling lubricant........1536
Bleeding air........1538
Change of lubrication interval........1544
System test........1546
Update of automatic lubrication system........1548
Volvo L50G Wheel Loaders Repair Service Manual
