Volvo L50-series Wheel Loaders Service Repair Manual
Volvo L50-series Wheel Loaders Service Repair Manual
Complete official service manual with Electrical Wiring Diagrams for L50 Volvo, L50B Volvo BM, L50C Volvo, L50C Volvo BM, L50C OR Volvo, L50C OR Volvo BM, L50D Volvo, L50E Volvo, L50F Volvo, L50G Volvo, L50H Volvo Wheel Loaders, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
Volvo L50/L50B/L50E/L50F/L50G/L50H 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.
Total Pages: 1,432
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
0 - GENERAL
1 - STANDARD PARTS, SERVICE
2 - ENGINE WITH MOUNTING AND EQUIPMENT
3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
4 - POWER TRANSMISSION
5 - BRAKE
6 - STEERING
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM
...
0 - GENERAL
Air cleaner, specifications
Air conditioning, specifications
Air-conditioning, weight
Alternator, specifications
Battery, specification
Battery, weight
Boom Suspension System (BSS400), specification
Boom Suspension System, tightening torques
Brake pump, specifications
Cab, tightening torques
Cab, weight
Conversion tables
Cooling fan motor, specifications
Cooling fan, specifications
Cooling system, capacity
Cooling system, specifications
Description
Drive axles, capacity
Drive axles, tightening torques
Drive axles, weight
Drive shafts, specifications
E1021B
E1664 Lifting tool
E1666 Spanner
E-2017
Electrical system, specifications
Engine, capacity
Engine, specifications
Engine, tightening torques
Engine, weight
Frame, tightening torque
Fuel feed pump, specifications
Fuel tank, capacity
Fuel tank, specifications
Fuel tank, tightening torques
Fuel tank, weight
Gearbox, capacity
Gearbox, tightening torques
Gearbox, weight
Hydraulic components, weight
Hydraulic connections, tightening torques
Hydraulic system, volume
Hydrostatic system, tightening torques
Hydrostatic system, weight
Infrared Thermometer
Injection pumps, specifications
Injectors, specifications
Lifting frame, specification
Lifting frame, weight
Lighting, specifications
Lubrication system, specifications
Oil-bath precleaner, volume
Operation numbers for additional work
Power transmission, specifications
Preheating, specifications
Propeller shaft, tightening torque
Pump 2 (P2) Steering and other hydraulics, specifications
Starter motor, specifications
Steering, specification
Steering, tightening torques
Steering, weight
Thermostat, specifications
Valve system specifications
Volvo standard tightening torques
Weight of cooling system
Wheel brakes, specification
Wheels, tightening torques
Working hydraulics, tightening torques
Working hydraulic system, specifications
1 - STANDARD PARTS, SERVICE
Alternative fuels
CE-marking, EMC-directive
Checklist after a fire or heat exposure
Cleanliness in hydraulic systems
Coolant, changing
Decontamination
Electric welding
Engine, changing oil and filter
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Environment
Fire prevention measures
Health hazards with paint, plastics and rubber
Hydraulic system, changing oil
Recommended lubricants
Repairing hydraulic system
Safety concerns everybody!
Safety rules when servicing
Safety when handling accumulators
Safety when handling oils and fuel
Safety when handling the machine
Safety when lifting and supporting complete machine
Safety when using lifting equipment
Safety when working on hydraulic systems
Safety when working with air conditioning refrigerant
Safety when working with batteries
Service interval
Some simple rules regarding tyre handling
Starting with booster batteries
Towing
Towing procedures
Transporting the machine
Waste handling
Working in environmentally contaminated areas
Working on the electrical system of the machine
Working under raised boom
2 - ENGINE WITH MOUNTING AND EQUIPMENT
Accelerator control cable, replacing
Air cleaner, description
Air cleaner, specifications
Cooling fan motor, specifications
Cooling fan, specifications
Cooling fan speed control, description
Cooling system, capacity
Cooling system, description
Cooling system, specifications
Crankshaft, description
Crankshaft front oil seal, replacing
Engine, capacity
Engine, description
Engine, installing
Engine, removing
Engine, specifications
Engine, tightening torques
Engine, weight
Fan motor, installing
Fan motor, removing
Fuel feed pump, specifications
Fuel system, bleeding
Fuel system, description
Fuel tank and combined tank unit, replacing
Fuel tank, capacity
Fuel tank, specifications
Fuel tank, tightening torques
Fuel tank, weight
Hydraulic cooling fan, description
Hydraulic cooling fan, speed sensor, replacing and adjusting clearance
Idling speed, checking and adjusting
Injection pump, one changing
Injection pumps, specifications
Injectors, specifications
Lubrication system, description
Lubrication system, specifications
Oil-bath precleaner, volume
Preheating, specifications
Pump 3 (P3) Cooling fan pump _ Brake pump, cooling fan maximum pressure, checking
Pump 3 (P3) Cooling fan pump _ Brake pumpCooling fan maximum speed, checking
Pump 3 (P3) Cooling fan pump _ Brake pumpFlow and pressure control, description
Pump 3 (P3) Cooling fan pump _ Brake pump, specifications
Pump 3 (P3) Cooling fan pump _ Brake pump Stand-by pressure, checking and adjusting
Sensor fault
Thermostat, replacing
Thermostat, specifications
Valves, adjusting
Valve system specifications
Weight of cooling system
3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
30 - GENERAL
Air filter pressure
Back-up alarm
Boom Suspension System (BSS)
Brake pressure charging
Brake pressure
Brake test
Central lubrication
Charge pressure hydrostatic system
Communication with data buses
Coolant temperature, engine
Coolant temperature, outlet radiator
Cooling fan control
Description of table for software functions
Differential lock
Downshifting signal
Electrical system, description
Electrical system, specifications
Electrical system, work instructions
Electronic control system, description
Engine oil pressure
Engine speed for V-ECU
Fuel Level
Gear Selector
Gearshifting solenoids
Hydraulic Oil Level
Hydraulic oil temperature
Instrument control unit I-ECU, functional description
Interruption in computer communication
Interval Wiper
Limp-Home mode, by-passed V-ECU
Output brake pressure
Overspeed, transmission
Parking brake, mechanical
Parking brake
Preheating of inlet air
Reduced computer communication
Secondary steering
Service interval
Starter lock-out
Starter motor engagement
System voltage
Tire radius
Transmission disengagement
Transmission oil filter
Transmission oil pressure
Transmission oil temperature
Travel Speed
Vehicle control unit V-ECU, description
Wiping during and after washing
31 - BATTERY
Battery, description
Battery, specification
Battery, weight
32 - ALTERNATOR; CHARGE REGULATOR
Alternator, description
Alternator, specifications
33 - STARTING SYSTEM
Preheating, description
Preheating, specifications
Starter motor, specifications
Starting system, description
35 - LIGHTING
Lighting, description
Lighting, specifications
37 - CABLE; FUSE; RELAY
Cable and component designations
Cable and component marking explanations
Circuit list
Communication cable explanation
Component list 10 Signals, shift solenoids
Component list 11 sensors
Component list 12 switches
Component list 1 alternator, batteries, capacitors, electronic units
Component list 2 diodes
Component list 3 fuses
Component list 4 heating coils, instruments, service connections
Component list 5 lights
Component list 6 control-, warning lights
Component list 7 solenoid valves
Component list 9 relays
Component list Motors, resistors, monitoring system
Electrical distribution box, description
Electrical symbols and designations
Frame ground connections and signal ground
Wiring diagram 10
Wiring diagram 11
Wiring diagram 12
Wiring diagram 140
Wiring diagram 14
Wiring diagram 150
Wiring diagram 15B
Wiring diagram 15
Wiring diagram 16
Wiring diagram 170
Wiring diagram 175
Wiring diagram 17
Wiring diagram 17 Updateted CDC
Wiring diagram 18
Wiring diagram 19
Wiring diagram 1
Wiring diagram 20
Wiring diagram 21B
Wiring diagram 21C
Wiring diagram 21
Wiring diagram 23
Wiring diagram 24
Wiring diagram 25
Wiring diagram 26
Wiring diagram 2
Wiring diagram 32B
Wiring diagram 32
Wiring diagram 33
Wiring diagram 3
Wiring diagram 4
Wiring diagram 5
Wiring diagram 6
Wiring diagram 7
Wiring diagram 8
Wiring diagram 9
38 - INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM
Display panel and keypad, general
Display panel, information displays
Display panel, operating display
Information display, general
Instruments
Middle instrument panel with warning lights
Service display unit, brakes
Service display unit, electrical control input signals 1
Service display unit, electrical control input signals 2
Service display unit, electrical control input signals 3
Service display unit, electrical control output signals 1
Service display unit, electrical control output signals 2
Service display unit, electrical feed sensor
Service display unit, electrical system battery voltage
Service display unit, general
Service display unit, hydraulics
Service display unit, settings
Service display unit, transmission
4 - POWER TRANSMISSION
Description
Differential lock, adjusting
Drive axles, capacity
Drive axles, description
Drive axles, tightening torques
Drive axles, weight
Drive shafts, specifications
Front axle, installing
Front axle, removing
Gearbox, capacity
Gearbox, installing
Gearbox, removing
Gearbox, tightening torques
Gearbox, weight
Hub reduction gear, replacing seal
Hydrostatic dive, pressure,checking and adjusting
Hydrostatic pump, installingdamping element and hub
Hydrostatic pump, removing and installing
Hydrostatic system, neutral position
Hydrostatic system, tightening torques
Hydrostatic system, weight
Obligatory measures to be taken when repairing the hydrostatic system
Planetary gear
Power transmission, specifications
Propeller shaft, tightening torque
Rear axle, installing
Rear axle, removing
5 - BRAKE
Accumulator, checking (removed)
Brake and engine cooling fan, hydraulic diagram
Brake, description of function
Brake, description
Brake disc, rear wheel brakes, replacing
Brake discs, front wheel brakes, changing
Brake discs, front wheel brakes, checking wear
Brake discs, rear wheel brakes, checking wear
Brake system, bleeding
Checking and adjusting pressure in circuit
Checking function
Description
Foot brake pedal, adjusting angle and pedal clearance
Foot brake valve, description of function
Foot brake valve, description
Foot brake valve removed, reconditioning
Parking brake, adjusting
Parking brake, electrical system, description
Retardation, checking function
Wheel brakes, specification
Wiring diagram 15B
Wiring diagram 5
6 - STEERING
Hydraulic diagram, steering system, incl. CDC and secondary steering
Hydraulic pump, description
Lever steering, adjusting steering speed
Lever steering (CDC), electrical system, description
Lever steering (CDC), general description
Lever steering (CDC), hydraulic system, description
Lever steering, checking and adjusting control valve
Pump 2 (P2) Steering and other hydraulics, specifications
Secondary steering, description
Steering cylinder, reconditioning
Steering cylinder, replacing
Steering, description
Steering lever SE603, checking input _ output voltage
Steering pressure and stand-by pressure, checking and adjusting
Steering, specification
Steering, tightening torques
Steering valve, description
Steering valve, reconditioning
Steering, weight
Wiring diagram 16
Wiring diagram 17
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
Axle suspension, checking axial and radial clearance
Frame, description
Frame joint, changing bearings
Frame, tightening torque
Wheels, tightening torques
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
AC operational reliability, functional description
Air conditioning, performance test
Air conditioning, specifications
Air-conditioning, weight
Cab, installing
Cab, removing
Cab suspension, description
Cab, weight
Climate control system, description
Electrical system, functional description
Evaporator, cleaning
Wiring diagram 19
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM
90 - GENERAL
Cleanliness in hydraulic systems
Discarded accumulators
Hydraulic system, bleeding
Safety when working on hydraulic systems
91 - WORKING HYDRAULIC; SERVO HYDRAULICS
3rd hydraulic function, flow control
Attachment hydraulics GP, description
Boom Suspension System (BSS400), specification
Boom Suspension System, checking when operating with a load
Boom Suspension System, component description
Boom Suspension System, description
Boom Suspension System, hydraulic pressure in accumulator(s), releasing
Boom suspension system, reconditioning accumulator
Boom Suspension System, tightening torques
Boom Suspension System, troubleshooting 1
Boom Suspension System, troubleshooting 2
Central block, description
Control valve, description
Hydraulic components, weight
Hydraulic connections, tightening torques
Hydraulic diagram, control valve
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic pump, replacing
Hydraulic system, volume
Precharge pressure in accumulators, checking and adjusting
Pressure-reducing valve forBoom Suspension System, adjusting
Pump 2 (P2) Steering and other hydraulics, specifications
Pump 3 (P3) Cooling fan pump _ Brake pump, specifications
Servo pressure, checking and adjusting
Servo valve, description
Servo valve, operating controls, adjusting
Shock valve, lift function, checking and adjusting
Shock valve, tilt function, checking and adjusting
Stand-by pressure, checking and adjusting
Working hydraulics, description
Working hydraulics, tightening torques
Working hydraulic system, specifications
Working pressure, checking and adjusting
92 - MECHANICAL EQUIPMENT_ATTACHMENT
Attachment bracket cylinder, reconditioning
Attachment locking hydraulic cylinder (vision-optimised bracket), replacing
Hydraulic attachment lock with raised servo pressure, description
94 - UNIT, LOAD HANDLING
Boom, description
Lifting cylinder, replacing
Lifting cylinder, sectional view
Lifting frame, replacing bearings “A”
Lifting frame, replacing bearings “B”
Lifting frame, specification
Lifting frame, weight
Tilting arm, replacing bearings “GDF”
Tilting cylinder, replacing
Tilting cylinder, sectional view
“T” link, lower removed, replacing “GH” bearings
T-link, upper, removed, replacing bearings “HIJ”
99 - MISCELLANEOUS
Explanations to hydraulic diagram
Hydraulic diagram, 5th, 6th and 7th hydraulic functions
Hydraulic diagram, Boom Suspension System, single-acting lifting function, differential lock
Hydraulic diagram, GP hydraulics
Hydraulic diagram, lifting, tilting and floating position
Hydraulic diagram, working hydraulics, 3rd and 4th functions, attachment lock
Working hydraulics, components
0 - GENERAL
Boom suspension system
Brakes
Capacities
Description
Electrical system
Engine
E-tools
Hydrostatic power transmission
Product Identification Plates
Servo system
Steering system
Tightening torques
Time Guide
Weights, approx.Weights, approx
1 - STANDARD PARTS, SERVICE
17 - SERVICE
Charging of batteries
Cleanliness in hydraulic systems
Electric welding
Repairing hydraulic system
Repairing hydrostatic system
Towing
19 - GENERAL
A few simple rules for batteries
A few simple rules of safety
A few simple rules when inflating tyres
A few simple rules when servicing
Charging batteries
Danger in connection with polymer materials
Measures to prevent fire
Refrigerant in air-conditioning units
Safety concerns everybody!
Service position
Starting with booster batteries
2 - ENGINE WITH MOUNTING AND EQUIPMENT
21 - ENGINE
Description
23 - FUEL SYSTEM
Fuel system, air bleeding (TD40 GA)
Fuel system, air bleeding (TD40 KAE)
Injection timing, checking and adjusting
Low and high idling speed, checking and adjusting
Specifications
Specifications
25 - INLET & EXHAUST SYSTEM
Specifications
26 - COOLING SYSTEM
Specifications
27 - ENGINE CONTROL
Specifications
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS
30 - GENERAL
Description
Special instructions when working on the electrical system
Specifications
31 - BATTERY
Charging of batteries
Specifications
32 - ALTERNATOR; CHARGE REGULATOR
Specifications
33 - STARTING SYSTEM
Specifications
35 - LIGHTING
Headlights, adjusting
Specifications
37 - CABLE; FUSE; RELAY
Code key for diodes
Codes used in wiring diagrams
Electrical distribution box
Explanations to wiring diagrams
flow doc
Instruments and controls
List of circuits
Specifications
Wiring diagram, circuit 101 — 107
Wiring diagram, circuit 11 — 110
Wiring diagram, circuit 111 — 118
Wiring diagram, circuit 121 — 128
Wiring diagram, circuit 131 — 1310
Wiring diagram, circuit 13B1 — 13B10
Wiring diagram, circuit 13C1 — 13C10
Wiring diagram, circuit 141 — 1410
Wiring diagram, circuit 14B1 — 14B10
Wiring diagram, circuit 14C1 — 14C10
Wiring diagram, circuit 151 — 158
Wiring diagram, circuit 15B1 — 15B8
Wiring diagram, circuit 15C1 — 15C8
Wiring diagram, circuit 161 — 169
Wiring diagram, circuit 171 — 179
Wiring diagram, circuit 181 — 188
Wiring diagram, circuit 191 — 199
Wiring diagram, circuit 1B1 — 1B10
Wiring diagram, circuit 1C1 — 1C10
Wiring diagram, circuit 20B1 — 20B8
Wiring diagram, circuit 20C1 — 20C8
Wiring diagram, circuit 21 — 210
Wiring diagram, circuit 2B1 — 2B10
Wiring diagram, circuit 2D1 — 2D5
Wiring diagram, circuit 31 — 310
Wiring diagram, circuit 3B1 — 3B10
Wiring diagram, circuit 3C1 — 3C10
Wiring diagram, circuit 41 — 44
Wiring diagram, circuit 51 — 57
Wiring diagram, circuit 5D1 — 5D10
Wiring diagram, circuit 61 — 69
Wiring diagram, circuit 7B1 — 7B7
Wiring diagram, circuit 7C1 — 7C7
Wiring diagram, circuit 81 — 89
Wiring diagram, circuit 91 — 910
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM
Basic system
Contronic System
Emergency operation, electrical
Monitored functions
Other electrical functions (controlled by the control unit)
Units connected to the control unit, BCU
Units (functions) connected to the control unit, ECU
4 - POWER TRANSMISSION
42 - TRANSMISSION; HYDRAULIC CONTROL
Clutch shaft, high gear
Clutch shaft, low gear
Power shift gearbox, checking oil pressure
Power Shift gearbox, HST-75
Specifications
44 - HYDROSTATIC DRIVE
Description
Hydraulic diagrams, hydrostatic drive
Hydrostatic pump, removing and fitting
Hydrostatic system, checking oil pressure
Repairing hydrostatic unit
Specifications
45 - PROPELLER SHAFT
Specifications
46 - FRONT AXLE; REAR AXLE
Differential, front axle
Planetary gear
Specifications
5 - BRAKE
50 - GENERAL INFORMATION
Description of function
Description
51 - WHEEL BRAKE
Brake discs, changing (on both sides of the axle)
Brake discs, checking wear
Brake piston, changing of seals
52 - HYDRAULIC BRAKE SYSTEM
Brake system, checking and adjusting pressure in circuit
Brake system, checking function
Description of function
Hydraulic diagram, brake system
Specifications
55 - PARKING BRAKE
Description
Specifications
6 - STEERING
60 - GENERAL
Description
64 - STEERING
Hydraulic diagrams, steering system
Hydraulic pump, description
Pressure_flow compensator, description
Specifications
Steering cylinder
Steering pressure and stand-by pressure, checking and adjusting
Steering valve, description of function
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
71 - FRAME
General Description
Specifications
74 - FRAME LINK
Specifications
75 - AXLE SUSPENSION
Rear axle suspension
77 - WHEELS; TRACKS; TYRE; HUB; DRUM
Specifications
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
81 - CAB, NAKED; CANOPY
Specifications
87 - AIR CONDITIONING UNIT
AC SAFETY, description of function
Air conditioning with refrigerant R134a
Description of function
Description
Electrical system, description of function
Refrigerant for air conditioning
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS
91 - WORKING HYDRAULIC; SERVO HYDRAULICS
Accumulator, precharging pressure checking, adjusting
Boom suspension system
Central valve, description
Control valve, description
Hydraulic diagrams
Hydraulic oil pump, removing and fitting
Pressure-reducing valves, safety valve, checking, adjusting
Servo pressure, checking and adjusting
Servo valve, function
Shock valve, lifting function, checking and adjusting
Shock valve, tilting function, checking and adjusting
Specifications
Stand-by pressure, checking and adjusting
Working hydraulics, description
Working pressure, checking and adjusting
92 - MECHANICAL EQUIPMENT_ATTACHMENT
Specifications
94 - UNIT, LOAD HANDLING
Lifting cylinder
Specifications
Tilting cylinder
