Volvo L110G Wheel Loaders Service Repair Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Constructions L110G Wheel Loaders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo L110G 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 L110G Wheel Loaders Service Repair Manual.PDF
PRODUCT DETAILS:
Total Pages: 2,875 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword....2
0 - GENERAL....3
03 - SPECIFICATIONS....4
Tightening torques....5
Engine; software specifications....16
Valve mechanism; specifications....19
Flywheel; tightening torques....21
Oil sump; tightening torque....24
Lubrication system; tightening torques-....26
Exhaust aftertreatment system; specifications ....28
Conversion tables....30
Fuel system; specifications-....34
Lubrication system; specifications-....36
Engine; tightening torques-....38
Engine; specifications-....39
07 - STANDARD TIME....40
Operation numbers for additional work....41
08 - TOOL....43
E 1708; Checking point....44
E1711....46
E-2000....48
E-2001....50
E-2010....52
E-2015....53
E-2017....55
Infrared Thermometer....56
Leak detector 951 1207; description....60
88830557 User Instruction....64
1 - STANDARD PARTS; SERVICE....74
16 - LUBRICANT; FUEL; OTHER FLUID....75
Coolant....76
Recommended lubricants....78
Alternative fuels....81
17 - SERVICE....84
Service....87
Electric welding-....90
Arrival Inspection; according to Inspection Programme-1141....92
Arrival Inspection; according to Inspection Programme....93
Delivery Inspection; according to Inspection Programme....94
Maintenance of Stored Machines; according to Inspection Programme....95
Maintenance service; first 1000 hours....96
Maintenance service; every 50 hours....97
Maintenance service; every 250 hours....98
Maintenance service; every 500 hours....99
Maintenance service; every 1000 hours....101
Maintenance service; every 2000 hours....103
Maintenance service; every 4000 hours....105
Maintenance service; every 4500 hours....108
Maintenance service; every 6000 hours_{07-14}....109
Maintenance service; every 6000 hours_{06-55}....110
Maintenance service; every 8000 hours....111
Brake discs; measuring wear....112
Wheel brakes function; checking....115
Service position 2_{04-20}....116
Service position 1_{03-31}....118
Wheel brake; specification....120
Drive axles; oil; draining....121
Front axle; breather filter; replacing....123
Axle oil cooler; front axle; filter; replacing....124
Rear axle bearing; oil; draining....126
Hydraulic oil tank; draining....128
Transmission oil; draining....130
Engine oil; draining....132
Spark plug; replacing-5518....134
Valves; adjusting_{53-36}....136
Valves; adjusting_{51-43}....142
Oil plugs; installing....148
Take the hose away from the draining point of engine oil and replace the cap....149
Fuel filters; primary and secondary filter; replace....150
Engine oil filter; replacing....152
Fuel tank breather filter; replacing....153
Axle oil cooler; rear axle; filter; replacing....154
Engine air cleaner; replacing....155
Transmission oil filter; replacing....157
Transmission suction strainer; cleaning....159
Automatic central lubrication; filter; cleaning_replacing....160
Cab; extra prefilter; replacing....162
Rear axle; breather filter; replace....164
Engine oil; filling....165
Drive belts; check-3541....166
Hydraulic tank and transmission; breathing filter; replacing....167
Hydraulic oil tank; return oil filter; replace; and magnetic rod; clean....168
Hydraulic oil; filling....170
Transmission oil; filling....172
Rear axle bearing; oil; filling....174
Drive axles; oil; filling....176
Cab; prefilter; replace when required....178
Cab filter; replacing....180
Restore operating condition after all test and adjustment work....183
Warming up machine....184
Transmission oil; checking level....186
Hydraulic oil level; checking....188
Engine oil level; checking....190
Coolant level; checking....191
Brake system charging; checking....192
Steering system working pressure; checking and adjusting....196
Boom suspension accumulator; checking and adjusting_{58-14}....199
Boom suspension accumulator; checking and adjusting_{57-16}....203
Hydraulic pump; standby pressure and working pressure; checking and adjusting....207
Oil-bath air cleaner's reservoir (optional equipment); oil; check....211
Oil-bath air cleaner's reservoir (optional equipment); clean; and oil; change....214
Oil bath air cleaner oil; changing....217
Battery; cables and connections; check....220
Engine radiator; oil cooler and condensor (if installed); clean....222
Hinge; lubricating....225
Restore the machine to original condition....228
Coolant's freezing point; check....229
Tyres; wear and air pressure; checking....231
Lubrication; 50 hours maintenance interval....232
Lubrication; 250 hours maintenance interval....235
Lubrication; 500 hours maintenance interval....238
Lubrication; 1000 hours maintenance interval....242
Lubrication; 2000 hours maintenance interval....246
Lubrication; 4000 hours maintenance interval....250
Maintenance service; fire suppression system....254
Hydraulic oil tank; sediment drain....271
Coolant; changing....273
Rear axle pivot bearing; greasing....276
Parking brake; manually releasing....277
Towing....279
Electric welding....281
19 - GENERAL....282
Working on the electrical system of the machine....283
CE-marking; EMC-directive....285
Safety concerns everybody!....289
Checking function....293
Safety when handling the machine....294
Safety rules when servicing....299
Service position 2_{42-22}....302
Service position 1_{41-52}....304
Working under raised boom....306
Fire prevention measures....308
Some simple rules regarding tyre handling....312
Safety when lifting and supporting complete machine....314
Safety when working with batteries....318
Starting with booster batteries....321
Safety when handling oils and fuel....324
Safety when handling accumulators....326
Safety when working on hydraulic systems....328
Checklist after a fire or heat exposure....330
Health hazards with paint; plastics and rubber....333
Waste handling....336
Environmentally safe handling....340
Environmentally hazardous fluids....343
Working in environmentally contaminated areas....346
Decontamination....349
2 - ENGINE WITH MOUNTING AND EQUIPMENT....353
20 - GENERAL....354
Engine; description....355
Engine; software specifications....359
Component locations....362
Engine; capacities....365
Engine belts; replacing....366
E-ECU MID 128 pre-programmed; replacing....370
E-ECU MID 128 non-programmed; replacing....373
21 - ENGINE....376
Engine; specifications....377
Engine rotation speed sensor (crank shaft); replacing....378
Engine rotation speed sensor (camshaft); replacing....383
Engine; removing....386
Engine; installing....401
Engine; tightening torques....416
Cylinder compression; testing....418
Crankcase ventilation; description-2011....425
Crankcase ventilation; description....426
Crankcase ventilation separator; replacing....430
Valve mechanism; specifications....432
Valves; adjusting_{18-08}....434
Valves; adjusting_{17-38}....440
Flywheel; tightening torques....446
Crankshaft front oil seal; replacing....450
Oil sump; tightening torque....460
Engine mounting rear; changing....463
22 - LUBRICATING SYSTEM....469
Lubricating system; description....470
Lubrication system; specifications....475
Lubrication system; tightening torques....477
Lubrication system; component locations....479
Engine oil pressure; specification....482
Lubrication oil pressure; checking with pressure gauge....484
23 - FUEL SYSTEM....486
Fuel system; description....487
Fuel system; specifications....494
Fuel system; tightening torques....496
Carbon dioxide in fuel system; checking....503
Fuel system; component location....509
Feed pump pressure; checking....511
Fuel system; bleeding....513
Fuel pump; replacing....515
Stall speed; checking....517
Injectors; replacing....519
Injector sleeves; replacing....525
Fuel rail pressure sensor; replacing....534
High pressure fuel pump; replacing....537
Fuel control valve (FCV); replacing....540
Pressure relief valve (PRV); replacing....546
High pressure fuel system pressure; relieving....551
25 - INLET & EXHAUST SYSTEM....553
Inlet and exhaust system; description....555
Inlet and exhaust system; component location....561
Inlet and exhaust system; tightening torques....564
Exhaust pipe flexible tube; replacing....565
Auxiliary brake (engine braking); description....568
Exhaust Aftertreatment System; description....570
Exhaust Aftertreatment System; component location....582
Regeneration process; description....585
Exhaust aftertreatment system; specifications....590
DPF (Diesel particulate filter); checking and cleaning....592
Exhaust aftertreatment system; tightening torques....596
Spark plug control unit; replacing....598
Glow plug; replacing....600
Glow plug control unit; replacing....602
Fuel metering unit A; replacing....605
Fuel metering unit B; replacing....610
Air pump safety valve; replacing....615
ACM (Aftertreatment control module) non-programmed; replacing....617
ACM (Aftertreatment control module) pre-programmed; replacing....620
Spark plug; inspecting....623
Spark plug; replacing....625
Spark plug cable; replacing....627
Air pump; replacing....629
Throttle; replacing....631
Burner function; checking....633
Burner; replacing....639
DPF (Diesel particulate filter) bracket; replacing....643
NOx sensor; replacing....648
Exhaust aftertreatment system T-junction; replacing....650
DOC (Diesel oxidation catalyst); replacing....652
Turbocharger; description....655
Turbocharger; removing....658
Turbocharger; installing....663
Turbocharger; tightening torques....667
Wastegate; checking....670
Preheating coil; replacing....672
Charge air cooler; replacing....674
26 - COOLING SYSTEM....682
Cooling system; description....683
Cooling system; specifications....687
Carbon dioxide in coolant system; checking....688
Cooling system; component location....694
Cooling system pressure; checking....696
Radiator; removing....698
Radiator; installing....707
Coolant pump; replacing....714
Thermostat; replacing....718
Thermostat; specifications....722
Cooling fan; component location....724
Cooling fan; description....727
Reversible cooling fan; description....731
Cooling fan motor; description....735
Cooling fan; tightening torques....737
Temperature limits for cooling fan speed; specifications....739
Cooling fan rpm; specifications....740
Fan control valve; seal replacing....743
Drive belts; check....746
27 - ENGINE CONTROL....747
ECO - accelerator pedal....748
29 - MISCELLANEOUS....750
Exhaust Gas Recirculation (EGR); description....751
Exhaust gas recirculation (EGR); component location....756
EGR system; tightening torques....758
EGR reed valve; replacing....761
EGR cooler; replacing....765
EGR temperature sensor; replacing....773
EGR pressure sensor; replacing....775
EGR valve; replacing....778
EGR actuator; replacing....780
EGR venturi tube; replacing....783
EGR reed valve; inspecting....785
EGR system function; checking....789
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....792
30 - GENERAL....793
Electrical system; work instructions....799
Electrical system; description....801
Software; description....803
Electronic control system; description....804
Communication with data buses....813
VCADS Pro; Operations....815
Electrical system; specifications....817
Software parameters; description....818
General fault diagnosis information....831
Troubleshooting strategy....833
Collection of basic data....835
Error codes; showing....838
SAE error codes; translation to error messages; general....841
Bus communication supervision....844
Conditions when checking....846
Lead and connector checks....849
Troubleshooting tools....854
Special tools for troubleshooting....856
VCADS Pro; Error codes....858
VCADS Pro service tool....861
CU2501; description and measuring....865
CU2503; description and measuring....867
CU3605; description and measuring....869
CU6601; description and measuring....871
CU9901; description and measuring....876
E-ECU PID158; description and measuring....879
FX1005; description and measuring....880
FX1006; description and measuring....882
FX1007; description and measuring....885
FX1008; description and measuring....888
FX1009; description and measuring....891
FX1024; description and measuring....894
FX1025; description and measuring....898
FX1031; description and measuring....901
HE2501; description and measuring_{24-05}....904
HE2501; description and measuring_{22-40}....906
MA2301-MA2306; description and measuring....908
MA2508; description and measuring....911
MA2509; description and measuring....913
MA2510; description and measuring....915
MA2512; description and measuring....918
MA2601; description and measuring....921
MA2602; description and measuring....923
MA4603; description and measuring....925
MA5501; description and measuring....927
MA5503; description and measuring....930
MA9103; description and measuring....932
MA9104; description and measuring....935
MA9106; description and measuring....938
MO2502; description and measuring....940
MO2503; description and measuring....942
MO2505; description and measuring....944
MO3301; description and measuring....946
MO3612; description and measuring....948
MO3613; description and measuring....950
MO6402; description and measuring....952
MO8707; description and measuring....954
MO8711; description and measuring....956
Power supply; ACM (Aftertreatment Control Module); description and measuring....958
Power supply ECC; description and measuring....960
Power supply E-ECU; description and measuring....962
005 V Power supply E-ECU; description and measuring....964
Power supply I-ECU; description and measuring....966
Power supply V-ECU; description and measuring....968
Power supply V002-ECU; description and measuring....970
Power supply W-ECU; description and measuring....972
PWM2303; description and measuring....974
PWM2602; description and measuring....976
PWM4213 - PWM4218; description and measuring....978
PWM5202; description and measuring....981
PWM6601; description and measuring....983
PWM6602; description and measuring....985
PWM9101; description and measuring....987
PWM9102; description and measuring....989
PWM9103; description and measuring....991
PWM9104; description and measuring....993
PWM9105; description and measuring....995
PWM9106; description and measuring....997
PWM9107; description and measuring....999
PWM9108; description and measuring....1001
R2701; description and measuring....1003
RE002; description and measuring....1005
RE006; description and measuring....1007
RE008; description and measuring....1009
RE09; description and measuring....1011
RE010; description and measuring....1013
RE015; description and measuring....1015
RE2501; description and measuring....1017
RE6401; description and measuring....1019
RE8712; description and measuring....1021
SAE J1708_1587 Information link; description and measuring....1023
SAE J1939_CAN1 Control link; description and measuring....1026
SAE J1939_CAN2 Control link; description and measuring....1029
SAE J1939-1 SubNet 1; description and measuring....1032
SE2203; description and measuring....1035
SE2301; description and measuring....1037
SE2303; description and measuring....1039
SE2309; description and measuring....1042
SE2512; description and measuring....1044
SE2513; description and measuring....1047
SE2515; description and measuring....1049
SE2516; description and measuring....1051
SE2519; description and measuring....1053
SE2520; description and measuring....1055
SE2521; description and measuring....1058
SE2522; description and measuring....1061
SE2523; description and measuring....1063
SE2524; description and measuring....1065
SE2525; description and measuring....1068
SE2526; description and measuring....1070
SE2603; description and measuring....1073
SE2604; description and measuring....1075
SE2606; description and measuring....1077
SE2701; description and measuring....1079
SE2702; description and measuring....1081
SE2703; description and measuring_{38-30}....1084
SE2703; description and measuring_{37-57}....1086
SE2704; description and measuring....1088
SE4202; description and measuring....1090
SE4203; description and measuring....1092
SE4209; description and measuring....1094
SE4213; description and measuring....1096
SE4218; description and measuring....1098
SE4219; description and measuring....1100
SE4307; description and measuring....1102
SE4312; description and measuring....1104
SE4609; description and measuring....1106
SE5201; description and measuring....1108
SE5203; description and measuring_{24-19}....1111
SE5203; description and measuring_{23-39}....1113
SE5222; description and measuring....1115
SE5223; description and measuring....1117
SE5501; description and measuring....1119
SE6404; description and measuring....1121
SE6407; description and measuring....1123
SE6411; description and measuring....1125
SE6601; description and measuring....1128
SE8702; description and measuring....1132
SE8705; description and measuring....1134
SE8706; description and measuring....1136
SE8708; description and measuring....1138
SE8709; description and measuring....1140
SE9116; description and measuring....1143
SE9117; description and measuring....1146
SE9119; description and measuring....1149
SE9147; description and measuring....1151
SE9148; description and measuring....1154
SW2506; description and measuring....1157
SW3630; description and measuring....1159
SW3801; description and measuring....1161
SW4205_SW4206; description and measuring....1164
SW4208; description and measuring....1167
SW4209; description and measuring....1169
SW4211; description and measuring....1171
SW4212; description and measuring....1173
SW4217; description and measuring....1176
SW4219; description and measuring....1178
SW4220; description and measuring....1180
SW5501; description and measuring....1182
SW8701; description and measuring....1184
SW9143; description and measuring....1186
SW9148; description and measuring....1188
SW9149; description and measuring....1190
VCADS Pro socket; measuring....1193
VCADS Pro; connecting problems....1196
31 - BATTERY....1199
System voltage....1200
Key feed....1202
Battery; description....1204
Battery; weight....1205
Battery; specifications....1206
Battery condition; checking....1207
Battery; charging....1210
Batteries; replacing....1212
32 - ALTERNATOR; CHARGE REGULATOR....1214
Alternator; specification....1215
Alternator 80 A; specification....1216
Alternator; description_{44-09}....1217
Alternator; description_{43-48}....1223
Alternator; removing....1224
Alternator; installing....1228
33 - STARTING SYSTEM....1232
Starter motor; specifications....1233
Booting sequence....1234
Preheating; specifications....1236
Preheating; description....1237
Starter lock; replacing....1240
35 - LIGHTING....1242
Lighting; specifications....1243
Lighting; description....1244
36 - OTHER ELECTRICAL EQUIPMENT....1247
Intermittent wiper and washer....1248
Connectors; position....1250
Connectors; overview....1261
Vehicle control unit V-ECU; description....1265
Vehicle control unit V2-ECU; description....1267
Engine control unit E-ECU; description....1269
I-ECU MID 140 non-programmed; replacing....1271
I-ECU MID 140 pre-programmed; replacing....1273
V-ECU MID 187 non-programmed; replacing....1275
V-ECU MID 187 pre-programmed; replacing....1277
Hood opening....1279
37 - CABLE; FUSE; RELAY....1281
Electrical symbols and designations....1285
Cable and component designations....1289
Cable and component marking explanations....1291
Components list....1294
ACM; I_O list....1311
ECC; I_O list....1314
E-ECU; I_O list....1317
I-ECU; I_O list....1321
V-ECU; I_O list....1325
V002-ECU; I_O list....1330
W-ECU; I_O list....1335
Table of contents; wiring diagrams....1336
Wiring diagram - Start....1339
Wiring diagram - Aftertreatment....1343
Wiring diagram - Brake....1348
Wiring diagram - BSS....1352
Wiring diagram - Electrically controlled battery disconnector....1355
Wiring diagram - Gear....1359
Wiring diagram WD201....1363
Wiring diagram WD202....1367
Wiring diagram WD260....1370
Wiring diagram WD261....1373
Wiring diagram WD262....1376
Wiring diagram WD263....1380
Wiring diagram WD264....1383
Wiring diagram WD265....1386
Wiring diagram WD266....1389
Wiring diagram WD267....1394
Wiring diagram WD268....1398
Wiring diagram WD270....1401
Wiring diagram WD270 Update G....1404
Wiring diagram WD301....1407
Wiring diagram WD301 Update G_{14-44}....1411
Wiring diagram WD301 Update G_{14-24}....1415
Wiring diagram WD302....1419
Wiring diagram WD303....1422
Wiring diagram WD303 Update G....1425
Wiring diagram WD304_{12-42}....1428
Wiring diagram WD304_{12-22}....1431
Wiring diagram WD306....1434
Wiring diagram WD306 Update G....1437
Wiring diagram WD308....1440
Wiring diagram WD320....1443
Wiring diagram WD321....1446
Wiring diagram WD322....1451
Wiring diagram WD323....1454
Wiring diagram WD324....1457
Wiring diagram WD325....1460
Wiring diagram WD326....1463
Wiring diagram WD330....1466
Wiring diagram WD331....1470
Wiring diagram WD333....1474
Wiring diagram WD333 Update G....1478
Wiring diagram WD334....1482
Wiring diagram WD335....1485
Wiring diagram WD335 Update G....1488
Wiring diagram WD337 Update G....1491
Wiring diagram WD350....1495
Wiring diagram WD350 Update G....1498
Wiring diagram WD351....1501
Wiring diagram WD352....1504
Wiring diagram WD352 Update G....1507
Wiring diagram WD360....1510
Wiring diagram WD361....1513
Wiring diagram WD362....1516
Wiring diagram WD362 Update G....1519
Wiring diagram WD363....1522
Wiring diagram WD363 Update G....1525
Wiring diagram WD364 Update G....1528
Wiring diagram WD371....1531
Wiring diagram WD372....1534
Wiring diagram WD373....1537
Wiring diagram WD374....1540
Wiring diagram WD374 Update G....1543
Wiring diagram WD375....1546
Wiring diagram WD375 Update G....1549
Wiring diagram WD376....1552
Wiring diagram WD401....1555
Wiring diagram WD402....1558
Wiring diagram WD403....1561
Wiring diagram WD404....1564
Wiring diagram WD405....1568
Wiring diagram WD406....1571
Wiring diagram WD501....1574
Wiring diagram WD501 Update G....1578
Wiring diagram WD601....1582
Wiring diagram WD602....1586
Wiring diagram WD604....1589
Wiring diagram WD801....1592
Wiring diagram WD802....1596
Wiring diagram WD804....1599
Wiring diagram WD804 Update G....1602
Wiring diagram WD805....1605
Wiring diagram WD806....1608
Wiring diagram WD807....1611
Wiring diagram WD808....1614
Wiring diagram WD831 Update G....1617
Wiring diagram WD903....1620
Wiring diagram WD904....1623
Wiring diagram WD905....1626
Wiring diagram WD909....1629
Wiring diagram WD910....1633
Wiring diagram WD911....1636
Wiring diagram WD911 Update G....1639
Wiring diagram WD913....1642
Wiring diagram WD914 Update G....1645
Wiring diagram WD915 Update G....1649
Battery disconnect switch; description....1652
Chassis connection....1654
Branching in cables....1656
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....1662
Instrument panels....1663
Middle instrument panel with warning lights....1665
Information display; general....1667
Information display; start lockout....1670
Information display; operating display....1672
Information display; engine....1674
Information display; transmission....1677
Information display; hydraulics....1679
Information display; axles _ brakes....1682
Information display; electrical system....1684
Information display; vehicle info....1686
Information display; vehicle messages....1689
Information display; service....1690
Information display; service mode....1693
Information display; settings....1697
Information display; check....1699
Alarm; description....1701
Central warning....1703
39 - MISCELLANEOUS....1704
CareTrack W-ECU; description....1705
CareTrack battery; replacing....1709
4 - POWER TRANSMISSION....1712
40 - GENERAL....1713
Drivetrain; component location....1714
VCADS Pro; Operations_{11-47}....1716
VCADS Pro; Operations_{11-29}....1718
Error codes when calibrating-1103....1720
42 - TRANSMISSION; HYDRAULIC CONTROL....1721
Transmission; component position_{09-43}....1722
Transmission; component location_{09-18}....1727
Transmission; specifications_{08-42}....1732
Transmission; specifications_{08-21}....1734
Hydraulic transmission; capacity....1736
Transmission; tightening torques_{07-33}....1737
Transmission; tightening torques_{07-12}....1739
Hydraulic transmission; description....1741
Transmission; specifications_{04-51}....1749
Transmission; specifications_{04-30}....1751
Transmission; removing....1753
Transmission; installing....1764
Hydraulic diagram transmission_{02-39}....1773
Hydraulic diagram transmission_{02-18}....1776
Lock up valve; replacing....1779
Transmission oil pressure; checking_{01-21}....1781
Transmission oil pressure; checking_{01-01}....1785
Gear selector valve; replacing one solenoid....1790
Seal for front output shaft; replacing....1794
Seal for rear output shaft; replacing....1797
Transmission; function check_{58-56}....1800
Transmission; function check_{58-38}....1801
Transmission; calibration....1802
45 - PROPELLER SHAFT....1804
Propeller shaft; tightening torque....1805
Propeller shaft; component description....1806
46 - FRONT AXLE; REAR AXLE....1808
Drive axles; description....1809
Front and rear axles; tightening torque....1811
Front and rear axles; specifications....1812
Front axle; component description....1813
Rear axle; component description....1816
Rear axle mounting; component description....1820
Front and rear axles; volume....1823
Automatic differential brake; Limited Slip; description....1824
Rear axle mounting; volume....1827
Hub seal; replacing ....1828
Hub reduction; removing ....1846
Hub reduction; installing ....1849
Axle; removing....1851
Axle suspension bushes and seals; replacing....1855
Axle suspension; tightening torque....1866
Axle; installing....1867
Hub reduction; removing....1871
Hub reduction; installing....1874
Hub seal; replacing....1876
Differential lock; description....1878
Differential lock; adjusting....1880
Differential lock; function check....1885
49 - MISCELLANEOUS....1887
Oil cooler; component description....1888
Heat exchanger; replacing....1889
5 - BRAKE....1893
50 - GENERAL....1894
VCADS Pro; Operations-....1895
Tech Tool; operations....1896
51 - WHEEL BRAKE....1897
Wheel brake; specification....1898
Brake discs; measuring wear....1899
Wheel brakes function; checking....1902
Brake discs; replacing....1903
Brake piston seals; replacing ....1909
Brake disc; replacing....1914
Brake piston seals; replacing....1920
52 - HYDRAULIC BRAKE SYSTEM....1925
Brake system; component location_{37-00}....1926
Brake system; component location_{36-39}....1929
Braking system; description_{36-04}....1932
Braking system; description_{35-43}....1937
Brake system; specifications....1941
Brake system circuit pressure; checking and adjusting....1942
Brake system; bleeding_{34-25}....1945
Brake system; bleeding_{34-04}....1947
Brake system retardation function; checking....1949
Automatic brake function; checking....1950
Brake system charging; checking....1952
Axle oil cooler; component location....1957
Axle oil cooler; description....1959
Foot brake valve; description....1962
Automatic brake valve; description....1963
Brake accumulator; description....1965
Brake accumulator; specifications....1967
Accumulator (removed) charging pressure; checking....1968
Accumulator; removing....1970
Accumulator; installing....1972
Accumulators; checking in machine....1974
Accumulator; discarding ....1976
55 - PARKING BRAKE....1979
Parking brake; specifications....1980
Parking brake; component location....1981
Parking brake; component description....1983
Parking brake; function description....1985
Parking brake discs and seals; replacing....1991
Parking brake function; checking....1997
6 - STEERING....1999
60 - GENERAL....2000
Steering system; component location....2001
Steering system; description....2003
Steering system function; checking....2011
VCADS Pro; Operations ....2013
Lever steering CDC; tightening torques....2014
64 - STEERING....2016
Steering; specifications....2017
Steering cylinder removed; reconditioning incl replacing bearings....2018
Steering cylinder; description....2024
Steering valve; description....2026
Steering cylinder; tightening torque....2028
Shift valve; description-5556....2030
Steering system working pressure; checking and adjusting....2033
Left steering cylinder bearings; replacing....2036
Right steering cylinder; replacing bearings....2046
Left steering cylinder; removing....2053
Right steering cylinder; removing....2062
Steering cylinder removed; reconditioning excl replacing bearings....2069
Left steering cylinder; installing....2073
Right steering cylinder; installing....2081
Steering cylinder; repacking....2088
Accumulator; discarding-....2091
Secondary steering pump; specifications....2093
Secondary steering; component location....2094
Secondary steering; description....2096
Secondary steering pump; description....2100
Pressure monitor; description-4808....2101
Secondary steering pump working pressure; checking and adjusting....2103
66 - LEVEL STEERING....2105
Comfort Drive Control (CDC); description....2106
CDC valve; lever steering; description....2111
Lever steering (CDC); specifications....2114
Comfort Drive Control (CDC); component location....2115
Comfort drive control (CDC) angle sensor; changing....2117
Comfort Drive Control; servo pressure; checking....2120
Error codes when calibrating-4415....2122
Comfort Drive Control (CDC) joystick; changing....2125
Comfort drive control (CDC) solenoid valve; changing....2130
Lever steering (CDC) function; checking....2132
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....2135
70 - GENERAL....2136
Frame; description....2137
71 - FRAME....2140
Counterweight; tightening torques....2141
Counterweight; weight....2142
Counterweight; removing....2144
Counterweight; installing....2147
74 - FRAME LINK....2151
Frame joint; tightening torques....2152
Frame joint; description....2153
Frame joint; replacing bearings....2155
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....2176
Wheel; tightening torque....2177
Rear wheel; removing....2178
Rear wheel; installing....2180
Front wheel; removing....2182
Front wheel; installing....2184
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....2186
80 - GENERAL....2187
Cab; description....2188
81 - CAB; NAKED; CANOPY....2190
Cab; removing....2191
Cab; installing....2205
Cabin; tightening torques....2221
Viscous cab suspension; description....2222
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....2224
Plastic hood; repairing....2225
Engine hood; raising and securing....2230
Engine hood; removing....2232
Engine hood; installing....2236
Actuator; replacing....2240
83 - DOORS; HATCH; COVER PLATE; (all)....2245
Electric door opener; description....2246
Electric door opener; control unit; replacing....2250
Electric door opener; locking motor; replacing....2252
Electric door opener; rotor switch; replacing....2254
Electric door opener; opening support motor; replacing....2256
Door lock cylinder; replacing_{23-16}....2259
Door lock cylinder; replacing_{22-56}....2267
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....2275
Windows; general....2276
Side window; replacing_{21-47}....2278
Windscreen; replacing_{21-19}....2288
Window pane; installing....2298
Windows; general; gluing....2303
85 - CAB INTERIOR; UPHOLSTERY....2306
Operator's seat; securing....2307
87 - AIR CONDITIONING UNIT....2309
Climate control system; description....2310
ECC MID 146 non-programmed ECU; replacing....2315
ECC MID 146 pre-programmed ECU; replacing....2318
Troubleshooting; air conditioning unit (AC)....2321
Climate unit; removing....2325
Climate unit; installing....2333
Pause heater; description....2339
Pause heater; replacing....2341
Fan motor; replacing....2344
Air mix door actuator; replacing....2347
Heat control valve; replacing....2353
Air conditioning; tightening torques....2357
Air conditioning; specifications....2358
Air conditioning; refrigerant; weight_{12-23}....2360
Air conditioning; refrigerant; weight_{12-06}....2361
Air conditioning; checking performance....2363
Drying filter; replacing....2365
Condenser; replacing....2369
Compressor; replacing....2375
Evaporator; replacing....2381
Expansion valve; replacing....2389
Refrigerant; draining....2400
Refrigerant; filling incl vacuum pumping....2403
88 - INTERIOR EQUIPMENT....2407
Accelerator pedal; replace....2408
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....2410
90 - GENERAL....2411
Hydraulic diagram; basic machine - Image....2412
Hydraulic diagram; complete - Image....2413
Explanations to hydraulic diagram....2415
Hydraulic components; cleanliness when handling....2424
Hydraulic diagram; complete_{01-26}....2427
Hydraulic diagram; complete_{01-05}....2430
Hydraulic diagram; basic machine....2433
VCADS Pro; Operations....2436
Hydraulic system; volume....2438
Hydraulic system; bleeding....2439
V2-ECU; MID 249; changing non-programmed ECU....2442
V2-ECU; MID 249; changing pre-programmed ECU....2444
Hydraulic system; warming up....2446
Control valve; tightening torques....2448
Accumulator; discarding-5745....2449
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....2452
Error codes when calibrating....2455
Hydraulic oil tank; description....2459
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump....2461
Hydraulic connections; tightening torques....2463
Hydraulic couplings....2465
Working hydraulic system; component location....2469
Working hydraulic system; description....2471
Control valve; description....2479
Central valve; description....2483
Control valve; specifications....2485
Back-up valve; checking and adjusting....2486
Shock valve lift function; checking....2489
Shock valve; tilt function; checking....2492
Back-up valve; replacing....2495
Lift; solenoid valve; changing....2498
Lower; solenoid valve; changing....2500
Tilt in; solenoid valve; changing....2502
Tilt out; solenoid valve; changing....2504
Lift_lower; angle sensor; changing....2506
Tilt in_out; angle sensor; changing....2509
Tilt; checking....2520
Lift_lower function; checking....2522
Hydraulic pumps; description....2526
Hydraulic pump flow regulation; description....2528
Hydraulic pump (P1); specifications....2532
Hydraulic pump (P2); specifications....2533
Hydraulic pump (P3); specifications....2534
Function times; specifications....2535
Hydraulic pumps; tightening torques....2536
Lifting time; checking....2537
Hydraulic pump; standby pressure and working pressure; checking and adjusting....2538
LS (load sense) pressure; checking....2542
Hydraulic pump P1; removing....2545
Hydraulic pump P1; installing....2550
Hydraulic pump P2; removing....2554
Hydraulic pump P2; installing....2559
Hydraulic pump P3; removing....2563
Hydraulic pump P3; installing....2566
Hydraulic pump P3; checking....2569
Servo system; specifications....2572
Single lever control electric servo; replacing....2573
Servo pressure; checking and adjusting....2584
Servo pressure; at the spool in control valve; checking....2587
Accumulator removed; checking....2589
Servo accumulator; removing_{36-32}....2591
Servo accumulator; removing_{36-12}....2593
Servo accumulator; installing_{35-43}....2595
Servo accumulator; installing_{35-25}....2597
Accumulator; discarding....2599
Boom suspension system; component location....2601
Boom Suspension System; component description....2603
Boom Suspension System; description....2606
3rd; or 3rd_4th hydraulic function; description....2611
Boom Suspension System; specifications....2616
Boom Suspension System; tightening torques....2617
3rd_4th hydraulic function; specifications....2619
3rd_4th hydraulic function; tightening torques....2620
Boom suspension accumulator; checking and adjusting....2621
Boom suspension system; right accumulator; removing_{30-15}....2625
Boom suspension system; right accumulator; removing_{29-55}....2629
Boom suspension system; right accumulator; installing_{29-11}....2633
Boom suspension system; right accumulator; installing_{28-51}....2637
Boom suspension system; left accumulator; removing_{28-22}....2640
Boom suspension system; left accumulator; removing_{28-02}....2644
Boom suspension system; left accumulator; installing_{27-31}....2648
Boom suspension system; left accumulator; installing_{27-11}....2652
Boom suspension system; hydraulic oil pressure in accumulators; depressurizing....2655
Boom suspension system; pressure reduction; safety valve; checking and adjusting....2658
Accumulator; boom suspension system; discarding....2660
Boom suspension accumulator; reconditioning....2662
3rd_4th hydraulic function; pressure; checking and adjusting....2665
3rd_4th hydraulic function; solenoid valve; replacing....2668
3rd_4th hydraulic function; shock valve; checking....2671
Boom suspension system; checking....2674
3rd_4th hydraulic; functional check....2679
3rd; or 3rd_4th hydraulic function; component location....2682
92 - MECHANICAL EQUIPMENT_ATTACHMENT....2684
Hydraulic attachment bracket; description....2685
Attachment locking; checking....2690
94 - UNIT; LOAD HANDLING....2692
Hydraulic cylinder; piston's lock brace; installing....2693
Lift cylinder; tightening torques....2695
Tilt cylinder; tightening torques....2697
Lift cylinder; repacking in machine....2699
Tilt cylinder; repacking in machine....2716
99 - MISCELLANEOUS....2731
Fire suppression system; specification....2732
Fire suppression system; component location....2733
Fire suppression system; functional description....2735
Fire suppression system; component description....2739
Fire suppression system; actions after manual activation....2746
Fire suppression system; actions after activation....2764
Central lubrication system; description....2781
Pump unit; description....2786
Shift valve; description....2789
Pressure monitor; description....2791
Dosage valves; description....2793
Automatic lubrication system; specifications....2797
Recommended lubricants....2799
Grease Locations....2801
TP-Linkage's bearing points....2805
Diagnostic tools; description....2807
Parameter settings....2809
Software; parameter settings and read-outs....2811
Automatic lubrication pump unit; reconditioning....2818
Filling lubricant....2840
Bleeding air....2842
Change of lubrication interval....2848
System test....2850
Update of automatic lubrication system....2852
Volvo L110G Wheel Loaders Service Repair Manual
