Volvo Constructions L50F Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Constructions L50F, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions L50F 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.
L50F Volvo Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,343 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - GENERAL...2
00 - DESCRIPTION; COMPLETE MACHINE...3
Description...4
Machine dimensions...5
Position of components...7
Product plates...10
03 - SPECIFICATIONS...12
Measurement conversion tables...13
Volvo standard tightening torques...18
Engine; specifications...20
Engine; weights...21
Engine; capacity...22
Engine; tightening torque...23
Cooling system; capacity ...25
Fuel tank; volume...26
Electrical system; specifications...27
Battery; specifications...28
Lights; specifications...29
Power transmission; specifications ...30
Front axle; specification...31
Front axle; weight ...32
Front axle; capacity...33
Rear axle; specification...34
Rear axle; weight...35
Rear axle; capacity ...36
Axles; tightening torques ...37
Tire size...38
Brakes; specifications ...39
Lever steering (CDC); specifications ...41
Hydraulic system; specification...42
Hydraulic system; volume...43
Frame; weight ...44
Cab mounts; tightening torques ...45
Counterweight; tightening torques_...46
Counterweight; tightening torques ...48
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...50
Transporting the machine...51
07 - STANDARD TIME...54
Operation numbers for additional work...55
08 - TOOL...57
E-2000...58
E-tool Cab support...60
1 - STANDARD PARTS; SERVICE...61
16 - LUBRICANT; FUEL; OTHER FLUID...62
Recommended lubricants ...63
Coolant with freezing and corrosion protection...65
Coolant...67
Alternative fuels...72
17 - SERVICE...75
Service...77
Service and maintenance...78
Work on the machine's electrical system...80
Cleanliness; braking and hydraulic system...81
Charging batteries...82
Electric welding...83
Arrival Inspection; according to Inspection Programme...84
Delivery Inspection; according to Inspection Programme...85
Delivery Instructions; according to Inspection Programme...86
Maintenance of Stored Machines; according to Inspection Programme...87
Service position 2_{23-20}...88
Service position 1_{22-59}...90
Maintenance service; every 10 hours...92
Maintenance service; every 50 hours...93
Maintenance service; every 500 hours...94
Maintenance service; every 1000 hours...95
Maintenance service; every 1500 hours...97
Maintenance service; every 2000 hours...99
Maintenance service; every 3000 hours...101
Maintenance service; every 6000 hours...103
Test running and checking...104
Leakage; checking...105
Lubrication...106
Engine belt tension; checking...108
Valves; adjusting ...110
Engine oil level; checking...115
Engine oil and filter; changing...116
Water separator; checking...118
Fuel filters; replacing...120
Fuel tank breather filter; replacing...122
Engine air cleaner primary filter; replacing...124
Engine air cleaner secondary filter; replacing...126
Coolant level; checking...127
Coolant; changing...129
Coolant freezing point; checking...131
Radiator; cleaning...133
MATRIS and Tech Tool; reading...135
Battery; checking...136
Transmission oil filter; replacing...137
Propeller shaft movement; checking...140
Axle oil; changing_{11-17}...142
Axle oil; changing_{10-56}...145
Axle oil; changing_{10-36}...148
Service brake disc wear; checking...151
Brake pressure and function; checking...153
Parking brake pads; checking...158
Steering pressure; checking_{08-31}...159
Steering pressure; checking_{08-11}...162
Steering cylinders; locking of pivot pins; checking...165
Tyre wear and air pressure; checking...167
Wheel nuts torque; checking...168
Cab main filter; replacing...169
Hydraulic oil level; checking...171
Hydraulic oil; changing...173
Hydraulic oil filters; replacing...175
Hydraulic tank sediment; draining...177
Hydraulic pressure; checking...179
Towing...182
19 - GENERAL...183
Safety concerns everybody!...184
CE-marking; EMC-directive...186
Safety when handling the machine...190
Safety rules when servicing...194
Service position 2_{00-35}...197
Service position 1_{00-14}...199
Service position 2_{59-44}...201
Service position 1_{59-24}...203
Loader boom; safety strut...205
Working under raised boom...208
Fire prevention measures...210
Some simple rules regarding tyre handling...213
Safety when lifting and supporting complete machine...215
Safety when using lifting equipment...217
Safety when working with batteries...219
Starting with booster batteries...222
Safety when handling oils and fuel...224
Safety when handling accumulators...225
Safety when working on hydraulic systems...226
Checklist after a fire or heat exposure...228
Health hazards with paint; plastics and rubber...229
Environmental handling for the future...231
Waste handling...233
Environmentally safe handling...234
Environmentally hazardous fluids...236
Safety when working with refrigerant...237
Working in environmentally contaminated areas...240
Decontamination...241
2 - ENGINE WITH MOUNTING AND EQUIPMENT...243
20 - GENERAL...244
Engine; description...245
Component locations...246
Engine; weights...248
21 - ENGINE...249
Cylinder compression; testing...250
Engine; removing...252
Engine; installing...262
Cylinder head; description...272
Valves; description...274
Valves; adjusting...276
Engine timing gears; description...281
Crankshaft; description...282
Connecting rod; description...283
22 - LUBRICATING SYSTEM...285
Lubrication system; principle of operation...286
Oil pump; description...288
Oil cooler; replacing...289
23 - FUEL SYSTEM...293
Fuel system; description...294
Fuel feed pump; description...296
Feed pump; replacing...297
Fuel tank; removing...301
Fuel tank; installing...306
Idling speed; checking and adjusting...310
Injection valve; check...312
25 - INLET & EXHAUST SYSTEM...315
Turbocharger; description...316
26 - COOLING SYSTEM...318
Cooling system; description...319
Cooling system; capacity...320
Radiator; removing...321
Radiator; installing...329
Coolant pump; replacing...337
Thermostat; replacing...340
27 - ENGINE CONTROL...342
Accelerator Pedal...343
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...344
30 - GENERAL...345
Electrical system; work instructions...348
Electrical system; description...350
Communication; vehicle electronics_{25-58}...352
Communication; vehicle electronics_{25-38}...354
Electronic control system; description_{25-08}...356
Electronic control system; description_{24-48}...358
Machine; Calibration...360
Software parameters; description...370
Parameter; setting...376
General fault diagnosis information...381
Troubleshooting strategy...383
Collection of basic data...385
Information display; check ...387
Error codes; build-up...389
SAE error codes; translation to error messages; general...392
Bus communication supervision...394
Conditions when checking...396
Lead and connector checks...399
Troubleshooting tools...403
Special tools for troubleshooting...404
CU6601; description and measuring...405
MA2307; description and measuring...409
MA2602; description and measuring...411
MA4220; description and measuring...413
MA4221; description and measuring...415
MA4228; description and measuring...417
MA4603; description and measuring...419
MA4710; description and measuring...421
MA4720; description and measuring...423
MA9172; description and measuring...425
MA9173; description and measuring...427
MA9174; description and measuring...429
MO6401; description and measuring...431
Power supply I-ECU; description and measuring...433
Power supply T-ECU; description and measuring...435
Power supply V-ECU; description and measuring...437
Power supply V2-ECU; description and measuring...439
PWM2601; description and measuring...441
PWM4225; description and measuring...443
PWM4226; description and measuring...445
PWM4227; description and measuring...447
PWM6601; description and measuring...449
PWM6602; description and measuring...451
R2701; description and measuring...453
RE02; description and measuring...455
RE06; description and measuring...457
RE09; description and measuring...459
RE10; description and measuring...461
RE15; description and measuring...463
RE2319; description and measuring...465
RE2501; description and measuring...467
RE6401; description and measuring...469
RE8701; description and measuring...471
SAE J1708_1587 Information link; description and measuring...473
SAE J1939_CAN1 Control link; description and measuring_50-16...476
SAE J1939_CAN1 Control link; description and measuring_49-29...479
SAE J1939_CAN1 Control link; description and measuring_48-37...482
SAE J1939_CAN1 Control link; description and measuring...485
SAE J1939_CAN2 Control link; description and measuring...488
SE2203; description and measuring...491
SE2303; description and measuring...493
SE2502; description and measuring...495
SE2603; description and measuring...497
SE2606; description and measuring...499
SE2701; description and measuring...501
SE2702; description and measuring...503
SE4201; description and measuring...505
SE4405; description and measuring...507
SE4406; description and measuring...509
SE4407; description and measuring...511
SE6401; description and measuring...513
SE6403; description and measuring...515
SE6404; description and measuring...517
SE6601; description and measuring...519
SE8503; description and measuring...521
SE8702; description and measuring...523
SE8706; description and measuring...525
SE8708; description and measuring...527
SE8709; description and measuring...529
SE9105; description and measuring...531
SE9109; description and measuring...533
SW4205_SW4206; description and measuring...535
SW4208; description and measuring...537
SW4217; description and measuring...539
SW8701; description and measuring...541
Communication; vehicle electronics_{29-09}...543
Communication; vehicle electronics_{28-49}...545
Component descriptions...547
Limp home...550
Transmission shutdown...551
31 - BATTERY...552
Battery; description...553
Battery; charging...554
33 - STARTING SYSTEM...555
Booting sequence...556
35 - LIGHTING...557
Lighting; description...558
36 - OTHER ELECTRICAL EQUIPMENT...560
Reduced computer communication...561
Connector I_O description ...563
Electronic climate control unit ECC; description...584
Instrument control unit I-ECU; functional description...585
Vehicle control unit V-ECU; description...586
Vehicle control unit V2-ECU; description...588
Control units; changing...589
I-ECU MID 140 non-programmed; replacing...590
I-ECU MID 140 pre-programmed; replacing...592
37 - CABLE; FUSE; RELAY...594
Electrical symbols and designations...596
Cable and component designations...599
Cable and component marking explanations...601
Component list Alternator; batteries; capacitors; electronic units; voltage outlet...602
Component list Fuses...604
Component list Heating coils; instruments; service socket...609
Component list Lights...611
Component list; motors...613
Component list; PWM valves...615
Component list Relays...617
Component list; sensors...620
Component list Solenoid valves...623
Component list; Sounders...626
Component list Switches...628
Connector I_O description...631
Table of contents; wiring diagrams...652
Wiring diagram WD201_{41-52}...654
Wiring diagram WD201_{41-33}...657
Wiring diagram WD202...659
Wiring diagram WD203...661
Wiring diagram WD301...662
Wiring diagram WD302...665
Wiring diagram WD303...668
Wiring diagram WD304...673
Wiring diagram WD305...676
Wiring diagram WD306...679
Wiring diagram WD307...682
Wiring diagram WD308...683
Wiring diagram WD309...686
Wiring diagram WD310...689
Wiring diagram WD311...692
Wiring diagram WD312...694
Wiring diagram WD401...696
Wiring diagram WD402...699
Wiring diagram WD403...701
Wiring diagram WD404...703
Wiring diagram WD501...706
Wiring diagram WD601...709
Wiring diagram WD602...711
Wiring diagram WD603...714
Wiring diagram WD801...716
Wiring diagram WD802...719
Wiring diagram WD803...722
Wiring diagram WD901...725
Wiring diagram WD902...728
Wiring diagram WD903...729
Wiring diagram WD904...732
Wiring diagram WD905...734
Wiring diagram WD906...736
Battery disconnect switch; description...738
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...739
Instrument panels...740
Middle instrument panel with warning lights...742
Information display; general...744
Information display; start lockout...747
Information display; operating display...749
Information display; engine...750
Information display; transmission...752
Information display; hydraulics...753
Information display; axles _ brakes...754
Information display; electrical system...755
Information display; vehicle info...756
Information display; vehicle messages...758
Information display; service mode...759
Information display; settings...761
Information display; check...762
Central warning...764
39 - MISCELLANEOUS...765
CareTrack W-ECU; description...766
4 - POWER TRANSMISSION...770
40 - GENERAL...771
Power transmission; description...772
42 - TRANSMISSION; HYDRAULIC CONTROL...774
Hydrostatic transmission; description...775
Transmission circuit hydraulic schematic...777
Transmission solenoid; replacing...779
Transmission sensor; replacing...781
Induction sensor for output shaft; replacing...783
Transmission; removing...786
Transmission; installing...790
Transmission; disassembling...797
Transmission; function check_{12-47}...801
Transmission; function check_{12-17}...811
44 - HYDROSTATIC DRIVE...815
Hydraulic diagram transmission - Image...816
Travel motor; description...819
Hydrostatic pump; description_{10-56}...822
Hydrostatic pump; description_{10-36}...825
Power transmission; specifications...828
Hydraulic diagram transmission_{09-44}...829
Hydraulic diagram transmission_{09-23}...832
Hydraulic diagram transmission_{09-03}...835
Hydraulic motor; replacing...838
Start hydraulic motor control; check and adjust...843
Hydraulic pump coupling; description...846
Shaft seal replacing...848
Hydrostatic pump charge pressure; checking and adjusting...851
Start hydraulic pump control; checking and adjusting_{05-30}...853
Start hydraulic pump control; checking and adjusting_{05-10}...856
Hydrostatic pump cut off valve; checking and adjusting_{04-40}...858
Hydrostatic pump cut off valve; checking and adjusting_{04-20}...861
Hydrostatic pump high pressure valve; checking and adjusting_{03-41}...864
Hydrostatic pump high pressure valve; checking and adjusting_{03-17}...869
Hydrostatic pump mechanical zero position; checking and adjusting...874
45 - PROPELLER SHAFT...877
Propeller shaft; changing...878
46 - FRONT AXLE; REAR AXLE...881
Drive axles; description...882
Front axle; weight...886
Rear axle; capacity...887
Axles; tightening torques...888
Front axle; removing_{58-59}...889
Front axle; removing_{58-39}...892
Front axle; installing_{58-09}...895
Front axle; installing_{57-49}...898
5 - BRAKE...901
50 - GENERAL...902
Description brake system_{01-40}...903
Description brake system_{01-22}...904
Brakes; specifications...905
Hydraulic diagram; brake system...907
51 - WHEEL BRAKE...916
Brake linings; checking wear...917
52 - HYDRAULIC BRAKE SYSTEM...919
Brake system hydraulic function; checking...920
Service brake pressure; checking...925
Brake system; adjusting unloading pressure...927
Brake system; bleeding...930
Accumulator; checking...932
Accumulator (removed) charging pressure; checking...934
55 - PARKING BRAKE...936
Parking brake; replacing control cable...937
Parking brake; replacing brake disc...943
Parking brake brake pads; replacing...946
6 - STEERING...951
60 - GENERAL...952
Axle; removing...953
Axle; installing...958
Steering system; description...963
Steering system; specifications_{54-35}...965
Steering system; specifications_{54-17}...966
64 - STEERING...967
Steering system; troubleshooting and elimination...968
Hydraulic diagram; steering...971
Steering wheel; tightening torques...973
Steering pressure; checking_{52-05}...975
Steering pressure; checking_{51-44}...978
Steering pressure; checking_{51-19}...981
Steering pressure; checking_{50-59}...984
Steering system working pressure; checking and adjusting_{50-29}...987
Steering system working pressure; checking and adjusting_{50-08}...990
Steering valve; reconditioning (removed)...993
Secondary steering; description...1001
66 - LEVEL STEERING...1002
Comfort Drive Control (CDC); description...1003
Lever steering (CDC); specifications...1007
Error codes when calibrating...1008
Hydraulic diagram; steering incl. lever steering (CDC)...1010
Comfort drive control (CDC) angle sensor; changing...1013
Comfort drive control (CDC) solenoid valve; changing...1019
Comfort Drive Control (CDC) control valve; removing...1022
Comfort drive control (CDC) control valve; installing...1025
Lever steering (CDC) function; checking...1028
Comfort Drive Control; servo pressure; checking...1029
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...1031
70 - GENERAL...1032
Frame and track unit; description...1033
Frame; weight...1035
71 - FRAME...1036
Counterweight; tightening torques...1037
Counterweight; removing...1039
Counterweight; installing...1042
74 - FRAME LINK...1044
Frame joint; separating machine...1045
Frame joint; assembly of separated machine...1056
Frame joint; replacing bearings...1068
75 - AXLE SUSPENSION...1072
Axle suspension; replacing bushes and seals...1073
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...1076
Wheel; tightening torque...1077
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...1078
80 - GENERAL...1079
Cab description...1080
81 - CAB; NAKED; CANOPY...1081
Repairs of minor damage on internal and external plastic parts (scratches; dents; breaks)...1082
Cab; removing...1084
Cab; installing...1094
Viscous cab suspension; description...1103
Cab mounts; tightening torques...1105
82 - ENGINE HOOD; MUDGUARD; FOOT STEP...1106
Engine hood; removing...1107
Engine hood; installing...1110
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...1113
Windows; general...1114
Side window; replacing_{28-49}...1116
Windscreen; replacing_{28-24}...1125
87 - AIR CONDITIONING UNIT...1134
Air conditioning unit; check function...1135
Climate control system; description...1138
Air conditioning; capacity...1141
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...1142
90 - GENERAL...1143
Hydraulic diagram; Boom Suspension System - Image...1145
Hydraulic diagram; working hydraulics; 3rd and 4th functions; attachment lock - Image...1146
Hydraulic diagram; working hydraulic system - Image...1147
Hydraulic diagram with option components-Image...1151
Hydraulic diagram with option components - Image...1159
Cleanliness when working on hydraulic components...1162
Hydraulic diagram with option components...1163
Hydraulic diagram with option components_{24-42}...1167
Hydraulic diagram with option components_{24-24}...1169
Hydraulic diagram with option components_{24-03}...1171
Hydraulic diagram with option components_{23-43}...1173
Hydraulic diagram with option components_{23-26}...1175
Hydraulic diagram; working hydraulic system_{22-58}...1177
Hydraulic diagram; working hydraulic system_{22-38}...1179
Hydraulic diagram; working hydraulic system_{22-20}...1181
Hydraulic diagram; working hydraulic system_{22-02}...1183
Hydraulic diagram; working hydraulics; 3rd and 4th functions; attachment lock...1185
Hydraulic diagram; cooling fan_{21-05}...1187
Hydraulic diagram; cooling fan_{20-47}...1189
Hydraulic diagram; cooling fan_{20-27}...1191
Hydraulic diagram; cooling fan_{20-07}...1193
Hydraulic diagram; Boom Suspension System...1196
Hydraulic diagram; control valve_{19-07}...1199
Hydraulic diagram; control valve_{18-47}...1203
General information to note when working on the hydraulic system...1208
Hydraulic oil; storage and handling...1210
Hydraulic system; repair of hydraulic components in workshop...1211
Hydraulic components; storing and transporting...1213
Troubleshooting chart...1214
Vacuum pump; connection...1217
Accumulator; discarding...1219
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...1221
Hydraulic system; description...1222
Hydraulic oil tank; description...1223
Main control valve; description_{14-56}...1225
Main control valve; description_{14-35}...1231
Main control valve; removing...1237
Main control valve; installing...1241
Port relief valve pressure; checking and adjusting...1245
Hydraulic pump; description...1250
Hydraulic pump; standby pressure; checking and adjusting...1252
Hydraulic pump; max working pressure; checking and adjusting...1255
Servo valve; description...1257
Boom Suspension System; general description...1261
Boom suspension system; checking...1263
92 - MECHANICAL EQUIPMENT_ATTACHMENT...1268
Hydraulic attachment bracket (quickfit); description...1269
Implement attachment; repacking removed hydraulic cylinder...1270
Attachment bracket cylinder; reconditioning...1274
Attachment locking hydraulic cylinder (vision-optimised bracket); replacing...1276
99 - MISCELLANEOUS...1279
Central lubrication system; description...1280
Pump unit; description...1285
Shift valve; description...1288
Pressure monitor; description...1290
Dosage valves; description...1292
Automatic lubrication system; specifications...1296
Recommended lubricants...1298
Diagnostic tools; description...1300
Parameter settings...1302
Software; parameter settings and read-outs...1304
Automatic lubrication pump unit; reconditioning...1311
Filling lubricant...1333
Bleeding air...1335
Change of lubrication interval...1341
System test...1343
Update of automatic lubrication system...1345
Volvo Constructions L50F Repair Service Manual
