Volvo Construction L50D Wheel Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for L50D Volvo Wheel Loaders, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo Construction L50D 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.
L50D Volvo Wheel Loaders Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 756 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
0 - Foreword...2
0 - GENERAL...3
00 - DESCRIPTION; COMPLETE MACHINE...4
Description ...4
Product identification plates...5
03 - SPECIFICATIONS...7
Air cleaner, specification ...7
Air conditioning specifications ...8
Air-conditioning, weight ...9
Alternator, specification ...10
Battery, specifications ...11
Boom Suspension System (BSS400), specification ...12
Boom Suspension System, tightening torques ...13
Cab, tightening torques ...14
Cab, weight ...15
Cold-start control, specification ...16
Conversion tables...17
Cooling fan, specification ...21
Cooling system, capacity ...22
Cooling system, specification ...23
Cooling system, weight ...24
Drive axles, capacity ...25
Drive axles, specification ...26
Drive axles, tightening torques ...27
Drive axles, weight ...28
Electrical system, specifications ...29
Engine, capacity-[4918]...30
Engine, specification-[4844]...31
Engine, tightening torques ...32
Engine, weight ...33
Frame, tightening torque ...34
Frame, weight ...35
Fuel feed pump specifications ...36
Fuel tank, capacity ...37
Fuel tank, specification ...38
Fuel tank, tightening torques ...39
Fuel tank, weight ...40
Gearbox, capacity ...41
Gearbox, tightening torques ...42
Gearbox, weight ...43
Hydrostatic system, tightening torques ...44
Hydrostatic system, weight ...45
Injection pump specifications ...46
Injector specifications ...47
Lifting frame, specification ...48
Lifting frame, weight ...49
Lights, specifications ...50
Lubrication system, specification ...51
Power transmission, specification ...52
Propeller shaft, tightening torques ...53
Starter motor, specifications ...54
Steering, specification ...55
Steering, tightening torques ...56
Steering, weight ...57
Thermostat, specification ...58
Turbocharger, specification ...59
Volvo standard tightening torques...60
Wheel brakes, specification...62
Wheels ...63
Working hydraulics system, specification ...64
Working hydraulics, capacity ...65
Working hydraulics, tightening torques ...66
Working hydraulics, weight ...67
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...68
Transporting the machine...68
07 - STANDARD TIME...70
Time Guide...70
08 - TOOL...79
E1021B...79
E1664 Lifting tool...81
E1666 Spanner...82
1 - STANDARD PARTS, SERVICE...83
16 - LUBRICANT; FUEL; OTHER FLUID...84
Recommended lubricants...84
17 - SERVICE...86
Axles, oil change...86
Cleanliness in hydraulic system ...87
Electric welding...88
Engine, changing oil and replacing filter...89
Hydraulic system, oil change...92
Repairing hydraulic system...94
Service interval ...95
Starting with booster batteries ...97
Towing procedures...99
Towing...100
Working on the electrical system of the machine...102
19 - GENERAL...103
CE marking and declaration of conformity...103
Checklist after a fire or heat exposure...104
Environment...105
Fire prevention measures...106
Health risks associated with paints, plastics and rubber...109
Safety concerns everybody!...111
Safety for work on hydraulic systems...112
Safety rules when servicing...114
Safety when handling oils and fuel...118
Safety when handling the machine...119
Safety when lifting and supporting the machine...122
Safety when working on boom...123
Safety when working with air conditioning refrigerant...125
Safety when working with batteries...127
Some simple rules regarding tyre handling...129
Starting with booster batteries...131
Working under raised boom...132
2 - ENGINE WITH MOUNTING AND EQUIPMENT...134
20 - GENERAL...135
Engine, capacity...135
Engine, description...136
Engine, specification...138
Engine, tightening torques...139
Engine, weight...140
21 - ENGINE...141
Crankshaft, description...141
Engine, installing...142
Engine, removing...144
Valves, checking and adjusting...149
22 - LUBRICATING SYSTEM...151
Lubrication system, specification...151
23 - FUEL SYSTEM...152
Fuel feed pump specifications...152
Fuel system, bleeding...153
Fuel tank and combined tank unit, replacing...155
Fuel tank, capacity...157
Fuel tank, specification...158
Fuel tank, tightening torques...159
Fuel tank, weight...160
Idle speed, checking and adjusting...161
Injection pump specifications...163
Injection pump, installing...164
Injection pump, removing...169
Injection timing adjustment at low engine temperature, description...173
Injector specifications...175
25 - INLET & EXHAUST SYSTEM...176
Air cleaner, description...176
Air cleaner, specification...177
Pressure drop indicator, checking...178
Turbocharger, specification...180
26 - COOLING SYSTEM...181
Coolant, changing...181
Cooling fan speed control, description...183
Cooling fan, specification...184
Cooling system, capacity...185
Cooling system, description...186
Cooling system, specification...187
Cooling system, weight...188
Fan motor, installing...189
Fan motor, removing...192
Hydraulic cooling fan, description...195
Hydraulic cooling fan, speed sensor, replacing and adjusting clearance...196
Pump 3 (P3) Cooling fan pump _ Brake pump Stand-by pressure, checking and adjusting...197
Pump 3 (P3) Cooling fan pump _ Brake pump, cooling fan maximum pressure, checking...200
Pump 3 (P3) Cooling fan pump _ Brake pump-[0018]...202
Pump 3 (P3) Cooling fan pump _ Brake pump...204
Sensor fault...206
Thermostat, specification...207
27 - ENGINE CONTROL...208
Cold-start control, specification...208
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...209
30 - GENERAL...210
Air filter pressure...210
Back-up alarm...211
Boom Suspension System (BSS)...212
Brake pressure charging...214
Brake pressure...215
Brake test...216
Central lubrication...217
Charge pressure hydrostatic system...218
Communication with data buses...219
Control units, software functions...221
Coolant temperature, engine...223
Coolant temperature, outlet radiator...224
Cooling fan control...225
Description of table for software functions...227
Differential lock...228
Downshifting signal...229
Electrical system, description...230
Electrical system, specifications...231
Electrical system, work instructions...232
Electronic control system, description...233
Engine oil pressure...235
Engine speed for V-ECU...236
Fuel level...237
Gear selector...238
Gear-shifting solenoids...240
Hydraulic oil level...241
Hydraulic oil temperature...242
Instrument control unit I-ECU, functional description...243
Interruption in computer communication...245
Interval wiper...246
Limp-Home, by-passed V-ECU...247
Output brake pressure...250
Overspeed transmission...251
Parking brake, mechanical...252
Parking brake...253
Preheating of inlet air...255
Reduced computer communication...257
Secondary steering...258
Service interval...260
Starter lock-out...261
Starter motor engagement...262
System voltage...263
Transmission disengagement...264
Transmission oil filter...265
Transmission oil pressure...266
Transmission oil temperature...267
Travel speed...268
Tyre radius...269
Vehicle control unit V-ECU, functional description...270
Wiping during and after washing...272
31 - BATTERY...273
Battery, charging...273
Battery, description...274
Battery, specifications...275
32 - ALTERNATOR; CHARGE REGULATOR...276
Alternator, description...276
Alternator, specification...277
33 - STARTING SYSTEM...278
Preheating, description...278
Starter motor, specifications...279
Starting system, description...280
35 - LIGHTING...282
Lighting, description...282
Lights, specifications...284
37 - CABLE; FUSE; RELAY...285
Cable and component designations...285
Cable and component marking explanations...287
Circuit list...288
Communication cable explanation...291
Electrical components...292
Electrical distribution box, description...309
Electrical symbols and designations...311
Ground connections...313
Positive feed...314
Signal ground...315
Wiring diagram 1...316
Wiring diagram 10...318
Wiring diagram 11...319
Wiring diagram 12...320
Wiring diagram 14...321
Wiring diagram 140...322
Wiring diagram 15...323
Wiring diagram 150...324
Wiring diagram 15B...325
Wiring diagram 16...326
Wiring diagram 17...327
Wiring diagram 170...328
Wiring diagram 175...329
Wiring diagram 18...330
Wiring diagram 19...332
Wiring diagram 2...333
Wiring diagram 20...334
Wiring diagram 21...335
Wiring diagram 21B...337
Wiring diagram 21C...338
Wiring diagram 23...339
Wiring diagram 24...340
Wiring diagram 25...341
Wiring diagram 26...342
Wiring diagram 3...343
Wiring diagram 32...344
Wiring diagram 32B...345
Wiring diagram 4...346
Wiring diagram 5...347
Wiring diagram 6...348
Wiring diagram 7...349
Wiring diagram 8...350
Wiring diagram 9...352
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...353
Display panel and keypad, general...353
Display panel, general...356
Display panel, information displays...357
Display panel, initial display...361
Display panel, operating display...362
Display panel, setting...363
Instruments...365
Middle instrument panel with warning lights...366
Service display unit, brakes...368
Service display unit, electrical control input signals 1...369
Service display unit, electrical control input signals 2...372
Service display unit, electrical control input signals 3...373
Service display unit, electrical control output signals 1...376
Service display unit, electrical control output signals 2...379
Service display unit, electrical feed sensor...380
Service display unit, electrical system battery voltage...381
Service display unit, engine...382
Service display unit, general...384
Service display unit, hydraulics...387
Service display unit, settings...388
Service display unit, transmission...392
4 - POWER TRANSMISSION...393
40 - GENERAL...394
Hydrostatic system, tightening torques...394
Power transmission, specification...395
42 - TRANSMISSION; HYDRAULIC CONTROL...396
Gearbox, capacity...396
Gearbox, tightening torques...397
Gearbox, weight...398
44 - HYDROSTATIC DRIVE...399
Hydrostatic pump, installing...399
Hydrostatic pump, removing and installing...402
Hydrostatic system, neutral position...406
Hydrostatic system, weight...412
Obligatory measures to be taken when repairing the hydrostatic system...413
45 - PROPELLER SHAFT...415
Propeller shaft, tightening torques...415
46 - FRONT AXLE; REAR AXLE...416
Drive axles, capacity...416
Drive axles, description...417
Drive axles, specification...418
Drive axles, tightening torques...419
Drive axles, weight...420
Front axle, installing...421
Front axle, removing...423
Planetary gear...426
Rear axle, installing...427
5 - BRAKE...430
50 - GENERAL...431
Brake and engine cooling fan, hydraulic diagram...431
Brake, description of function...434
Brake, description...437
Wiring diagram 15B - Image...439
Wiring diagram 15B...440
Wiring diagram 5 - Image...441
Wiring diagram 5...442
51 - WHEEL BRAKE...443
Brake disc, rear wheel brakes, replacing...443
Brake discs, front wheel brakes, changing...452
Brake discs, front wheel brakes, checking wear...461
Brake discs, rear wheel brakes, checking wear...463
Wheel brakes, specification...465
52 - HYDRAULIC BRAKE SYSTEM...466
Accumulator, checking (removed)...466
Brake pedal, adjusting angle...468
Brake system, bleeding...469
Checking and adjusting pressure in circuit...471
Checking function...473
Discarded accumulators...477
Foot brake valve removed, reconditioning...478
Foot brake valve, description of function...482
Retardation, checking function...483
55 - PARKING BRAKE...484
Description...484
Parking brake, adjusting...486
Parking brake, electrical system, description...488
6 - STEERING...490
60 - GENERAL...491
Steering, description...491
Steering, specification...492
Steering, tightening torques...493
Steering, weight...494
64 - STEERING...495
Hydraulic diagram, steering system, incl. CDC and secondary steering-[3940]...495
Hydraulic diagram, steering system, incl. CDC and secondary steering.-.Image...498
Hydraulic pump, description...499
Secondary steering, description...502
Steering cylinder, reconditioning...506
Steering cylinder, replacing...509
Steering pressure and stand-by pressure, checking and adjusting...513
Steering valve, description...516
Steering valve, reconditioning...522
Wiring diagram 16 - Image...530
Wiring diagram 16...531
66 - LEVEL STEERING...532
Hydraulic diagram, steering system, incl. CDC and secondary steering - Image...532
Hydraulic diagram, steering system, incl. CDC and secondary steering...533
Lever steering (CDC), electrical system, description...536
Lever steering (CDC), general description...538
Lever steering (CDC), hydraulic system, description...541
Lever steering, adjusting steering speed...543
Lever steering, checking and adjusting control valve...544
Steering lever SE603, checking input_output voltage...546
Wiring diagram 17 - Image...548
Wiring diagram 17...549
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...550
70 - GENERAL...551
Description...551
71 - FRAME...552
Frame, tightening torque...552
Frame, weight...553
74 - FRAME LINK...554
Frame joint bearing...554
Frame joint, replacing bearings...555
75 - AXLE SUSPENSION...580
Axle suspension, checking axial and radial clearance...580
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...582
Wheels...582
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...583
81 - CAB, NAKED; CANOPY...584
Cab suspension, description...584
Cab, installing...586
Cab, removing...588
Cab, tightening torques...591
Cab, weight...592
87 - AIR CONDITIONING UNIT...593
AC operational reliability, functional description...593
Air conditioning specifications...594
Air conditioning, performance test...595
Air-conditioning, weight...597
Climate control system, description ...598
Climate control system, description...601
Electrical system, functional description...605
Evaporator, cleaning...606
Wiring diagram 19 - Image...610
Wiring diagram 19...611
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...612
90 - GENERAL...613
Cleanliness in hydraulic system...613
Hydraulic system, bleeding...614
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...616
3rd hydraulic function, flow control...616
Attachment hydraulics GP, description...618
Boom Suspension System (BSS400), specification...620
Boom Suspension System, checking when operating with a load...621
Boom Suspension System, description...623
Boom Suspension System, electrical system, description...626
Boom Suspension System, hydraulic pressure in accumulator(s), releasing...629
Boom Suspension System, hydraulic system, description...631
Boom Suspension System, tightening torques...637
Boom Suspension System, troubleshooting...638
Boom suspension system, reconditioning accumulator...639
Central valve, description...641
Control valve, description...643
Hydraulic diagram, control valve - Image...657
Hydraulic diagram, control valve...658
Hydraulic oil tank, creating vacuum...661
Hydraulic pump, replacing...663
Precharge pressure in accumulators, checking and adjusting...664
Pressure-reducing valve for...667
Servo pressure, checking and adjusting...669
Servo valve, description...671
Servo valve, operating control, adjusting...674
Shock valve, lifting function, checking and adjusting...677
Shock valve, tilting function, checking and adjusting...680
Stand-by pressure, checking and adjusting...685
Working hydraulics system, specification...687
Working hydraulics, capacity...688
Working hydraulics, description...689
Working hydraulics, tightening torques...691
Working hydraulics, weight...692
Working pressure, checking and adjusting...693
92 - MECHANICAL EQUIPMENT_ATTACHMENT...695
Cylinder for attachment locking, replacing...695
Hydraulic attachment bracket, description...696
94 - UNIT, LOAD HANDLING...697
Boom, description...697
Lifting cylinder, replacing...699
Lifting cylinder, sectional view...703
Lifting frame, replacing bearings A...704
Lifting frame, replacing bearings B...708
Lifting frame, specification...713
Lifting frame, weight...714
T-link, upper, removed, replacing bearings HIJ...715
Tilting arm, replacing bearings GDF...722
Tilting cylinder, replacing...727
Tilting cylinder, sectional view...731
T link, lower removed, replacing GH bearings...732
99 - MISCELLANEOUS...736
Hydraulic diagram, 5th, 6th and 7th hydraulic functions - Image...736
Hydraulic diagram, 5th, 6th and 7th hydraulic functions...737
Hydraulic diagram, Boom Suspension System, single-acting lifting function, differential lock - Image...740
Hydraulic diagram, Boom Suspension System, single-acting lifting function, differential lock...741
Hydraulic diagram, GP hydraulics - Image...744
Hydraulic diagram, GP hydraulics...745
Hydraulic diagram, lifting, tilting and floating position - Image...748
Hydraulic diagram, lifting, tilting and floating position...749
Hydraulic diagram, working hydraulics, 3rd and 4th functions, attachment lock - Image...752
Hydraulic diagram, working hydraulics, 3rd and 4th functions, attachment lock...753
Working hydraulics, components...756
