Volvo L60G, L60G Z Wheel Loaders Service Repair Manual
Complete repair service manual with electrical wiring diagrams for Volvo L60G, L60G Z Wheel Loaders, with technical information to maintain, diagnose, repair, and service like professional mechanics.
Volvo L60G, L60G Z 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.
L060G Z Volvo Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,422 pages
File Format: PDF (Windows & Mac & Linux)
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, WHEELTRACK UNIT
(8) MACHINERY HOUSE, CAB, EXTERIOR TRIM PARTS ANYWHERE
(9) HYDRAULIC SYSTEM, DIGGING-HANDLING-GRANDING EQUIPM., MISC. EQUIP
TABLE OF CONTENTS
0 - Foreword.......2
0 - GENERAL.......3
00 - DESCRIPTION; COMPLETE MACHINE.......4
Conversion tables.......4
Tightening torques.......8
07 - STANDARD TIME.......17
Operation numbers for additional work.......17
08 - TOOL.......19
E 1708, Checking point.......19
E-2001.......21
E-2014.......22
E-2017.......24
Infrared Thermometer.......25
1 - STANDARD PARTS, SERVICE.......29
16 - LUBRICANT; FUEL; OTHER FLUID.......30
Alternative fuels.......30
Coolant.......33
Recommended lubricants.......35
17 - SERVICE.......37
Arrival Inspection, according to Inspection Programme.......37
Automatic central lubrication filter, replacing.......38
Axle breather filters, replacing.......40
Basic service.......42
Battery, checking.......43
Boom suspension accumulator, checking.......45
Cab main filter, replacing.......49
Cab prefilter, replacing.......51
Coolant freezing point, checking.......53
Coolant level, checking.......55
Coolant, changing.......57
Coolers, cleaning.......60
Delivery Inspection, according to Inspection Programme.......63
Drive axle oil, changing.......64
Electric welding.......67
Engine air cleaner primary filter, replacing.......69
Engine air cleaner secondary filter, replacing.......71
Engine belt condition, checking.......72
Engine oil and filter, changing.......74
Engine oil level, checking.......77
Extra fuel prefilter, replacing.......79
Fuel filter, replacing.......81
Fuel tank breather filter, replacing.......83
Hinge, lubricating.......84
Hydraulic oil level, checking.......86
Hydraulic oil tank breather filter, replacing.......87
Hydraulic oil, changing.......88
Hydraulic tank return oil filter and magnetic rod, cleaning and replacing.......91
Hydraulic tank sediment, draining.......93
Lubrication, every 1000 hours.......95
Lubrication, every 250 hours.......97
Lubrication, every 50 hours.......100
Lubrication, every 500 hours.......103
Maintenance of Stored Machines, according to Inspection Programme.......105
Maintenance service, as required.......106
Maintenance service, every 1000 hours.......107
Maintenance service, every 2000 hours.......109
Maintenance service, every 250 hours.......111
Maintenance service, every 4000 hours.......112
Maintenance service, every 50 hours.......114
Maintenance service, every 500 hours.......115
Maintenance service, every 6000 hours.......117
Maintenance service, first 1000 hours.......118
Oil-bath air cleaner reservoir filter insert, cleaning.......119
Oil-bath air cleaner reservoir oil, changing.......121
Oil-bath air cleaner reservoir oil, checking.......123
Parking brake function, checking .......125
Restoring of the machine.......127
Service brake disc wear, checking.......128
Service brake, testing .......131
Service position 1.......132
Service position 2.......134
Service.......136
Towing.......139
Transmission oil level, checking.......141
Transmission oil, filter and suction strainer, changing and cleaning.......143
Tyre wear and air pressure, checking.......147
Valves, adjusting-[4521].......149
Water separator, checking.......157
19 - GENERAL.......158
CE-marking, EMC-directive.......158
Checking function.......162
Checklist after a fire or heat exposure.......163
Decontamination.......166
Environmental handling for the future.......170
Environmentally hazardous fluids.......173
Environmentally safe handling.......176
Fire prevention measures.......179
Health hazards with paint, plastics and rubber.......183
Safety concerns everybody!.......186
Safety rules when servicing.......190
Safety when handling accumulators.......193
Safety when handling oils and fuel.......195
Safety when handling the machine.......197
Safety when lifting and supporting complete machine.......202
Safety when using lifting equipment.......206
Safety when working on hydraulic systems.......208
Safety when working with air conditioning refrigerant.......210
Safety when working with batteries.......213
Service position 1_{10-23-30}.......216
Service position 2_{10-23-58}.......218
Some simple rules regarding tyre handling.......220
Starting with booster batteries.......222
Waste handling.......224
Working in environmentally contaminated areas.......228
Working under raised boom.......231
2 - ENGINE WITH MOUNTING AND EQUIPMENT.......233
20 - GENERAL.......234
E-ECU MID 128 non-programmed, replacing.......234
E-ECU MID 128 pre-programmed, replacing.......236
Engine belts, replacing.......238
Engine, capacities.......240
Engine, component locations.......241
Engine, description.......244
Engine, tightening torques.......247
Fuel system, tightening torques.......249
Tech Tool, operations-[1116].......250
21 - ENGINE.......251
Crankcase ventilation, description.......251
Crankshaft front oil seal, replacing.......252
Cylinder compression, PC test.......260
Cylinder compression, testing.......261
Engine rotation speed sensor (camshaft), replacing.......265
Engine rotation speed sensor (crank shaft), replacing.......267
Engine, installing.......270
Engine, removing.......281
Engine, specifications.......292
Idle, VCADS Pro.......294
Internal Exhaust Gas Recirculation (IEGR), description.......295
Speed sensor, specifications.......301
VCADS Pro, MID 128, programming E-ECU.......302
VCADS Pro, central systems updating, replace component.......303
Valve system specifications.......304
Valves, adjusting.......305
22 - LUBRICATING SYSTEM.......313
Lubricating system, description.......313
Lubrication oil pressure, checking with pressure gauge.......317
Lubrication system, specifications.......319
23 - FUEL SYSTEM.......320
Carbon dioxide in fuel system, checking.......320
Feed pump pressure, checking.......326
Fuel control valve (FCV), checking.......328
Fuel control valve (FCV), description.......331
Fuel control valve (FCV), replacing.......333
Fuel feed pump, description.......336
Fuel feed pump, specifications.......337
Fuel filter, checking.......338
Fuel filter, description.......340
Fuel rail pressure sensor, replacing.......342
Fuel rail, description.......344
Fuel system, bleeding.......346
Fuel system, component location.......348
Fuel system, description.......351
Fuel system, specifications.......358
High pressure fuel pump, checking.......359
High pressure fuel pump, description.......363
High pressure fuel pump, replacing.......364
Injectors, description.......372
Injectors, replacing.......374
Pressure relief valve (PRV), inspecting.......376
Pressure relief valve (PRV), replacing.......379
Stall speed, checking.......381
25 - INLET & EXHAUST SYSTEM.......383
Air cleaner, description.......383
Auxiliary brake (engine braking), description.......384
Inlet and exhaust system, description.......385
Preheating, description.......389
Turbocharger, description.......391
Turbocharger, inspecting.......393
Turbocharger, replacing.......395
26 - COOLING SYSTEM.......399
Carbon dioxide in coolant system, checking.......399
Coolant pump, replacing.......405
Cooling fan motor, description.......411
Cooling fan motor, replacing.......413
Cooling fan rpm, specifications.......423
Cooling fan, component location.......424
Cooling fan, description.......426
Cooling fan, tightening torques.......430
Cooling system, description.......432
Radiator, installing.......435
Radiator, removing.......441
Reversible cooling fan, description.......449
Temperature limits for cooling fan speed, specifications.......453
Thermostat, specifications.......454
27 - ENGINE CONTROL.......455
Accelerator pedal, replacing.......455
ECO - accelerator pedal.......459
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.......461
30 - GENERAL.......462
Bus communication supervision.......462
Collection of basic data.......464
Communication with data buses.......466
Conditions when checking.......468
Electrical system, description.......471
Electrical system, specifications.......473
Electrical system, work instructions.......474
Electronic control system, description.......476
FX1007, description and measuring.......481
FX1008, description and measuring.......484
FX1009, description and measuring.......486
General fault diagnosis information.......488
HE2501, description and measuring.......489
Information display, check.......491
Lead and connector checks.......493
MA2301-MA2306, description and measuring.......497
MA2504, description and measuring.......500
MA2601, description and measuring.......502
MA2602, description and measuring.......504
MA4603, description and measuring.......506
MA5501, description and measuring.......508
MA5503, description and measuring.......510
MA9103, description and measuring.......512
MA9104, description and measuring.......515
MA9106, description and measuring.......518
MA9114, description and measuring.......520
MA9127, description and measuring.......523
MA9141, description and measuring.......525
MA9142, description and measuring.......527
MA9143, description and measuring.......529
MO3301, description and measuring.......531
MO6402, description and measuring.......533
PWM2303, description and measuring.......535
PWM2602, description and measuring.......537
PWM4213 - PWM4218, description and measuring.......539
Power supply E-ECU, description and measuring.......542
Power supply I-ECU, description and measuring.......544
Power supply V-ECU, description and measuring.......546
Power supply W-ECU, description and measuring.......548
RE02, description and measuring.......550
RE09, description and measuring.......552
RE10, description and measuring.......554
RE15, description and measuring.......556
RE2501, description and measuring.......558
RE6401, description and measuring.......560
SAE J1708_1587 Information link, description and measuring.......562
SAE J1939_CAN1 Control link, description and measuring.......565
SAE J1939_CAN2 Control link, description and measuring.......567
SAE error codes, translation to error messages, general.......569
SE2203, description and measuring.......571
SE2301, description and measuring.......573
SE2302, description and measuring.......575
SE2303, description and measuring.......577
SE2309, description and measuring.......579
SE2501, description and measuring.......581
SE2502, description and measuring.......583
SE2603, description and measuring.......585
SE2604, description and measuring.......587
SE2606, description and measuring.......589
SE2701, description and measuring.......591
SE2702, description and measuring.......593
SE2703, description and measuring.......595
SE2704, description and measuring.......597
SE4202, description and measuring.......599
SE4213, description and measuring.......601
SE4219, description and measuring.......603
SE4307, description and measuring.......605
SE5201, description and measuring.......607
SE5203, description and measuring.......609
SE5501, description and measuring.......611
SE6404, description and measuring.......613
SE6407, description and measuring.......615
SE9156, description and measuring.......617
SE9157, description and measuring.......619
SW3801, description and measuring.......621
SW4205_SW4206, description and measuring.......623
SW4208, description and measuring.......625
SW4209, description and measuring.......627
SW4211, description and measuring.......629
SW4212, description and measuring.......630
SW5501, description and measuring.......632
SW9143, description and measuring.......634
Software parameters, description.......635
Software, description.......643
Special tools for troubleshooting.......644
Tech Tool, operations .......645
Tech Tool, operations-[2834].......646
Troubleshooting strategy.......647
Troubleshooting tools.......649
VCADS Pro socket, measuring.......650
VCADS Pro, connecting problems.......653
31 - BATTERY.......655
Batteries, replacing.......655
Battery condition, checking.......657
Battery, charging.......660
Battery, description.......661
Battery, specifications.......662
Key feed.......663
System voltage.......665
32 - ALTERNATOR; CHARGE REGULATOR.......666
Alternator 80 A, description.......666
Alternator 80 A, specification.......667
33 - STARTING SYSTEM.......668
Booting sequence.......668
Preheating, specifications.......669
Starter motor, specifications.......670
35 - LIGHTING.......671
Lighting, description.......671
Lighting, specifications.......674
36 - OTHER ELECTRICAL EQUIPMENT.......675
Connectors, overview.......675
Connectors, position.......679
Engine control unit E-ECU, description.......688
I-ECU MID 140 non-programmed, replacing.......689
I-ECU MID 140 pre-programmed, replacing.......691
Instrument control unit I-ECU, functional description.......693
Intermittent wiper and washer.......695
Limp Home.......698
V-ECU MID 187 non-programmed, replacing.......699
V-ECU MID 187 pre-programmed, replacing.......701
Vehicle control unit V-ECU, description.......703
37 - CABLE; FUSE; RELAY.......705
Battery disconnector switch, description.......705
Branching in cables.......706
Cable and component designations.......711
Cable and component marking explanations.......713
Chassis connection.......716
Components list.......718
E-ECU, I_O list.......730
Electrical symbols and designations.......734
I-ECU, I_O list.......737
Table of contents, wiring diagrams.......741
V-ECU, I_O list.......743
Wiring diagram WD201.......747
Wiring diagram WD202.......751
Wiring diagram WD203.......755
Wiring diagram WD204.......759
Wiring diagram WD205.......762
Wiring diagram WD206.......765
Wiring diagram WD301.......768
Wiring diagram WD302.......772
Wiring diagram WD304.......775
Wiring diagram WD307.......778
Wiring diagram WD320.......781
Wiring diagram WD321.......784
Wiring diagram WD322.......787
Wiring diagram WD323.......790
Wiring diagram WD324.......793
Wiring diagram WD325.......797
Wiring diagram WD330.......800
Wiring diagram WD331.......804
Wiring diagram WD333.......807
Wiring diagram WD334.......811
Wiring diagram WD335.......814
Wiring diagram WD350.......817
Wiring diagram WD351.......820
Wiring diagram WD360.......823
Wiring diagram WD361.......826
Wiring diagram WD362.......829
Wiring diagram WD363.......832
Wiring diagram WD371.......835
Wiring diagram WD372.......838
Wiring diagram WD373.......841
Wiring diagram WD375.......844
Wiring diagram WD376.......847
Wiring diagram WD401.......850
Wiring diagram WD402.......853
Wiring diagram WD403.......856
Wiring diagram WD404.......859
Wiring diagram WD405.......863
Wiring diagram WD501.......867
Wiring diagram WD604.......871
Wiring diagram WD801.......874
Wiring diagram WD802.......878
Wiring diagram WD804.......881
Wiring diagram WD805.......884
Wiring diagram WD806.......887
Wiring diagram WD901.......890
Wiring diagram WD902.......894
Wiring diagram WD903.......897
Wiring diagram WD904.......901
Wiring diagram WD913.......904
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.......907
Alarm, description.......907
Information display, general.......909
Information display, service mode.......912
Instrument panels.......916
Machine hours.......918
Middle instrument panel with warning lights.......919
Travelling speed.......920
39 - MISCELLANEOUS.......921
CareTrack W-ECU, description.......921
CareTrack battery, replacing.......925
4 - POWER TRANSMISSION.......927
40 - GENERAL.......928
Drivetrain, component location.......928
Error codes when calibrating.......930
Front and rear axles, tightening torque.......931
Front and rear axles, volume.......932
Hydraulic transmission, capacity.......933
Propeller shaft, tightening torque.......934
Tech Tool, operations-[3028].......935
Transmission, tightening torques.......936
42 - TRANSMISSION; HYDRAULIC CONTROL.......937
Gear selector valve, replacing one solenoid.......937
Hydraulic diagram transmission - Image.......940
Hydraulic diagram transmission.......941
Hydraulic transmission, description.......944
Seal for front output shaft, replacing.......951
Seal for rear output shaft, replacing.......956
Transmission oil pressure, checking.......959
Transmission, calibration.......962
Transmission, component position.......963
Transmission, function check.......966
Transmission, installing.......967
Transmission, removing.......977
Transmission, specifications.......986
45 - PROPELLER SHAFT.......988
Propeller shaft, component description.......988
46 - FRONT AXLE; REAR AXLE.......989
Automatic differential brake, Limited Slip, description.......989
Axle suspension bushes and seals, replacing.......992
Differential lock, adjusting.......995
Differential lock, description.......998
Differential lock, function check.......1000
Drive axles, description.......1002
Front and rear axles, specifications.......1003
Front axle, component description.......1004
Hub reduction, installing-[1322].......1009
Hub reduction, installing.......1012
Hub reduction, removing-[1354].......1015
Hub reduction, removing.......1017
Hub seal, replacing-[1520].......1019
Hub seal, replacing.......1039
Rear axle mounting, component description.......1059
Rear axle, component description.......1060
49 - MISCELLANEOUS.......1065
Oil cooler, component location.......1065
6 - STEERING.......1066
60 - GENERAL.......1067
Steering cylinder, tightening torque.......1067
Steering system function, checking.......1068
Steering system, component location.......1070
Steering system, description.......1072
64 - STEERING.......1078
Accumulator, discarding .......1078
Pressure monitor, description.......1080
Secondary steering pump, description.......1082
Secondary steering pump, specifications.......1083
Secondary steering, component location.......1084
Secondary steering, description.......1086
Steering cylinder, description.......1089
Steering system working pressure, checking and adjusting.......1091
Steering valve, description.......1094
Steering, specifications.......1096
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.......1097
70 - GENERAL.......1098
Counterweight, tightening torques.......1098
Frame joint, tightening torques.......1099
Frame, description.......1100
Wheel, tightening torque.......1104
71 - FRAME.......1105
Counterweight, installing.......1105
Counterweight, removing.......1107
74 - FRAME LINK.......1109
Frame joint, description.......1109
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.......1111
Front wheel, installing.......1111
Front wheel, removing.......1113
Rear wheel, installing.......1115
Rear wheel, removing.......1117
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.......1119
80 - GENERAL.......1120
Air conditioning, tightening torques.......1120
Cab, component description.......1121
Cab, description.......1122
Cab, tightening torque.......1124
81 - CAB, NAKED; CANOPY.......1125
Cab, installing.......1125
Cab, removing.......1135
Viscous cab suspension, changing one unit.......1145
82 - ENGINE HOOD; MUDGUARD; FOOT STEP.......1148
Engine hood, installing.......1148
Engine hood, removing.......1152
83 - DOORS; HATCH; COVER PLATE, (all).......1156
Door lock, replacing.......1156
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.......1159
Side window, replacing_{02-23-08}.......1159
Window pane, installing.......1168
Windows, general, gluing.......1173
Windows, general.......1176
Windscreen, replacing_{02-22-37}.......1178
85 - CAB INTERIOR; UPHOLSTERY.......1187
Operator's seat, securing.......1187
87 - AIR CONDITIONING UNIT.......1189
Air conditioning unit, specifications.......1189
Air mix door actuator, replacing.......1191
Climate system, description.......1196
Climate unit, installing.......1202
Climate unit, removing.......1207
Compressor, replacing.......1213
Cooling system temperature sensor, replacing.......1217
Cooling unit, leak detection.......1223
Cooling unit, performance test.......1225
Evaporator, replacing.......1227
Expansion valve, replacing.......1233
Fan motor, replacing.......1238
Heat control valve, replacing.......1240
Heater core, replacing.......1243
Refrigerant, draining.......1245
Refrigerant, filling incl vacuum pumping.......1248
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.......1251
90 - GENERAL.......1252
3rd_4th hydraulic function, tightening torques-[0426].......1252
Accumulator, discarding-[0612].......1253
Control valve, tightening torques.......1255
Hydraulic connections, tightening torques.......1256
Hydraulic system, bleeding.......1257
Hydraulic system, description.......1260
Hydraulic system, volume.......1262
Hydraulic system, warming up.......1263
Lift cylinder, tightening torques.......1265
Tilt cylinder, tightening torques.......1266
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.......1267
3rd, or 3rd_4th hydraulic function, description.......1267
3rd_4th hydraulic function, specifications.......1269
3rd_4th hydraulic function, tightening torques.......1270
Accumulator removed, checking.......1271
Accumulator, boom suspension system, discarding.......1273
Accumulator, discarding.......1275
Angle sensor, lift, adjusting.......1277
Angle sensor, tilt, adjusting.......1278
Back-up valve, checking and adjusting.......1279
Back-up valve, replacing.......1281
Boom Suspension System, component description.......1283
Boom Suspension System, description.......1285
Boom Suspension System, specifications.......1290
Boom Suspension System, tightening torques.......1291
Boom suspension system, checking.......1293
Boom suspension system, component location.......1298
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing.......1301
Boom suspension system, pressure reduction, safety valve, checking and adjusting.......1304
Central valve, description.......1306
Control valve, description.......1308
Control valve, specifications.......1317
Function times, specifications.......1318
Hydraulic couplings.......1319
Hydraulic oil tank, description.......1323
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump.......1325
Hydraulic pump (P2), specifications.......1327
Hydraulic pump (P3), specifications.......1328
Hydraulic pump P2, installing.......1329
Hydraulic pump P2, removing.......1331
Hydraulic pump P3, checking_{01-48-38}.......1335
Hydraulic pump P3, checking_{01-49-05}.......1339
Hydraulic pump P3, installing.......1342
Hydraulic pump P3, removing.......1345
Hydraulic pump flow regulation, description.......1348
Hydraulic pump, stand-by pressure (LS-line removed), checking and adjusting.......1351
Hydraulic pump, standby pressure and working pressure, checking and adjusting.......1355
Hydraulic pumps, description.......1358
Lift_lower function, checking.......1361
Lifting time, checking.......1363
Servo accumulator, installing.......1364
Servo accumulator, removing.......1366
Servo pressure, checking and adjusting.......1368
Servo system, description.......1371
Servo system, specifications.......1375
Servo valve, control, adjusting.......1376
Servo valve, description.......1379
Shock valve lift function, checking.......1381
Shock valve, tilt function, checking.......1384
Tilt, checking.......1389
Working hydraulic system, component location.......1390
Working hydraulic system, description.......1392
92 - MECHANICAL EQUIPMENT_ATTACHMENT.......1399
Attachment locking, checking.......1399
Hydraulic attachment bracket, description.......1401
99 - MISCELLANEOUS.......1405
Explanations to hydraulic diagram.......1405
Hydraulic diagram, basic machine - Image.......1414
Hydraulic diagram, basic machine.......1415
Hydraulic diagram, complete - Image.......1418
Hydraulic diagram, complete.......1419
Volvo L60G, L60G Z Wheel Loaders Service Repair Manual
