Volvo L250H Wheel Loaders Service Repair Manual
Complete service repair manual with electrical wiring diagrams for Volvo L250H Wheel Loaders, with all the workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions L250H Wheel Loaders workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Total Pages: 3,401
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; WHEEL_TRACK UNIT
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM
0 - Foreword....2
0 - GENERAL....3
03 - SPECIFICATIONS....4
Tightening torques....5
Conversion tables....16
07 - STANDARD TIME....20
Operation numbers for additional work....21
08 - TOOL....23
E1680; Holder....24
E 1708; Checking point....26
E1711....28
E-2001....30
E-2005....32
E-2007....34
E-2014....36
E-2015....38
E-2016....40
E-2017....42
E-2018....43
Infrared Thermometer....45
Leak detector 951 1207; description....49
88830268 User Instruction....53
88830557 User Instruction....55
1 - STANDARD PARTS; SERVICE....65
16 - LUBRICANT; FUEL; OTHER FLUID....66
AdBlue®_DEF....67
Coolant....73
Recommended lubricants_{11-18-20}....75
Recommended lubricants_{11-18-01}....80
Alternative fuels....84
17 - SERVICE....87
Service....90
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 100 hours....96
Maintenance service; first 1000 hours....97
Maintenance service; every 50 hours....98
Maintenance service; every 250 hours....99
Maintenance service; every 500 hours....100
Maintenance service; every 1000 hours....102
Maintenance service; every 2000 hours_{11-13-22}....105
Maintenance service; every 2000 hours_{11-13-06}....109
Maintenance service; every 4000 hours_{11-12-32}....113
Maintenance service; every 4000 hours_{11-12-16}....117
Maintenance service; every 4500 hours....121
Maintenance service; every 6000 hours_{11-10-56}....123
Maintenance service; every 6000 hours_{11-10-40}....125
Maintenance service; every 8000 hours....127
Service position 1....128
Service position 2....131
Restoring of the machine....134
Lubrication; every 50 hours....135
Lubrication; every 250 hours....137
Lubrication; every 500 hours....139
Lubrication; every 1000 hours....141
Hinge; lubricating....143
Basic service....147
Engine belt condition; checking....148
Valves; adjusting_{11-06-08}....150
Engine oil level; checking....168
Engine oil and filter; changing_{11-04-47}....169
Engine oil and filter; changing_{11-04-29}....172
Fuel filters; replacing....175
Extra fuel prefilter; replacing....178
Fuel tank breather filter; replacing_{11-03-05}....180
Fuel tank breather filter; replacing_{11-02-47}....182
Air drier cartridge; replacing....184
Air drier filter; replacing....186
Diesel particulate filter; checking and cleaning....189
AdBlue®_DEF tank breather filter; replacing....196
Engine air cleaner primary filter; replacing_{11-00-49}....198
Engine air cleaner primary filter; replacing_{11-00-31}....201
Engine air cleaner secondary filter; replacing....204
Oil-bath air cleaner reservoir oil; checking....207
Oil-bath air cleaner reservoir oil; changing....210
Oil-bath air cleaner reservoir filter insert; cleaning....213
Coolant level; checking....215
Coolant; changing....217
Coolant freezing point; checking....220
Coolers; cleaning....223
Venturi tube; checking....225
MATRIS and Tech Tool; reading....229
Software update; checking....230
Battery; checking....234
Transmission; calibrating....235
Transmission oil level; checking....236
Transmission oil; filter and suction strainer; changing and cleaning....238
Transmission breather filter; replacing....241
Drive axle oil; changing....242
Rear axle bearing oil; changing....245
Rear axle pivot bearing; greasing....247
Axle breather filters; replacing....249
Service brake disc wear; checking....251
Service brake; testing....254
Brake pressure and function; checking....256
Axle oil cooler filter; replacing_{10-52-04}....257
Axle oil cooler filter; replacing_{10-51-47}....260
Parking brake function; checking....263
Tyre wear and air pressure; checking....264
Alternative exit; checking....266
Cab prefilter; replacing....268
Cab main filter; replacing....270
Cab extra prefilter cyclone type; replacing....272
Hydraulic oil level; checking....274
Hydraulic oil; changing....275
Hydraulic oil tank breather filter; replacing....277
Hydraulic tank sediment; draining....278
Hydraulic tank return oil filter and magnetic rod; cleaning and replacing_{10-47-42}....280
Hydraulic tank return oil filter and magnetic rod; cleaning and replacing_{10-47-25}....282
Hydraulic pressure; checking....285
Boom suspension accumulator; checking....288
Fire suppression system; checking....293
Automatic central lubrication filter; replacing....313
Parking brake; manually releasing....315
Towing....317
19 - GENERAL....319
Working on the electrical system of the machine....320
CE-marking; EMC-directive....322
Safety concerns everybody!....324
Checking function....325
Safety when handling the machine....326
Safety rules when servicing....330
Service position 2_{04-42-32}....333
Service position 1_{04-41-47}....335
Working under raised boom....337
Fire prevention measures....339
Some simple rules regarding tyre handling....342
Safety when lifting and supporting complete machine....344
Safety when working with batteries....348
Starting with booster batteries....350
Safety when handling oils and fuel....352
Safety when working on hydraulic systems....353
Checklist after a fire or heat exposure....355
Health hazards with paint; plastics and rubber....356
Environmental handling for the future....358
Waste handling....359
Environmentally safe handling....360
Environmentally hazardous fluids....362
Safety when working with air conditioning refrigerant....363
Working in environmentally contaminated areas....365
Decontamination....366
2 - ENGINE WITH MOUNTING AND EQUIPMENT....367
20 - GENERAL....368
Engine; description_{04-02-58}....369
Engine; description_{04-02-22}....373
Engine; description_{04-01-51}....377
Tech Tool; operations_{03-13-46}....381
Tech Tool; operations_{03-13-27}....384
Engine control module (ECM); replacing pre-programmed_{03-12-56}....386
Engine control module (ECM); replacing pre-programmed_{03-11-54}....390
Engine control module (ECM); replacing non-programmed_{03-10-29}....393
Engine control module (ECM); replacing non-programmed_{03-09-22}....397
Engine; capacities_{02-50-07}....400
Engine; capacities_{02-49-49}....402
Engine belts; replacing....404
Engine; reference values....407
21 - ENGINE....410
Cylinder compression; testing....411
Engine; specifications....436
Engine rotation speed sensor (crank shaft); replacing....439
Engine; removing_{12-41-45}....442
Engine; removing_{12-16-41}....456
Engine; installing_{11-47-17}....469
Engine; installing_{11-45-47}....476
Engine; tightening torques....489
Crankcase ventilation; description_{09-55-55}....500
Crankcase ventilation; description_{09-55-09}....506
Crankcase ventilation separator; replacing....509
Rocker arms; replacing....512
Internal Exhaust Gas Recirculation (IEGR); description....514
Valves; adjusting_{09-49-25}....520
Valve cover; removing....534
Valve cover; installing....536
EGR valve (internal); replacing....540
Camshaft setting; checking_{09-31-58}....550
Camshaft setting; checking_{09-30-24}....556
Camshaft; replacing_{09-25-15}....562
Crankshaft front oil seal; replacing_{09-21-40}....578
Crankshaft front oil seal; replacing_{09-20-01}....592
Crankshaft rear oil seal; replacing....606
Oil level sensor; replacing....610
Engine mount rubber cushion; replacing_{09-13-53}....612
Engine mount rubber cushion; replacing_{09-13-06}....626
22 - LUBRICATING SYSTEM....640
Lubrication system; description_{10-28-25}....641
Lubrication system; description_{10-28-43}....648
Lubrication system; description_{10-28-45}....654
Lubrication system; specifications....661
Lubrication oil consumption; checking....662
Lubrication system; component locations_{09-07-29}....665
Lubrication system; component locations_{09-06-52}....670
Lubrication system; tightening torques....674
Lubrication oil pressure; checking with pressure gauge....677
Oil cooler; replacing_{09-04-04}....679
Oil cooler; replacing_{09-03-39}....683
Oil cooler; leakage check....687
23 - FUEL SYSTEM....689
Fuel system; description_{08-59-40}....690
Fuel system; description_{08-58-57}....697
Fuel system; specifications....706
Fuel system; tightening torques....707
Air in fuel system; checking....713
Carbon dioxide in fuel system; checking....717
Fuel system basics; checking....719
Fuel system; component location....721
Fuel system hand pump; replacing....724
Feed pump pressure; checking....728
Feed pump; replacing....730
Fuel system; bleeding....732
Feed pump removed; reconditioning....735
Fuel tank; volume....739
Fuel tank; replacing_{08-50-08}....740
Fuel tank; replacing_{08-49-22}....755
Stall speed; checking....764
Injectors; checking....766
Yoke; injector; checking....775
Injectors; replacing_{08-44-20}....778
Injector sleeves; replacing_{08-41-12}....787
Injector sleeves; replacing_{08-38-45}....796
25 - INLET & EXHAUST SYSTEM....803
Inlet and exhaust system; description_{08-37-09}....805
Inlet and exhaust system; description_{08-36-23}....810
Inlet and exhaust system; specification_{08-35-26}....815
Inlet and exhaust system; specification_{08-35-05}....818
Inlet and exhaust system; component location_{08-34-33}....821
Inlet and exhaust system; component location_{08-34-04}....825
Inlet and exhaust system; tightening torques_{08-33-18}....828
Inlet and exhaust system; tightening torques_{08-32-25}....836
Silencer; removing....842
Silencer; installing....847
Exhaust pipe flexible tube; replacing_{08-29-53}....852
Exhaust pipe flexible tube; replacing_{08-29-29}....857
Auxiliary brake (engine braking); description....860
Exhaust Aftertreatment System; description....861
Exhaust Aftertreatment System; component location....875
Regeneration process; description....881
AdBlue®_DEF tank; volume....886
AdBlue®_DEF tank; replacing....887
AdBlue®_DEF; draining....903
Muffler with console; removing....908
Muffler with console; installing....915
AdBlue®_DEF quality; checking....921
SCR (Selective catalytic reduction) dosing system; checking....924
AdBlue®_DEF pump unit diagnostics; description....929
Exhaust aftertreatment fuel system diagnostics; description....935
DPF (Diesel particulate filter); checking and cleaning....938
ACM (Aftertreatment control module) non-programmed; replacing....943
ACM (Aftertreatment control module) pre-programmed; replacing....945
Compressor; replacing....947
NOx sensor; replacing....951
Inlet throttle; replacing....954
High pressure air system pressure; checking....956
Exhaust aftertreatment system fuel flow; checking....962
Muffler; replacing....965
AdBlue®_DEF pump unit; replacing....971
AdBlue®_DEF pump unit; components; replacing....976
AdBlue®_DEF nozzle; replacing....981
AdBlue®_DEF tank armature; replacing....984
AdBlue®_DEF tank armature; cleaning....986
AdBlue®_DEF tank armature suction filter; replacing....989
Aftertreatment fuel nozzle; replacing....991
Aftertreatment fuel nozzle; cleaning....993
Aftertreatment fuel dosing unit; replacing....994
AdBlue®_DEF hoses; replacing....996
AdBlue®_DEF....999
AdBlue®_DEF tank; cleaning....1001
Air drier cartridge; replacing....1006
Air drier filter; replacing....1008
Turbocharger; inspecting_{08-04-26}....1011
Turbocharger; inspecting_{08-04-02}....1014
Turbocharger; replacing_{08-03-27}....1017
Turbocharger; replacing_{08-02-59}....1026
Variable turbocharger actuator; replacing....1033
26 - COOLING SYSTEM....1038
Cooling system; description_{08-01-18}....1039
Cooling system; description_{08-00-42}....1044
Cooling system; description_{08-00-03}....1050
Cooling system; description_{07-59-32}....1055
Cooling system; specifications....1061
Carbon dioxide in coolant system; checking....1062
Cooling system; component location_{07-57-36}....1064
Cooling system; component location_{07-57-07}....1068
Cooling system; tightening torques....1071
Coolant with anti-freeze and corrosion protection; recommendation....1074
Cooling system pressure; checking....1075
Radiator; replacing....1077
Cooling fan; component location....1088
Cooling fan; description....1091
Reversible cooling fan; description_{07-50-23}....1097
Reversible cooling fan; description_{07-49-59}....1102
Cooling fan motor; description....1107
Cooling fan; tightening torques....1109
Temperature limits for cooling fan speed; specifications_{07-48-21}....1110
Temperature limits for cooling fan speed; specifications_{07-48-01}....1112
Cooling fan rpm; specifications....1115
Fan control valve; seal replacing....1117
Reversible cooling fan; tightening torques....1119
27 - ENGINE CONTROL....1120
ECO - accelerator pedal....1121
28 - IGNITION AND CONTROL SYSTEM....1123
Cable harness O-ring; replacing....1124
29 - MISCELLANEOUS....1134
EGR venturi tube; cleaning....1135
Exhaust Gas Recirculation (EGR); description....1139
Exhaust gas recirculation (EGR); component location....1144
EGR system; tightening torques....1147
EGR cooler; replacing....1149
EGR cooler pressure; testing_{07-39-18}....1159
EGR cooler pressure; testing_{07-38-55}....1164
EGR valve; replacing....1168
EGR venturi tube; replacing....1173
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....1176
30 - GENERAL....1177
Electrical system; work instructions....1185
Electrical system; tightening torques....1187
Electrical system; description....1192
Electronic control system; description_{07-33-52}....1193
Electronic control system; description_{07-31-57}....1201
Electrical system; specifications....1208
Tech Tool; operations ....1209
Limp home function; description....1210
Software parameters; description....1212
General fault diagnosis information....1225
Troubleshooting strategy....1227
Collection of basic data....1228
Conditions when checking....1230
Lead and connector checks....1232
Troubleshooting tools....1236
Tech Tool; operations....1237
AL3201; description and measuring_{07-22-42}....1238
AL3201; description and measuring_{07-21-16}....1241
BB1 Communication bus; description and measuring_{07-19-30}....1244
BB1 Communication bus; description and measuring_{07-17-44}....1249
BB1 Communication bus; description and measuring_{07-15-59}....1254
BB1 Communication bus; description and measuring_{07-14-27}....1258
BB2 Communication bus; description and measuring_{07-12-27}....1263
BB2 Communication bus; description and measuring_{07-10-37}....1268
BB2 Communication bus; description and measuring_{07-08-42}....1273
BB2 Communication bus; description and measuring_{07-07-01}....1278
CU3605; description and measuring....1283
CU6601; description and measuring_{07-03-29}....1285
CU6601; description and measuring_{07-01-13}....1291
CU9901; description and measuring....1297
FX1005; description and measuring....1299
FX1006; description and measuring....1301
FX1007; description and measuring....1304
FX1008; description and measuring....1307
FX1009; description and measuring....1310
FX1024; description and measuring....1313
FX1025; description and measuring....1316
FX1065; description and measuring....1319
FX1066; description and measuring....1322
FX1079; description and measuring_{06-43-54}....1325
FX1079; description and measuring_{06-43-05}....1328
FX1089; description and measuring....1331
HE2501; description and measuring_{06-40-22}....1334
HE2501; description and measuring_{06-39-34}....1337
HE2511; description and measuring....1340
HE2512; description and measuring....1342
Instrument Cluster (IC); description and measuring_{06-36-30}....1344
Instrument Cluster (IC); description and measuring_{06-35-36}....1347
Load Assist; sensor network; description and measuring....1350
MA2301-MA2306; description and measuring....1353
MA2503; description and measuring....1358
MA2517; description and measuring....1360
MA2601; description and measuring....1362
MA2602; description and measuring....1364
MA4603; description and measuring_{09-57-50}....1366
MA4603; description and measuring_{09-56-46}....1369
MA5501; description and measuring....1372
MA5503; description and measuring....1375
MA8701; description and measuring....1377
MA9103; description and measuring....1379
MA9104; description and measuring....1382
MA9114; description and measuring....1385
MO2501; description and measuring....1388
MO2503; description and measuring....1390
MO2507; description and measuring....1392
MO3301; description and measuring....1394
MO3612; description and measuring....1397
MO3613; description and measuring....1399
MO6401; description and measuring....1401
MO8703; description and measuring....1403
MO8707; description and measuring....1406
MO8711; description and measuring....1409
Power supply; ACM (Aftertreatment Control Module); description and measuring....1411
Power supply CCM; description and measuring....1414
Power supply ECM; description and measuring....1416
Power supply GPMECU 1; description and measuring....1418
Power supply GPMECU 2; description and measuring....1420
Power supply GPMECU 3; description and measuring....1422
Power supply HMICU; description and measuring....1424
Power supply SID; description and measuring....1426
Power supply W-ECU; description and measuring....1428
PWM2502; description and measuring....1430
PWM2503; description and measuring....1432
PWM2602; description and measuring....1434
PWM4203; description and measuring....1436
PWM4213 - PWM4218; description and measuring....1438
PWM5202; description and measuring....1442
PWM6601; description and measuring....1444
PWM6602; description and measuring....1446
PWM9101; description and measuring....1448
PWM9102; description and measuring....1450
PWM9103; description and measuring....1452
PWM9104; description and measuring....1454
PWM9105; description and measuring....1456
PWM9106; description and measuring....1458
R2701; description and measuring....1460
RE02; description and measuring....1463
RE03; description and measuring....1465
RE04; description and measuring....1467
RE07; description and measuring....1469
RE08; description and measuring....1471
RE09; description and measuring....1473
RE10; description and measuring....1475
RE11; description and measuring....1478
RE12; description and measuring....1480
RE13; description and measuring....1482
RE14; description and measuring....1484
RE15; description and measuring....1486
RE16; description and measuring_{08-51-10}....1488
RE16; description and measuring_{08-50-42}....1490
RE17; description and measuring_{08-50-03}....1492
RE17; description and measuring_{08-49-35}....1494
RE18; description and measuring_{08-48-56}....1496
RE18; description and measuring_{08-48-25}....1498
RE2301; description and measuring....1501
RE2501; description and measuring_{08-46-23}....1503
RE2501; description and measuring_{08-45-30}....1506
RE2502; description and measuring....1509
RE3102; description and measuring....1511
RE3504; description and measuring....1513
RE3507; description and measuring....1516
RE3524; description and measuring....1518
RE3531; description and measuring....1520
RE3610; description and measuring....1523
RE3705; description and measuring....1525
RE5502; description and measuring....1528
RE6401; description and measuring....1530
RE8712; description and measuring....1532
RF1; description and measuring....1534
SAE J1939-1 SubNet 1; description and measuring....1536
SE2203; description and measuring....1539
SE2301; description and measuring....1541
SE2303; description and measuring....1543
SE2509; description and measuring....1546
SE2510; description and measuring....1548
SE2512; description and measuring....1551
SE2513; description and measuring_{08-23-04}....1553
SE2513; description and measuring_{08-22-17}....1557
SE2514; description and measuring....1561
SE2515; description and measuring....1563
SE2516; description and measuring....1566
SE2519; description and measuring....1569
SE2521; description and measuring....1571
SE2522; description and measuring....1574
SE2533; description and measuring_{08-15-13}....1577
SE2533; description and measuring_{08-14-27}....1581
SE2539; description and measuring....1585
SE2540; description and measuring....1588
SE2542; description and measuring....1591
SE2603; description and measuring....1594
SE2604; description and measuring....1596
SE2606; description and measuring....1598
SE2701; description and measuring....1600
SE2702; description and measuring....1602
SE2703; description and measuring....1605
SE2704; description and measuring....1607
SE4202; description and measuring....1609
SE4203; description and measuring....1611
SE4209; description and measuring....1613
SE4213; description and measuring....1615
SE4218; description and measuring....1617
SE4219; description and measuring....1619
SE4226; description and measuring....1621
SE4227; description and measuring....1623
SE4307; description and measuring....1625
SE4312; description and measuring....1627
SE4609; description and measuring....1629
SE5201; description and measuring....1631
SE5203; description and measuring....1634
SE5222; description and measuring....1636
SE5223; description and measuring....1638
SE5501; description and measuring....1640
SE6404; description and measuring....1642
SE6407; description and measuring....1644
SE6411; description and measuring....1646
SE6601; description and measuring_{07-44-19}....1649
SE6601; description and measuring_{07-42-56}....1655
SE8301; description and measuring....1660
SE8702; description and measuring....1663
SE8705; description and measuring_{07-39-31}....1665
SE8705; description and measuring_{07-38-54}....1668
SE8706; description and measuring....1671
SE8708; description and measuring....1673
SE8709; description and measuring....1675
SE9116; description and measuring....1677
SE9117; description and measuring....1680
SE9119; description and measuring....1683
SE9147; description and measuring....1686
SE9148; description and measuring....1689
SE9482; description and measuring....1692
SE9483; description and measuring....1694
SE9484; description and measuring....1696
SE9485; description and measuring....1698
SE9486; description and measuring....1700
SE9901; description and measuring....1702
SW2506; description and measuring....1704
SW3630; description and measuring....1706
SW3701; description and measuring....1708
SW3801; description and measuring....1711
SW4205_SW4206; description and measuring....1713
SW4208; description and measuring....1716
SW4209; description and measuring....1718
SW4210; description and measuring....1720
SW4211; description and measuring....1722
SW4217; description and measuring....1724
SW4219; description and measuring....1726
SW4220; description and measuring....1728
SW4222; description and measuring....1730
SW5501; description and measuring....1732
SW8701; description and measuring....1735
SW9144; description and measuring_{07-10-52}....1737
SW9144; description and measuring_{07-10-24}....1739
SW9148; description and measuring....1741
SW9149; description and measuring....1743
SW9174; description and measuring....1745
SW9175; description and measuring_{07-07-14}....1747
SW9175; description and measuring_{07-06-39}....1749
31 - BATTERY....1752
System voltage....1753
Key feed....1754
Battery; description....1755
Battery; weight....1756
Battery; specifications....1757
Battery condition; checking....1758
Battery; charging....1761
Batteries; replacing....1763
32 - ALTERNATOR; CHARGE REGULATOR....1765
Alternator 80 A; specification....1766
Alternator; description....1767
Alternator 80 A; description....1771
33 - STARTING SYSTEM....1772
Starter motor; specifications....1773
Starter motor; description....1774
Starter motor; tightening torques....1776
Booting sequence....1777
Starter motor; replacing_{06-58-16}....1778
Starter motor; replacing_{06-57-54}....1781
Preheating; specifications....1783
Preheating; description....1784
Starter lock; replacing....1786
35 - LIGHTING....1788
Lighting; specifications....1789
36 - OTHER ELECTRICAL EQUIPMENT....1790
Intermittent wiper and washer....1791
Connectors; position....1797
Connectors; overview....1809
GPMECU1 non-programmed; replacing....1813
GPMECU1 pre-programmed; replacing....1815
GPMECU2 non-programmed; replacing....1817
GPMECU2 pre-programmed; replacing....1819
GPMECU3 non-programmed; replacing....1821
GPMECU3 pre-programmed; replacing....1823
HMICU non-programmed; replacing....1825
HMICU pre-programmed; replacing....1828
Hood opening....1830
37 - CABLE; FUSE; RELAY....1832
Electrical symbols and designations....1837
Cable and component designations....1840
Cable and component marking explanations....1842
Components list....1844
ACM; I_O list....1856
CCM; I_O list....1859
ECM (Engine Control Module); I_O list_{06-42-44}....1861
GPMECU1; I_O list....1865
GPMECU2; I_O list....1869
GPMECU3; I_O list....1873
HMICU; I_O list....1877
W-ECU; I_O list....1879
Table of contents; wiring diagrams....1880
Wiring diagram - CDC....1883
Wiring diagram - Start....1887
Wiring diagram - Aftertreatment_{06-38-53}....1890
Wiring diagram - Aftertreatment_{06-38-12}....1896
Wiring diagram - Brake....1901
Wiring diagram - BSS....1905
Wiring diagram - Electrically controlled battery disconnector - Key operated; with emergency stop....1908
Wiring diagram - Electrically controlled battery disconnector - Manual; with emergency stop....1912
Wiring diagram - Electrically controlled battery disconnector - Manual; without emergency stop....1915
Wiring diagram - Gear....1919
Wiring diagram WD201....1922
Wiring diagram WD202....1926
Wiring diagram WD208....1929
Wiring diagram WD210....1932
Wiring diagram WD211....1935
Wiring diagram WD212....1939
Wiring diagram WD214_{06-31-45}....1943
Wiring diagram WD214_{06-31-19}....1947
Wiring diagram WD220....1951
Wiring diagram WD221_{06-30-18}....1954
Wiring diagram WD221_{06-29-55}....1960
Wiring diagram WD223....1965
Wiring diagram WD224....1968
Wiring diagram WD275....1971
Wiring diagram WD301_{06-27-49}....1974
Wiring diagram WD301_{06-27-27}....1978
Wiring diagram WD302....1982
Wiring diagram WD303....1986
Wiring diagram WD304_{06-25-59}....1989
Wiring diagram WD304_{06-25-36}....1993
Wiring diagram WD305....1998
Wiring diagram WD306_{06-24-36}....2001
Wiring diagram WD306_{06-24-13}....2004
Wiring diagram WD320_{06-23-35}....2007
Wiring diagram WD320_{06-23-13}....2010
Wiring diagram WD321_{06-22-39}....2013
Wiring diagram WD321_{06-22-15}....2016
Wiring diagram WD322_{06-21-41}....2019
Wiring diagram WD322_{06-21-18}....2022
Wiring diagram WD324_{06-20-38}....2026
Wiring diagram WD324_{06-20-15}....2030
Wiring diagram WD325....2034
Wiring diagram WD326....2037
Wiring diagram WD327....2040
Wiring diagram WD330....2044
Wiring diagram WD331....2048
Wiring diagram WD333....2052
Wiring diagram WD334....2056
Wiring diagram WD335_{06-16-18}....2060
Wiring diagram WD335_{06-15-55}....2063
Wiring diagram WD337....2066
Wiring diagram WD350....2070
Wiring diagram WD351....2073
Wiring diagram WD352....2076
Wiring diagram WD360_{06-13-17}....2079
Wiring diagram WD360_{06-12-54}....2082
Wiring diagram WD360_{06-12-32}....2085
Wiring diagram WD361....2088
Wiring diagram WD362....2091
Wiring diagram WD363....2094
Wiring diagram WD371_{06-10-38}....2097
Wiring diagram WD371_{06-10-15}....2100
Wiring diagram WD372....2103
Wiring diagram WD373_{06-09-08}....2106
Wiring diagram WD373_{06-08-46}....2109
Wiring diagram WD374_{06-08-12}....2112
Wiring diagram WD374_{06-07-49}....2115
Wiring diagram WD375....2118
Wiring diagram WD376....2121
Wiring diagram WD401....2124
Wiring diagram WD402....2127
Wiring diagram WD403....2130
Wiring diagram WD404....2133
Wiring diagram WD405....2137
Wiring diagram WD406....2141
Wiring diagram WD501....2144
Wiring diagram WD601_{06-02-56}....2148
Wiring diagram WD601_{06-02-33}....2151
Wiring diagram WD602_{06-01-55}....2154
Wiring diagram WD602_{06-01-32}....2157
Wiring diagram WD604....2160
Wiring diagram WD801....2163
Wiring diagram WD802_{05-59-48}....2167
Wiring diagram WD802_{05-59-25}....2171
Wiring diagram WD804....2175
Wiring diagram WD805....2179
Wiring diagram WD806....2183
Wiring diagram WD807....2187
Wiring diagram WD808....2191
Wiring diagram WD831....2195
Wiring diagram WD901....2198
Wiring diagram WD902....2201
Wiring diagram WD903....2204
Wiring diagram WD904_{05-53-36}....2208
Wiring diagram WD904_{05-53-14}....2211
Wiring diagram WD908-[5218]....2214
Wiring diagram WD908....2217
Wiring diagram WD909....2220
Wiring diagram WD910....2224
Wiring diagram WD911_{05-50-18}....2227
Wiring diagram WD911_{05-49-56}....2230
Wiring diagram WD912....2233
Wiring diagram WD913_{05-48-55}....2236
Wiring diagram WD913_{05-48-33}....2239
Wiring diagram WD915_{05-46-05}....2243
Wiring diagram WD915_{05-45-43}....2246
Battery disconnect switch; description....2249
Electrical distribution box; description....2252
Chassis connection....2264
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....2266
Rear vision system....2267
Information display; general....2270
Information display; service mode....2274
Volvo Co-Pilot; description_{05-41-18}....2276
Volvo Co-Pilot; description_{05-40-56}....2280
Volvo Co-Pilot; description_{05-40-29}....2282
Volvo Co-Pilot; description_{05-40-07}....2286
Volvo Co-Pilot; component location....2288
Volvo Co-Pilot; specifications....2289
Volvo Co-Pilot; tightening torques....2290
Volvo Co-Pilot application; installing....2291
Volvo Co-Pilot; replacing....2293
Volvo Co-Pilot SIM card; installing_{05-37-25}....2295
Volvo Co-Pilot SIM card; installing_{05-36-54}....2302
USB tethering....2305
Volvo Co-Pilot Android software; updating online (OtA)_{05-35-54}....2309
Volvo Co-Pilot Android software; updating online (OtA)_{05-35-36}....2312
Volvo Co-Pilot; software updating....2314
Reverse warning system; description....2317
39 - MISCELLANEOUS....2321
CareTrack W-ECU; description....2322
W-ECU; replacing; non-programmed....2326
W-ECU; replacing; pre-programmed....2328
4 - POWER TRANSMISSION....2330
40 - GENERAL....2331
Tech Tool; operations_....2332
Drivetrain; component location....2334
Error codes when calibrating....2336
Front and rear axles; volume....2342
42 - TRANSMISSION; HYDRAULIC CONTROL....2343
Hydraulic diagram transmission - Image....2344
Transmission; component location....2345
Transmission; specifications ....2350
Hydraulic transmission; capacity....2352
Transmission; tightening torques....2353
Hydraulic transmission; description....2355
Hydraulic transmission calibration; description....2366
Hydraulic transmission; warming up....2369
Transmission; specifications....2370
Transmission; removing....2372
Transmission; installing....2382
Hydraulic diagram transmission....2391
Lock up valve; replacing....2394
Transmission oil pressure; checking....2399
Gear selector valve; replacing one solenoid....2405
Transmission; function check....2408
Transmission; calibration....2410
45 - PROPELLER SHAFT....2412
Propeller shaft; tightening torque....2413
Propeller shaft; component description....2414
46 - FRONT AXLE; REAR AXLE....2415
Drive axles; description....2416
Front and rear axles; tightening torque....2421
Front and rear axles; specifications....2423
Front axle; component description....2424
Rear axle; component description....2425
Rear axle mounting; component description....2426
Front and rear axles; volume....2429
Automatic differential brake; Limited Slip; description....2430
Rear axle mounting; volume....2433
Hub seal; replacing ....2434
Hub reduction; removing ....2448
Hub reduction; installing ....2451
Axle; removing....2454
Axle suspension; replacing bushes and seals....2456
Axle suspension; tightening torque....2467
Axle; installing....2468
Hub reduction; removing....2471
Hub reduction; installing....2474
Hub seal; replacing....2477
Differential lock; description_{07-25-54}....2493
Differential lock; description_{07-25-35}....2498
Differential lock; adjusting....2503
Differential lock; function check....2508
49 - MISCELLANEOUS....2509
Oil cooler; component location....2510
Heat exchanger; replacing....2511
5 - BRAKE....2516
50 - GENERAL....2517
Tech Tool; operations....2518
51 - WHEEL BRAKE....2519
Wheel brake; specification....2520
Brake discs; measuring wear....2521
Front wheel brake; tightening torque....2524
Brake discs; replacing....2525
Brake piston seals; replacing ....2530
Brake disc; replacing....2534
Brake piston seals; replacing....2539
52 - HYDRAULIC BRAKE SYSTEM....2542
Brake system; component location....2543
Braking system; description....2545
Brake system; specifications....2555
Brake system circuit pressure; checking and adjusting....2556
Brake system; bleeding....2558
Brake system retardation function; checking....2560
Automatic brake function; checking....2561
Brake system charging; checking....2562
Axle oil cooler; component location....2566
Axle oil cooler; description....2568
Foot brake valve; description....2571
Automatic brake valve; description....2572
Brake accumulator; description....2573
Brake accumulator; specifications....2575
Accumulator (removed) charging pressure; checking....2576
Accumulator; removing....2578
Accumulator; installing....2580
Accumulators; checking in machine....2582
6 - STEERING....2584
60 - GENERAL....2585
Tech Tool; operations....2586
Steering system; component location....2587
Steering system; description....2589
Steering system function; checking....2597
Lever steering CDC; tightening torques....2599
64 - STEERING....2600
Steering; specifications....2601
Steering cylinder; description....2602
Steering valve; description....2604
Steering cylinder; tightening torque....2605
Shift valve; description....2606
Steering system working pressure; checking and adjusting....2608
Left steering cylinder; removing....2611
Right steering cylinder; removing....2615
Left steering cylinder; installing....2620
Right steering cylinder; installing....2625
Steering accumulator; removing....2630
Steering accumulator; installing....2632
Accumulator; discarding....2634
Steering accumulator removed; checking....2636
Secondary steering pump; specifications....2638
Secondary steering; component location....2639
Secondary steering; description....2641
Pressure monitor; description....2645
Secondary steering pump working pressure; checking and adjusting....2646
66 - LEVEL STEERING....2649
Comfort Drive Control (CDC); description....2650
CDC valve; lever steering; description....2657
Lever steering (CDC); specifications....2659
Comfort Drive Control (CDC); component location....2660
Comfort drive control (CDC) angle sensor; changing....2662
Comfort Drive Control; servo pressure; checking....2666
Comfort Drive Control (CDC) joystick; changing....2668
Comfort drive control (CDC) solenoid valve; changing....2673
Lever steering (CDC) function; checking....2675
Calibration of Comfort Drive Control (CDC); function description....2678
Calibration of Comfort Drive Control (CDC); specification....2683
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....2684
70 - GENERAL....2685
Frame; description....2686
Counterweight; tightening torques....2689
71 - FRAME....2690
Counterweight; tightening torques....2691
Counterweight; weight....2692
Counterweight; removing....2694
Counterweight; installing....2697
74 - FRAME LINK....2699
Frame joint; tightening torques....2700
Frame joint; description....2701
Frame joint; replacing bearings....2703
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....2731
Wheel; tightening torque....2732
Rear wheel; removing....2733
Rear wheel; installing....2736
Front wheel; removing....2739
Front wheel; installing....2742
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....2745
80 - GENERAL....2746
Cab; description....2747
Air conditioning; tightening torques ....2749
Tech Tool; operations....2750
81 - CAB; NAKED; CANOPY....2751
Cab; position 1....2752
Cab; position 1; restoring....2756
Cab; position 2....2759
Cab; position 2; restoring....2765
Cabin; tightening torques....2770
Cab tilt cylinder; replacing....2771
Viscous cab suspension; description....2780
Viscous cab suspension; changing one unit....2782
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....2785
Plastic hood; repairing....2786
Engine hood; raising and securing....2791
Actuator; replacing....2793
83 - DOORS; HATCH; COVER PLATE; (all)....2797
Electric door opener; description....2798
Electric door opener; control unit; replacing....2802
Electric door opener; locking motor; replacing....2804
Electric door opener; rotor switch; replacing....2806
Electric door opener; opening support motor; replacing....2808
Door lock cylinder; replacing_{08-11-32}....2810
Door lock cylinder; replacing_{08-11-13}....2818
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....2826
Windows; general....2827
Side window; replacing_{08-10-20}....2828
Windscreen; replacing_{08-10-01}....2838
Window pane; installing....2848
Windows; general; gluing....2852
85 - CAB INTERIOR; UPHOLSTERY....2854
Operator seat; tightening torques....2855
Operator's seat; securing....2860
Driver seat; component description_{08-07-43}....2862
Driver seat; component description_{08-07-25}....2865
Driver seat; component description_{08-07-07}....2868
Driver seat; component description_{08-06-49}....2871
87 - AIR CONDITIONING UNIT....2874
CCM; replacing....2875
Climate control system; description....2879
Climate unit; removing....2884
Climate unit; installing....2893
Pause heater; description....2899
Fan motor; replacing....2901
Air mix door actuator; replacing....2903
Heater core; replacing....2908
Heat control valve; replacing....2910
Air conditioning; tightening torques....2914
Air conditioning; specifications....2915
Air conditioning; refrigerant; weight....2917
Air conditioning; checking performance....2918
Cooling unit; leak detection....2920
Drying filter; replacing....2922
Condenser; replacing....2926
Compressor; replacing....2931
Evaporator; replacing....2936
Expansion valve; replacing....2944
Air conditioning; function description....2955
Air conditioning; component location....2958
Refrigerant; draining....2960
Refrigerant; filling incl vacuum pumping....2962
Troubleshooting; air conditioning unit (AC)....2965
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....2968
90 - GENERAL....2969
Hydraulic diagram; complete - Image....2970
Hydraulic diagram; basic machine - Image....2978
Explanations to hydraulic diagram....2979
Hydraulic components; cleanliness when handling....2986
Hydraulic diagram; complete_{009-20-22}....2987
Hydraulic diagram; complete_{009-20-03}....2991
Hydraulic diagram; basic machine....2995
Hydraulic system; volume....2999
Hydraulic system; bleeding....3000
Hydraulic system; warming up....3002
Tech Tool; Operations....3004
Control valve; tightening torques....3006
3th_4th hydraulic function; tightening torques....3007
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....3009
Calibration of working hydraulics; specifications....3012
Error codes when calibrating....3015
Hydraulic oil tank; description....3021
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump....3022
Hydraulic connections; tightening torques....3024
Hydraulic couplings....3025
Pressure back-up valve; replacing....3028
Working hydraulic system; component location....3031
Working hydraulic system; description....3034
Control valve; description....3044
Central valve; description....3048
Control valve; specifications....3050
Back-up valve; checking and adjusting....3051
Shock valve lift function; checking....3053
Shock valve; tilt function; checking....3056
Lift; solenoid valve; changing....3059
Lower; solenoid valve; changing....3061
Tilt in; solenoid valve; changing....3063
Tilt out; solenoid valve; changing....3065
Lift_lower; angle sensor; changing_{009-08-51}....3067
Lift_lower; angle sensor; changing_{009-08-32}....3072
Tilt in_out; angle sensor; changing_{009-08-05}....3077
Tilt in_out; angle sensor; changing_{009-07-46}....3085
Tilt; checking....3091
Lift_lower function; checking....3092
Calibration of lift_ lower function; description....3096
Calibration of tilt in_out function; description....3101
Hydraulic pumps; description....3106
Hydraulic pump flow regulation; description....3110
Hydraulic pump (P001); specifications....3114
Hydraulic pump (P002); specifications....3115
Hydraulic pump (P003); specifications....3116
Function times; specifications....3117
Hydraulic pumps; tightening torques....3119
Hydraulic pump; standby pressure and working pressure; checking and adjusting....3120
LS (load sense) pressure; checking....3125
Hydraulic pump P001; removing....3128
Hydraulic pump P001; installing....3131
Hydraulic pump P002; removing....3134
Hydraulic pump P002; installing....3137
Hydraulic pump P003; removing....3141
Hydraulic pump P003; installing....3146
Hydraulic pump P003; checking....3150
Servo system; specifications....3154
Servo system; description....3155
Lever control; electric servo; description....3159
Servo pressure; checking and adjusting....3162
Accumulator removed; checking....3165
Servo accumulator; removing....3167
Servo accumulator; installing....3169
Accumulator; discarding....3171
Boom suspension system; component location....3173
Boom Suspension System; component description....3175
Boom Suspension System; description....3177
3th_4th hydraulic function; description_{08-55-08}....3184
3th_4th hydraulic function; description_{08-54-49}....3189
Boom Suspension System; specifications....3195
Boom Suspension System; tightening torques....3196
3th_4th hydraulic function; specifications....3197
Boom suspension accumulator; checking and adjusting....3199
Boom suspension system; right accumulator; removing....3203
Boom suspension system; right accumulator; installing....3207
Boom suspension system; left accumulator; removing....3211
Boom suspension system; left accumulator; installing....3215
Boom suspension system; hydraulic oil pressure in accumulators; depressurizing....3219
Boom suspension system; pressure reduction; safety valve; checking and adjusting....3222
Accumulator; boom suspension system; discarding....3224
Boom suspension accumulator; reconditioning....3226
3th_4th hydraulic function; pressure; checking and adjusting....3228
3th_4th hydraulic function; solenoid valve; replacing....3231
3th_4th hydraulic function; shock valve; checking....3233
Boom suspension system; checking....3236
Calibration of 003rd_4th hydraulic function; description....3241
94 - UNIT; LOAD HANDLING....3244
Lifting cylinder; description....3245
Hydraulic cylinder; piston's lock brace; installing....3247
Tilt cylinder; description....3249
Lift cylinder; tightening torques....3251
Tilt cylinder; tightening torques....3252
Lift cylinder; repacking in machine....3254
Tilt cylinder; repacking in machine....3262
Load Assist; description....3270
Load Assist; tightening torques....3275
Load Assist; reference values....3276
Load Assist; front frame position sensor bracket; replacing....3278
Load Assist; position sensors; replacing_{008-43-20}....3279
Load Assist; position sensors; replacing_{008-43-03}....3282
Load Assist; lifting arm position sensor; bracket; replacing....3285
Load Assist; GDF linkage position sensor bracket; replacing....3286
Load Assist; pressure sensor; lift- and lower function; replacing....3289
Calibration of Load Assist; lifting arm position sensor....3291
Calibration of Load Assist; front frame position sensor....3293
Calibration of Load Assist; GDF-linkage position sensor....3296
Load Assist; component location....3298
99 - MISCELLANEOUS....3300
Fire Suppression System; tightening torques....3301
Fire suppression system; specification....3302
Fire suppression system; component location....3303
Fire suppression system; functional description....3305
Fire suppression system; component description....3311
Fire suppression system; actions after manual activation....3317
Fire suppression system; actions after activation....3338
Central lubrication system; description....3357
Pump unit; description....3361
Shift valve; description....3364
Pressure monitor; description....3365
Dosage valves; description....3366
Automatic lubrication system; specifications....3369
Recommended lubricants....3370
Lubrication points; central lubrication....3371
Z-Linkage bearing points....3375
Diagnostic tools; description....3376
Parameter settings....3378
Software; parameter settings and read-outs....3380
Automatic lubrication pump unit; reconditioning....3386
Filling lubricant....3406
Bleeding air....3408
Change of lubrication interval....3412
System test....3413
Update of automatic lubrication system....3415
Volvo L250H Wheel Loaders Service Repair Manual
