Volvo L60G Wheel Loader Service and Repair Manual PDF

Size: 166.41 MB
Language: English
Make: Volvo
Machine: Wheel Loader
Document: Service and Repair Manual, Hydraulic and Electrical Diagram
Model: Volvo L60G

US $50
Categories: Manual,Heavy Equipment
Brands: Volvo

Description

Volvo L60G Wheel Loader Service and Repair Manual PDF

Size: 166.41 MB
Language: English
Make: Volvo
Machine: Wheel Loader
Document: Service and Repair Manual, Hydraulic and Electrical Diagram
Model: Volvo L60G
Page: 5424 Pages

Detail Contents:
Volvo L60G
Description

  • 3rd 4th hydraulic function, valve, description
    3rd, or 3rd 4th hydraulic function, component location
    3rd, or 3rd 4th hydraulic function, description
    Air conditioning, tightening torques
    Alternator, description
    Automatic differential brake, Limited Slip, description
    Auxiliary brake (engine braking), description
    Battery disconnector switch, description
    Battery, charging
    Battery, description
    Boom Suspension System, component description
    Boom suspension system, component location
    Boom Suspension System, description
    Booting sequence
    Brake accumulator, description
    Brake system, component location
    Braking system, description
    Cab and air conditioning
    Cab, description
    CareTrack W-ECU, description
    CDC valve, lever steering, description
    Central lubrication system, description
    Central valve, description
    Change of lubrication interval
    Climate control system, description
    Comfort Drive Control (CDC), component location
    Comfort Drive Control (CDC), description
    Communication with data buses
    Component locations
    Connectors, overview
    Connectors, position
    Control valve, description
    Cooling fan motor, description
    Cooling fan, component location
    Cooling fan, description
    Cooling system, component location
    Cooling system, description
    Crankcase ventilation, description
    Diagnostic tools, description
    Differential lock, description
    Dosage valves, description
    Drive axles, description
    Drivetrain, component location
    ECO – accelerator pedal
    Electric door opener, description
    Electric welding
    Electrical symbols and designations
    Electrical system, description
    Electrical system, work instructions
    Electronic control system, description
    Engine control unit E-ECU, description
    Engine, description
    Exhaust Aftertreatment System, component location
    Exhaust Aftertreatment System, description
    Exhaust gas recirculation (EGR), component location
    Filling lubricant
    Fire suppression system, component description
    Foot brake valve, description
    Frame joint, description
    Frame, description
    Front axle, component description
    Fuel system, component location
    Fuel system, description
    Hood opening
    Hydraulic attachment bracket, description
    Hydraulic oil tank, description
    Hydraulic pump flow regulation, description
    Hydraulic pumps, description
    Hydraulic transmission, description
    Inlet and exhaust system, component location
    Inlet and exhaust system, description
    Instrument panels
    Intermittent wiper and washer
    Key feed
    Leak detector 951 1207, new model
    Lighting, description
    Lubricating system, description1
    Lubricating system, description2
    Lubrication system, component locations
    Middle instrument panel with warning lights
    Oil cooler, component description
    Parameter settings
    Parking brake, component location
    Parking brake, function description
    Pause heater, description
    Preheating, description
    Pressure monitor, description
    Propeller shaft, component description
    Pump unit, description
    Rear axle mounting, component description
    Rear axle, component description
    Regeneration process, description
    Reversible cooling fan, description
    Secondary steering, component location
    Secondary steering, description
    Service
    Servo system, description
    Servo valve, description
    Shift valve, description
    Software, description
    Steering cylinder, description
    Steering system, component location
    Steering system, description
    Steering valve, description
    System voltage
    TP-Linkage’s bearing points
    Transmission, component position
    Troubleshooting, air conditioning unit (AC)
    Turbocharger, description
    VCADS Pro, Operations
    Vehicle control unit V2-ECU, description
    Vehicle control unit V-ECU, description
    Viscous cab suspension, description
    Windows, general, gluing
    Windows, general
    Working hydraulic system, component location1
    Working hydraulic system, component location2
    Working hydraulic system, description

Diagrams

  • Explanations to hydraulic diagram
    Hydraulic diagram transmission
    Hydraulic diagram, complete Figure 1
    Hydraulic diagram, complete
    Table of contents, wiring diagrams
    Wiring diagram – Aftertreatment
    Wiring diagram – Brake1
    Wiring diagram – Brake2
    Wiring diagram – BSS
    Wiring diagram – Electrically controlled battery disconnector
    Wiring diagram – Gear
    Wiring diagram – Start
    Wiring diagram WD201
    Wiring diagram WD202
    Wiring diagram WD260
    Wiring diagram WD261
    Wiring diagram WD262
    Wiring diagram WD263
    Wiring diagram WD264
    Wiring diagram WD265
    Wiring diagram WD266
    Wiring diagram WD267
    Wiring diagram WD301
    Wiring diagram WD302
    Wiring diagram WD303
    Wiring diagram WD304
    Wiring diagram WD306
    Wiring diagram WD308
    Wiring diagram WD320
    Wiring diagram WD321
    Wiring diagram WD322
    Wiring diagram WD323
    Wiring diagram WD324
    Wiring diagram WD325
    Wiring diagram WD326
    Wiring diagram WD330
    Wiring diagram WD331
    Wiring diagram WD333
    Wiring diagram WD334
    Wiring diagram WD335
    Wiring diagram WD337 Update G
    Wiring diagram WD350
    Wiring diagram WD351
    Wiring diagram WD352
    Wiring diagram WD360
    Wiring diagram WD361
    Wiring diagram WD362
    Wiring diagram WD363 Update G
    Wiring diagram WD363
    Wiring diagram WD371
    Wiring diagram WD372
    Wiring diagram WD373
    Wiring diagram WD374
    Wiring diagram WD375
    Wiring diagram WD376
    Wiring diagram WD401
    Wiring diagram WD402
    Wiring diagram WD403
    Wiring diagram WD404
    Wiring diagram WD405
    Wiring diagram WD406
    Wiring diagram WD501
    Wiring diagram WD601
    Wiring diagram WD602
    Wiring diagram WD604
    Wiring diagram WD801
    Wiring diagram WD802
    Wiring diagram WD804
    Wiring diagram WD805
    Wiring diagram WD806
    Wiring diagram WD807
    Wiring diagram WD808
    Wiring diagram WD831 Update G
    Wiring diagram WD901
    Wiring diagram WD902
    Wiring diagram WD904
    Wiring diagram WD905
    Wiring diagram WD906
    Wiring diagram WD911
    Wiring diagram WD913
    Wiring diagram WD915 Update G

Installation Instruction

  • 3rd 4th hydraulic function, installing new
    3rd hydraulic function, installing new
    After market engine, transfer of components
    Anti theft device, installing new
    Attachment locking, installing new
    Back up alarm, installing new
    Battery disconnector switch, installing new
    Boom suspension system, installing new
    Cab front work light LED, installing new
    Cab illuminated entrance LED, installing new
    Cab rear work light LED, installing new
    Cab side work light LED, installing new
    Cab, air pre cleaner, installing new
    CareTrack, installing new
    Engine heater 120V, installing new
    Engine heater 240V, installing new
    Forward view camera, installing new
    Front work light LED, installing new
    Fuel filter extra, installing new
    Grill work light LED, installing new
    Hand throttle, instaling new
    Lever steering (CDC), electric, installing new
    Pre-cleaner cyclone type, installing new
    Pre-cleaner oil bath type, installing new
    Pre-cleaner turbo type, installing new
    Protection for lighting, front, installing new
    Radio, installing new1
    Radio, installing new2
    Radio, installing new3
    Rear view camera, installing new
    Rear view mirror, installing new
    Reversible fan, installing new
    Rotating beacon, installing new
    Single lever control, installing new
    Wind shield guard, installing new
    Work light front, installing new
    Work light rear, installing new1
    Work light rear, installing new2

Repair

  • 3rd 4th hydraulic function, checking and adjusting pressure
    3rd 4th hydraulic function, shock valve, checking
    3rd 4th hydraulic, functional check
    Accelerator pedal, replace
    Accumulator removed, checking charging pressure
    Accumulator removed, checking
    Accumulator, boom suspension system, discarding
    Accumulator, discarding
    Accumulator, discarding1
    Accumulator, installation
    Accumulator, removal
    Accumulators, checking in machine
    ACM (After treatment control module), replacing, non-programmed
    ACM (After treatment control module), replacing, pre-programmed
    Actuator, replacing
    Air conditioning, checking performance
    Air mix door actuator, replacing
    Air pump, replacing
    Attachment locking, functional check
    Automatic central lubrication, filter, cleaning replacing
    Automatic lubrication pump unit, reconditioning
    Axle suspension, replacing bushes and seals
    Axle, installing
    Axle, removing
    Back-up valve, checking and adjusting
    Back-up valve, replacing
    Batteries, replacing
    Battery condition, check
    Battery, cables and connections, check
    Bleeding air
    Boom suspension accumulator, check and adjusting
    Boom suspension accumulator, reconditioning
    Boom suspension system, functional check
    Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
    Boom suspension system, left accumulator, installation
    Boom suspension system, left accumulator, removal
    Boom suspension system, pressure reduction, safety valve, checking and adjusting
    Brake disc, replacing
    Brake discs, measuring wear
    Brake piston, replacing seals
    Brake system charging, checking
    Brake system, bleeding
    Brake system, check and adjusting pressure in circuit
    Brake system, checking function, retardation
    Burner, replacing
    Cab, extra prefilter, replacing
    Cab, installing
    Cab, main filter, replacing
    Cab, prefilter, replace when required
    Cab, removing
    Carbon dioxide in coolant system, checking
    Carbon dioxide in fuel system, check
    CareTrack battery, replacing
    Charge air cooler, installing
    Charge air cooler, removing
    Climate unit, installing
    Climate unit, removing
    Comfort drive control (CDC), angle sensor, changing
    Comfort drive control (CDC), solenoid valve, changing
    Comfort Drive Control, servo pressure, checking
    Compression test
    Coolant level, checking
    Coolant pump, replacing
    Coolant, change
    Coolant’s freezing point, check
    Cooling system, pressure control
    Counterweight, fitting
    Counterweight, removing
    Crankshaft, replacing front oil seal
    Diesel particulate filter, checking and cleaning
    Differential lock, adjusting
    Differential lock, function check
    Door lock cylinder, replacing
    Drive axles, oil, draining
    Drive axles, oil, filling
    Drive belts, check
    E 1708, Checking point
    E1706
    E1711
    E-2000
    E-2001
    E-2017
    ECC, MID 146, changing non-programmed ECU
    ECC, MID 146, changing pre-programmed ECU
    E-ECU, MID 128, changing non-programmed ECU
    E-ECU, MID 128, changing pre-programmed ECU
    EGR Actuator, replacing
    EGR cooler, cleaning
    EGR cooler, replacing
    EGR pressure sensor, replacing
    EGR reed valve, checking
    EGR reed valve, replacing
    EGR temperature sensor, replacing
    EGR valve, replacing
    EGR Venturi tube, replacing
    Electric door opener, control unit, replacing
    Electric door opener, locking motor, replacing
    Electric door opener, opening support motor, replacing
    Electric door opener, rotor switch, replacing
    Engine air cleaner, replacing
    Engine belts, replacing
    Engine hood, installing
    Engine hood, manually operating
    Engine hood, removing
    Engine oil filter, replacing
    Engine oil level, checking
    Engine oil, draining
    Engine oil, filling
    Engine radiator, oil cooler and condensor (if installed), clean
    Engine rotation speed sensor (camshaft), replacing
    Engine rotation speed sensor (crank shaft), replacing
    Engine, installing
    Engine, removing
    Error codes when calibrating
    Evaporator, replacing incl draining and filling
    Evaporator, replacing
    Exhaust pipe, flexible tube, replacing
    Expansion valve, replacing
    Fan motor, replacing
    Feed pump, checking feed pressure
    Fire suppression system, actions after activation
    Fire suppression system, actions after manual activation
    Fire suppression system, component location
    Frame joint, replacing bearings
    Front axle, breather filter, replacing
    Front wheel, installation
    Front wheel, removal
    Fuel control valve (FCV), replacing
    Fuel filters, primary and secondary filter, replace
    Fuel metering unit A, replacing
    Fuel metering unit B, replacing
    Fuel pump, replacing
    Fuel rail pressure sensor, replacing
    Fuel system, bleeding
    Fuel tank breather filter, replacing
    Gear selector valve, replacing one solenoid
    Glow plug control unit, replacing
    Glow plug, replacing
    Grease Locations
    Heat control valve, replacing
    Heater core, replacing
    High pressure fuel pump, replacing
    High pressure fuel system, pressure relief
    Hinge, lubricating
    Hub reduction, installing
    Hub reduction, removing
    Hub, replacing seal
    Hub, replacing seal1
    Hydraulic couplings
    Hydraulic oil level, checking
    Hydraulic oil tank, draining
    Hydraulic oil tank, return oil filter, replace, and magnetic rod, clean
    Hydraulic oil tank, sediment drain
    Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
    Hydraulic oil, filling
    Hydraulic pump P2, installation
    Hydraulic pump P2, removal
    Hydraulic pump P3, checking function
    Hydraulic pump P3, installation
    Hydraulic pump P3, removal
    Hydraulic pump, checking and adjusting standby pressure and working pressure
    Hydraulic system, bleeding
    Hydraulic system, warming up
    Hydraulic tank and hydraulic transmission, ventilation filter, replacing
    I-ECU, MID 140, changing non-programmed ECU
    I-ECU, MID 140, changing pre-programmed ECU
    Injector sleeves, replacing
    Injectors, replacing all
    Lever steering (CDC), functional check
    Lift cylinder, repacking in machine
    Lift lower function, checking
    Lifting time, checking
    Lubrication oil pressure, checking with pressure gauge
    Lubrication, 50 hours maintenance interval
    Lubrication, 250 hours maintenance interval
    Lubrication, 500 hours maintenance interval
    Lubrication, 1000 hours maintenance interval
    Lubrication, 2000 hours maintenance interval
    Lubrication, 4000 hours maintenance interval
    Maintenance service, every 50 hours
    Maintenance service, every 250 hours
    Maintenance service, every 500 hours
    Maintenance service, every 1000 hours
    Maintenance service, every 2000 hours
    Maintenance service, every 4000 hours
    Maintenance service, every 4500 hours
    Maintenance service, every 6000 hours
    Maintenance service, fire suppression system
    Maintenance service, first 1000 hours
    Mechanical release of parking brake
    NOx sensor, replacing
    Oil bath air cleaner oil, changing
    Oil plugs, installing
    Oil-bath air cleaner’s reservoir (optional equipment), clean, and oil, change
    Oil-bath air cleaner’s reservoir (optional equipment), oil, check
    Operator’s seat, securing
    Oxidation catalyst, replacing
    Parking Brake – Assembly
    Parking Brake – Disassembly
    Parking Brake – Installation
    Parking brake assembly, removing
    Parking brake, adjusting
    Parking brake, function checking
    Parking brake, replacing brake pads
    Pause heater, replacing
    Plastic hood, repairing
    Pressure relief valve (PRV), replacing
    Radiator, installing
    Radiator, removing
    Rear axle, breather filter, replace
    Rear wheel, installing
    Rear wheel, removing
    Refrigerant, draining
    Refrigerant, filling incl vacuum pumping
    Restore operating condition after all test and adjustment work
    Restore the machine to original condition
    Seal for front output shaft, replacing
    Seal for rear output shaft, replacing
    Secondary steering pump, checking and adjusting working pressure
    Servo accumulator, installation1
    Servo accumulator, installation2
    Servo accumulator, removal1
    Servo accumulator, removal2
    Servo pressure, checking and adjusting1
    Servo pressure, checking and adjusting2
    Servo pressure, checking at the spool in control valve
    Shift valve, checking
    Shock valve lift function, checking
    Shock valve, tilt function, checking
    Spark plug cable, replacing
    Spark plug control unit, replacing
    Spark plug, checking
    Spark plug, replacing
    Stall speed, checking
    Steering system, checking and adjusting working pressure
    Steering system, function check
    System test
    Tilt cylinder, repacking in machine
    Tilt, functional check
    Towing
    Transmission oil filter, replacing
    Transmission oil pressure, checking
    Transmission oil, checking level
    Transmission oil, draining
    Transmission oil, filling
    Transmission suction strainer, cleaning
    Transmission, calibration
    Transmission, function check
    Transmission, installing
    Transmission, removing
    Turbocharger, installing
    Turbocharger, removing
    Tyres, wear and air pressure, checking
    V2-ECU, MID 249, changing non-programmed ECU
    V2-ECU, MID 249, changing pre-programmed ECU
    Valves, adjusting
    Valves, adjusting1
    VCADS Pro, connecting problems
    VCADS Pro, Operations
    V-ECU, MID 187, changing non-programmed ECU
    V-ECU, MID 187, changing pre-programmed ECU
    Warming up machine
    Waste gate, testing
    Wheel brakes, functional check
    Window pane, installation
    Windscreen, replacing

Safety

  • CE-marking, EMC-directive
    Checking function
    Checklist after a fire or heat exposure
    Decontamination
    Environmental handling for the future
    Environmentally hazardous fluids
    Environmentally safe handling
    Fire prevention measures
    Health hazards with paint, plastics and rubber
    Safety concerns everybody!
    Safety rules when servicing
    Safety when handling accumulators
    Safety when handling oils and fuel
    Safety when handling the machine
    Safety when lifting and supporting complete machine
    Safety when working on hydraulic systems
    Safety when working with air conditioning refrigerant
    Safety when working with batteries
    Service position 1
    Service position 2
    Some simple rules regarding tyre handling
    Starting with booster batteries
    Waste handling
    Working in environmentally contaminated areas
    Working under raised boom

Service Bulletins

  • AC compressor, fill with oil
    Action for reducing risk of fire
    Action to be taken in case of abnormal lubricating oil consumption
    Air bleeding of the central lubrication system
    Air cleaner
    Air pump
    Air-suspended operator seat, ISRI
    Alternative lubricants for axles with wet brakes
    Amendments in Service Manual Engine, D10B; Drive Axle, AWB 40B and Drive Axle, AWB 41AWB 50
    Approved silencers
    Automatic greasing systems of foreign manufacture
    Automatic transmission lubricants
    Battery and alternator test procedure
    Battery cable chafing against the rear frame
    Better front visibility on L90C
    Biodegradable hydraulic fluids
    Bracket for coolant pump
    Brake return spring moved
    Burner ignition device improvement
    Cables cut under operator seat
    CDC function, disengaging
    CDC-system, product improvements
    Central lubrication, oxide on pins
    Central lubrication
    Central lubrication1
    Chafing battery cable
    Cleaning of the machine
    Coding ECU (Electronic Control Unit)
    Coolant pump for engine intercooler
    Cranking problems
    D- arm cracks
    D4H – D8H EATS air pump improvement
    DEF AdBlue AUS32 sampling, method
    Detecting leaks with inspection lamp
    Diesel test standards 1
    Diesel test standards
    Discontinued recommendation for usage of anti-corrosion agent in cooling system
    ECU improvements
    ECU, functional check
    EGR cooler leaking coolant internally
    Electrically heated operator seat, service solution
    Engine coolant expansion tank
    Fluid levels
    Fork arms, information warranty matters, altered procedures
    Fuel pressure read-out
    Fuel sampling, method
    Fuse box decal with wrong information
    Greasing of hydraulic pump drive shaft
    Heater unit, external leakage
    Improved EATS air pump
    Improved hour recorder
    Improved securement for cab filter primary filter
    Improved wiper motor
    Installation of ferrites on the cable harness to the air pump
    Instructions for crack in lifting frame
    Instructions for drilling in ROPS structure
    Instructions for shielded metal arc welding
    Lamp bracket with rubber suspension
    Limitation, TP-linkage
    Lock cylinder for attachment bracket
    Loose seat base
    Maintenance service, every 2000 hours
    New brake pressure sensor
    New BSS valve
    New cab heater element
    New CareTrack W-ECU2
    New condenser
    New control valve
    New gear lever combi-switch
    New I-ECU introduction
    New NOx sensor for Tier 4i Stage IV engines D6H-D8H
    New propeller shafts
    New rear frame
    New rotator, stand 90897
    New software for full-automatic regeneration (option)
    New software release V2013.2.1
    New software release V2013.4.0
    New software release V2013.6.0
    New software release V2014.6.0
    New software V2014.3.0
    New software version V2013.6.1
    New sound absorbers
    New starter switch
    New switch for attachment lock
    New TechTool VCADS Pro interface
    New tightening torque process for the D4H, D6H cylinder head bolts
    New V-ECU and V2-ECU
    New warranty routines for Bosch diesel equipment
    New wheel loaders L60G, L70G and L90G
    Non – VCE buckets and attachments
    Oil analyses
    Oil sampling, method
    Oils for Volvos wheel loaders equipped with AWB axles (Axle Wet Brakes)
    Operator adaptation of electric servo lever functions with VCADS Pro
    Production development list for Volvo BM transmissions
    Protection against unauthorised tampering with injection pumps
    Protection cover
    Protection of the cab’s main wire harness
    Quality of illustrations in technical reports
    Radio band setting
    Raising and supporting machines (up to and including the E models)
    Rear axle mounting
    Recommendations for Oil Sampling Intervals
    Reinforced attachment bracket
    Repair instructions for attachments
    Repair report for central lubrication pumps
    Replacement of rubber collar on expansion tank
    Replacing operator seat shock absorber
    Reporting of product misuse & near-miss report
    Reports
    Reversible fan causing error codes
    Rusting lifting eye
    Seals
    Secondary steering Introduction of non-return valve
    Semi-automatic regeneration
    Service solution for GDF-link on L90C
    Service solution for modifying the boom suspension system
    Software in E-ECU for engines supplied as spare part
    Stay between entry steps and rear frame
    Transporting a wheel loader on another vehicle
    Tyres, various types
    Ventilation servo casing
    Water intrusion in cab
    Water separator improvement
    Windshield guard interferes with nipple

Special Tools, Misc

  • 01 Time Guide Currrent generation
    11 Time Guide Previous generation
    21 Time Guide Old generation
    35 GRD G700B LabourTimeGuide
    40 RM Compaction Time guide old version
    41 RM Compaction ABG Time Guide
    42 RM Paving Systems ABG Time Guide
    Special tool catalog
    Special Tools Recommendations

Specifications

  • 3rd 4th hydraulic function, specifications
    3rd 4th hydraulic function, tightening torques
    Air conditioning, specifications
    Alternator 80 A, specification
    Alternator, specification
    Automatic lubrication system, specifications
    Battery, specifications
    Battery, weight
    Boom Suspension System, specifications
    Boom Suspension System, tightening torques
    Brake accumulator, specifications
    Brake system, specifications
    Cabin, tightening torques
    Control valve, lever steering (CDC), specifications
    Control valve, specifications
    Control valve, torque value
    Conversion tables
    Coolant1
    Coolant2
    Cooling fan rpm, specifications
    Cooling system, tightening torques
    Counterweight, weight
    EGR system, tightening torques
    Electrical system, specifications
    Engine oil pressure, specification
    Engine, fill quantities
    Engine, software specifications
    Engine, specification
    Engine, tightening torques
    Exhaust aftertreatment system, specifications
    Fire suppression system, specification
    Frame joint, tightening torques
    Front and rear axles, specifications
    Front and rear axles, tightening torque
    Front and rear axles, volume
    Fuel system, specifications
    Function times, specifications
    Hydraulic connections, tightening torques
    Hydraulic pump (P2), specifications
    Hydraulic pump (P3), specifications
    Hydraulic pumps, tightening torques
    Hydraulic system, volume
    Hydraulic transmission, capacity
    Inlet and exhaust system, tightening torques
    Lever steering (CDC), specifications
    Lift cylinder, tightening torques
    Lighting, specifications
    Lubrication system, specifications
    Lubrication system, tightening torques
    Parking brake, specifications
    Preheating, specifications
    Propeller shaft, tightening torque
    Recommended lubricants
    Secondary steering pump, specifications
    Servo system, specifications
    Standard tightening torques
    Starter motor, specifications
    Steering cylinder, tightening torque
    Steering, specifications
    Temperature limits for cooling fan speed, specifications
    Thermostat, specifications
    Tightening torque, fuel system
    Tightening torques, cooling fan
    Tilt cylinder, tightening torques
    Transmission, specifications
    Transmission, tightening torques
    Wheel brake, specification
    Wheel, tightening torque

Other Products