Volvo L60H Wheel Loader Service and Repair Manual PDF

Volvo L60H Wheel Loader Service and Repair Manual PDF

Size: 139.39 MB
Language: English
Make: Volvo
Machine: Wheel Loader
Document: Service and Repair Manual, Hydraulic and Electrical Diagram
Model: Volvo L60H
Page: 4997 Pages

Detail Contents:
1 Volvo L90H
Description

• 3rd 4th hydraulic function, valve, description
  3rd, or 3rd 4th hydraulic function, component location
  3rd, or 3rd 4th hydraulic function, description
  ACM, I-O list
  Air conditioning, function description
  Air conditioning, tightening torques
  Air conditioning, tightening torques1
  Alternator 80 A, description
  Automatic differential brake, Limited Slip, description
  Auxiliary brake (engine braking), 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
  Cable and component designations
  Cable and component marking explanations
  Calibration of Comfort Drive Control (CDC), function description
  CareTrack W-ECU, description
  CCM, I-O list
  CDC valve, lever steering, description
  Central lubrication system, description
  Central valve, description
  Change of lubrication interval
  Chassis connection
  Climate control system, description
  Comfort Drive Control (CDC), component location
  Comfort Drive Control (CDC), description
  Components list
  Connectors, position
  Control valve, description
  Coolant with anti-freeze and corrosion protection, recommendation
  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
  Driver seat, component description1
  Driver seat, component description2
  Drivetrain, component location
  ECM, I-O list
  ECO – accelerator pedal
  Electric door opener, description
  Electrical symbols and designations
  Electrical system, description
  Electrical system, work instructions
  Electronic control system, description
  Engine, description
  Exhaust Aftertreatment System, component location
  Exhaust Aftertreatment System, description
  Exhaust gas recirculation (EGR), component location
  Exhaust Gas Recirculation (EGR), description
  Filling lubricant
  Fire suppression system, component description
  Fire suppression system, functional description
  Foot brake valve, description
  Frame joint, description
  Frame, description
  Front axle, component description
  Fuel system, component location
  Fuel system, description
  GPMECU1, I-O list
  GPMECU2, I-O list
  GPMECU3, I-O list
  HMICU, I-O list
  Hood opening
  Hydraulic attachment locking, description
  Hydraulic components, cleanliness when handling
  Hydraulic oil tank, description
  Hydraulic pump flow regulation, description
  Hydraulic pumps, description
  Hydraulic transmission calibration, description
  Hydraulic transmission, description
  Information display, general
  Information display, service mode
  Inlet and exhaust system, component location
  Inlet and exhaust system, description
  Intermittent wiper and washer
  Key feed
  Leak detector 951 1207, new model
  Lever control, hydraulic servo, description
  Lifting cylinder, description
  Lighting, description
  Lubricating system, description
  Lubrication points, central lubrication
  Lubrication system, component locations
  Parameter settings
  Parking brake, component location
  Parking brake, function description
  Pause heater, description
  Preheating, description
  Pressure monitor, description
  Pressure monitor, description1
  Propeller shaft, component description
  Pump unit, description
  Rear axle, component description
  Reversible cooling fan, description
  Secondary steering, component location
  Secondary steering, description
  Service
  Servo system, description
  Servo valve, description
  Shift valve, description
  Software parameters, description
  Software, parameter settings and read-outs
  Steering cylinder, description
  Steering system, component location
  Steering system, description
  Steering valve, description
  System voltage
  Tech Tool, operations
  Tech Tool, operations1
  Tech Tool, operations2
  Tech Tool, operations3
  Tech Tool, operations4
  Tech Tool, operations5
  Tightening torque parking brake
  Tilt cylinder, description
  TP-Linkage’s bearing points
  Transmission, component position
  Viscous cab suspension, description
  W-ECU, I-O list
  Windows, general, gluing
  Windows, general
  Working hydraulic system, component location
  Working hydraulic system, description

Diagrams

• Explanations to hydraulic diagram
  Hydraulic diagram transmission
  Hydraulic diagram, basic machine Figure 1
  Hydraulic diagram, basic machine
  Hydraulic diagram, complete Figure 1
  Hydraulic diagram, complete
  Table of contents, wiring diagrams
  Wiring diagram – Aftertreatment
  Wiring diagram – Brake
  Wiring diagram – BSS
  Wiring diagram – CDC
  Wiring diagram – Electrically controlled battery disconnector – Key operated, with emergency stop
  Wiring diagram – Electrically controlled battery disconnector – Manual, with emergency stop
  Wiring diagram – Electrically controlled battery disconnector – Manual, without emergency stop
  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 WD268
  Wiring diagram WD269
  Wiring diagram WD270
  Wiring diagram WD301
  Wiring diagram WD302
  Wiring diagram WD303
  Wiring diagram WD304
  Wiring diagram WD305
  Wiring diagram WD306
  Wiring diagram WD320
  Wiring diagram WD321
  Wiring diagram WD322
  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
  Wiring diagram WD350
  Wiring diagram WD351
  Wiring diagram WD352
  Wiring diagram WD360
  Wiring diagram WD361
  Wiring diagram WD362
  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 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 WD831
  Wiring diagram WD901
  Wiring diagram WD902
  Wiring diagram WD903
  Wiring diagram WD904
  Wiring diagram WD905
  Wiring diagram WD908
  Wiring diagram WD911
  Wiring diagram WD913
  Wiring diagram WD915

Installation Instruction

• Alternator 120 Amp, installing new
  Attachment worklight, installing new
  Back up alarm, 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
  Care track
  CareTrack, installing new
  Forward view camera, installing new
  Front work light LED, installing new
  Grill work light LED, installing new
  Hand throttle, instaling new
  Pre-cleaner cyclone type, installing new
  Pre-cleaner oil bath type, installing new
  Pre-cleaner turbo type, installing new
  Radiator grill guard, installaing new
  Radio, installing new1
  Radio, installing new2
  Rear view mirror, installing new
  Rotating beacon, installing new
  Warning beacon flashing strobe light, installing new
  Wind shield guard, installing new

Repair

• 3rd 4th hydraulic function, shock valve, checking
  3rd 4th hydraulic, functional check
  Accumulator removed, checking charging pressure
  Accumulator, boom suspension system, discarding
  Accumulator, discarding
  Accumulator, discarding1
  Accumulator, discarding2
  Accumulator, installation
  Accumulator, removal
  Accumulators, checking in machine
  ACM (After treatment control module), replacing, non-programmed
  Actuator, replacing
  AdBlue® DEF dosing injector, replacing
  AdBlue® DEF mixing tube, replacing
  AdBlue® DEF pump unit filter, replacing
  AdBlue® DEF pump unit, filter, replacing
  AdBlue® DEF pump unit, flushing
  AdBlue® DEF pump unit, replacing
  AdBlue® DEF quality, checking
  AdBlue® DEF tank, breather filter, replacing
  AdBlue® DEF tank, replacing
  AdBlue® DEF tank, tank armature, replacing
  AdBlue® DEF, draining
  Air conditioning, checking performance
  Air mix door actuator, replacing
  Attachment locking, functional check
  Automatic central lubrication filter, replacing
  Automatic lubrication pump unit, reconditioning
  Axle breather filters, replacing
  Back-up valve, checking and adjusting
  Back-up valve, replacing
  Basic service
  Batteries, replacing
  Battery condition, check
  Battery, checking
  Bleeding air
  Boom suspension accumulator, check and adjusting
  Boom suspension accumulator, checking
  Boom suspension accumulator, reconditioning
  Boom suspension system, functional check
  Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
  Boom suspension system, pressure reduction, safety valve, checking and adjusting
  Brake disc, replacing
  Brake disc, replacing1
  Brake discs, measuring wear
  Brake piston, replacing seals
  Brake piston, replacing seals1
  Brake pressure and function, checking
  Brake system charging, checking
  Brake system, bleeding
  Brake system, check and adjusting pressure in circuit
  Brake system, checking function, retardation
  Cab extra prefilter cyclone type, replacing
  Cab main filter, replacing
  Cab prefilter, replacing
  Carbon dioxide in coolant system, checking
  Carbon dioxide in fuel system, check
  CCM, replacing
  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 freezing point, checking
  Coolant level, checking
  Coolant pump, replacing
  Coolant valve, replacing
  Coolant, changing
  Coolers, cleaning
  Cooling system, pressure control
  Cooling unit, leak detection
  Counterweight, fitting
  Counterweight, removing
  Diesel oxidation catalyst, replacing
  Diesel particulate filter, check and clean
  Diesel particulate filter, checking and cleaning
  Diesel particulate filter, regenerating
  Differential lock, adjusting
  Differential lock, function check
  Door lock cylinder, replacing
  Drive axle oil, changing
  E1706
  E1711
  E-2001
  E-2005
  E-2014
  E-2015
  E-2017
  ECM (Engine control module), replacing non-programmed
  ECM (Engine control module), replacing non-programmed1
  ECM (Engine control module), replacing pre-programmed
  EGR cooler, replacing
  EGR reed valve, replacing
  EGR valve, replacing
  EGR venturi tube, cleaning
  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 primary filter, replacing
  Engine air cleaner secondary filter, replacing
  Engine belt condition, checking
  Engine belts, replacing
  Engine hood, installing
  Engine hood, removing
  Engine oil and filter, changing
  Engine oil level, checking
  Engine pre cleaner cyclone type, cleaning
  Error codes when calibrating
  Error codes when calibrating1
  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, checking
  Fire suppression system, component location
  Front wheel, installation
  Front wheel, removal
  Fuel control valve (FCV), replacing
  Fuel filters, replacing
  Fuel rail pressure sensor, replacing
  Fuel rail, replacing
  Fuel system, bleeding
  Fuel tank breather filter, replacing
  GPMECU1, changing non-programmed ECU
  GPMECU1, changing pre-programmed ECU
  GPMECU2, changing non-programmed ECU
  GPMECU2, changing pre-programmed ECU
  GPMECU3, changing non-programmed ECU
  GPMECU3, changing pre-programmed ECU
  Grease Locations
  Heat control valve, replacing
  Heater core, replacing
  High pressure fuel pipes, replacing
  High pressure fuel pump, replacing
  Hinge, lubricating
  HMICU, changing non-programmed ECU
  HMICU, changing pre-programmed ECU
  Hub reduction, installing
  Hub reduction, installing1
  Hub reduction, removing
  Hub reduction, removing1
  Hub, replacing seal
  Hub, replacing seal1
  Hydraulic couplings
  Hydraulic oil level, checking
  Hydraulic oil tank breather filter, replacing
  Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
  Hydraulic oil, changing
  Hydraulic pressure, checking
  Hydraulic pump P3, checking function
  Hydraulic pump, checking and adjusting standby pressure and working pressure
  Hydraulic system, bleeding
  Hydraulic system, warming up
  Hydraulic tank return oil filter and magnetic rod, cleaning and replacing
  Hydraulic tank sediment, draining
  Inductive sensor, lift, adjusting
  Inductive sensor, tilt, adjusting
  Injector sleeves, replacing
  Injectors, replacing all
  Inlet throttle, replacing
  Lever steering (CDC), functional check
  Lift lower function, checking
  Lubrication oil pressure, checking with pressure gauge
  Lubrication, every 50 hours
  Lubrication, every 250 hours
  Lubrication, every 500 hours
  Lubrication, every 1000 hours
  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, first 1000 hours
  MATRIS and Tech Tool, reading
  Mechanical release of parking brake
  Oil cooler, component location
  Oil-bath air cleaner reservoir filter insert, cleaning
  Oil-bath air cleaner reservoir oil, changing
  Oil-bath air cleaner reservoir oil, checking
  Operator’s seat, securing
  Parking Brake – Assembly
  Parking Brake – Disassembly
  Parking Brake – Installation
  Parking brake assembly, removing
  Parking brake function, checking
  Parking brake pads, checking
  Parking brake, adjusting
  Parking brake, function checking
  Parking brake, replacing brake pads
  Pressure relief valve (PRV), replacing
  Refrigerant, draining
  Refrigerant, filling incl vacuum pumping
  Restoring of the machine
  SCR muffler, replacing
  SCR system, dosing test
  Seal for front output shaft, replacing
  Seal for rear output shaft, replacing
  Secondary steering pump, checking and adjusting working pressure
  Service brake disc wear, checking
  Service brake, testing
  Servo pressure, checking and adjusting
  Servo pressure, checking at the spool in control valve
  Shift valve, checking
  Shock valve lift function, checking
  Shock valve, tilt function, checking
  Stall speed, checking
  Starter motor, replacing
  Steering accumulator removed, checking
  Steering accumulator, installing
  Steering accumulator, removing
  Steering system, checking and adjusting working pressure
  Steering system, function check
  System test
  Tech Tool, operations
  Tilt, functional check
  Transmission oil level, checking
  Transmission oil, filter and suction strainer, changing and cleaning
  Transmission, calibration
  Transmission, function check
  Troubleshooting, air conditioning unit (AC)
  Turbocharger, replacing
  Tyre wear and air pressure, checking
  Update of automatic lubrication system
  Valve cover, installing
  Valve cover, removing
  Valves, adjusting
  Valves, adjusting1
  W-ECU, replacing, non-programmed
  W-ECU, replacing, pre-programmed
  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 to be taken in case of abnormal lubricating oil consumption
  Alternative lubricants for axles with wet brakes
  Automatic greasing systems of foreign manufacture
  Automatic transmission lubricants
  Battery and alternator test procedure
  Cleaning of the machine
  DEF AdBlue AUS32 sampling, method
  Discontinued recommendation for usage of anti-corrosion agent in cooling system
  ECU, functional check
  Fork arms, information warranty matters, altered procedures
  Fuel sampling, method
  Greasing of hydraulic pump drive shaft
  Instructions for crack in lifting frame
  Instructions for drilling in ROPS structure
  Instructions for shielded metal arc welding
  New TechTool VCADS Pro interface
  New wheel loaders, L60H, L70H and L90H
  Oil sampling, method
  Portable refillable O-ring kits
  Quality of illustrations in technical reports
  Recommendations for Oil Sampling Intervals
  Repair instructions for attachments
  Reporting of product misuse & near-miss report
  Reports
  Seals
  Tyres, various types
  Volvo Product incident accident report & Interview Form

Special Tools, Misc

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

Specifications

• 3rd 4th hydraulic function, specifications
  3rd 4th hydraulic function, tightening torques
  AdBlue® DEF
  AdBlue® DEF1
  Air conditioning, specifications
  Alternator 80 A, 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
  Calibration of Comfort Drive Control (CDC), specification
  Control valve, specifications
  Control valve, torque value
  Coolant
  Cooling fan rpm, specifications
  Cooling system, specifications
  Cooling system, tightening torques
  Counterweight, tightening torques
  Counterweight, weight
  EGR system, tightening torques
  Electrical system, specifications
  Engine, capacities
  Engine, specification
  Engine, tightening torques
  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, tightening torques
  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
  Recommended lubricants1
  Secondary steering pump, specifications
  Servo system, specifications
  Standard tightening torques
  Starter motor, specifications
  Starter motor, tightening torques
  Steering cylinder, tightening torque
  Steering, specifications
  Temperature limits for cooling fan speed, specifications
  Tightening torques, cooling fan
  Tilt cylinder, tightening torques
  Transmission, specifications
  Transmission, specifications1
  Transmission, tightening torques
  Valve mechanism, specifications
  Wheel brake, specification
  Wheel, tightening torque

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