Service manual Volvo L60G Wheel Loader | 2020

Volvo L60G Wheel Loader 2020 (Preview)

Descriptions
(0) GENERAL
Leak detector 951 1207, description
(1) STANDARD PARTS, SERVICE
Electric welding (2)
Electric welding
Service
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Auxiliary brake (engine braking), description
Cooling fan motor, description
Cooling fan, description
Cooling system, description
Crankcase ventilation, description
ECO – accelerator pedal
Engine, description
Exhaust Aftertreatment System, description
Exhaust Gas Recirculation (EGR), description
Fuel system, description
Inlet and exhaust system, description
Lubricating system, description
Regeneration process, description
Reversible cooling fan, description
Turbocharger, description
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
ACM, I O list
Alarm, description (2)
Alarm, description
Alternator, description (2)
Alternator, description
Battery disconnector switch, description
Battery, charging
Battery, description
Booting sequence
Branching in cables
Bus communication supervision
Cable and component designations
Cable and component marking explanations
CareTrack W-ECU, description
Central warning
Chassis connection
Collection of basic data
Communication with data buses
Components list
Conditions when checking
Connectors, overview
ECC, I O list
E-ECU, I O list
Electrical symbols and designations
Electrical system, description
Electrical system, work instructions
Electronic control system, description
Engine control unit E-ECU, description
Error codes, showing
General fault diagnosis information
Hood opening
I-ECU, I O list
Information display, axles brakes
Information display, check (2)
Information display, check
Information display, electrical system
Information display, engine
Information display, general
Information display, hydraulics
Information display, operating display
Information display, service mode
Information display, service
Information display, settings
Information display, start lockout
Information display, transmission
Information display, vehicle info
Information display, vehicle messages
Instrument panels
Intermittent wiper and washer
Key feed
Lead and connector checks
Lighting, description
Middle instrument panel with warning lights
Preheating, description
SAE error codes, translation to error messages, general
Software parameters, description
Software, description
Special tools for troubleshooting
System voltage
Troubleshooting strategy
Troubleshooting tools
V2-ECU, I O list
VCADS Pro service tool
VCADS Pro socket, measuring
VCADS Pro, Error codes
V-ECU, I O list
Vehicle control unit V2-ECU, description
Vehicle control unit V-ECU, description
W-ECU, I O list
(4) POWER TRANSMISSION
Automatic differential brake, Limited Slip, description
Differential lock, description
Drive axles, description
Front axle, component description
Hydraulic transmission, description
Oil cooler, component description
Propeller shaft, component description
Rear axle mounting, component description
Rear axle, component description
VCADS Pro, Operations
(5) BRAKE
Brake accumulator, description
Braking system, description
Foot brake valve, description
Parking brake, function description
Tightening torque
VCADS Pro, Operations
(6) STEERING
CDC valve, lever steering, description
Comfort Drive Control (CDC), description
Pressure monitor, description
Secondary steering, description
Steering cylinder, description
Steering system, description
Steering valve, description
VCADS Pro, Operations
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Frame joint, description
Frame, description
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, tightening torques
Cab, description
Climate control system, description
Electric door opener, description
Pause heater, description
Troubleshooting, air conditioning unit (AC)
Viscous cab suspension, description
Windows, general, gluing
Windows, general
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
3rd 4th hydraulic function, valve, description
3rd, or 3rd 4th hydraulic function, description
Boom Suspension System, component description
Boom Suspension System, description
Central lubrication system, description
Central valve, description
Change of lubrication interval
Control valve, description
Diagnostic tools, description
Dosage valves, description
Filling lubricant
Fire suppression system, component description
Hydraulic attachment bracket, description
Hydraulic components, cleanliness when handling
Hydraulic oil tank, description
Hydraulic pump flow regulation, description
Hydraulic pumps, description
Parameter settings
Pressure monitor, description
Pump unit, description
Servo system, description
Servo valve, description
Shift valve, description
Software, parameter settings and read-outs
TP-Linkage’s bearing points
VCADS Pro, Operations
Working hydraulic system, description
Diagrams
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Table of contents, wiring diagrams
Wiring diagram – Aftertreatment
Wiring diagram – Brake 2
Wiring diagram – Brake
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 Update G 2
Wiring diagram WD301 Update G
Wiring diagram WD301
Wiring diagram WD302
Wiring diagram WD303 Update G
Wiring diagram WD303
Wiring diagram WD304 2
Wiring diagram WD304
Wiring diagram WD306
Wiring diagram WD308 Update G
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 Update G
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 Update G
Wiring diagram WD360
Wiring diagram WD361
Wiring diagram WD362
Wiring diagram WD363 Update G
Wiring diagram WD363
Wiring diagram WD364 Update G
Wiring diagram WD371 Update G
Wiring diagram WD372 Update G
Wiring diagram WD373
Wiring diagram WD374
Wiring diagram WD375 Update G
Wiring diagram WD375
Wiring diagram WD376
Wiring diagram WD401
Wiring diagram WD402 Update G
Wiring diagram WD402
Wiring diagram WD403
Wiring diagram WD404
Wiring diagram WD405
Wiring diagram WD407 Update G
Wiring diagram WD501 Update G
Wiring diagram WD501
Wiring diagram WD601
Wiring diagram WD602
Wiring diagram WD604
Wiring diagram WD801
Wiring diagram WD802
Wiring diagram WD804 Update G
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 WD903
Wiring diagram WD904
Wiring diagram WD905
Wiring diagram WD906
Wiring diagram WD908
Wiring diagram WD911
Wiring diagram WD913
Wiring diagram WD915 Update G
(4) POWRER TRANSMISSION
Hydraulic diagram transmission
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
Explanations to hydraulic diagram
Hydraulic diagram, complete
Installation instructions
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 main switch, installing new
Boom suspension system, installing new
Cab front work light LED, installing new
Cab rear work light LED, installing new
Cab side work light LED, installing new
Cab, air pre cleaner, installing new
care track
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, installing new
High Sulphur Fuel Conversion kit, installing 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
Radiator grille guard, installing new
Radio, installing new (2)
Radio, installing new (3)
Radio, installing new
Rear view camera, installing new (2)
Rear view camera, installing new
Reversible fan, installing new
Rotating beacon, installing new
Single lever control, 2nd hydraulic function, installing new
Wind shield guard, installing new
Work light front, installing new
Work light rear, installing new (2)
Work light rear, installing new
Repair
(0) GENERAL
88830557 User Instruction
E 1708, Checking point
E1706
E1711
E-2000
E-2001
E-2017
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
Boom suspension accumulator, checking and adjusting
Brake discs, measuring wear
Brake system charging, checking
Diesel particulate filter, checking and cleaning
Front axle, breather filter, replacing
Hydraulic pump, standby pressure and working pressure, checking and adjusting
Oil plugs, installing
Parking brake, manually releasing
Rear axle, breather filter, replace
Spark plug, replacing
Steering system working pressure, checking and adjusting
Towing
Valves, adjusting
Wheel brakes function, checking
(2) ENGINE WITH MOUNTING AND EQUIPMENT
ACM (Aftertreatment control module) non-programmed, replacing
ACM (Aftertreatment control module) pre-programmed, replacing
Air pump safety valve, replacing
Air pump, replacing
Burner function, checking
Burner, replacing
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, checking
Charge air cooler, installing
Charge air cooler, removing
Coolant pump, replacing
Cooling system pressure, checking
Crankcase ventilation separator, replacing
Crankshaft front oil seal, replacing
Cylinder compression, testing
Diesel particulate filter, checking and cleaning
DOC (Diesel oxidation catalyst), replacing
E-ECU MID 128 non-programmed, replacing
E-ECU MID 128 pre-programmed, replacing
EGR actuator, replacing
EGR cooler, replacing
EGR pressure sensor, replacing
EGR reed valve, inspecting
EGR reed valve, replacing
EGR system function, checking
EGR temperature sensor, replacing
EGR valve, replacing
EGR venturi tube, replacing
Engine belts, replacing
Engine mounting rear, changing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor (crank shaft), replacing
Engine, installing
Engine, removing
Exhaust aftertreatment system T-junction, replacing
Exhaust pipe flexible tube, replacing
Feed pump pressure, checking
Fuel control valve (FCV), replacing
Fuel metering unit A, replacing
Fuel metering unit B, replacing
Fuel pump, replacing
Fuel rail pressure sensor, replacing
Fuel system, bleeding
Glow plug control unit, replacing
Glow plug, replacing
High pressure fuel pump, replacing
High pressure fuel system pressure, relieving
Injector sleeves, replacing
Injectors, replacing
Lubrication oil pressure, checking with pressure gauge
NOx sensor, replacing
Pressure relief valve (PRV), replacing
Radiator, installing
Radiator, removing
Spark plug cable, replacing
Spark plug control unit, replacing
Spark plug, inspecting
Spark plug, replacing
Stall speed, checking
Turbocharger, installing
Turbocharger, removing
Valves, adjusting
VCADS Pro, Operations
Wastegate, checking
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Batteries, replacing
Battery condition, checking
I-ECU MID 140 non-programmed, replacing
I-ECU MID 140 pre-programmed, replacing
Starter lock, replacing
VCADS Pro, connecting problems
VCADS Pro, Operations
V-ECU MID 187 non-programmed, replacing
V-ECU MID 187 pre-programmed, replacing
(4) POWRER TRANSMISSION
Axle suspension bushes and seals, replacing
Axle, installing
Axle, removing
Differential lock, adjusting
Differential lock, function check
Error codes when calibrating
Gear selector valve, replacing one solenoid
Heat exchanger, replacing
Hub reduction, installing 2
Hub reduction, installing
Hub reduction, removing 2
Hub reduction, removing
Hub seal, replacing 2
Hub seal, replacing
Seal for front output shaft, replacing
Seal for rear output shaft, replacing
Transmission oil pressure, checking
Transmission, function check
Transmission, installing
Transmission, removing
(5) BRAKE
Accumulator (removed) charging pressure, checking
Accumulator, discarding
Accumulator, installing
Accumulator, removing
Accumulators, checking in machine
Brake disc, replacing
Brake discs, measuring wear
Brake discs, replacing
Brake piston seals, replacing 2
Brake piston seals, replacing
Brake system charging, checking
Brake system circuit pressure, checking and adjusting
Brake system retardation function, checking
Brake system, bleeding
Parking brake assembly, removing 2
Parking brake assembly, removing
Parking brake brake pads, replacing
Parking brake function, checking
Parking brake, assembling
Parking brake, disassembling
Parking brake, installing
Wheel brakes function, checking
(6) STEERING
Accumulator, discarding
Comfort drive control (CDC) angle sensor, changing
Comfort drive control (CDC) solenoid valve, changing
Comfort Drive Control, servo pressure, checking
Error codes when calibrating
Left steering cylinder, installing
Left steering cylinder, removing
Lever steering (CDC) function, checking
Right steering cylinder, installing
Right steering cylinder, removing
Secondary steering pump working pressure, checking and adjusting
Steering cylinder removed, reconditioning excl replacing bearings
Steering system function, checking
Steering system working pressure, checking and adjusting
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Counterweight, installing
Counterweight, removing
Frame joint, replacing bearings
Front wheel, installing
Front wheel, removing
Rear wheel, installing
Rear wheel, removing
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Accelerator pedal, replace
Actuator, replacing
Air conditioning, checking performance
Air mix door actuator, replacing
Cab, installing
Cab, removing
Climate unit, installing
Climate unit, removing
Compressor, replacing
Condenser, replacing
Door lock cylinder, replacing 2
Door lock cylinder, replacing
Drying filter, replacing
ECC MID 146 non-programmed ECU, replacing
ECC MID 146 pre-programmed ECU, 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 hood, installing
Engine hood, manually operating
Engine hood, raising and securing
Engine hood, removing
Evaporator, replacing
Expansion valve, replacing
Fan motor, replacing
Heat control valve, replacing
Heater core, replacing
Operator’s seat, securing
Plastic hood, repairing
Refrigerant, draining
Refrigerant, filling incl vacuum pumping
Side window, replacing
Window pane, installing
Windscreen, replacing
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
3rd 4th hydraulic function, pressure, checking and adjusting
3rd 4th hydraulic function, shock valve, checking
3rd 4th hydraulic, functional check
Accumulator removed, checking
Accumulator, boom suspension system, discarding
Accumulator, discarding 2
Accumulator, discarding
Attachment locking, checking
Automatic lubrication pump unit, reconditioning
Back-up valve, checking and adjusting
Back-up valve, replacing
Bleeding air
Boom suspension accumulator, checking and adjusting
Boom suspension accumulator, reconditioning
Boom suspension system, checking
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom suspension system, left accumulator, installing
Boom suspension system, left accumulator, removing
Boom suspension system, pressure reduction, safety valve, checking and adjusting
Fire suppression system, actions after activation
Fire suppression system, actions after manual activation
Hydraulic couplings
Hydraulic cylinder, piston’s lock brace, installing
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic pump P2, installing
Hydraulic pump P2, removing
Hydraulic pump P3, checking
Hydraulic pump P3, installing
Hydraulic pump P3, removing
Hydraulic pump, standby pressure and working pressure, checking and adjusting
Hydraulic system, bleeding
Hydraulic system, warming up
Lift cylinder, repacking in machine 2
Lift cylinder, repacking in machine
Lift lower function, checking
Lifting time, checking
LS (load sense) pressure, checking
Servo accumulator, installing 2
Servo accumulator, installing
Servo accumulator, removing
Servo pressure, at the spool in control valve, checking
Servo pressure, checking and adjusting
Shock valve lift function, checking
Shock valve, tilt function, checking
System test
Tilt cylinder, repacking in machine
Tilt, checking
V2-ECU, MID 249, changing non-programmed ECU
V2-ECU, MID 249, changing pre-programmed ECU
Safety
(1) STANDARD PARTS, SERVICE
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 2
Service position 1
Service position 2 2
Service position 2
Some simple rules regarding tyre handling
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
Working on the electrical system of the machine
Working under raised boom
Specifications
(0) GENERAL
Conversion tables
EGR system, tightening torques
Engine, software specifications
Engine, specifications
Engine, tightening torques
Fuel system, specifications
Lubrication system, specifications (2)
Lubrication system, specifications
Thermostat, specifications
Tightening torques
(1) STANDARD PARTS, SERVICE
Alternative fuels
Coolant
Recommended lubricants
Wheel brake, specification
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Cooling fan rpm, specifications
Cooling fan, tightening torques
Cooling system, specifications
Cooling system, tightening torques
EGR system, tightening torques
Engine oil pressure, specification
Engine, fill quantities
Engine, software specifications
Engine, specifications
Engine, tightening torques
Exhaust aftertreatment system, specifications
Fuel system, specifications
Fuel system, tightening torques
Inlet and exhaust system, tightening torques
Lubrication system, specifications
Lubrication system, tightening torques
Oil sump, tightening torque
Preheating, specifications
Temperature limits for cooling fan speed, specifications
Thermostat, specifications
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator 80 A, specification
Alternator, specification
Battery, specifications
Battery, weight
Electrical system, specifications
Lighting, specifications
Preheating, specifications
Starter motor, specifications
(4) POWER TRANSMISSION
Front and rear axles, tightening torque (2)
Front and rear axles, tightening torque
Front and rear axles, volume
Hydraulic transmission, capacity
Propeller shaft, tightening torque
Transmission, specifications (2)
Transmission, specifications (3)
Transmission, specifications (4)
Transmission, specifications
Transmission, tightening torques
(5) BRAKE
Brake accumulator, specifications
Brake system, specifications
Parking brake, specifications
Wheel brake, specification
(6) STEERING
Lever steering (CDC), specifications
Secondary steering pump, specifications
Steering cylinder, tightening torque
Steering, specifications
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Counterweight, tightening torques
Counterweight, weight
Frame joint, tightening torques
Wheel, tightening torque
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, refrigerant, weight (2)
Air conditioning, refrigerant, weight
Air conditioning, specifications
Cabin, tightening torques
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
3rd 4th hydraulic function, specifications
3rd 4th hydraulic function, tightening torques
Automatic lubrication system, specifications
Boom Suspension System, specifications
Boom Suspension System, tightening torques
Control valve, specifications
Control valve, tightening torques
Fire suppression system, specification
Function times, specifications
Hydraulic connections, tightening torques
Hydraulic pump (P2), specifications
Hydraulic pump (P3), specifications
Hydraulic pumps, tightening torques
Hydraulic system, volume
Lift cylinder, tightening torques
Recommended lubricants
Servo system, specifications
Tilt cylinder, tightening torques