Volvo L45G Compact Wheel Loader Workshop Repair Service Manual PDF Download - MVLVCONL45G.zip
A full service and repair guide, complete with Electrical Wiring Diagrams, for the Volvo L45G Compact Wheel Loaders—packed with every technical detail needed to maintain, troubleshoot, fix, and service the machine just like an expert technician.
The workshop service and repair manual for Volvo Constructions L45G Compact Wheel Loaders covers:
* 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.
Volvo L45G Compact Wheel Loader Repair Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,484 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
0 - Foreword....2
0 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Description....4
Machine dimensions....5
03 - SPECIFICATIONS....8
Measurement conversion tables....8
Volvo standard tightening torques....13
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION....15
Transporting the machine....15
07 - STANDARD TIME....18
Operation numbers for additional work....18
08 - TOOL....20
E-2000....20
E-tool Cab support....22
Infrared Thermometer....23
1 - STANDARD PARTS, SERVICE....27
16 - LUBRICANT; FUEL; OTHER FLUID....28
Alternative fuels....28
Coolant with freezing and corrosion protection....31
Recommended lubricants ....33
17 - SERVICE....36
Arrival Inspection, according to Inspection Programme....36
Axle oil, changing_{01-08-45}....37
Axle oil, changing_{01-09-13}....40
Axle oil, changing_{01-09-41}....43
Battery, checking....46
Brake pressure and function, checking....47
Cab main filter, replacing....52
Charging batteries....54
Cleanliness, braking and hydraulic system....55
Coolant freezing point, checking....56
Coolant level, checking....58
Coolant, changing....60
Delivery Inspection, according to Inspection Programme....62
Delivery Instructions, according to Inspection Programme....63
Diesel particulate filter, checking and cleaning....64
Electric welding....68
Engine air cleaner primary filter, replacing....69
Engine air cleaner secondary filter, replacing....71
Engine belt tension, checking....72
Engine oil and filter, changing....74
Engine oil level, checking....76
Fuel filters, replacing....77
Fuel tank breather filter, replacing....79
Hydraulic oil filters, replacing....81
Hydraulic oil level, checking....83
Hydraulic oil, changing....85
Hydraulic pressure, checking....87
Hydraulic tank sediment, draining....90
Leakage, checking....92
Lubrication....93
MATRIS and Tech Tool, reading....95
Maintenance of Stored Machines, according to Inspection Programme....96
Maintenance service, every 10 hours....97
Maintenance service, every 1000 hours....98
Maintenance service, every 1500 hours....100
Maintenance service, every 2000 hours....102
Maintenance service, every 3000 hours....104
Maintenance service, every 4500 hours....106
Maintenance service, every 50 hours....107
Maintenance service, every 500 hours....108
Maintenance service, every 6000 hours....109
Parking brake pads, checking....110
Propeller shaft movement, checking....111
Radiator, cleaning....113
Service and maintenance....115
Service brake disc wear, checking....117
Service position 1_{01-26-14}....119
Service position 2_{01-26-43}....121
Service....123
Spark plugs, replacing....124
Steering cylinders, locking of pivot pins, checking....126
Steering pressure, checking ....128
Tech Tool, operations-[2856]....131
Test running and checking....132
Towing....133
Transmission oil filter, replacing....134
Tyre wear and air pressure, checking....137
Valves, adjusting-[1854]....138
Water separator, checking....144
Wheel nuts torque, checking....146
Work on the machine's electrical system....147
19 - GENERAL....148
CE-marking, EMC-directive....148
Checklist after a fire or heat exposure....152
Decontamination....153
Environmental handling for the future....155
Environmentally hazardous fluids....157
Environmentally safe handling....158
Fire prevention measures....160
Health hazards with paint, plastics and rubber....163
Loader boom, safety strut....165
Safety concerns everybody!....168
Safety rules when servicing....170
Safety when handling accumulators....173
Safety when handling oils and fuel....174
Safety when handling the machine....175
Safety when lifting and supporting complete machine....179
Safety when using lifting equipment....181
Safety when working on hydraulic systems....183
Safety when working with batteries....185
Safety when working with refrigerant....188
Service position 1_{12-53-02}....191
Service position 2_{12-53-30}....193
Some simple rules regarding tyre handling....195
Starting with booster batteries....197
Waste handling....199
Working in environmentally contaminated areas....200
Working under raised boom....201
2 - ENGINE WITH MOUNTING AND EQUIPMENT....203
20 - GENERAL....204
Component locations....204
Electric components location....206
Engine, capacity....210
Engine, description....211
Engine, weights....215
Tech Tool, operations-....216
21 - ENGINE....218
Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope....218
Crankcase ventilation, description....224
Engine mounting, tightening torque....225
Engine, installing....227
Engine, removing....236
Engine, specifications....246
Valve cover, installing....247
Valve cover, removing....251
Valves, adjusting....256
22 - LUBRICATING SYSTEM....262
Lubricating system, description....262
Lubrication oil pressure, checking....266
Lubrication system, specifications....268
23 - FUEL SYSTEM....269
Carbon dioxide in fuel system, checking....269
Fuel control valve (FCV), replacing....275
Fuel feed pump, description....279
Fuel pump, replacing....280
Fuel rail pressure sensor, replacing....282
Fuel system, bleeding....284
Fuel system, description....286
Fuel system, specifications....292
Fuel system, tightening torques....293
Fuel tank, installing....294
Fuel tank, removing....298
High pressure fuel pump, replacing....303
Injectors, replacing....306
25 - INLET & EXHAUST SYSTEM....312
ACM (Aftertreatment control module) non-programmed, replacing....312
ACM (Aftertreatment control module) pre-programmed, replacing....314
Air pump, replacing....316
Burner function, checking....320
Burner, replacing....325
DOC (Diesel oxidation catalyst), replacing....328
DPF (Diesel particulate filter), checking and cleaning....331
Exhaust Aftertreatment System, description....335
Exhaust aftertreatment system, specifications....346
Glow plug, replacing....349
Injector sleeves, replacing....351
Inlet and exhaust system, description....361
Inlet and exhaust system, tightening torques....365
Perform a service regeneration....367
Regeneration process, description....368
Spark plug cable, replacing....371
Spark plug control unit, replacing....373
Spark plug, inspecting....375
Spark plug, replacing....377
Turbocharger, description....379
Turbocharger, replacing....381
Wastegate, checking....385
26 - COOLING SYSTEM....387
Coolant pump, replacing....387
Cooling fan rpm, specifications....390
Cooling system pressure, checking....391
Cooling system, capacity....393
Cooling system, description....394
Fan belt and_or alternator belt, replacing....396
Thermostat, replacing....399
29 - MISCELLANEOUS....403
EGR actuator, replacing....403
EGR cooler, replacing....406
EGR reed valve, replacing....410
EGR system function, checking....414
EGR system, tightening torques....416
Exhaust Gas Recirculation (EGR), description....419
Exhaust gas recirculation (EGR), component location....423
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....425
30 - GENERAL....426
Automatic engine shut down, description....426
Bus communication supervision....428
CU2501, description and measuring....430
CU2503, description and measuring....432
CU6601, description and measuring....434
Collection of basic data....438
Communication with data buses-[5656]....440
Communication with data buses....442
Component descriptions....444
Conditions when checking....447
Electrical system, description....450
Electrical system, specifications....452
Electrical system, work instructions....453
Electronic control system, description....455
Error codes, build-up....460
FX1005, description and measuring....463
FX1007, description and measuring....466
FX1008, description and measuring....469
FX1031, description and measuring....472
General fault diagnosis information....475
HE2501, description and measuring....477
Information display, check ....479
Lead and connector checks....481
Limp home....485
MA2301-MA2304, description and measuring....486
MA2508, description and measuring....488
MA2509, description and measuring....490
MA2510, description and measuring....492
MA2512, description and measuring....494
MA2602, description and measuring....496
MA4220, description and measuring_{11-00-23}....498
MA4220, description and measuring_{11-02-54}....500
MA4221, description and measuring_{10-57-02}....502
MA4221, description and measuring_{10-59-01}....504
MA4228, description and measuring....506
MA4603, description and measuring....508
MA4710, description and measuring....510
MA4720, description and measuring....512
MA9172, description and measuring....514
MA9173, description and measuring....516
MA9174, description and measuring....518
MO2502, description and measuring....520
MO2505, description and measuring....523
MO3301, description and measuring....525
MO6401, description and measuring....527
Machine, Calibration....529
PPID 437 explanation....536
PWM2303, description and measuring....537
PWM2602, description and measuring....539
PWM4225, description and measuring....541
PWM4226, description and measuring....543
PWM4227, description and measuring....545
PWM6601, description and measuring....547
PWM6602, description and measuring....549
Power supply I-ECU, description and measuring....551
Power supply T-ECU, description and measuring....553
Power supply V-ECU, description and measuring....555
Power supply V2-ECU, description and measuring....557
Power supply, ACM (Aftertreatment Control Module), description and measuring....559
R2701, description and measuring....561
R4201, description and measuring....563
RE02, description and measuring....565
RE06, description and measuring....567
RE09, description and measuring....569
RE10, description and measuring....571
RE15, description and measuring....573
RE2501, description and measuring....575
RE6401, description and measuring....577
RE8712, description and measuring....579
SAE J1708_1587 Information link, description and measuring....581
SAE J1939_CAN1 Control link, description and measuring....584
SAE J1939_CAN2 control link, description and measuring....587
SAE error codes, translation to error messages, general....590
SAEJ1939_CAN7 Control link, description and measuring....592
SE2203, description and measuring....595
SE2301, description and measuring....597
SE2303, description and measuring....599
SE2309, description and measuring....601
SE2512, description and measuring....603
SE2519, description and measuring....605
SE2520, description and measuring....607
SE2521, description and measuring....609
SE2522, description and measuring....611
SE2523, description and measuring....613
SE2524, description and measuring....615
SE2525, description and measuring....617
SE2526, description and measuring....619
SE2603, description and measuring....621
SE2606, description and measuring....623
SE2701, description and measuring....625
SE2702, description and measuring....627
SE2703, description and measuring....629
SE4201, description and measuring....631
SE4405, description and measuring_{04-27-34}....633
SE4405, description and measuring_{04-28-38}....635
SE4406, description and measuring....637
SE4407, description and measuring....639