Volvo L45H Compact Wheel Loader Workshop Repair Service Manual PDF - MVLVCONL45H.zip
Full service and repair documentation, including Electrical Wiring Diagrams, for the Volvo L45H Compact Wheel Loaders — everything you need to service, troubleshoot, fix, and rebuild these machines with the skill of a professional technician.
This workshop service and repair manual for the Volvo Construction L45H Compact Wheel Loaders contains:
* 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 L45H Compact Wheel Loaders Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,627 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
0 - GENERAL.....2
00 - DESCRIPTION; COMPLETE MACHINE.....3
Machine Dimensions_{10-19-44}.....3
Machine Dimensions_{10-20-14}.....5
03 - SPECIFICATIONS.....7
Measurement conversion tables.....7
Volvo standard tightening torques.....12
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION.....14
Transporting the machine.....14
07 - STANDARD TIME.....17
Operation numbers for additional work.....17
08 - TOOL.....19
E-2000.....19
E-tool Cab support.....21
Infrared Thermometer.....22
1 - STANDARD PARTS, SERVICE.....26
16 - LUBRICANT; FUEL; OTHER FLUID.....27
AdBlue®_DEF .....27
Alternative fuels.....33
Coolant with freezing and corrosion protection.....36
Lubricants and filling capacities.....38
Recommended lubricants .....40
17 - SERVICE.....42
AdBlue®_DEF pump unit filter, replacing.....42
AdBlue®_DEF tank breather filter, replacing.....45
Arrival Inspection, according to Inspection Programme.....47
Axle oil, changing.....48
Battery, checking.....51
Brake pressure and function, checking.....52
CE-marking, EMC-directive.....56
Cab main filter, replacing.....60
Charging batteries.....62
Checklist after a fire or heat exposure.....63
Cleanliness, braking and hydraulic system.....64
Coolant freezing point, checking.....65
Coolant level, checking.....67
Coolant, changing.....69
Decontamination.....71
Delivery Inspection, according to Inspection Programme.....73
Delivery Instructions, according to Inspection Programme.....74
Diesel particulate filter, checking and cleaning.....75
Diesel particulate filter, regenerating.....81
Electric welding.....82
Engine air cleaner primary filter, replacing.....83
Engine air cleaner secondary filter, replacing.....85
Engine belt tension, checking.....86
Engine oil and filter, changing.....88
Engine oil level, checking.....90
Environmental handling for the future.....91
Environmentally hazardous fluids.....93
Environmentally safe handling.....94
Fire prevention measures.....96
Fuel filters, replacing.....99
Fuel tank breather filter, replacing.....101
Health hazards with paint, plastics and rubber.....103
Hydraulic oil filters, replacing.....105
Hydraulic oil level, checking.....107
Hydraulic oil, changing.....109
Hydraulic pressure, checking.....111
Hydraulic tank sediment, draining.....114
Leakage, checking.....116
Loader boom, safety strut.....117
Lubrication.....120
MATRIS and Tech Tool, reading.....123
Maintenance of Stored Machines, according to Inspection Programme.....124
Maintenance service, every 10 hours.....125
Maintenance service, every 1000 hours.....126
Maintenance service, every 1500 hours.....128
Maintenance service, every 2000 hours.....130
Maintenance service, every 3000 hours.....132
Maintenance service, every 50 hours.....134
Maintenance service, every 500 hours.....135
Maintenance service, every 6000 hours.....136
Maintenance service, every 8000 hours.....137
Parking brake pads, checking.....138
Propeller shaft movement, checking.....139
Radiator, cleaning.....141
Safety concerns everybody!.....143
Safety rules when servicing.....145
Safety when handling accumulators.....148
Safety when handling oils and fuel.....149
Safety when handling the machine.....150
Safety when lifting and supporting complete machine.....154
Safety when using lifting equipment.....156
Safety when working on hydraulic systems.....158
Safety when working with batteries.....160
Safety when working with refrigerant.....163
Service and maintenance.....166
Service brake disc wear, checking.....168
Service position 1_{09-33-29}.....170
Service position 1_{10-03-19}.....172
Service position 2_{09-33-57}.....174
Service position 2_{10-04-11}.....176
Service.....178
Software update, checking.....179
Some simple rules regarding tyre handling.....183
Starting with booster batteries.....185
Steering cylinders, locking of pivot pins, checking.....187
Tech Tool, operations_ .....189
Test running and checking.....190
Towing.....191
Tyre wear and air pressure, checking.....192
Valves, adjusting .....193
Waste handling.....199
Water separator, checking.....200
Wheel nuts torque, checking.....202
Work on the machine's electrical system.....203
Working in environmentally contaminated areas.....204
Working under raised boom.....205
2 - ENGINE WITH MOUNTING AND EQUIPMENT.....207
20 - GENERAL.....208
Component locations.....208
Engine control module (ECM), replacing non-programmed.....210
Engine control module (ECM), replacing pre-programmed.....212
Engine, description.....214
Engine, reference values.....220
Tech Tool, Operations_ .....223
21 - ENGINE.....225
Crankcase ventilation, description.....225
Cylinder compression, testing.....226
Engine mounting, tightening torque.....229
Engine, capacity.....231
Engine, installing.....232
Engine, removing.....240
Engine, replacing_{09-14-47}.....248
Engine, replacing_{09-15-12}.....250
Engine, specifications.....253
Engine, tightening torques.....254
Engine, weights.....260
Valve cover, installing.....261
Valve cover, removing.....264
Valves, adjusting.....267
22 - LUBRICATING SYSTEM.....273
Lubrication oil consumption, checking.....273
Lubrication oil pressure, checking.....277
Lubrication system, component locations.....279
Lubrication system, description.....281
Lubrication system, specifications .....286
Lubrication system, tightening torques.....287
23 - FUEL SYSTEM.....290
Carbon dioxide in fuel system, checking.....290
Fuel control valve (FCV), replacing.....296
Fuel pump, replacing.....300
Fuel rail pressure sensor, replacing.....302
Fuel rail, replacing.....304
Fuel system, bleeding.....307
Fuel system, component location.....309
Fuel system, description.....311
Fuel system, specifications.....318
Fuel system, tightening torques.....320
Fuel tank, installing.....328
Fuel tank, removing.....334
High pressure fuel pipes, replacing.....342
High pressure fuel pump, replacing.....344
Injectors, replacing.....347
Pressure relief valve (PRV), replacing.....353
25 - INLET & EXHAUST SYSTEM.....355
ACM (Aftertreatment control module) non-programmed, replacing.....355
ACM (Aftertreatment control module) pre-programmed, replacing.....357
AdBlue®_DEF dosing injector, replacing.....359
AdBlue®_DEF hoses, replacing.....362
AdBlue®_DEF pump unit, replacing.....365
AdBlue®_DEF quality, checking.....371
AdBlue®_DEF tank armature suction filter, replacing_{08-37-44}.....374
AdBlue®_DEF tank armature suction filter, replacing_{08-38-11}.....376
AdBlue®_DEF tank armature, cleaning_{08-38-53}.....378
AdBlue®_DEF tank armature, cleaning_{08-39-21}.....381
AdBlue®_DEF tank armature, replacing.....384
AdBlue®_DEF tank, replacing.....386
AdBlue®_DEF, draining.....391
AdBlue®_DEF.....393
Crystallization of AdBlue®_DEF, checking.....398
DPF (Diesel particulate filter), checking and cleaning.....403
Exhaust Aftertreatment System, description.....404
Inlet and exhaust system, component location.....417
Inlet and exhaust system, description.....419
Inlet and exhaust system, specification.....425
Inlet and exhaust system, tightening torques.....426
Inlet throttle, replacing.....432
Regeneration log, checking.....434
Regeneration process, description.....445
SCR (Selective catalytic reduction) muffler, replacing.....452
Turbocharger, replacing.....458
Wastegate, checking.....461
26 - COOLING SYSTEM.....463
Carbon dioxide in coolant system, checking.....463
Coolant pump, replacing.....469
Cooling fan rpm, specifications.....472
Cooling system pressure, checking.....473
Cooling system, capacity.....475
Cooling system, component location.....476
Cooling system, description.....478
Cooling system, specifications.....482
Cooling system, tightening torques.....484
Fan belt and_or alternator belt, replacing.....486
Reversible cooling fan, description.....489
Thermostat, replacing.....493
29 - MISCELLANEOUS.....495
EGR actuator, replacing.....495
EGR cooler, replacing.....497
EGR reed valve, replacing.....504
EGR system, tightening torques.....509
EGR venturi tube, replacing.....511
Exhaust Gas Recirculation (EGR), description.....514
Exhaust gas recirculation (EGR), component location.....519
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....521
30 - GENERAL.....522
AL3201, description and measuring.....522
Automatic engine shut down, description.....525
BB1 Communication bus, description and measuring.....527
BB2 Communication bus, description and measuring.....530
CU6601, description and measuring.....534
CU9901, description and measuring.....538
Collection of basic data.....540
Component descriptions.....542
Conditions when checking.....545
Electrical system, special instructions for servicing, action when working on machine.....548
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator.....549
Electrical system, special instructions for servicing, electrical components, batteries.....550
Electrical system, special instructions for servicing, electronic components.....552
Electrical system, special instructions for servicing, general.....553
Electrical system, specifications.....555
Electronic control system, description.....556
Error codes, build-up.....562
FX1005, description and measuring.....563
FX1007, description and measuring.....565
FX1008, description and measuring.....569
FX1074, description and measuring.....572
FX1079, description and measuring.....575
General fault diagnosis information.....578
HE2501, description and measuring.....580
HE2511, description and measuring.....582
HE2512, description and measuring.....584
HE2513, description and measuring.....586
Information display, check.....588
Instrument Cluster (IC), description and measuring.....590
Lead and connector checks.....592
Limp home.....596
MA2301-MA2304, description and measuring.....597
MA2517, description and measuring.....599
MA2519, description and measuring.....601
MA2602, description and measuring.....603
MA4220, description and measuring.....605
MA4221, description and measuring.....607
MA4603, description and measuring.....609
MA4710, description and measuring.....611
MA4720, description and measuring.....613
MA8701, description and measuring.....615
MA9172, description and measuring.....617
MA9173, description and measuring.....619
MA9174, description and measuring.....621
MO2503, description and measuring.....623
MO2505, description and measuring.....625
MO3301, description and measuring.....628
MO6401, description and measuring.....631
MO8703, description and measuring.....633
MO8707, description and measuring.....636
PWM2303, description and measuring.....638
PWM2602, description and measuring.....640
PWM6601, description and measuring.....642
PWM6602, description and measuring.....644
Power supply CCM, description and measuring.....646
Power supply ECM, description and measuring.....648
Power supply GPMECU 1, description and measuring.....650
Power supply GPMECU 2, description and measuring.....652
Power supply GPMECU 3, description and measuring.....654
Power supply HMICU, description and measuring.....656
Power supply W-ECU, description and measuring.....658
Power supply, ACM (Aftertreatment Control Module), description and measuring.....660
R2701, description and measuring.....662
RE02, description and measuring.....664
RE09, description and measuring.....666
RE10, description and measuring.....668
RE15, description and measuring.....670
RE2501, description and measuring.....672
RE2502, description and measuring.....674
RE6401, description and measuring.....676
RE8712, description and measuring.....678
SAE J1939-1 SubNet 1, description and measuring.....680
SE2203, description and measuring.....683
SE2301, description and measuring.....685
SE2303, description and measuring.....687
SE2309, description and measuring.....689
SE2511, description and measuring.....691