Volvo L90D Wheel Loader Repair Service Manual

Description

Table of Content L90D Service Information

• GENERAL
  • DESCRIPTION, COMPLETE MACHINE
    • General
      • Product identification plates
  • SPECIFICATIONS
    • General
      • Tightening torques
      • Tightening torques
      • Volvo standard tightening torques
  • TRANSPORT INSTRUCTION.; STORAGE INSTRUCTION; OPERATING INSTRUCTION
    • General
      • Transporting the machine
  • STANDARD TIME
    • General
  • TOOL
    • General
      • Section 4 Power transmission

• STANDARD PARTS, SERVICE
  • LUBRICANT; FUEL; OTHER FLUID
    • General
      • Recommended lubricants
  • SERVICE
    • Maintenance
      • Charging of batteries
      • Cleanliness, brake and hydraulic systems
      • Repairing the hydraulic system
      • Safety filter (secondary filter)
    • Emergency measures
      • Manual release of parking brake, L90D
        (later version)
      • Manual release of parking brake, L120D
      • Manual release of parking brake, L90D
      • Starting with booster batteries
      • Transporting wheel loader on another vehicle

• ENGINE WITH MOUNTING AND EQUIPMENT
  • GENERAL
    • General, engine installation and its function
      • Engine, installing
      • Specifications, tightening torques
      • Specifications, capacities
      • Specifications, general
      • Specifications, tightening torques
  • ENGINE
    • Cylinder head
      • Description, cylinder head
    • Cylinder block with crankcase ventilation
      • Description, pistons and piston rings, L90D
      • Description, cylinder block
    • Valve mechanism
    • Engine transmission; camshaft
      • Description, engine transmission
    • Crank shaft; connecting rod; vibration damper; fly wheel
      • Description, crankshaft
  • LUBRICATING SYSTEM
    • General, common info about 221 – 224
      • Description, lubrication and oil system
      • Specifications, L120D
    • Oil cooler
      • Oil cooler, description
  • FUEL SYSTEM
    • General (common info about 233 – 238)
      • Description, general
    • Fuel pump; filter; strainer
    • Fuel tank; fuel filling pump
      • Specifications, capacities, L120D
    • Injection pump; regulator; pump companion
      • Injection timing, checking and setting
      • Specifications, general, L120D
    • Injector; delivery pipe
      • Copper tubes for injectors, changing
  • INLET SYSTEM; EXHAUST SYSTEM
    • Turbo charger
    • Air cleaner with connections; air pre-heater
      • Specifications, air cleaner
  • COOLING SYSTEM
    • General, common info about 261 – 269
    • Radiator, mounting and connections included
      • Radiator, removing and installing
    • Coolant pump; thermostat
      • Coolant pump for Intercooler,
        removing and installing
      • Hydraulically driven cooling fan,
        checking and adjusting speed
      • Hydraulically driven cooling fan L120D, description
      • Hydraulically driven cooling fan,
        checking and adjusting max. pressure
  • ENGINE CONTROL
    • Stop control
      • Stop solenoid, adjusting stroke
      • Stop solenoid, troubleshooting advice

• ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
  • GENERAL
    • Comprehensive info, electrical system
      • 2 Software functions, engine
      • 3 Software functions, electrical system
      • 4 Software functions, power transmission
      • 5 Software functions, brakes
      • 6 Software functions, steering system
      • 9 Software functions, hydraulic system
      • Air filter pressure
      • APS II
      • Axle oil temperature
      • Back-up alarm
      • Boom Suspension System (BSS)
      • Brake pressure
      • Brake test
      • Break in computer communication
      • Central lubrication
      • Communication with data buses
      • Control units, software functions
      • Coolant temperature, engine
      • Coolant temperature, outlet, radiator
        (L120D with hydraulically driven radiator fan)
      • Description of software functions table
      • Differential lock
      • Downshift audible signal (beep)
      • Electrical system, description
      • Electrical system, instructions for working on the electrical system
      • Electrical system, specifications
      • Electronic control system, description
      • Engine oil pressure
      • Engine Shut Down (power reduction)
      • Engine Shutdown
      • Engine speed for V-ECU
      • Fuel level
      • Gear selector
      • Gearshifting solenoids
      • Hydraulic oil temperature
        (L120D with hydraulically driven radiator fan)
      • Instrument control unit I-ECU, functional description
      • Interval wiper
      • Limp-Home, by-passed V-ECU
      • Output brake pressure
      • Overspeed transmission
      • Parking brake, electric
      • Parking brake, mechanical (L90D)
      • Preheating of induction air
      • Radiator fan control
        (L120D with hydraulically driven radiator fan)
      • Reduced computer communication
      • Secondary steering
      • Service interval
      • Starter inhibitor
      • Starter motor engagement
      • System voltage
      • Transmission disengagement
      • Transmission oil filter
      • Transmission oil pressure
      • Transmission oil temperature
      • Travel speed
      • Tyre radius
      • Vehicle control unit V-ECU, functional description
      • Wiping during and after washing
  • BATTERY; ENERGY STORAGE SYSTEM; MOUNTING PARTS
    • General, common info about 311 – 313
      • Battery, charging
      • Battery, description
      • Battery, specifications
  • ALTERNATOR; CHARGING; ELECTRIC MOTOR; ELECTRIC DRIVES
    • General, common info about 321 – 322
      • Alternator, description
      • Alternator, specifications
  • STARTING SYSTEM
    • General, common info about 331 – 334
      • Starter motor, specifications
      • Starting system, description
    • Electric air pre-heater, excluding element
      • Preheating, description
  • LIGHTING
    • General, common info about 351 – 356
      • Lighting, description
      • Lighting, specifications
  • CABLE; FUSE; RELAY
    • General, common info about 371 – 379
      • Chassis connections
      • Electrical components
      • Electrical symbols and designations
      • Explanations of cable and component markings
      • Key to communication cables
      • Positive feed
      • Signal earth
      • Wiring diagram 8.
        Rotating beacon, direction indicators, brake lights
      • Wiring diagram 11.
        Gearshifting solenoids, transmission disengagement
      • Wiring diagram 12.
        Sensor transmission oil, mode selector, kickdown
      • Wiring diagram 19.
        Heating, ventilation, air conditioning (AC)
      • Wiring diagram 22.
        Work hydraulics, 3rd, 4th, 5th hydraulic functions
      • Wiring diagram 23.
        Boom Suspension System (BSS), hydraulic oil temperature
      • Wiring diagram 32.
        Mechanical parking brake with rider truck safety norms
      • Wiring diagram 32B.
        Parking brake with rider truck safety norms
    • Electrical distribution box; fuse box; junction box
      • Electrical distribution box, description
  • INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM
    • General, common info about 383 – 387
    • Warning/information unit, display unit
      • Display panel and keypad, general
      • Display panel, general
      • Display panel, information displays
      • Display panel, initial display
      • Display panel, operating display
      • Display panel, setting
      • Middle instrument panel with warning lamps
      • Service display unit, axles and brakes
      • Service display unit, electrical control input signals 1
      • Service display unit, electrical control input signals 2
      • Service display unit, electrical control input signals 3
      • Service display unit, electrical control output signals 1
      • Service display unit, electrical control output signals 2
      • Service display unit, electrical input sensor
      • Service display unit, electrical system battery voltage
      • Service display unit, engine
      • Service display unit, general
      • Service display unit, hydraulics
      • Service display unit, settings
      • Service display unit, transmission

• POWER TRANSMISSION
  • GENERAL
    • General, common info about 410 – 436
      • Specifications, L90D
  • CLUTCH; TORQUE CONVERTER
    • Clutch control, manual or fixed
      • Specifications, L90D and L120D, general
    • Hydrodynamic coupling, torque converter
      • Specifications, L120D
  • TRANSMISSION, HYDRAULIC CONTROL
    • General
      • Specifications, capacities
      • Specifications, general
      • Specifications, weight
    • Transmission, hydraulic control
      • Clutch pressure chart, L90D∗
      • Clutch pressure chart, L120D∗
      • Gear selector valve, description
      • Hydraulic transmission, checking oil pressure
      • Symbol diagram, HT131, L90D
      • Symbol diagram, HT205, L120D
      • Transmission, installing
  • GEARBOX,
    • Distributing gearbox
      • Specifications, capacities
  • FRONT AXLE; REAR AXLE
    • General, common info about 461 – 468
      • Specifications, L90D, general
      • Specifications, L120D, general
      • Specifications, L120D, weight
    • Front axle
      • Front axle, installing
      • Specifications, L90D, capacities
      • Specifications, L120D, capacities
    • Rear axle 1
      • Rear axle, installing
      • Specifications, capacities
    • Differential lock, with control
      • Differential lock, adjusting

• BRAKE
  • GENERAL
    • Comprehensive info about brakes
  • WHEEL BRAKE
    • General, common info about 511 – 519
      • Specifications, general
  • HYDRAULIC BRAKE SYSTEM
    • General, common info about 520 – 522
      • Brake system, bleeding
      • Brake system, retardation, checking function
      • Foot brake pedal, adjusting angle and pedal clearance
      • Pressure in circuit, checking and adjusting
    • Brake valve
      • Specifications, general
    • Brake accumulator; hydraulic pump
      • Discarded accumulators
      • Specifications, L120D, general
  • PARKING BRAKE
    • General, common info about 551 – 554
      • Parking brake (hydraulic), brake pad
        replacement, later version
      • Parking brake (hydraulically controlled), checking and adjustment, later version

• STEERING
  • GENERAL
    • Comprehensive info, steering
  • STEERING
    • General, common info about 641 – 647
      • Hydraulic diagram, steering,
        from and including chassis no. 17372
      • Hydraulic diagram, steering, incl. lever steering (CDC)
      • Hydraulic diagram, steering, incl. lever steering (CDC)
        and secondary steering
      • Hydraulic diagram, steering, incl. secondary steering
      • Hydraulic diagram, steering, from and
        including chassis no. 14445
      • Hydraulic diagram, steering, incl. lever steering (CDC)
      • Hydraulic diagram, steering, incl. lever steering (CDC) and secondary steering
      • Hydraulic diagram, steering, incl. secondary steering
    • Hydraulic equipment
      • Hold (stand-by) pressure and working pressure,
        checking and adjusting
      • Shift valve L120D, description
      • Shift valve, reconditioning (removed)
      • Specification L120D, general
      • Steering pump, description
      • Steering valve, description
    • Supplementary steering
  • LEVER STEERING
    • General
      • Hydraulic system, description
      • Lever steering, checking and adjusting control valve
      • Wiring diagrams 17 and 9

• FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
  • GENERAL
    • Comprehensive info about frame and track unit/wheels
  • FRAME
    • General, common info about 711 – 718
      • Specifications, tightening torques
    • Frame, complete
      • L120D specifications, weight
    • Protection; belly plate; bumper
      • Specifications, weight
    • Counterweight
      • L120D specifications, weight
  • WHEELS; TRACKS; TYRE; HUB; DRUM
    • General, common info about 771 – 775
      • L120D specifications, weight

• MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
  • CAB, NAKED; CANOPY
    • General
      • Cab suspension, description
      • Cab, installing
      • Cab, removing
      • Tightening torques
  • AIR CONDITIONING UNIT
    • General, common info about 872 – 877
    • Cooling unit
      • Air conditioning, checking performance
      • Air-conditioning unit, specifications
      • Evaporator in the air-conditioning unit, cleaning

• HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
  • WORKING HYDRAULICS; SERVO HYDRAULICS
    • General, common info about 911 – 917
      • Hydraulic diagram, working hydraulic system
      • Hydraulic diagram L90D, complete
      • Hydraulic diagram L120D, complete
      • Hydraulic diagram, working hydraulic system
        incl. attachment locking and 3rd/4th function
      • Hydraulic diagram, working hydraulic system
        incl. attachment locking and 3rd function
      • Specifications, L120D, capacities
      • Specifications, general
    • Working hydraulics
      • Shock and anti-cavitation valve
      • Specification L120D, general
      • Specification L90D, general
      • Specifications, L120D, capacities
      • Specifications, L90D, capacities
      • Specifications, weight
    • Pump, working hydraulics
      • Back-up valve, opening pressure, checking
      • L90D specifications, weight
      • L120D specifications, weight
      • Shock valve, lift function, checking and adjusting
      • Shock valve, tilt function, checking and adjusting
      • Specification L90D, general
      • Specification L120D, general
      • Specifications, tightening torques
    • Servo hydraulic system
      • Pressure back-up for servo circuit,
        checking accumulator
      • Servo pressure, checking and adjusting
        (machine with separate attachment locking)
      • Servo pressure, checking and adjusting
        (machine without separate attachment locking)
      • Servo pressure, checking by spool in control valve
      • Servo valve, functional description
      • Specification L90D, general
      • Specification L120D, general
      • Specifications, weight
    • Other hydraulic equipment
      • Boom Suspension System (BSS400), checking function
      • Boom Suspension System (BSS400), electrical system description
      • Boom Suspension System (BSS400), hydraulic system description
      • Precharge pressure in accumulators,
        checking and adjusting
      • Pressure reducing valve (CT8) for
        Boom Suspension System, adjusting
      • Specification L120D, general
  • UNIT, LOAD HANDLING
    • Lifting frame work with mounting and link arm system
      • L90D specifications, weight
      • L120D specifications, weight
      • Specification L90D, general
      • Specification L120D, general
      • Specifications, tightening torques
      • Tilt cylinder