Axles: Volvo, fully floating axle shafts with planetary-type hub reductions. Cast-steel axle housing. Fixed front axle and oscillating rear axle. Engine: 6-cylinder, in-line, direct-injected, turbocharged, intercooled 4-stroke diesel engine with wet replaceable cylinder liners.
Air cleaning: three-stage. SAE J gross Electrical system with circuit boards, well protected by fuses. The system is pre-wired for installation of optional equipment. Central warning system: Central warning light for the following functions, buzzer with gear engaged : Engine oil pressure, transmission oil pressure, brake pressure, parking brake, axle oil temperature, steering system pressure, coolant temperature, transmission oil temperature, hydraulic oil temperature, overspeeding in engaged gear, brake charging, computer malfunction.
Battery capacity Cold cranking capacity, ea Reserve capacity, ea Alternator rating Starter-motor output Parking brake: Enclosed wet multi-disc brake built into the transmission.
Spring-loaded application. Electro-hydraulic release via a switch on the instrument panel. Automatically applied when the key is turned off.
The TP-linkage uses a very open bucket design, has very good roll back in all positions and fills the bucket very well. This means that the actual volume carried is often larger than the rated capacity of the bucket.
Bucket fill factors for different materials and how they affect the actual bucket volume are shown in the table. Example: Sand and gravel. Result: The 3,3 m3 bucket carries 3,5 m3. For optimum stability always consult the bucket selection chart. The table shows optimum bucket choice with regard to the material density.
Service brakes: Volvo, dual-circuit system with nitrogencharged accumulators for dead engine braking. Fully hydraulically operated, enclosed internal oil circulation-cooled, outboard mounted disc brakes.
Transmission declutch during braking can be preselected with a switch on the instrument panel. Brake performance test in the Contronic II system. A simple and reliable brake system with few moving parts. Selfadjusting oil circulation cooled wet disc brakes give long service intervals. Brake wear indicator and brake test in Contronic II are included in the brake system. The Volvo engine offers high torque and quick response at low rpm.
The machine operates efficiently at low engine speeds which contributes to good fuel economy, less noise, reduced wear and longer life. Torque multiplication Measured with tires Front axle Rear axle Oscillation, rear axle Transmission: Volvo Power Shift transmission of countershaft type with single lever control.
Fuel tank Starta motorn och kontrollera funktionen. Read all signs and instructions on the machine and the safety instructions in the operators manual, before you start working on the machine. The installation instructions are based on the use of special tools, the E-tool and standard tools generally available on the market, and also on our operators manuals and service manuals. The equipment should be installed by qualified personnel of an authorised workshop.
Volvo CE Customer Support AB disclaims all responsibility if tools and work methods other than those described in the instructions are used. Connect the hose from the left lifting arm to the left port on the change-over valve, marked A1. Connect the hose from the right lifting arm to the right port on the change-over valve, marked B1. Use the existing flange halves and the flange bolts.
See Fig 4, 5 and Fig. Fit the hoses and O-rings on the change-over valve for the 4th function. Connect the hose 7 to port B2 and the hose 9 to port A2. See Fig. Fit the hoses on the lifting frame. Fit the nipples, sealing washers and the dust cover. Use the existing clamps and attachments for the 3rd hydraulic function. In those cases the machine is equipped with an attachment lock, must the terminal block removes and moves to the left side of the terminal block for the 4th hydraulic function.
The hose from port A on the terminal block connects to port PS on the right side of the change-over valve. The hose from port B on the terminal block connects to port PS on the left side of the change-over valve. Connect the switch contact SW to the existing cable harness under the control lever carrier. Contact marked SW Connect the contact marked MA on the cable harness to the solenoid valve MA on the front frame.
Clamp the cable harness tight to the existing point of the attachment. In those cases the machine is equipped with the differential lock, replace the clamp with a double clamp. Part No. B The 3rd function to the left lifting arm, port A1 on the change-over valve. C Port PB on the change-over valve to the port A1 on the control valve. D Port PA on the change-over valve to the port B1 on the control valve.
E Port PS, right side on the change-over valve to the port A on the terminal block on the front frame. F Port PS, left side on the change-over valve to the port B on the terminal block on the front frame. G The 4th function to the right lifting arm, port B2 on the change-over valve. H The 4th function to the left lifting arm, port A2 on the change-over valve. This Service Bulletin is to be considered as technical information only and is not subject to any reimbursement programs outside normal warranty.
Cause Remanufactured AC compressors are not filled with oil when delivered from the warehouse. The most common reason for claiming remanufactured AC compressors is seized AC compressor. Action To make sure the remanufactured AC compressor is filled with oil before installing it to the machine, a tag with information about the need to fill the AC compressor with oil prior to installation has been added.
AC safety, description If system pressure becomes too high, above 21—25 bar — psi , or too low, below 1—2 bar SE closes the circuit again at 3 bar and 14—18 bar — psi respectively. RE will now remain activated until its supply of current is broken with SW Even if the pressure is normal and SE closes the operating current circuit so that RE is activated, the air-conditioning unit will not restart because RE is activated and so does not supply current to MA via RE connection If the pressure monitor turns off the air-conditioning unit because system pressure is too high or too low, the operator must turn off the air-conditioning unit and then turn it on again so that it will restart.
This function is provided to inform the operator that the pressure has been abnormal. CAUTION After a stoppage caused by a pressure fault in the system, the air-conditioning unit must always be checked by authorized personnel. Maintain greatest possible cleanliness during all work with the brake system. Wipe off all pipe and hose connections before they are disconnected. Plug all pipes, hoses, etc. If the functional check of the brake system indicates that one or more of the accumulators has insufficient precharge pressure or is missing precharge pressure, each accumulator can be checked individually as follows:.
If the system is opened without first releasing the pressure, oil under high pressure will rush out. Release the brake system pressure by depressing the brake pedal repeatedly 30—40 times. Pressure checking 4. Check the accumulators one at a time. Connect the checking equipment according to [Invalid linktarget].
Pump oil into the accumulator. After a few pump strokes, the pressure will increase rapidly to the precharge pressure and will then continue to increase slowly.
Precharge pressure: min. Installing 6. Install the accumulators. Check functionality according to [Invalid linktarget]. It frequently happens that construction machines work in environments where inflammable material collects on the machine. To reduce the risk of fire, check the following points when carrying out maintenance work on the machine.
Guard over silencer Protective screen for radiator to prevent collection and blockage by wood chips, sawdust and similar. Cyclone pre-cleaner of turbo ll type to increase the cleaning capacity, particularly against coarse dust, sawdust, wood chips etc.
This is self-emptying and is not connected to the ejector connection on the exhaust pipe. This connection is plugged, meaning that the spark extinguishing function of the silencer is still effective. Keep the machine and equipment free from dirt, waste material, fuel and oil spillage. Instruct the machine owner to keep the machine clean at all times. If high-pressure washing is used for cleaning, take care not to damage the insulation on the electric cables, which can happen even at a relatively low water pressure and temperature.
Engine Clean off all debris from the engine, particularly around the exhaust system, turbocharger and alternator. Check that there is no fuel or oil leakage and that the hoses are clamped in such a way that no chafing occurs. Fuel filling. Take care when filling up with fuel that none is spilt outside the filling pipe. If fuel has run out when filling up, wipe it up immediately. Do not fill up with fuel near an open fire. If the machine is left unattended, always turn off the battery disconnection switch.
Check the electric cables for abrasion and that they are not subjected to wear. Batteries Battery and starter motor Alternator and starter motor Cable to engine starter element Wire to engine stop solenoid In cases where these cables have been disconnected it is important to make sure that they are fitted and clamped in such a way that there is no risk of abrasion. Unfused cables must not come into contact with oil or fuel hoses. When fitting any extra equipment, make sure that all cables are fused and arranged and clamped in such a way that there is.
Check that there is no oil leakage and that pipes and hoses are protected, undamaged and properly clamped. Protecting plates bottom guard plates On machines which are provided with bottom guard plates it is important that debris which has collected inside and on the plates is removed every day. The guard plates must be handled with care as they are very heavy. Instructions for correct handling of the plates can be found in the instruction book or supplement for the respective machine.
Hydraulic system Check that there is no leakage. Welding Take great care when carrying out welding work on the machine. Make sure that fire extinguishing equipment is available. Take particular care when welding close to fuel and oil lines and tanks. Later model wheel loaders engine stop is controlled through the ignition switch.
Get out of the cab Turn off the main current with the battery disconnection switch Start fire extinguishing work and alert the fire service if necessary. Introduction The oil consumption is in many cases used as a measure of the condition of the engine. Normally all engines use a certain amount of oil. The film of oil that lubricates the upper piston rings is combusted at the same time as the fuel, which gradually causes the oil level to drop.
There are of course also other factors that affects the oil consumption, e. Here follows a short description of influencing factors, checking and measuring methods and which action can be taken to manage any problems. Factors influencing the oil consumption Larger engines have as a rule a higher oil consumption than small engines. Oil has the ability to penetrate the smallest openings. All affected bolts should be check-tightened.
A too high oil level causes more oil to be thrown up on the cylinder walls and this increases the oil consumption. The oil level should be kept slightly below the full mark on the oil dipstick. Only check the oil level a few minutes after the engine has stopped to allow the oil to run back to the sump, see Fig. Figure 1 Too thin oil will result in a higher oil consumption because of difficulties of maintaining a sealing film of oil between piston rings and cylinder wall at high temperatures.
Too thick oil provides unsatisfactory lubrication and thereby increased wear, which in the long run will result in increased oil consumption. Continuously high engine speed will result in warmer and thereby thinner oil.
Increased oil consumption as described above. Frequent use of engine retarding causes increased oil consumption. Faulty and worn piston rings, oil scraper rings, ring grooves, pistons, cylinders, valve guides result in high oil consumption, as oil leaks into the combustion chamber.
Abnormally low oil consumption Some attention should also be given to low oil consumption, because the low oil consumption may be illusory. Used up oil may have been compensated through condensation water, coolant or fuel dilution, thus keeping the level unchanged. Intermixed coolant gives the oil a greyish tint, whereas intermixed fuel does not show. These factors result in impaired lubrication and should lead to more frequent oil changes. Intermixed fuel also mean an additional safety risk as the flash point of the oil is lowered.
Take samples of lubricating oil and have them analysed. On an engine that has reached working temperature, the oil dipstick can be read off three minutes after stop. If the engine has been started, but not reached working temperature, wait for at least five minutes. Copy the enclosed report form and make a note of the hour recorder reading at the start of the test period.
Begin with full fuel tank and new oil filled to the upper marking on oil the dipstick. Note the hour recorder reading and amounts every time you fill fuel, oil or coolant. Do not top up the oil until the level has reached the minimum line. Never fill oil to above the maximum line. In case the oil is changed during the test period, check the oil level before draining and then fill to the same level.
At the end of the test period, top up with oil to the maximum line and make a note of the amount. Add up the noted information which then forms the base for calculating the oil consumption. The oil consumption is always stated as a relation between consumed oil and the amount of used fuel during the same period.
Example: An engine has during hours used 18 litres of oil and litres of fuel. Only after — operating hours, when the piston rings have bedded-in in the cylinders, is it possible correctly to determine the oil consumption. Oil consumption of 0. A copy of the report form should be enclosed with the claim. In stage 1 a cyclone cleaner separates heavier particles which are automatically carried away through an ejector in the exhaust system. The main filter stage two is a paper filter that can be cleaned and therefore has lengthy replacement intervals.
However, it should be changed after it has been cleaned five times, or if it is damaged. It catches the impurities and so quickly becomes clogged, which is indicated by the warning lamp. To improve reliability in demanding environments the machine can be equipped with an oil-bath air cleaner. This is connected in series before the regular air cleaner, the filter changing intervals of which are thus extended. Components such as the recirculation filter, evaporator and condenser must be clean 1.
Warm up the machine to normal working temperature and park it in the shade. Measure the ambient temperature and relative humidity. Do this in the shade. Close windows and doors. Ventilation hatches should be closed and all air outlets in the cab should be fully open.
Rear wall, right air nozzle 4. Run the engine at rpm. Set the cab fan switch to position 4, set the recirculation control to maximum and the heater control to minimum. Turn on the air conditioning. The performance of the air conditioning is checked by measuring the temperature of the air coming out of the right air vent on the rear wall. Within a time period of max. Measured at the right-hand air nozzle in the rear wall.
Luftkonditionering Satslista Art. Kit no Art. Placera brickorna under skruvskallarna. Se Fig. Klamma slangen mot ramen. Air filter pressure The function monitors how clogged the air filter is and informs the operator when it is time to change it or if there is a system malfunction.
The values should be regarded as guiding values. A lower pressure on the low-pressure side may occasionally be observed. Using non-approved products may affect warranties in case of component problems. WB gives lower fuel consumption, maximizes machine performance and improves the durability of the machine. Only when using Volvo Super Wet Brake Transaxle Oil WB will the machine achieve maximum performance and service life, as well as the best possible fuel economy.
Alternator, description The alternator is a 60A alternating current generator with a normal charging voltage of Machines operating in an aggressive environment may as an alternative be fitted with a brushless 50 A alternator. Machines that have been equipped with a large number of components using electric power, such as extra work lights, can be equipped with a A alternator as an alternative. When the engine is turned off, the batteries normally give a voltage of approx.
If the batteries do not seem to take a charge, this may be due to incorrect charging voltage from the alternator. Also check the acidity in the battery electrolyte, see [Invalid linktarget]. Resistance across rotor winding Resistance in stator winding. Publication numbers for the Service Manuals concerned. Lock the adjusting screws with the lock nuts. The following silencers have been tested and been given approval numbers according to the table below.
The silencer with part No. This SB is to be considered as a technical information and comprises normal warranties within the rules for the same. APS II The function controls gearshifting based on the current operating mode and determines which gear should be used and when shifting should take place to protect the transmission.
Engine brake downshifting is activated with SW Transmission disengagement is activated with SW Directional gear. When shifting from N neutral to F or R, the travel speed gear is changed from selected to engaged gear as in the following: Selected - Engaged gear Figure 2 Mode selector, SW Start When starting from a stationary machine with the gear selector in position 3 or 4, directional gear F or R is selected and the machine starts in 2nd gear.
When the machine is in motion, starting takes place in 3rd gear, as in the table. Changing travel direction Change of travel direction at lower travel speed takes place in 2nd gear. If travel speed is too high, 3rd gear is engaged first and then, when the machine is stationary, 2nd gear engages as in the table below.
Gear 2 3 Automatic shifting Shifting is automatic. Automatic shifting takes place between gears, Forward: 2nd — 3rd — 4th; Reverse: 2nd — 3rd — 4th. Downshiftingto 1st gear does not take place until Kickdown has been activated with any of the Kickdown controls on the steering column, lever console or lever steering if lever steering is installed. Upshiftingto 2nd gear takes place on further activation of any of the Kickdown controls or if certain critical engine speed and travel speed limits are exceeded.
The gearshifting points vary depending on whether the engine is pulling or retarding. At least 1 second must elapse between two upshifts or downshifts. The time between an upshift and a downshift or the reverse must be at least 3 seconds.
Kickdown Kick-down means downshifting to 1st gear by activating the Kick-down function on the gear selector control, or on the control lever console. The time for downshifting to 1st gear depends on the mode selector setting as well as the engine and travel speeds. Engagement of 1st gear is indicated by a short signal from the buzzer.
In order to then upshift to 2nd gear, the Kick-down button must be activated once again. Changing travel direction Change of travel direction at a lower speed takes place in 2nd gear. If travel speed is too high, 3rd gear will be engaged first and then, when speed has been reduced, 2nd gear will be engaged.
Additional downshifting to 1st gear, see kickdown. As a safety feature, upshifting to a higher gear takes place if certain critical engine and travel speeds are exceeded. Locking cylinder for attachment bracket with part Nos , , , There have been cases where the locking cylinder in the cast attachment bracket, with part Nos , , , , has worked loose in its attachment.
Because of this, the attachment has been altered in that bolt and support sleeve have been replaced. The bolt has been replaced with one with a bigger diameter and the support sleeve has been replaced with a longer sleeve. The new bolt and sleeve can also be installed on earlier attachment brackets. Item in Fig. Secure the lifting frame at normal working height.
Remove the cover plate over the locking cylinder. Remove the bolt and the sleeve, which fix the cylinder.
Drill so that the existing hole will run through the lower member of the attachment bracket, see item 3 in Fig. Use an 8. Then make the hole wider from the other side. Use a Tap the hole to M12x1. Fix the cylinder and install the new bolt 1 and sleeve 2, see Fig. Tightening torque 85 Nm 85 kgf m 63 lbf ft. Re-install the cover plate and restore the machine. Cause and action It has come to our attention that our customers and dealers are equipping our machines with automatic greasing systems of foreign manufacture.
Be prepared for it when it happens by simply purchasing this service manual for later use! See below for a list of items that most of our manuals cover. Some manuals actually cover more items that are not even listed! This manual came Your Satisfaction is very important to us. The manual includes pictures and easy to follow directions on what tools are needed and how the repair is performed. Just imagine how much you can save by doing simple repairs yourself. Many people buy this manual just to have it around for when the inevitable happens.
Sooner or later, maintenance will need to be performed. Be prepared for it when it happens by simply purchasing this service manual for later use!
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