Volvo BM L50C Wheel Loader Shop Manual
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Volvo BM L50C Wheel Loader Shop Manual
The strength and speed of Volvo BM wheel loaders is the result of an in-house manufactured drive train, composed entirely of robust and compatible Volvo BM components and perfectly matched to the working hydraulics and lift-arm system. ’I‘P Linkage provides superior breakout. capacity and parallel linkage action throughout the lifting range. Thanks to high break- out force in the top position. Volvo BM loaders have no problem picking up logs from high timber trucks. Parallel lift-arm action facilitates stacking of lumber pallets and packages. Handling timber is a precision job. Vfith pilot-operated working hydraulics, it is possible to operate all movements simultaneously with fingertip control. The duty-proven reliable Automatic Power Shift system (APS ll) enables you to concentrate on driving. Productivity-enhaneing technology, long life and high availability have made Volvo BM wheel loaders synonymous with excellence in timber ltzutdling all over the world.
Volvo BM Gare Cab protects the machine’s most important component :
The Volvo BM Care Cah is a protected and ergonomically designed workstation. t’ilowpcrated working hydraulics and a conveniently adjustable operator’s seat enable the openitor to work long shifts with high precision. The curved wind- shield without comer pillars and the large. well-situated glazed areas provide excellent all-round visibility. contribut- ing to safct}r 0n the workplace. Heavy insulation and rubber vibration isolatom tttalte the Volvo BM Care Cab quiet and vibration-free. The cah‘s climate control system supplies tempered, filtered flesh ainAir conditioning is available as an option.
TABLE OF CONTENTS:
Volvo BM L50C Wheel Loader Shop Manual
1 Volvo L50C.................................................................................... 1 1A Volvo L50C................................................................................... 8 2 Volvo L50C.................................................................................... 15 3 Volvo L50C.................................................................................... 36 3rd function, flow control...................................................................... 45 4 Volvo L50C.................................................................................... 46 4th hydraulic function, description............................................................. 53 4th hydraulic function, wiring diagram.......................................................... 54 5th 6th hydraulic functions and attachment...................................................... 55 5th 6th hydraulic functions, adjusting speed flow............................................... 56 5th 6th hydraulic functions, basic adjustment of speed flow..................................... 58 5th 6th hydraulic functions, description........................................................ 60 5th 6th hydraulic functions, draining the quick-action couplings................................ 61 5th 6th hydraulic functions, electrical functions............................................... 62 5th 6th hydraulic functions, monitoring function, checking...................................... 64 5th 6th hydraulic functions, wiring diagram..................................................... 66 AC compressor, fill with oil.................................................................... 68 AC SAFETY, description of function.............................................................. 69 Accumulator, Boom Suspension System,............................................................ 70 Action for reducing risk of fire................................................................ 72 Action to be taken in case of abnormal lubricating oil consumption.............................. 74 Adjusting axial clearance on loader unit........................................................ 78 Air cleaner, specifications..................................................................... 80 Air-suspended operator seat, ISRI............................................................... 81 Alternative lubricants for axles with wet brakes................................................ 83 Amendments in Service Manual Engine, D10B; Drive Axle, AWB 40B and Drive Axle, AWB 41 AWB 50.... 84 Attachment hydraulics GP, description........................................................... 85 Attachment hydraulics GP, wiring diagram........................................................ 87 Attachment locking.............................................................................. 88 Automatic greasing systems of foreign manufacture............................................... 98 Automatic transmission lubricants............................................................... 99 Axle suspension, checking axial and radial clearance............................................ 101 Axle, installing................................................................................ 103 Axle, removing.................................................................................. 105 Battery and alternator test procedure........................................................... 108 Battery, charging............................................................................... 110 Biodegradable hydraulic fluids.................................................................. 111 Boom Suspension System, description............................................................. 114 Boom Suspension System, hydraulic diagram....................................................... 118 Boom Suspension System, safety valve, checking, adjusting....................................... 120 Boom Suspension System, wiring diagram.......................................................... 123 Brake discs, checking wear (with built-in wear indicator)....................................... 124 Brake discs, checking wear (without built-in wear indicator).................................... 126 Brake discs, replacing.......................................................................... 128 Brake system, checking and adjusting pressure in circuit........................................ 135 Brakes.......................................................................................... 137 Capacities and weights.......................................................................... 138 Capacities and weights1......................................................................... 139 Care Track...................................................................................... 140 Change in tightening torque, AWB10.............................................................. 146 Checking speed with multimeter.................................................................. 147 Cleaning of the machine......................................................................... 149 Cleanliness when working on hydraulic systems................................................... 151 Clutch shaft, high-gear......................................................................... 152 Clutch shaft, low-gear.......................................................................... 153 Code key for diodes............................................................................. 154 Codes used in wiring diagrams................................................................... 156 Coding ECU (Electronic Control Unit)............................................................ 164 Cold-starting control, specifications........................................................... 167 Control unit BCU................................................................................ 168 Control unit ECU................................................................................ 169 Control valve, description...................................................................... 171 DEF AdBlue AUS32 sampling, method............................................................... 184 Description of function......................................................................... 187 Description..................................................................................... 188 Description1................................................................................ 188 Description2................................................................................ 192 Description3................................................................................ 198 Description4................................................................................ 200 Description5................................................................................ 201 Description6................................................................................ 202 Description7................................................................................ 204 Description8................................................................................ 207 Detecting leaks with inspection lamp............................................................ 208 Diesel test standards........................................................................... 209 Differential carrier assembly, front axle....................................................... 212 Discontinued recommendation for usage of anti-corrosion agent in cooling system................. 213 E 1664 Lifting tool............................................................................. 214 E 1666 Spanner.................................................................................. 215 E1752 Lifting yoke.............................................................................. 216 ECU, functional check........................................................................... 217 Electric welding................................................................................ 222 Electrical distribution box..................................................................... 223 Electrical system, description of function...................................................... 226 Engine, fitting................................................................................. 228 Engine, removing................................................................................ 230 Engine.......................................................................................... 237 E-tools......................................................................................... 240 Explanations of wiring diagrams,................................................................ 241 Feed pump, checking feed pressure TD40KAE....................................................... 243 Fender.......................................................................................... 245 Flow control for 3rd hydraulic function......................................................... 247 Fluid levels.................................................................................... 254 Foot brake valve (removed), reconditioning...................................................... 255 Foot brake valve, description of function....................................................... 258 Fork arms, information warranty matters, altered procedures..................................... 259 Frame joint bearing, lower, sectional view...................................................... 261 Frame joint bearing, upper, sectional view...................................................... 262 Frame joint, replacing bearings................................................................. 263 Fuel sampling, method........................................................................... 283 Fuel system, air bleeding TD40 KAE, TD40 GFE.................................................... 286 Fuel system, air bleeding TD40GA................................................................ 287 Fuel tank and combined tank unit, changing...................................................... 288 Fuel tank, specifications....................................................................... 291 Functional check................................................................................ 292 Gearbox, checking oil pressure.................................................................. 297 Gearbox, installing............................................................................. 299 Gearbox, removing............................................................................... 305 Gearbox, sectional view......................................................................... 312 General description............................................................................. 313 General description1............................................................................ 314 GRD G700B LabourTimeGuide Old version........................................................... 315 G700B Labour Time Guide Foreword.pdf........................................................ 317 Foreword, Labour Time Guide............................................................. 317 The standard times are issued for the purpose of:................................... 317 The following is not included in the listed times:.................................. 317 Greasing of hydraulic pump drive shaft.......................................................... 417 Headlights, adjusting........................................................................... 418 Hit Belt1....................................................................................... 419 Hit Belt2....................................................................................... 423 Hydraulic diagram basic machine, 3rd 4th,....................................................... 426 Hydraulic diagram basic machine, 3rd4th,........................................................ 428 Hydraulic diagram, basic machine................................................................ 430 Hydraulic diagram, brake system................................................................. 432 Hydraulic diagram, lever steering CDC Basic Machine............................................. 434 Hydraulic diagram, steering system Basic Machine................................................ 436 Hydraulic oil pump, removing and fitting........................................................ 437 Hydraulic pump, description..................................................................... 439 Hydraulic system................................................................................ 441 Hydrostatic pump, removing and fitting.......................................................... 442 Hydrostatic system, checking oil pressure....................................................... 446 Hydrostatic system, neutral position............................................................ 450 Improved securement for cab filter primary filter............................................... 455 Injection pump, fitting and adjusting injection timing, TD40KAE................................. 457 Injection pump, fitting, TD40GFE................................................................ 460 Injection pump, removing TD40GFE................................................................ 464 Injection pump, removing, TD40KAE............................................................... 468 Injection pump, specifications.................................................................. 471 Injection timing adjustment at low engine temp., TD40GFE........................................ 472 Injection timing, checking and adjusting, TD40GA................................................ 474 Injection timing, checking and adjusting, TD40KAE............................................... 475 Injectors and delivery pipes, specifications.................................................... 478 Installation kit for Operators seat1............................................................ 479 Installation kit for Operators seat2............................................................ 483 Instructions for crack in lifting frame......................................................... 489 Instructions for shielded metal arc welding..................................................... 491 Instruments and controls........................................................................ 494 Intercooler, specifications..................................................................... 496 Kit for fitting the radio....................................................................... 497 Lifting arm, replacing bearings A............................................................... 508 Lifting cylinder, replacing..................................................................... 512 Lifting cylinder, sectional view................................................................ 515 Lifting frame, replacing bearings B............................................................. 516 Limp-Home operation, by-passing control units................................................... 521 Lock cylinder for attachment bracket............................................................ 522 Low and high idling speed, checking and adjusting............................................... 523 Menu overview, service display unit............................................................. 525 Monitored functions ECU......................................................................... 526 MS.Internal.Documents........................................................................... 528 New TechTool VCADS Pro interface................................................................ 534 New warranty routines for Bosch diesel equipment................................................ 536 Non - VCE buckets and attachments............................................................... 538 Obligatory measures when repairing the hydrostatic system....................................... 539 Oil analyses.................................................................................... 542 Oil sampling, method............................................................................ 545 Oils for Volvos wheel loaders equipped with AWB axles (Axle Wet Brakes)......................... 552 Other electrical functions controlled by the control unit, ECU.................................. 554 Paper sintered type brake disc and mechanical wear indicator.................................... 555 Parking brake, adjusting........................................................................ 576 Planetary gear.................................................................................. 578 Plugs and restrictors in control valve.......................................................... 579 Portable refillable O-ring kits................................................................. 583 Power transmission.............................................................................. 584 Pressure drop in hydrostatic circuit............................................................ 585 Product identification plates................................................................... 587 Production development list for Volvo BM transmissions.......................................... 588 Protecting grating.............................................................................. 601 Quality of illustrations in technical reports................................................... 603 Raising and supporting machines (up to and including the E models).............................. 606 Rear axle suspension............................................................................ 611 Recommendations for Oil Sampling Intervals...................................................... 612 Recovering reclaiming refrigerant R134a using recovery unit FRS-10 GS........................... 614 Reinforcing lifting frame B-arm attachment (service solution)................................... 635 Repair instructions for attachments............................................................. 637 Repairing hydraulic system...................................................................... 639 Replacing brake discs........................................................................... 640 Replacing operator seat shock absorber.......................................................... 644 Reporting of product misuse & near-miss report.................................................. 646 Reports......................................................................................... 649 Retardation, functional check................................................................... 651 RM Compaction ABG Time Guide Old................................................................ 653 Foreword.................................................................................... 653 Drum........................................................................................ 654 Hydraulic................................................................................... 655 Electrical.................................................................................. 656 Engine...................................................................................... 657 Structural.................................................................................. 658 Drive system................................................................................ 659 Water....................................................................................... 660 RM Compaction Time guide old version............................................................ 661 Drum........................................................................................ 662 Hydraulic................................................................................... 666 Electrical.................................................................................. 670 Engine...................................................................................... 674 Structural.................................................................................. 678 Drive system................................................................................ 686 Water....................................................................................... 690 RM Paving Systems ABG Time Guide Old............................................................ 692 Foreword.................................................................................... 692 Screeds..................................................................................... 693 Hydraulics.................................................................................. 694 Structural.................................................................................. 696 Engine...................................................................................... 697 Drive system................................................................................ 698 Electrical.................................................................................. 699 Rotating beacon................................................................................. 700 Seals........................................................................................... 702 Secondary steering Introduction of non-return valve............................................. 703 Service display unit............................................................................ 704 Service solution for loader unit, improved D-pin locking........................................ 711 Servo pressure, checking and adjusting.......................................................... 712 Servo valve, description........................................................................ 713 Servo valve, single control lever............................................................... 715 Shock valve, lifting function, checking and adjusting........................................... 720 Shock valve, tilting function, checking and adjusting........................................... 723 Software in E-ECU for engines supplied as spare part............................................ 727 Special instructions when working on the electrical system...................................... 728 Special tool catalog............................................................................ 729 General..................................................................................... 729 Index ...................................................................................... 731 Hooks....................................................................................... 743 1. Enviroment and Safety equipment ......................................................... 755 2. Measuring equipment...................................................................... 787 3. Tightening and Loosening tools........................................................... 889 4. Lifting equipment........................................................................ 935 5. Pullers and Pressing equipment........................................................... 959 6. Drifts...................................................................................1041 7. Guide pins and Guide sleeves.............................................................1167 8. Pliers...................................................................................1237 9. Fixtures.................................................................................1249 10. Tech Tool...............................................................................1269 11. Spare parts.............................................................................1279 Special Tools Recommendations...................................................................1303 Specifications, coolant pump and thermostat.....................................................1304 Specifications..................................................................................1305 Specifications1.............................................................................1305 Specifications2.............................................................................1306 Specifications3.............................................................................1307 Specifications4.............................................................................1308 Specifications5.............................................................................1309 Specifications6.............................................................................1310 Specifications7.............................................................................1311 Specifications8.............................................................................1312 Specifications9.............................................................................1313 Specifications10............................................................................1314 Standard tightening torques.....................................................................1316 Standard tightening torques1....................................................................1317 Stand-by pressure, checking and adjusting.......................................................1318 Steering cylinder, reconditioning...............................................................1320 Steering cylinder, replacing....................................................................1323 Steering cylinder, sectional view...............................................................1327 Steering pressure and stand-by pressure, checking and adjusting.................................1328 Steering valve, description.....................................................................1331 Steering valve, reconditioning..................................................................1335 Steering........................................................................................1343 T link, upper, removed, replacing bearings HIJ..................................................1344 Tightening torques..............................................................................1350 Tightening torques1.............................................................................1352 Tilting and lifting cylinders...................................................................1354 Tilting arm, replacing bearings GDF.............................................................1356 Tilting cylinder, replacing.....................................................................1361 Tilting cylinder, sectional view................................................................1365 Time Guide Currrent generation..................................................................1366 Time Guide Old generation.......................................................................2542 Time Guide Previous generation..................................................................3370 Time Guide......................................................................................4160 T-link, lower, removed, replacing bearings GH...................................................4168 Tool box........................................................................................4172 Towing..........................................................................................4174 Transporting a wheel loader on another vehicle..................................................4176 Turbocharger, specifications....................................................................4177 Tyres, various types............................................................................4178 Units connected to control unit BCU.............................................................4180 Units connected to control unit ECU.............................................................4181 Valve adjustment................................................................................4183 Valves, adjusting...............................................................................4185 Ventilation servo casing........................................................................4187 Volvo Product incident accident report & Interview Form.........................................4190 Water separator improvement.....................................................................4193 Windshield washer...............................................................................4196 Wiring diag. 22D. 4th hydr. fctn., actvt. thru. brake press. chg. attachm. locking brake........4207 Wiring diagram 1. Main diagram BCU..............................................................4210 Wiring diagram 1B. Main diagram ECU.............................................................4213 Wiring diagram 1C. Main diagram Limp-Home operation ECU.........................................4216 Wiring diagram 2. BCU...........................................................................4219 Wiring diagram 2. BCU1..........................................................................4222 Wiring diagram 2D. Intermittent wiper BCU.......................................................4225 Wiring diagram 3. Gear shifting BCU.............................................................4227 Wiring diagram 3B. Gear shifting ECU............................................................4230 Wiring diagram 3C. Limp-Home opn. ECU...........................................................4233 Wiring diagram 4. Gear shift solenoids ECU......................................................4236 Wiring diagram 5. Engine TD40GA, TD40GFE........................................................4238 Wiring diagram 5D. Engine TD40KAE...............................................................4241 Wiring diagram 5D. Preheating engine TD40KAE. W.e.fr. serial number 11233.......................4244 Wiring diagram 6. Hydraulics....................................................................4247 Wiring diagram 6B. Single lever ctrl. w. boom kick-out and bucket pos...........................4250 Wiring diagram 7B. Secondary steering ECU.......................................................4253 Wiring diagram 7C. Secondary steering with ECU by-passed........................................4256 Wiring diagram 8. Pressure draining, brake pressure charging,...................................4259 Wiring diagram 8D. Brake pressure charging, attachment locking..................................4262 Wiring diagram 9. Travel lights.................................................................4265 Wiring diagram 10. Working lights, rotating warning beacon......................................4268 Wiring diagram 11. Stop lights, direction indicators, hazard flashers...........................4271 Wiring diagram 12. Radio, heated seat...........................................................4274 Wiring diagram 13. Instruments, sensors BCU.....................................................4277 Wiring diagram 13B. Instr, sensors ECU..........................................................4280 Wiring diagram 13C. Instruments, sensors ECU during Limp-Home operation.........................4283 Wiring diagram 14. Instr., alternator BCU.......................................................4286 Wiring diagram 14B. Instr., alternator ECU......................................................4289 Wiring diagram 14C. Instruments, alternator ECU during Limp-Home operation......................4292 Wiring diagram 15. Dual control Forward Reverse BCU.............................................4295 Wiring diagram 15B. Dual control Forward Reverse ECU............................................4298 Wiring diagram 15C. Dual control Forward Reverse during Limp-Home operation ECU.................4301 Wiring diagram 15D. Single lever control........................................................4304 Wiring diagram 16. Air conditioning (AC)........................................................4307 Wiring diagram 17. Service display unit.........................................................4310 Wiring diagram 18. Boom Susp. System (BSS)......................................................4313 Wiring diagram 19. Mechanical parking brake with Rider truck safety norm........................4316 Wiring diagram 19D. Hydraulic parking brake.....................................................4319 Wiring diagram 20B. Lever steering (CDC) w. adjust. ramp gen. Up to and incl. sn 10631..........4321 Wiring diagram 20B. Lever steering (CDC) w. non-adjust ramp gen. W.e.fr.........................4324 Wiring diagram 21. 4th hydraulic function, activation...........................................4327 Wiring diagram 21. 4th hydraulic function, activation1..........................................4329 Wiring diagram 21D. 4th hydraulic function, activation..........................................4331 Wiring diagram 21D. 4th hydraulic function, activation1.........................................4333 Wiring diagram 22. 4th hydraulic function,......................................................4335 Wiring diagram 22. 4th hydraulic function,1.....................................................4338 Wiring diagram 23. 3rd hydraulic function.......................................................4341 Wiring diagram 23. 3rd hydraulic function1......................................................4344 Wiring diagram 25. 5th and 6th hydr. function...................................................4347 Wiring diagram 25. 5th and 6th hydr. function1..................................................4350 Wiring diagram 26. Automatic greasing...........................................................4353 Wiring diagram 27. Automatic greasing with......................................................4356 Wiring diagram 28. Mechanical and hydraulic.....................................................4359 Wiring diagram 28B. Mechanical and hydraulic parking brake with ECU.............................4362 Work light1.....................................................................................4365 Work light2.....................................................................................4368 Working hydraulics, description.................................................................4371 Working pressure, checking and adjusting........................................................4375
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