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Foreword

The following applies to the use of Volvo Construction Equipment guideline times

Listed times indicate guideline times for maintenance and repairs of machines manufactured by Volvo
CE (Volvo Construction Equipment AB).
Guideline time is the time that the mechanic normally needs to perform an operation according to
the instructions normally found in each machine's service manual or component manual, and that is
performed according to the conditions listed below.

Feedback address for Time Guide: servicemanuals@volvo.com

Applicability

The time for performing an operation varies with a number of parameters, e.g., environment (where
the work is done), training and equipment. Guideline times are developed with the following
conditions:

Workshop in an indoor environment with a solid and level concrete floor.


Workshop equipped with lifting device that has lifting capacity and lifting height adapted to a
majority of operations (except lifting complete machine units/machine frames) performed on
machines handled by the workshop.
Use of approved support and lifting equipment, in addition to the equipment indicated in each
machine's service manual.
Workshop equipped with compressed air, electricity and lighting.
Use of indicated Volvo CE special tools.
Tools stored in easily accessed location, in the immediate vicinity of the workplace.
Where applicable, oils/fluids are handled in an environmentally correct manner.

For guideline times to apply it is required, in addition to the above conditions, that the mechanic has
the training and experience required for the machine and the work that is being done (e.g., Basic
Course Electricity and hydraulics as well as machine course step 1 Volvo CE Service school).

Guideline times apply when one person performs the operation. However, in the operations actions
may be performed that require help from another person. In these cases, the time for that step which
requires two persons has been doubled. The guideline times do not apply if more than one mechanic
performs the entire operation.

Actions not included in guideline times are:

Transport of machine to and from workshop site.


Troubleshooting not described as a separate operation.
Retrieval of spare parts, consumables and tools that are not stored in easily accessed location.
Washing of the whole or parts of the machine before repair/maintenance.
Actions that due to deformation, corrosion or external damage increase the repair time.
Additional work that due to retrofitted equipment reduces access, unless these work steps are
mentioned in the method description in each service manual.

Other

For every operation there is an operation number, heading and guideline time. The description for
how the work is done is normally found in the service manual for each machine under the
corresponding operation number.

7/11/2012 Volvo Construction Equipment 1


Foreword
New format of operation number

In the time guide, each operation number has a heading with a three-digit function group number
(see function group below) as well as a three-digit running number.

Example: Op no. 210-070 Engine removing

210- 070
Function group Running number (Sequential number)

Example of discontinued op. no. is 21070 alt. 21070-1 (Engine removing).

Function group:
According to Volvo Construction Equipment function group index, where the first digit indicates
section and is divided in the following functions, which follows the same design as other service
information:

1. Standard parts, service


2. Engine with mounting and equipment
3. Elec.system; Warning system; Information system; Instrumentsl
4. Power transmission
5. Brakes
6. Steering
7. Frame; Springs; Damping; Axle suspension; Wheel/track unit
8. Machinery house; Cab; Exterior trim parts anywhere
9. Hydraulic system; Digging/handling/grading equipment; Misc. Equip. hydraulics

The second and third digit (10) indicate sub-group, which in turn divides the functions within the group,
also this follows the same design as other service information.

Running number:
Running number or sequential number 001 to 899 (in the example 070) is a number to identify each
operation.

Other

Equipment:
Running number 901 to 999 are reserved for installation times for equipment (installation
instructions).

Earlier (discontinued) format of operation numbers:


From 2005-03-08, only the new format for operation numbers shall be used, with the exception of
operations for VCADS Pro. Already published service information makes use of the earlier format for
operation numbers.

VCADS Pro:
For the time being, VCADS Pro operations will adhere to the same design as before, XXXXX-X, and
will have a code digit (-3) for test procedures.

2 Volvo Construction Equipment 7/11/2012


Contents
Foreword ......................................................................................................................................... 1
A20C ................................................................................................................................................ 5
A25C .............................................................................................................................................. 13
A25C 4x4 ....................................................................................................................................... 21
A25D .............................................................................................................................................. 29
A25D 4x4 ....................................................................................................................................... 39
A30C .............................................................................................................................................. 49
A30D .............................................................................................................................................. 57
A35C .............................................................................................................................................. 67
A35D .............................................................................................................................................. 75
A40 ................................................................................................................................................ 85
A40D .............................................................................................................................................. 93
EL70 ............................................................................................................................................ 103
EL70C .......................................................................................................................................... 115
EW140B ...................................................................................................................................... 125
EW160B ...................................................................................................................................... 129
EW180B ...................................................................................................................................... 133
EW200B ...................................................................................................................................... 137
G710B ......................................................................................................................................... 141
G720B ......................................................................................................................................... 145
G726B ......................................................................................................................................... 149
G730B ......................................................................................................................................... 153
G740B ......................................................................................................................................... 157
G746B ......................................................................................................................................... 161
G780B ......................................................................................................................................... 165
L110E .......................................................................................................................................... 169
L120D .......................................................................................................................................... 175
L120E .......................................................................................................................................... 185
L150D .......................................................................................................................................... 193
L150E .......................................................................................................................................... 203
L180D .......................................................................................................................................... 213
L180D HL .................................................................................................................................... 223
L180E .......................................................................................................................................... 233
L180E HL ..................................................................................................................................... 243
L220D .......................................................................................................................................... 251
L220E .......................................................................................................................................... 261
L330D .......................................................................................................................................... 271
L50D ............................................................................................................................................ 279
L50E ............................................................................................................................................ 289
L60E ............................................................................................................................................ 293
L70D ............................................................................................................................................ 299
L70E ............................................................................................................................................ 309
L90D ............................................................................................................................................ 315
L90E ............................................................................................................................................ 325
VB-T 78 ETC ............................................................................................................................... 333
VB-T 78 GTC ............................................................................................................................... 335

7/11/2012 Volvo Construction Equipment 3


4 Volvo Construction Equipment 7/11/2012
A20C
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
171-001 1.00 Arrival inspection, according to programme
171-002 1.00 Delivery inspection, according to programme
172-002 7.00 Warranty inspection 100 hours
172-004 9.50 Warranty inspection 1000 hours
173-002 0.25 Maintenance service, daily
173-004 0.75 Maintenance service, every 50 hours
173-007 2.50 Maintenance service, every 250 hours
173-010 3.00 Maintenance service, every 500 hours
173-012 8.00 Maintenance service, every 1000 hours
173-014 16.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-066 0.50 Drop box, changing oil/cleaning suction strainer
173-074 1.00 Hydraulic oil tank, changing oil and filter
173-075 1.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank
173-085 3.00 Brake system, changing oil/fluid and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 2.00 Compression test
210-070 5.50 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 7.00 Engine, installing
210-073 5.50 Engine and transmission, removing
210-074 7.00 Engine and transmission, mounting
214-012 1.00 Valves, adjusting
214-096 1.50 Valve cap, changing

22 LUBRICATING SYSTEM
221-021 0.75 Lubrication oil pressure, check

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-004 0.50 Feed pump, checking feed pressure
236-001 0.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
236-003 0.25 Idling speed, checking
236-004 0.25 Iow idling speed, checking and adjusting

7/11/2012 Volvo Construction Equipment 5


A20C
Op.no. time (h) Notes

236-030 1.75 Injection timing, checking and adjusting


236-031 1.00 Injection timing adjuster, checking
236-044 1.00 Injection timing, checking
236-073 3.50 Injection pump, replacing incl setting injection
timing
237-001 3.50 Injectors cylinder head removed, replacing copper
sleeve
237-002 1.75 Injectors, replacing all

25 INLET SYSTEM; EXHAUST SYSTEM


255-070 0.50 Turbocharger, removing
255-071 1.50 Turbocharger, replacing
255-072 1.00 Turbocharger, installing
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.50 Air cleaner, primary filter replacing
256-004 0.50 Air cleaner, secondary filter replacing
258-002 1.00 Intercooler, replacing

26 COOLING SYSTEM
261-002 0.25 Coolant, checking anti-freeze resistance
261-004 1.00 Coolant, changing
261-008 1.50 Radiator, replacing
261-010 1.00 Radiator, adjusting
263-001 1.00 Fan motor, removing
263-002 1.00 Fan motor, changing piston rings
263-003 1.00 Fan motor, installing
263-004 1.00 Fan motor, checking working pressure
263-005 0.25 Fan motor, adjusting working pressure
263-006 1.00 Fan hydraulically driven, removing pump
263-007 1.00 Fan hydraulically driven, fitting pump
263-009 0.75 Fan hydraulically driven, replacing oil return filter
263-010 0.50 Pump 3 (P3) standby pressure, checking
263-012 0.50 Fan belt and/or alternator belt, replacing
263-013 0.50 Fan belt and/or alternator belt, checking and
adjusting tension
263-022 0.50 Fan belt and/or alternator-, compressor belt,
replacing all belts

27 ENGINE CONTROL
272-001 1.00 Accelerator control, anti-gas cylinder, adjusting

6 Volvo Construction Equipment 7/11/2012


A20C
Op.no. time (h) Notes

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.50 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-074 1.50 Charging test in machine (with measuring
instrument)

33 STARTING SYSTEM
331-018 1.25 Starter motor, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-008 0.50 Headlamp reflector and/or glass, replacing one
incl adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.50 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.50 Flasher unit, replacing relay
361-010 0.50 Flasher switch, replacing
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-016 0.50 Horn switch, replacing
363-002 1.50 Windscreen wiper front, replacing motor
363-003 0.50 Windscreen wiper, replacing switch
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.50 Switch, replacing
364-008 1.50 Brake light switch, replacing
367-020 1.00 ECU, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-001 0.25 Load sensor, adjusting
386-002 0.50 Load sensor, control measurement

7/11/2012 Volvo Construction Equipment 7


A20C
Op.no. time (h) Notes

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 1.00 Transmission, check oil pressure
421-051 1.00 Transmission, resistance measuring of solenoides
421-054 4.00 Seal for rear output shaft, replacing
421-059 0.50 Transmission retarder valve, adjusting air
pressure
421-060 0.50 Transmission, resistans measuring control system
421-061 0.50 Induction sensor for output shaft, changing
421-062 2.00 Induction sensor for turbine speed, changing
421-065 3.00 Control system, replacing
421-070 7.00 Transmission, removing
421-072 7.00 Transmission, installing
421-073 5.50 Transmission, removing (together with engine)
421-074 7.00 Transmission, installing (together with engine)
421-078 2.00 Transmission, remove and fitting from a non
mounted engine
421-079 0.25 Transmission, replacing breather filter

43 GEARBOX,
434-002 1.75 Dropbox, replacing seal for front otput shaft
434-004 2.00 Dropbox, replacing seal for rear output shaft
434-015 7.00 Dropbox, replacing seal for input shaft
434-016 1.00 Dropbox, oil pump, replacing
434-061 1.00 Differential lock longitudinal, adjusting
engagement
434-073 3.00 Dropbox, installing
434-074 2.00 Dropbox, removing

45 PROPELLER SHAFT
451-004 1.00 Propeller shaft, rear, replacing
451-005 1.00 Propeller shaft for rear boggie axel, replacing
451-006 3.50 Intermediate shaft and/or bearing, replacing (in
frame joint)
451-007 0.50 Propeller shaft, in frame joint, replacing
451-010 0.75 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning
451-014 3.50 Propeller shaft between transmission and
dropbox, replacing

46 FRONT AXLE; REAR AXLE


461-043 4.00 Hub, replacing seal
468-005 0.50 Differential lock rear, adjusting engagement

8 Volvo Construction Equipment 7/11/2012


A20C
Op.no. time (h) Notes

48 POWER TAKE OFF


482-000 20.00 Flywheel housing and complete power take off,
changing
482-001 3.00 Power take off engine crankshaft for hydraulic
pump removed

49 MISCELLANEOUS
491-006 2.00 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
510-001 1.00 Brake linings, checking wear
510-002 0.25 Brake disc for service brake, checking
511-001 0.50 Brake pads for service brake, checking
511-002 4.00 Brake disc, replacing one
511-004 3.00 Brake pads, replacing on both sides of axel
511-005 1.50 Brake pads, replacing (one wheel, front axle)
511-045 2.00 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-001 0.50 Brake linings, checking wear rear axle
512-002 4.00 Brake disc, replacing one
512-004 3.00 Brake pads, replacing on both sides of axle
512-005 1.50 Brake pads, replacing (one wheel, first boggie
axle)
512-045 2.50 Brake caliper, replacing one
512-081 1.00 Brake caliper, removed, reconditioning

52 HYDRAULIC BRAKE SYSTEM


520-037 1.00 Brake system, bleeding

55 PARKING BRAKE
550-002 0.50 Parking brake, adjusting
550-005 2.00 Parking brake, replacing brake disc
550-009 0.50 Spring brake cylinder, replacing
550-010 1.00 Spring brake cylinder removed, reconditioning
550-012 2.00 Parking brake , replacing brake caliper
550-013 0.75 Parking brake caliper (air), removed
reconditioning
550-014 1.50 Parking brake, replacing brake pads
551-003 1.00 Parking brake, (removed) reconditioning of brake
caliper

56 COMPRESSED-AIR BRAKE
561-004 1.00 Compressor, replacing

7/11/2012 Volvo Construction Equipment 9


A20C
Op.no. time (h) Notes

561-022 0.25 Pressure regulator, adjusting


563-010 1.00 Relay valve (load unit), reconditioning incl.
removing and fitting
563-073 1.00 Foot brake valve (pneumatic) removed,
reconditioning

6 STEERING
64 STEERING
642-026 3.00 Steering gear, replacing
642-058 1.00 Steering gear, check.and adj.
643-010 3.50 Steering linkage, checking and adjusting
645-001 0.50 Steering cylinder bearing, checking clearanse
645-006 5.00 Steering cylinder, replacing
645-028 0.50 Steering system, checking and adjusting working
pressure
645-054 1.00 Steering cylinder, replacing bearings
645-060 3.00 Steering cylinder, repacking in machine
645-080 2.00 Steering valve neutral position and valve spool
end float, checking
645-081 3.00 Steering valve removed, reconditioning
645-082 3.00 Steering valve, replacing
645-084 1.00 Damping cylinder, checking spring force
645-085 1.50 Damping cylinder, changing seal
647-093 2.00 Auxiliary steering, replacing hydraulic pump
647-095 0.50 Auxiliary steering, adjusting working- and stand-by
pressure

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
711-020 3.00 Load unit frame, checking measurements

72 SUSPENSION
727-001 5.00 Spring element front, replacing all

74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-006 4.00 Frame joint, measuring and adjusting clearence
741-036 2.00 Frame joint, replacing bearings
742-007 10.00 Frame joint, replacing hitch
742-038 1.50 Articulated joint, checking clearence
742-040 9.00 Steering joint, replacing bearings

10 Volvo Construction Equipment 7/11/2012


A20C
Op.no. time (h) Notes

75 AXLE SUSPENSION
754-020 3.50 Load unit triangular stay, replacing link bearing
(rubber bearing)
754-021 1.00 Front bogie axle cross stay, adjusting
754-031 1.00 Rear bogie axle cross stay, adjusting
756-010 3.00 Bogie member, replacing rubber element
756-012 1.00 Cross stay rubber bushing (bearing), replacing
(front)
756-014 1.00 Cross stay rubber bushing (bearing), replacing,
(rear)
756-015 3.00 Cross stay, checking and adjusting
756-024 1.00 Bogie beam, changing rubber spring, one side
(front)
756-026 3.00 Bogie, replacing all rubber elements both sides
756-027 2.00 A-frame bushing, front on load unit, changing

76 SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL /


SIDE CONTROL
761-001 1.50 Shock absorber front, replacing all

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.50 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
843-002 1.00 Windscreen, replacing
843-012 1.50 Rear window, replacing
843-013 1.00 Side window, replacing
843-048 1.00 Door window, replacing

87 AIR CONDITIONING UNIT


873-004 2.00 Heater core, replacing
873-006 2.00 Fan motor, replacing
873-008 1.50 Heat control valve, replacing
874-002 1.50 Refrigerant, draining
874-003 0.50 Cooling unit, performance test
874-005 2.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling

7/11/2012 Volvo Construction Equipment 11


A20C
Op.no. time (h) Notes

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
912-081 0.50 Tipping control, adjusting
912-087 0.50 Tipping limitation, adjusting
913-003 0.50 Hydraulic pump, checking and adjusting standby
pressure
913-008 2.00 Hydraulic pump, ground dependent, changing

94 UNIT, LOAD HANDLING


945-010 1.50 Tilt cylinder removed, repacking

95 LOAD CARRIER
951-001 0.50 Tipping control, adjusting
951-002 2.00 Tipping valve, changing wire
951-003 0.50 Dump body position indicator, adjusting
951-004 4.00 Hoist cylinder, changing
951-006 2.50 Hoist cylinder removed, reconditioning
951-009 1.00 Dump limitation, adjusting
951-010 2.00 Tipping valve, replacing
951-040 3.00 Dump body joint, changing tipping bearing
951-041 1.50 Dump body, adjusting against frame

12 Volvo Construction Equipment 7/11/2012


A25C
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
171-001 1.00 Arrival inspection, according to programme
171-002 1.00 Delivery inspection, according to programme
172-002 7.00 Warranty inspection 100 hours
172-004 10.00 Warranty inspection 1000 hours
173-002 0.25 Maintenance service, daily
173-004 0.75 Maintenance service, every 50 hours
173-007 3.00 Maintenance service, every 250 hours
173-010 3.00 Maintenance service, every 500 hours
173-012 8.00 Maintenance service, every 1000 hours
173-014 16.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-066 0.50 Drop box, changing oil/cleaning suction strainer
173-074 1.00 Hydraulic oil tank, changing oil and filter
173-075 1.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank
173-085 3.00 Brake system, changing oil/fluid and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 2.00 Compression test
210-070 5.50 Engine, removing
210-072 7.00 Engine, installing
210-073 5.50 Engine and transmission, removing
210-074 7.00 Engine and transmission, mounting
214-012 0.75 Valves, adjusting
214-096 1.50 Valve cap, changing

22 LUBRICATING SYSTEM
221-021 0.75 Lubrication oil pressure, check

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-004 0.50 Feed pump, checking feed pressure
236-001 0.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
236-003 0.50 Idling speed, checking
236-004 0.50 Iow idling speed, checking and adjusting
236-030 0.50 Injection timing, checking and adjusting

7/11/2012 Volvo Construction Equipment 13


A25C
Op.no. time (h) Notes

236-031 1.00 Injection timing adjuster, checking


236-044 0.50 Injection timing, checking
236-073 3.50 Injection pump, replacing incl setting injection
timing
237-002 1.75 Injectors, replacing all

25 INLET SYSTEM; EXHAUST SYSTEM


255-070 0.50 Turbocharger, removing
255-071 1.50 Turbocharger, replacing
255-072 1.00 Turbocharger, installing
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.50 Air cleaner, primary filter replacing
256-004 0.50 Air cleaner, secondary filter replacing
258-002 1.00 Intercooler, replacing

26 COOLING SYSTEM
261-002 0.25 Coolant, checking anti-freeze resistance
261-004 1.00 Coolant, changing
261-008 1.50 Radiator, replacing
261-010 1.00 Radiator, adjusting
261-072 0.50 Coolant filter, changing
263-001 0.75 Fan motor, removing
263-002 1.00 Fan motor, changing piston rings
263-003 1.00 Fan motor, installing
263-004 1.00 Fan motor, checking working pressure
263-005 0.25 Fan motor, adjusting working pressure
263-006 1.00 Fan hydraulically driven, removing pump
263-007 1.00 Fan hydraulically driven, fitting pump
263-009 0.75 Fan hydraulically driven, replacing oil return filter
263-010 0.50 Pump 3 (P3) standby pressure, checking
263-012 0.50 Fan belt and/or alternator belt, replacing
263-013 0.50 Fan belt and/or alternator belt, checking and
adjusting tension
263-022 0.50 Fan belt and/or alternator-, compressor belt,
replacing all belts

27 ENGINE CONTROL
272-001 1.00 Accelerator control, anti-gas cylinder, adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking

14 Volvo Construction Equipment 7/11/2012


A25C
Op.no. time (h) Notes

311-002 1.50 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-074 1.50 Charging test in machine (with measuring
instrument)

33 STARTING SYSTEM
331-018 1.25 Starter motor, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-008 0.50 Headlamp reflector and/or glass, replacing one
incl adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.50 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.50 Flasher unit, replacing relay
361-010 0.50 Flasher switch, replacing
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-016 0.50 Horn switch, replacing
362-900 1.00 Rotating beacon, installing new
363-002 1.50 Windscreen wiper front, replacing motor
363-003 0.50 Windscreen wiper, replacing switch
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.50 Switch, replacing
364-008 1.50 Brake light switch, replacing
367-020 0.50 ECU, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-001 0.25 Load sensor, adjusting
386-002 0.50 Load sensor, control measurement

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 1.00 Transmission, check oil pressure
421-051 1.00 Transmission, resistance measuring of solenoides
421-054 4.00 Seal for rear output shaft, replacing

7/11/2012 Volvo Construction Equipment 15


A25C
Op.no. time (h) Notes

421-059 0.50 Transmission retarder valve, adjusting air


pressure
421-060 0.50 Transmission, resistans measuring control system
421-061 0.50 Induction sensor for output shaft, changing
421-062 2.00 Induction sensor for turbine speed, changing
421-065 3.00 Control system, replacing
421-070 7.00 Transmission, removing
421-072 7.00 Transmission, installing
421-073 5.50 Transmission, removing (together with engine)
421-074 7.00 Transmission, installing (together with engine)
421-078 2.00 Transmission, remove and fitting from a non
mounted engine
421-079 0.25 Transmission, replacing breather filter

43 GEARBOX,
434-002 1.75 Dropbox, replacing seal for front otput shaft
434-004 2.00 Dropbox, replacing seal for rear output shaft
434-015 7.00 Dropbox, replacing seal for input shaft
434-016 1.00 Dropbox, oil pump, replacing
434-059 0.75 Dropbox, replacing pneumatic air cylinder for high
and low gear
434-060 0.50 Dropbox, adjusting control for high and low gear
434-061 1.00 Differential lock longitudinal, adjusting
engagement
434-073 3.00 Dropbox, installing
434-074 2.00 Dropbox, removing

45 PROPELLER SHAFT
451-004 1.00 Propeller shaft, rear, replacing
451-005 1.00 Propeller shaft for rear boggie axel, replacing
451-006 3.50 Intermediate shaft and/or bearing, replacing (in
frame joint)
451-007 0.50 Propeller shaft, in frame joint, replacing
451-010 0.75 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning
451-014 3.50 Propeller shaft between transmission and
dropbox, replacing

46 FRONT AXLE; REAR AXLE


461-043 4.00 Hub, replacing seal
468-005 0.50 Differential lock rear, adjusting engagement

48 POWER TAKE OFF


482-000 20.00 Flywheel housing and complete power take off,
changing
482-001 3.00 Power take off engine crankshaft for hydraulic
pump removed

16 Volvo Construction Equipment 7/11/2012


A25C
Op.no. time (h) Notes

49 MISCELLANEOUS
491-006 3.50 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
510-001 1.00 Brake linings, checking wear
510-002 0.25 Brake disc for service brake, checking
511-001 0.50 Brake pads for service brake, checking
511-002 4.00 Brake disc, replacing one
511-004 3.00 Brake pads, replacing on both sides of axel
511-005 1.50 Brake pads, replacing (one wheel, front axle)
511-045 2.00 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-001 0.50 Brake linings, checking wear rear axle
512-002 4.00 Brake disc, replacing one
512-004 3.00 Brake pads, replacing on both sides of axle
512-005 1.50 Brake pads, replacing (one wheel, first boggie
axle)
512-045 2.00 Brake caliper, replacing one
512-081 1.00 Brake caliper, removed, reconditioning

52 HYDRAULIC BRAKE SYSTEM


520-037 1.00 Brake system, bleeding

55 PARKING BRAKE
550-002 0.50 Parking brake, adjusting
550-005 2.00 Parking brake, replacing brake disc
550-009 0.50 Spring brake cylinder, replacing
550-010 1.00 Spring brake cylinder removed, reconditioning
550-012 2.00 Parking brake , replacing brake caliper
550-013 0.75 Parking brake caliper (air), removed
reconditioning
550-014 1.50 Parking brake, replacing brake pads
551-003 0.50 Parking brake, (removed) reconditioning of brake
caliper

56 COMPRESSED-AIR BRAKE
561-004 1.00 Compressor, replacing
561-022 0.25 Pressure regulator, adjusting
563-010 1.00 Relay valve (load unit), reconditioning incl.
removing and fitting
563-073 1.00 Foot brake valve (pneumatic) removed,
reconditioning

7/11/2012 Volvo Construction Equipment 17


A25C
Op.no. time (h) Notes

6 STEERING
64 STEERING
642-026 3.00 Steering gear, replacing
643-010 3.50 Steering linkage, checking and adjusting
645-001 0.50 Steering cylinder bearing, checking clearanse
645-006 5.00 Steering cylinder, replacing
645-028 0.50 Steering system, checking and adjusting working
pressure
645-054 1.00 Steering cylinder, replacing bearings
645-060 3.00 Steering cylinder, repacking in machine
645-080 2.00 Steering valve neutral position and valve spool
end float, checking
645-081 3.00 Steering valve removed, reconditioning
645-082 3.00 Steering valve, replacing
645-084 1.00 Damping cylinder, checking spring force
645-085 1.50 Damping cylinder, changing seal
647-093 2.00 Auxiliary steering, replacing hydraulic pump
647-095 0.50 Auxiliary steering, adjusting working- and stand-by
pressure

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
711-020 3.00 Load unit frame, checking measurements

72 SUSPENSION
727-001 5.00 Spring element front, replacing all

74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-006 4.00 Frame joint, measuring and adjusting clearence
741-036 2.00 Frame joint, replacing bearings
742-007 10.00 Frame joint, replacing hitch
742-038 1.50 Articulated joint, checking clearence
742-040 9.00 Steering joint, replacing bearings
742-044 1.00 Articulated joint, replacing bushing
742-046 1.50 Frame joint, changing metallic bearing (machine
separated)

75 AXLE SUSPENSION
754-010 3.00 Replacing link bearing (rubber bearing), front axle
754-020 2.00 Load unit triangular stay, replacing link bearing
(rubber bearing)

18 Volvo Construction Equipment 7/11/2012


A25C
Op.no. time (h) Notes

754-021 1.00 Front bogie axle cross stay, adjusting


754-022 1.00 Triangular stay link bearing attachments, adjusting
754-031 1.00 Rear bogie axle cross stay, adjusting
756-010 3.00 Bogie member, replacing rubber element
756-011 6.00 Bogie member, replacing rubber bearing (one
side)
756-012 1.00 Cross stay rubber bushing (bearing), replacing
(front)
756-014 1.00 Cross stay rubber bushing (bearing), replacing,
(rear)
756-015 3.00 Cross stay, checking and adjusting
756-024 1.00 Bogie beam, changing rubber spring, one side
(front)
756-026 3.00 Bogie, replacing all rubber elements both sides
756-027 1.50 A-frame bushing, front on load unit, changing

76 SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL /


SIDE CONTROL
761-001 1.50 Shock absorber front, replacing all

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.50 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
843-002 1.00 Windscreen, replacing
843-012 1.50 Rear window, replacing
843-013 1.00 Side window, replacing
843-048 1.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-002 1.00 Air suspension for operators seat, changing

87 AIR CONDITIONING UNIT


873-004 2.00 Heater core, replacing
873-006 2.00 Fan motor, replacing
873-008 1.50 Heat control valve, replacing
874-002 1.50 Refrigerant, draining
874-003 0.50 Cooling unit, performance test
874-005 2.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling

7/11/2012 Volvo Construction Equipment 19


A25C
Op.no. time (h) Notes

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
913-003 0.50 Hydraulic pump, checking and adjusting standby
pressure
913-008 2.00 Hydraulic pump, ground dependent, changing

94 UNIT, LOAD HANDLING


945-010 1.50 Tilt cylinder removed, repacking

95 LOAD CARRIER
951-001 0.50 Tipping control, adjusting
951-002 2.00 Tipping valve, changing wire
951-003 0.50 Dump body position indicator, adjusting
951-004 5.00 Hoist cylinder, changing
951-006 3.50 Hoist cylinder removed, reconditioning
951-010 2.00 Tipping valve, replacing
951-040 3.00 Dump body joint, changing tipping bearing
951-041 3.00 Dump body, adjusting against frame

20 Volvo Construction Equipment 7/11/2012


A25C 4x4
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
171-001 1.00 Arrival inspection, according to programme
171-002 1.00 Delivery inspection, according to programme
172-002 7.00 Warranty inspection 100 hours
172-004 10.00 Warranty inspection 1000 hours
173-002 0.25 Maintenance service, daily
173-004 0.75 Maintenance service, every 50 hours
173-007 3.00 Maintenance service, every 250 hours
173-010 3.00 Maintenance service, every 500 hours
173-012 8.00 Maintenance service, every 1000 hours
173-014 16.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-066 0.50 Drop box, changing oil/cleaning suction strainer
173-074 1.00 Hydraulic oil tank, changing oil and filter
173-075 1.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank
173-085 3.00 Brake system, changing oil/fluid and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 2.00 Compression test
210-070 5.50 Engine, removing
210-072 7.00 Engine, installing
210-073 5.50 Engine and transmission, removing
210-074 7.00 Engine and transmission, mounting
214-012 0.75 Valves, adjusting
214-096 1.50 Valve cap, changing

22 LUBRICATING SYSTEM
221-021 0.75 Lubrication oil pressure, check

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-004 0.50 Feed pump, checking feed pressure
236-001 0.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
236-003 0.50 Idling speed, checking
236-004 0.50 Iow idling speed, checking and adjusting
236-030 0.50 Injection timing, checking and adjusting

7/11/2012 Volvo Construction Equipment 21


A25C 4x4
Op.no. time (h) Notes

236-031 1.00 Injection timing adjuster, checking


236-044 0.50 Injection timing, checking
236-073 3.50 Injection pump, replacing incl setting injection
timing
237-002 1.75 Injectors, replacing all

25 INLET SYSTEM; EXHAUST SYSTEM


255-070 0.50 Turbocharger, removing
255-071 1.50 Turbocharger, replacing
255-072 1.00 Turbocharger, installing
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.50 Air cleaner, primary filter replacing
256-004 0.50 Air cleaner, secondary filter replacing
258-002 1.00 Intercooler, replacing

26 COOLING SYSTEM
261-002 0.25 Coolant, checking anti-freeze resistance
261-004 1.00 Coolant, changing
261-008 1.50 Radiator, replacing
261-010 1.00 Radiator, adjusting
261-072 0.50 Coolant filter, changing
263-001 0.75 Fan motor, removing
263-002 1.00 Fan motor, changing piston rings
263-003 1.00 Fan motor, installing
263-004 1.00 Fan motor, checking working pressure
263-005 0.25 Fan motor, adjusting working pressure
263-006 1.00 Fan hydraulically driven, removing pump
263-007 1.00 Fan hydraulically driven, fitting pump
263-009 0.75 Fan hydraulically driven, replacing oil return filter
263-010 0.50 Pump 3 (P3) standby pressure, checking
263-012 0.50 Fan belt and/or alternator belt, replacing
263-013 0.50 Fan belt and/or alternator belt, checking and
adjusting tension
263-022 0.50 Fan belt and/or alternator-, compressor belt,
replacing all belts

27 ENGINE CONTROL
272-001 1.00 Accelerator control, anti-gas cylinder, adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking

22 Volvo Construction Equipment 7/11/2012


A25C 4x4
Op.no. time (h) Notes

311-002 1.50 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-074 1.50 Charging test in machine (with measuring
instrument)

33 STARTING SYSTEM
331-018 1.25 Starter motor, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-008 0.50 Headlamp reflector and/or glass, replacing one
incl adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.50 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.50 Flasher unit, replacing relay
361-010 0.50 Flasher switch, replacing
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-016 0.50 Horn switch, replacing
362-900 1.00 Rotating beacon, installing new
363-002 1.50 Windscreen wiper front, replacing motor
363-003 0.50 Windscreen wiper, replacing switch
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.50 Switch, replacing
364-008 1.50 Brake light switch, replacing
367-020 0.50 ECU, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-001 0.25 Load sensor, adjusting
386-002 0.50 Load sensor, control measurement

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 1.00 Transmission, check oil pressure
421-051 1.00 Transmission, resistance measuring of solenoides
421-054 4.00 Seal for rear output shaft, replacing

7/11/2012 Volvo Construction Equipment 23


A25C 4x4
Op.no. time (h) Notes

421-059 0.50 Transmission retarder valve, adjusting air


pressure
421-060 0.50 Transmission, resistans measuring control system
421-061 0.50 Induction sensor for output shaft, changing
421-062 2.00 Induction sensor for turbine speed, changing
421-065 3.00 Control system, replacing
421-070 7.00 Transmission, removing
421-072 7.00 Transmission, installing
421-073 5.50 Transmission, removing (together with engine)
421-074 7.00 Transmission, installing (together with engine)
421-078 2.00 Transmission, remove and fitting from a non
mounted engine
421-079 0.25 Transmission, replacing breather filter

43 GEARBOX,
434-002 1.75 Dropbox, replacing seal for front otput shaft
434-004 2.00 Dropbox, replacing seal for rear output shaft
434-015 7.00 Dropbox, replacing seal for input shaft
434-016 1.00 Dropbox, oil pump, replacing
434-059 0.75 Dropbox, replacing pneumatic air cylinder for high
and low gear
434-060 0.50 Dropbox, adjusting control for high and low gear
434-061 1.00 Differential lock longitudinal, adjusting
engagement
434-073 3.00 Dropbox, installing
434-074 2.00 Dropbox, removing

45 PROPELLER SHAFT
451-004 1.00 Propeller shaft, rear, replacing
451-005 1.00 Propeller shaft for rear boggie axel, replacing
451-006 3.50 Intermediate shaft and/or bearing, replacing (in
frame joint)
451-007 0.50 Propeller shaft, in frame joint, replacing
451-010 0.75 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning
451-014 3.50 Propeller shaft between transmission and
dropbox, replacing

46 FRONT AXLE; REAR AXLE


461-043 4.00 Hub, replacing seal
468-005 0.50 Differential lock rear, adjusting engagement

48 POWER TAKE OFF


482-000 20.00 Flywheel housing and complete power take off,
changing
482-001 3.00 Power take off engine crankshaft for hydraulic
pump removed

24 Volvo Construction Equipment 7/11/2012


A25C 4x4
Op.no. time (h) Notes

49 MISCELLANEOUS
491-006 3.50 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
510-001 1.00 Brake linings, checking wear
510-002 0.25 Brake disc for service brake, checking
511-001 0.50 Brake pads for service brake, checking
511-002 4.00 Brake disc, replacing one
511-004 3.00 Brake pads, replacing on both sides of axel
511-005 1.50 Brake pads, replacing (one wheel, front axle)
511-045 2.00 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-001 0.50 Brake linings, checking wear rear axle
512-002 4.00 Brake disc, replacing one
512-004 3.00 Brake pads, replacing on both sides of axle
512-005 1.50 Brake pads, replacing (one wheel, first boggie
axle)
512-045 2.00 Brake caliper, replacing one
512-081 1.00 Brake caliper, removed, reconditioning

52 HYDRAULIC BRAKE SYSTEM


520-037 1.00 Brake system, bleeding

55 PARKING BRAKE
550-002 0.50 Parking brake, adjusting
550-005 2.00 Parking brake, replacing brake disc
550-009 0.50 Spring brake cylinder, replacing
550-010 1.00 Spring brake cylinder removed, reconditioning
550-012 2.00 Parking brake , replacing brake caliper
550-013 0.75 Parking brake caliper (air), removed
reconditioning
550-014 1.50 Parking brake, replacing brake pads
551-003 0.50 Parking brake, (removed) reconditioning of brake
caliper

56 COMPRESSED-AIR BRAKE
561-004 1.00 Compressor, replacing
561-022 0.25 Pressure regulator, adjusting
563-010 1.00 Relay valve (load unit), reconditioning incl.
removing and fitting
563-073 1.00 Foot brake valve (pneumatic) removed,
reconditioning

7/11/2012 Volvo Construction Equipment 25


A25C 4x4
Op.no. time (h) Notes

6 STEERING
64 STEERING
642-026 3.00 Steering gear, replacing
643-010 3.50 Steering linkage, checking and adjusting
645-001 0.50 Steering cylinder bearing, checking clearanse
645-006 5.00 Steering cylinder, replacing
645-028 0.50 Steering system, checking and adjusting working
pressure
645-054 1.00 Steering cylinder, replacing bearings
645-060 3.00 Steering cylinder, repacking in machine
645-080 2.00 Steering valve neutral position and valve spool
end float, checking
645-081 3.00 Steering valve removed, reconditioning
645-082 3.00 Steering valve, replacing
645-084 1.00 Damping cylinder, checking spring force
645-085 1.50 Damping cylinder, changing seal
647-093 2.00 Auxiliary steering, replacing hydraulic pump
647-095 0.50 Auxiliary steering, adjusting working- and stand-by
pressure

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
711-020 3.00 Load unit frame, checking measurements

72 SUSPENSION
727-001 5.00 Spring element front, replacing all

74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-006 4.00 Frame joint, measuring and adjusting clearence
741-036 2.00 Frame joint, replacing bearings
742-007 10.00 Frame joint, replacing hitch
742-038 1.50 Articulated joint, checking clearence
742-040 9.00 Steering joint, replacing bearings
742-044 1.00 Articulated joint, replacing bushing
742-046 1.50 Frame joint, changing metallic bearing (machine
separated)

75 AXLE SUSPENSION
754-010 3.00 Replacing link bearing (rubber bearing), front axle
754-020 2.00 Load unit triangular stay, replacing link bearing
(rubber bearing)

26 Volvo Construction Equipment 7/11/2012


A25C 4x4
Op.no. time (h) Notes

754-021 1.00 Front bogie axle cross stay, adjusting


754-022 1.00 Triangular stay link bearing attachments, adjusting
754-031 1.00 Rear bogie axle cross stay, adjusting
756-010 3.00 Bogie member, replacing rubber element
756-011 6.00 Bogie member, replacing rubber bearing (one
side)
756-012 1.00 Cross stay rubber bushing (bearing), replacing
(front)
756-014 1.00 Cross stay rubber bushing (bearing), replacing,
(rear)
756-015 3.00 Cross stay, checking and adjusting
756-024 1.00 Bogie beam, changing rubber spring, one side
(front)
756-026 3.00 Bogie, replacing all rubber elements both sides
756-027 1.50 A-frame bushing, front on load unit, changing

76 SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL /


SIDE CONTROL
761-001 1.50 Shock absorber front, replacing all

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.50 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
843-002 1.00 Windscreen, replacing
843-012 1.50 Rear window, replacing
843-013 1.00 Side window, replacing
843-048 1.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-002 1.00 Air suspension for operators seat, changing

87 AIR CONDITIONING UNIT


873-004 2.00 Heater core, replacing
873-006 2.00 Fan motor, replacing
873-008 1.50 Heat control valve, replacing
874-002 1.50 Refrigerant, draining
874-003 0.50 Cooling unit, performance test
874-005 2.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling

7/11/2012 Volvo Construction Equipment 27


A25C 4x4
Op.no. time (h) Notes

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
913-003 0.50 Hydraulic pump, checking and adjusting standby
pressure
913-008 2.00 Hydraulic pump, ground dependent, changing

94 UNIT, LOAD HANDLING


945-010 1.50 Tilt cylinder removed, repacking

95 LOAD CARRIER
951-001 0.50 Tipping control, adjusting
951-002 2.00 Tipping valve, changing wire
951-003 0.50 Dump body position indicator, adjusting
951-004 5.00 Hoist cylinder, changing
951-006 3.50 Hoist cylinder removed, reconditioning
951-010 2.00 Tipping valve, replacing
951-040 3.00 Dump body joint, changing tipping bearing
951-041 3.00 Dump body, adjusting against frame

28 Volvo Construction Equipment 7/11/2012


A25D
Op.no. time (h) Notes

0 GENERAL
09 MISCELLANEOUS
090-001 0.70 Engine, basic check

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
170-005 0.25 Start of VCADS Pro computer and reading
machine data
171-001 1.00 Arrival inspection, according to programme
171-002 1.00 Delivery inspection, according to programme
172-002 3.50 Warranty inspection 100 hours
172-004 13.00 Warranty inspection 1000 hours 11000 - 19999
172-004 7.50 Warranty inspection 1000 hours 11000 - 19999
173-002 0.30 Maintenance service, daily
173-004 0.50 Maintenance service, every 50 hours
173-007 1.00 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 6.00 Maintenance service, every 1000 hours
173-014 11.00 Maintenance service, every 2000 hours

19 GENERAL
191-021 0.20 Service position 1

2 ENGINE WITH MOUNTING AND EQUIPMENT


20 GENERAL
200-068 1.00 E-ECU, MID 128, changing non-programmed 13001 - 15330
ECU
200-068 0.90 E-ECU, MID 128, changing non-programmed 11001 - 12077
ECU 61001 - 61118
200-068 1.25 E-ECU, MID 128, changing non-programmed 15001 - 19999
ECU 72101 - 79999
200-070 0.90 E-ECU, MID 128, changing pre-programmed ECU13001 - 19999
72001 - 79999
200-070 0.90 E-ECU, MID 128, changing pre-programmed ECU15001 - 19999
72101 - 79999
200-070 0.80 E-ECU, MID 128, changing pre-programmed ECU11001 - 12077
61001 - 61118

21 ENGINE
210-002 2.50 Compression test 11000 - 12999
61000 - 61118

7/11/2012 Volvo Construction Equipment 29


A25D
Op.no. time (h) Notes

210-002 5.50 Compression test 15000 - 19999


72100 - 79999
210-070 10.00 Engine, removing
210-072 11.00 Engine, installing
210-073 8.50 Engine and transmission, removing
210-074 8.50 Engine and transmission, mounting
212-051 1.00 Flywheel housing with power take-off (PTO),
removing from engine (out of machine)
212-052 1.50 Flywheel housing with power take-off (PTO),
mounting on engine (out of machine)
214-012 5.50 Valves, adjusting 15000 - 19999
72100 - 79999
214-012 5.50 Valves, adjusting 15000 - 19999
72100 - 79999
215-042 6.50 Camshaft, replacing
215-043 3.00 Camshaft setting, checking 13001 - 19999
72100 - 79999
216-014 3.00 Crankshaft, replacing front oil seal
216-014 1.75 Crankshaft, replacing front oil seal
216-018 24.00 Crankshaft, replacing rear oil seal 13000 - 19999
72000 - 79999
217-004 4.00 Oil sump gasket, changing
217-005 4.50 Oil level sensor, changing
218-001 1.50 Rubber cushion, replacing
218-007 4.00 Engine mounting rear, changing

22 LUBRICATING SYSTEM
221-022 0.60 Lubrication oil pressure, checking with pressure 71000 - 79999
gauge 11000 - 19999
223-006 5.00 Oil cooler, replacing

23 FUEL SYSTEM
230-001 0.50 Carbon monoxide in fuel system, check
233-001 0.70 Fuel system, bleeding 15000 - 19999
72100 - 79999
233-004 0.70 Feed pump, checking feed pressure 15001 - 19999
72101 - 79999
233-004 0.70 Feed pump, checking feed pressure 11001 - 12077
61001 - 61118
233-004 0.70 Feed pump, checking feed pressure 13001 - 15330
72001 - 72047
233-010 2.00 Fuel pump, inspection 11001 - 12077
61001 - 61118
236-002 0.90 Stall speed, checking
237-002 2.00 Injectors, replacing all
237-012 5.50 Unit injector, replacing 15000 - 19999
72100 - 79999

30 Volvo Construction Equipment 7/11/2012


A25D
Op.no. time (h) Notes

237-016 11.00 Injectors, replacing copper sleeve in machine 15000 - 19999


72100 - 79999
237-123 0.70 Injector shut off, manual

25 INLET SYSTEM; EXHAUST SYSTEM


255-002 1.25 Turbocharger, inspection
255-071 2.50 Turbocharger, replacing
256-006 0.70 Preheating coil, replacing
258-002 3.00 Intercooler, replacing
258-016 0.70 Cooling fan motor, intercooler, checking/adjusting
low rpm
258-017 0.80 Cooling fan motor, intercooler, checking/adjusting
high rpm

26 COOLING SYSTEM
260-002 5.50 Cooling system, flushing
261-004 0.90 Coolant, changing 13001 - 19999
72001 - 79999
261-004 0.90 Coolant, changing 11000 - 12999
61000 - 61118
261-004 0.90 Coolant, changing 11000 - 12999
61000 - 61118
261-004 0.90 Coolant, changing 13001 - 19999
72001 - 79999
261-011 1.50 Radiator, removing
261-013 2.00 Radiator, installing
262-002 2.00 Coolant pump, replacing
262-002 2.50 Coolant pump, replacing 11000 - 12999
61000 - 61118
262-071 0.90 Coolant pump removed, reconditioning
262-098 1.25 Thermostat, replacing 13001 - 19999
72001 - 79999
263-063 0.70 Cooling fan motor, radiator, checking/adjusting
low rpm
263-064 0.80 Cooling fan motor, radiator, checking/adjusting
high rpm

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
30 GENERAL
300-072 0.60 I-ECU, MID 140, changing non-programmed ECU
300-074 0.40 I-ECU, MID 140, changing pre-programmed ECU

31 BATTERY
311-002 0.90 Batteries, replacing

7/11/2012 Volvo Construction Equipment 31


A25D
Op.no. time (h) Notes

32 ALTERNATOR; CHARGE REGULATOR


321-002 0.90 Alternator, replacing incl function check 13001 - 19999
72001 - 79999
321-002 0.40 Alternator, replacing incl function check 11001 - 12077
61001 - 61118

33 STARTING SYSTEM
331-018 1.75 Starter motor, replacing 11001 - 12077
61001 - 61118
331-018 0.90 Starter motor, replacing 13001 - 19999
72001 - 79999

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.75 Headlight, complete, changing (high beam 1 pc.)
incl. setting
352-060 0.75 Headlight, complete, changing (low beam 1 pc.)
incl. setting/adjustment
353-016 0.50 Rear lamp, replacing one
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


360-001 0.75 Combination control (by steering wheel), changing
361-002 1.00 Flasher unit, replacing relay
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-900 1.00 Rotating beacon, installing new
363-002 1.25 Windscreen wiper front, replacing motor
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
366-060 0.70 C-ECU, MID178, changing non-programmed ECU11001 - 13574
61001 - 61118
366-062 0.70 C-ECU, MID178, changing pre-programmed ECU11001 - 13574
61001 - 61118
366-064 1.00 V-ECU, MID 187, changing non-programmed 13575 - 19999
ECU 72101 - 79999
366-064 1.50 V-ECU, MID 187, changing non-programmed 11001 - 13574
ECU 61001 - 61118
366-066 0.90 V-ECU, MID 187, changing pre-programmed ECU13575 - 19999
72101 - 79999
366-066 1.25 V-ECU, MID 187, changing pre-programmed ECU11001 - 13574
61001 - 61118

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-008 0.60 Engine rotation speed sensor, replacing 13001 - 19999

32 Volvo Construction Equipment 7/11/2012


A25D
Op.no. time (h) Notes

72001 - 79999
386-088 0.80 Engine rotation speed sensor (camshaft), 15001 - 19999
replacing 72101 - 79999

39 MISCELLANEOUS
390-902 2.00 CareTrack, installing new

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-001 1.75 Checking of main, torque converter and lubricating
oil pressure
421-002 1.75 Transmission, check oil pressure
421-047 0.50 Gear selector, replacing
421-054 2.00 Seal for rear output shaft, replacing 13001 - 19999
72001 - 79999
421-057 3.00 Retarder valve, replacing of seal
421-062 1.50 Induction sensor for turbine speed, changing
421-070 10.00 Transmission, removing 13001 - 19999
72001 - 79999
421-072 11.00 Transmission, installing 13001 - 19999
72001 - 79999
421-083 1.25 Transmission, remove from a non mounted engine
421-084 1.00 Transmission, fitting on a non mounted engine

43 GEARBOX,
432-076 0.70 T-ECU, MID 130, changing non-programmed
ECU
432-078 0.60 T-ECU, MID 130, changing pre-programmed ECU
434-064 0.50 Differential lock longitudinal, adjustment of sender
unit
434-073 4.00 Dropbox, installing
434-074 3.00 Dropbox, removing

45 PROPELLER SHAFT
451-006 6.50 Intermediate shaft and/or bearing, replacing (in 15534 - 19999
frame joint) 72219 - 79999

46 FRONT AXLE; REAR AXLE


461-011 8.00 Centre gear , removing and fitting
461-037 4.00 Hub reduction, removing
461-038 2.50 Hub reduction, installing
463-006 9.00 Spindle, replacing one side
463-011 8.00 Centre gear, removing and fitting
463-016 0.50 Dog clutch 6x6, checking and adjusting
463-079 2.00 Output shaft 6-wheel drive bearing, replacing

7/11/2012 Volvo Construction Equipment 33


A25D
Op.no. time (h) Notes

464-011 8.00 Centre gear, removing and fitting


464-084 9.50 Spindle, replacing one side
468-005 0.50 Differential lock rear, adjusting engagement
468-062 0.50 Transverse differential lock/axle, checking and
adjusting

48 POWER TAKE OFF


482-004 8.00 Power take-off, between engine and gearbox, 72001 - 79999
reconditioning 15001 - 19999

49 MISCELLANEOUS
491-006 1.25 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
511-002 4.00 Brake disc, replacing one
511-005 1.75 Brake pads, replacing (one wheel, front axle)
511-045 4.00 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-002 4.00 Brake disc, replacing one
512-005 1.75 Brake pads, replacing (one wheel, first boggie
axle)
512-045 4.00 Brake caliper, replacing one
512-045 4.00 Brake caliper, replacing one
513-005 1.75 Brake pads, replacing (one wheel, 2:d boggie axle)

52 HYDRAULIC BRAKE SYSTEM


520-037 1.00 Brake system, bleeding

55 PARKING BRAKE
550-005 3.00 Parking brake, replacing brake disc
550-009 1.00 Spring brake cylinder, replacing
550-012 2.00 Parking brake , replacing brake caliper
550-014 1.75 Parking brake, replacing brake pads
550-014 1.50 Parking brake, replacing brake pads
550-015 0.50 Manual release of parking brake
550-016 0.50 Parking brake lever, changing
553-000 0.40 Load and dump brake, working pressure, checking
and adjusting

56 COMPRESSED-AIR BRAKE
560-002 1.25 Compressed air brake, function check
560-003 0.10 Brake system, relieve pressure
561-004 2.50 Compressor, replacing 13001 - 19999
561-023 0.30 Relief/Cut-in pressure, check

34 Volvo Construction Equipment 7/11/2012


A25D
Op.no. time (h) Notes

561-024 0.30 Relief/Cut-in pressure, adjusting 13001 - 19999


563-004 1.75 Foot brake valve (pneum), replacing 11731 - 19999

6 STEERING
64 STEERING
642-026 3.00 Steering gear, replacing
642-058 1.00 Steering gear, check.and adj.
643-010 2.00 Steering linkage, checking and adjusting 71000 - 72209
11000 - 15513
643-010 1.50 Steering linkage, checking and adjusting 72210 - 79999
15514 - 19999
643-012 0.40 Steering angle, checking and adjusting 72210 - 79999
15514 - 19999
643-013 0.80 Steering times, checking and adjusting 72210 - 79999
15514 - 19999
643-014 1.00 Steering valve, neutral position, checking and 72210 - 79999
adjusting 15514 - 19999
643-017 2.50 Lever bracket, steering bearing, replacing 72210 - 79999
15514 - 19999
645-004 1.00 Steering cylinder, removing
645-005 1.25 Steering cylinder, installing
645-054 2.50 Steering cylinder, replacing bearings
645-054 0.60 Steering cylinder, replacing bearings 15207 - 19999
72148 - 79999
645-054 0.50 Steering cylinder, replacing bearings 11000 - 15206
71000 - 72148
645-060 2.00 Steering cylinder, repacking in machine
645-077 1.00 Steering cylinder removed, reconditioning incl
replacing bearings
645-084 1.00 Damping cylinder, checking spring force
645-085 1.25 Damping cylinder, changing seal
647-095 1.00 Auxiliary steering, adjusting working- and stand-by
pressure
647-096 1.00 Auxiliary steering, hydraulic pump, removing
647-097 2.00 Auxiliary steering, hydraulic pump, installation

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
715-015 0.90 Protecting plate, removal
715-016 1.50 Protecting plate, installation

7/11/2012 Volvo Construction Equipment 35


A25D
Op.no. time (h) Notes

74 FRAME LINK
741-001 7.50 Frame joint, separating machine 15534 - 19999
72219 - 79999
741-036 2.00 Frame joint, replacing bearings
741-041 1.50 Frame joint, changing bearing, machine separated15534 - 19999
(on load unit frame) 72219 - 79999
742-040 8.00 Steering joint, replacing bearings

75 AXLE SUSPENSION
754-010 1.50 Replacing link bearing (rubber bearing), front axle
756-011 5.50 Bogie member, replacing rubber bearing (one
side)
756-024 2.00 Bogie beam, changing rubber spring, one side
(front)
756-027 2.00 A-frame bushing, front on load unit, changing
756-028 2.50 A-frame bushing, rear on load unit, changing
756-029 0.90 Bogie beam, changing rubber bushing on
removed beam
756-030 7.00 Bogie beam, changing

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.60 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 4.00 Cab, removing
810-002 4.50 Cab, installing

82 ENGINE HOOD; MUDGUARD; FOOT STEP


821-002 0.60 Engine hood, installing
821-060 0.50 Electric hood pump, changing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.00 Door, replacing 11000 - 19999
71000 - 79999
61000 - 61118
831-006 0.60 Door lock, replacing
831-052 0.60 Cab door, removing door catch 11000 - 19999
71000 - 79999
61000 - 61118
831-053 0.30 Cab door, installing door catch 11000 - 19999
71000 - 79999
61000 - 61118

36 Volvo Construction Equipment 7/11/2012


A25D
Op.no. time (h) Notes

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 3.00 Windscreen, replacing
843-012 3.00 Rear window, replacing
843-013 2.50 Side window, replacing
843-048 2.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-002 1.00 Air suspension for operators seat, changing
852-003 0.80 Operator's seat, removing
852-004 0.40 Operator's seat, installing

87 AIR CONDITIONING UNIT


873-004 3.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.90 Heat control valve, replacing
873-009 0.90 Heat control, replacing
874-002 1.50 Refrigerant, draining
874-003 0.80 Cooling unit, performance test
874-008 2.50 Refrigerant, filling incl vacuum pumping
874-010 4.00 Condenser, replacing incl draining and filling
874-011 4.00 Receiver, replacing incl draining and filling
874-012 5.00 Evaporator, replacing incl draining and filling
874-014 1.75 Thermostat, replacing

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 0.40 Hydraulic system, bleeding 11731 - 19999
71001 - 79999
900-003 0.10 Hydraulic system, relieve pressure
900-005 0.30 Vacuum pump, connection
900-006 0.20 Vacuum pump, disconnection

91 WORKING HYDRAULICS; SERVO HYDRAULICS


912-078 0.60 Dump lever, changing
912-079 10.00 Steering and tipping valve, replacing
912-080 3.00 Steering and dumping valve (removed),
reconditioning
912-115 5.00 Steering and tipping valve, removal
912-116 5.00 Steering and tipping valve, installation
913-003 0.90 Hydraulic pump, checking and adjusting standby 11731 - 19999
pressure 72001 - 79999

7/11/2012 Volvo Construction Equipment 37


A25D
Op.no. time (h) Notes

913-004 0.80 Hydraulic pump, checking and adjusting max 11731 - 19999
working pressure 72001 - 79999
913-007 0.30 Hydraulic pump (removed), changing shaft seal
913-010 2.50 Hydraulic pump, replacing 11731 - 19999
71001 - 79999
913-010 2.50 Hydraulic pump, replacing 11000 - 11731
61000 - 61118
913-043 0.70 Torque limiting valve, checking and adjusting
913-068 1.50 Pump regulator, checking
914-095 0.90 Dumping lever, checking pressure

95 LOAD CARRIER
951-003 0.30 Dump body position indicator, adjusting
951-004 2.00 Hoist cylinder, changing
951-005 1.00 Hoist cylinder bearing, changing
951-005 0.90 Hoist cylinder bearing, changing
951-006 3.00 Hoist cylinder removed, reconditioning
951-007 1.00 Hoist cylinder, removal
951-008 1.00 Hoist cylinder, installation
951-011 0.30 Cylinder, rear flap, gas pressure, checking and
adjusting
951-030 0.40 Dump body alternative, lowering
951-040 2.50 Dump body joint, changing tipping bearing
951-041 2.50 Dump body, adjusting against frame

38 Volvo Construction Equipment 7/11/2012


A25D 4x4
Op.no. time (h) Notes

0 GENERAL
09 MISCELLANEOUS
090-001 0.70 Engine, basic check

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
170-005 0.25 Start of VCADS Pro computer and reading
machine data
171-001 1.00 Arrival inspection, according to programme
171-002 1.00 Delivery inspection, according to programme
172-002 3.50 Warranty inspection 100 hours
172-004 13.00 Warranty inspection 1000 hours 11000 - 19999
172-004 7.50 Warranty inspection 1000 hours 11000 - 19999
173-002 0.30 Maintenance service, daily
173-004 0.50 Maintenance service, every 50 hours
173-007 1.00 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 6.00 Maintenance service, every 1000 hours
173-014 11.00 Maintenance service, every 2000 hours

19 GENERAL
191-021 0.20 Service position 1

2 ENGINE WITH MOUNTING AND EQUIPMENT


20 GENERAL
200-068 1.00 E-ECU, MID 128, changing non-programmed 13001 - 15330
ECU
200-068 0.90 E-ECU, MID 128, changing non-programmed 11001 - 12077
ECU 61001 - 61118
200-068 1.25 E-ECU, MID 128, changing non-programmed 15001 - 19999
ECU 72101 - 79999
200-070 0.90 E-ECU, MID 128, changing pre-programmed ECU13001 - 19999
72001 - 79999
200-070 0.90 E-ECU, MID 128, changing pre-programmed ECU15001 - 19999
72101 - 79999
200-070 0.80 E-ECU, MID 128, changing pre-programmed ECU11001 - 12077
61001 - 61118

21 ENGINE
210-002 2.50 Compression test

7/11/2012 Volvo Construction Equipment 39


A25D 4x4
Op.no. time (h) Notes

210-002 5.50 Compression test 15000 - 19999


210-070 10.00 Engine, removing
210-072 11.00 Engine, installing
210-073 8.50 Engine and transmission, removing
210-074 8.50 Engine and transmission, mounting
212-051 1.00 Flywheel housing with power take-off (PTO),
removing from engine (out of machine)
212-052 1.50 Flywheel housing with power take-off (PTO),
mounting on engine (out of machine)
214-012 5.50 Valves, adjusting 15000 - 19999
214-012 5.50 Valves, adjusting 15000 - 19999
215-042 6.50 Camshaft, replacing
215-043 3.00 Camshaft setting, checking 13001 - 19999
216-014 3.00 Crankshaft, replacing front oil seal
216-014 1.75 Crankshaft, replacing front oil seal
216-018 24.00 Crankshaft, replacing rear oil seal
217-004 4.00 Oil sump gasket, changing
217-005 4.50 Oil level sensor, changing
218-001 1.50 Rubber cushion, replacing
218-007 4.00 Engine mounting rear, changing

22 LUBRICATING SYSTEM
221-022 0.60 Lubrication oil pressure, checking with pressure 11000 - 19999
gauge 71000 - 79999

23 FUEL SYSTEM
230-001 0.50 Carbon monoxide in fuel system, check
233-001 0.70 Fuel system, bleeding 15000 - 19999
72100 - 79999
233-004 0.70 Feed pump, checking feed pressure 15001 - 19999
72101 - 79999
233-004 0.70 Feed pump, checking feed pressure 61001 - 61118
11001 - 12077
233-004 0.70 Feed pump, checking feed pressure 13001 - 15330
72001 - 72047
233-010 2.00 Fuel pump, inspection 61001 - 61118
11001 - 12077
236-002 0.90 Stall speed, checking
237-002 2.00 Injectors, replacing all
237-012 5.50 Unit injector, replacing 15000 - 19999
237-016 11.00 Injectors, replacing copper sleeve in machine 15000 - 19999
237-123 0.70 Injector shut off, manual

25 INLET SYSTEM; EXHAUST SYSTEM


255-002 1.25 Turbocharger, inspection
255-071 2.50 Turbocharger, replacing

40 Volvo Construction Equipment 7/11/2012


A25D 4x4
Op.no. time (h) Notes

256-006 0.70 Preheating coil, replacing


258-002 3.00 Intercooler, replacing
258-016 0.70 Cooling fan motor, intercooler, checking/adjusting
low rpm
258-017 0.80 Cooling fan motor, intercooler, checking/adjusting
high rpm

26 COOLING SYSTEM
260-002 5.50 Cooling system, flushing
261-004 0.90 Coolant, changing 13001 - 19999
72001 - 79999
261-004 0.90 Coolant, changing
261-004 0.90 Coolant, changing
261-004 0.90 Coolant, changing 13001 - 19999
72001 - 79999
261-011 1.50 Radiator, removing
261-013 2.00 Radiator, installing
262-002 2.00 Coolant pump, replacing
262-002 2.50 Coolant pump, replacing
262-071 0.90 Coolant pump removed, reconditioning
262-098 1.25 Thermostat, replacing 13001 - 19999
72001 - 79999
263-063 0.70 Cooling fan motor, radiator, checking/adjusting
low rpm
263-064 0.80 Cooling fan motor, radiator, checking/adjusting
high rpm

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
30 GENERAL
300-072 0.60 I-ECU, MID 140, changing non-programmed ECU
300-074 0.40 I-ECU, MID 140, changing pre-programmed ECU

31 BATTERY
311-002 0.90 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 0.90 Alternator, replacing incl function check 13001 - 19999
72001 - 79999
321-002 0.40 Alternator, replacing incl function check 11001 - 12077
61001 - 61118

33 STARTING SYSTEM
331-018 1.75 Starter motor, replacing 11001 - 12077
61001 - 61118

7/11/2012 Volvo Construction Equipment 41


A25D 4x4
Op.no. time (h) Notes

331-018 0.90 Starter motor, replacing 13001 - 19999


72001 - 79999

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.75 Headlight, complete, changing (high beam 1 pc.)
incl. setting
352-060 0.75 Headlight, complete, changing (low beam 1 pc.)
incl. setting/adjustment
353-016 0.50 Rear lamp, replacing one
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


360-001 0.75 Combination control (by steering wheel), changing
361-002 1.00 Flasher unit, replacing relay
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-900 1.00 Rotating beacon, installing new
363-002 1.25 Windscreen wiper front, replacing motor
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
366-060 0.70 C-ECU, MID178, changing non-programmed ECU11001 - 13574
61001 - 61118
366-062 0.70 C-ECU, MID178, changing pre-programmed ECU11001 - 13574
61001 - 61118
366-064 1.00 V-ECU, MID 187, changing non-programmed 13575 - 19999
ECU 72101 - 79999
366-064 1.50 V-ECU, MID 187, changing non-programmed 11001 - 13574
ECU 61001 - 61118
366-066 0.90 V-ECU, MID 187, changing pre-programmed ECU13575 - 19999
72101 - 79999
366-066 1.25 V-ECU, MID 187, changing pre-programmed ECU11001 - 13574
61001 - 61118

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-008 0.60 Engine rotation speed sensor, replacing 13001 - 19999
72001 - 79999
386-088 0.80 Engine rotation speed sensor (camshaft), 15001 - 19999
replacing

39 MISCELLANEOUS
390-902 2.00 CareTrack, installing new

42 Volvo Construction Equipment 7/11/2012


A25D 4x4
Op.no. time (h) Notes

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-001 1.75 Checking of main, torque converter and lubricating
oil pressure
421-002 1.75 Transmission, check oil pressure
421-047 0.50 Gear selector, replacing
421-054 2.00 Seal for rear output shaft, replacing 13001 - 19999
72001 - 79999
421-057 3.00 Retarder valve, replacing of seal
421-062 1.50 Induction sensor for turbine speed, changing
421-070 10.00 Transmission, removing 13001 - 19999
72001 - 79999
421-072 11.00 Transmission, installing 13001 - 19999
72001 - 79999
421-083 1.25 Transmission, remove from a non mounted engine
421-084 1.00 Transmission, fitting on a non mounted engine

43 GEARBOX,
432-076 0.70 T-ECU, MID 130, changing non-programmed
ECU
432-078 0.60 T-ECU, MID 130, changing pre-programmed ECU
434-064 0.50 Differential lock longitudinal, adjustment of sender
unit
434-073 4.00 Dropbox, installing
434-074 3.00 Dropbox, removing

45 PROPELLER SHAFT
451-006 6.50 Intermediate shaft and/or bearing, replacing (in 15534 - 19999
frame joint) 72219 - 79999

46 FRONT AXLE; REAR AXLE


461-011 8.00 Centre gear , removing and fitting
461-037 4.00 Hub reduction, removing
461-038 2.50 Hub reduction, installing
463-016 0.50 Dog clutch 6x6, checking and adjusting
464-011 8.00 Centre gear, removing and fitting
464-084 9.50 Spindle, replacing one side
468-005 0.50 Differential lock rear, adjusting engagement
468-062 0.50 Transverse differential lock/axle, checking and
adjusting

48 POWER TAKE OFF


482-004 8.00 Power take-off, between engine and gearbox, 15001 - 19999
reconditioning 72001 - 79999

7/11/2012 Volvo Construction Equipment 43


A25D 4x4
Op.no. time (h) Notes

49 MISCELLANEOUS
491-006 1.25 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
511-002 4.00 Brake disc, replacing one
511-005 1.75 Brake pads, replacing (one wheel, front axle)
511-045 4.00 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-002 4.00 Brake disc, replacing one
512-045 4.00 Brake caliper, replacing one
512-045 4.00 Brake caliper, replacing one

52 HYDRAULIC BRAKE SYSTEM


520-037 1.00 Brake system, bleeding

55 PARKING BRAKE
550-005 3.00 Parking brake, replacing brake disc
550-009 1.00 Spring brake cylinder, replacing
550-012 2.00 Parking brake , replacing brake caliper
550-014 1.75 Parking brake, replacing brake pads
550-014 1.50 Parking brake, replacing brake pads
550-015 0.50 Manual release of parking brake
550-016 0.50 Parking brake lever, changing
553-000 0.40 Load and dump brake, working pressure, checking
and adjusting

56 COMPRESSED-AIR BRAKE
560-002 1.25 Compressed air brake, function check
560-003 0.10 Brake system, relieve pressure
561-004 2.50 Compressor, replacing 13001 - 19999
561-023 0.30 Relief/Cut-in pressure, check
561-024 0.30 Relief/Cut-in pressure, adjusting 13001 - 19999

6 STEERING
64 STEERING
642-026 3.00 Steering gear, replacing
642-058 1.00 Steering gear, check.and adj.
643-010 2.00 Steering linkage, checking and adjusting 11000 - 15513
71000 - 72209
643-010 1.50 Steering linkage, checking and adjusting 15514 - 19999

44 Volvo Construction Equipment 7/11/2012


A25D 4x4
Op.no. time (h) Notes

72210 - 79999
643-012 0.40 Steering angle, checking and adjusting 15514 - 19999
72210 - 79999
643-013 0.80 Steering times, checking and adjusting 15514 - 19999
72210 - 79999
643-014 1.00 Steering valve, neutral position, checking and 15514 - 19999
adjusting 72210 - 79999
643-017 2.50 Lever bracket, steering bearing, replacing 15514 - 19999
72210 - 79999
645-004 1.00 Steering cylinder, removing
645-005 1.25 Steering cylinder, installing
645-054 0.60 Steering cylinder, replacing bearings 15207 - 19999
72148 - 79999
645-054 0.50 Steering cylinder, replacing bearings 11000 - 15206
71000 - 72148
645-054 2.50 Steering cylinder, replacing bearings
645-060 2.00 Steering cylinder, repacking in machine
645-077 1.00 Steering cylinder removed, reconditioning incl
replacing bearings
645-084 1.00 Damping cylinder, checking spring force
645-085 1.25 Damping cylinder, changing seal
647-095 1.00 Auxiliary steering, adjusting working- and stand-by
pressure
647-096 1.00 Auxiliary steering, hydraulic pump, removing
647-097 2.00 Auxiliary steering, hydraulic pump, installation

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
715-015 0.90 Protecting plate, removal
715-016 1.50 Protecting plate, installation

74 FRAME LINK
741-001 7.50 Frame joint, separating machine 15534 - 19999
72219 - 79999
741-036 2.00 Frame joint, replacing bearings
741-041 1.50 Frame joint, changing bearing, machine separated15534 - 19999
(on load unit frame) 72219 - 79999
742-040 8.00 Steering joint, replacing bearings

75 AXLE SUSPENSION
754-010 1.50 Replacing link bearing (rubber bearing), front axle
756-011 5.50 Bogie member, replacing rubber bearing (one
side)
756-027 2.00 A-frame bushing, front on load unit, changing

7/11/2012 Volvo Construction Equipment 45


A25D 4x4
Op.no. time (h) Notes

756-028 2.50 A-frame bushing, rear on load unit, changing

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.60 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
82 ENGINE HOOD; MUDGUARD; FOOT STEP
821-002 0.60 Engine hood, installing
821-060 0.50 Electric hood pump, changing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.00 Door, replacing 61000 - 61118
11000 - 19999
71000 - 79999
831-006 0.60 Door lock, replacing
831-052 0.60 Cab door, removing door catch 61000 - 61118
11000 - 19999
71000 - 79999
831-053 0.30 Cab door, installing door catch 61000 - 61118
11000 - 19999
71000 - 79999

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 3.00 Windscreen, replacing
843-012 3.00 Rear window, replacing
843-013 2.50 Side window, replacing
843-048 2.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-002 1.00 Air suspension for operators seat, changing
852-003 0.80 Operator's seat, removing
852-004 0.40 Operator's seat, installing

87 AIR CONDITIONING UNIT


873-004 3.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.90 Heat control valve, replacing
873-009 0.90 Heat control, replacing
874-002 1.50 Refrigerant, draining
874-003 0.80 Cooling unit, performance test
874-008 2.50 Refrigerant, filling incl vacuum pumping
874-010 4.00 Condenser, replacing incl draining and filling
874-011 4.00 Receiver, replacing incl draining and filling
874-012 5.00 Evaporator, replacing incl draining and filling

46 Volvo Construction Equipment 7/11/2012


A25D 4x4
Op.no. time (h) Notes

874-014 1.75 Thermostat, replacing

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 0.40 Hydraulic system, bleeding 11731 - 19999
900-003 0.10 Hydraulic system, relieve pressure
900-005 0.30 Vacuum pump, connection
900-006 0.20 Vacuum pump, disconnection

91 WORKING HYDRAULICS; SERVO HYDRAULICS


912-078 0.60 Dump lever, changing
912-079 10.00 Steering and tipping valve, replacing
912-080 3.00 Steering and dumping valve (removed),
reconditioning
912-115 5.00 Steering and tipping valve, removal
912-116 5.00 Steering and tipping valve, installation
913-003 0.90 Hydraulic pump, checking and adjusting standby 11000 - 19999
pressure
913-004 0.80 Hydraulic pump, checking and adjusting max 11000 - 19999
working pressure
913-007 0.30 Hydraulic pump (removed), changing shaft seal
913-010 2.50 Hydraulic pump, replacing 11731 - 19999
913-010 2.50 Hydraulic pump, replacing 11000 - 11730
913-043 0.70 Torque limiting valve, checking and adjusting
913-068 1.50 Pump regulator, checking
914-095 0.90 Dumping lever, checking pressure

95 LOAD CARRIER
951-003 0.30 Dump body position indicator, adjusting
951-004 2.00 Hoist cylinder, changing
951-005 1.00 Hoist cylinder bearing, changing
951-005 0.90 Hoist cylinder bearing, changing
951-006 3.00 Hoist cylinder removed, reconditioning
951-007 1.00 Hoist cylinder, removal
951-008 1.00 Hoist cylinder, installation
951-011 0.30 Cylinder, rear flap, gas pressure, checking and
adjusting
951-030 0.40 Dump body alternative, lowering
951-040 2.50 Dump body joint, changing tipping bearing
951-041 2.50 Dump body, adjusting against frame

7/11/2012 Volvo Construction Equipment 47


48 Volvo Construction Equipment 7/11/2012
A30C
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
171-001 1.00 Arrival inspection, according to programme
171-002 1.25 Delivery inspection, according to programme
172-002 7.00 Warranty inspection 100 hours
172-004 10.00 Warranty inspection 1000 hours
173-002 0.25 Maintenance service, daily
173-004 0.75 Maintenance service, every 50 hours
173-007 4.00 Maintenance service, every 250 hours
173-010 4.00 Maintenance service, every 500 hours
173-012 7.00 Maintenance service, every 1000 hours
173-014 16.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-066 1.00 Drop box, changing oil/cleaning suction strainer
173-074 1.00 Hydraulic oil tank, changing oil and filter
173-075 1.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank
173-085 3.00 Brake system, changing oil/fluid and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 2.00 Compression test
210-070 8.50 Engine, removing
210-071 45.00 Engine removed, general overhaul
210-072 11.00 Engine, installing
210-073 5.50 Engine and transmission, removing
210-074 7.00 Engine and transmission, mounting
214-012 0.75 Valves, adjusting
214-096 1.50 Valve cap, changing

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-004 0.75 Feed pump, checking feed pressure
236-001 0.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
236-003 0.25 Idling speed, checking
236-004 0.25 Iow idling speed, checking and adjusting
236-030 1.50 Injection timing, checking and adjusting
236-031 1.00 Injection timing adjuster, checking

7/11/2012 Volvo Construction Equipment 49


A30C
Op.no. time (h) Notes

237-002 2.00 Injectors, replacing all

25 INLET SYSTEM; EXHAUST SYSTEM


255-070 0.50 Turbocharger, removing
255-071 1.50 Turbocharger, replacing
255-072 1.00 Turbocharger, installing
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.50 Air cleaner, primary filter replacing
256-004 0.50 Air cleaner, secondary filter replacing
258-002 1.50 Intercooler, replacing

26 COOLING SYSTEM
261-002 0.25 Coolant, checking anti-freeze resistance
261-004 1.50 Coolant, changing
261-008 2.50 Radiator, replacing
261-010 1.00 Radiator, adjusting
261-072 0.50 Coolant filter, changing
262-071 2.00 Coolant pump removed, reconditioning
263-001 0.75 Fan motor, removing
263-002 1.00 Fan motor, changing piston rings
263-003 1.00 Fan motor, installing
263-004 1.00 Fan motor, checking working pressure
263-005 0.25 Fan motor, adjusting working pressure
263-006 1.00 Fan hydraulically driven, removing pump
263-007 1.00 Fan hydraulically driven, fitting pump
263-009 0.75 Fan hydraulically driven, replacing oil return filter
263-010 0.50 Pump 3 (P3) standby pressure, checking
263-012 0.50 Fan belt and/or alternator belt, replacing
263-013 0.50 Fan belt and/or alternator belt, checking and
adjusting tension
263-022 0.50 Fan belt and/or alternator-, compressor belt,
replacing all belts

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.50 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 0.50 Alternator, replacing incl function check
321-074 1.50 Charging test in machine (with measuring
instrument)

50 Volvo Construction Equipment 7/11/2012


A30C
Op.no. time (h) Notes

33 STARTING SYSTEM
331-099 1.25 Starter motor removed, replacing carbon brush kit

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-008 0.50 Headlamp reflector and/or glass, replacing one
incl adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.50 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.50 Flasher unit, replacing relay
361-010 0.50 Flasher switch, replacing
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-016 0.50 Horn switch, replacing
362-900 1.00 Rotating beacon, installing new
363-002 1.50 Windscreen wiper front, replacing motor
363-003 0.50 Windscreen wiper, replacing switch
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.50 Switch, replacing
364-008 0.50 Brake light switch, replacing
367-020 0.50 ECU, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-001 1.75 Checking of main, torque converter and lubricating
oil pressure
421-050 0.75 Transmission, resistance measuring of
cableharness
421-051 0.50 Transmission, resistance measuring of solenoides
421-054 4.00 Seal for rear output shaft, replacing
421-057 0.50 Retarder valve, replacing of seal
421-059 0.50 Transmission retarder valve, adjusting air
pressure
421-060 0.50 Transmission, resistans measuring control system
421-061 1.00 Induction sensor for output shaft, changing
421-062 0.75 Induction sensor for turbine speed, changing

7/11/2012 Volvo Construction Equipment 51


A30C
Op.no. time (h) Notes

421-065 5.00 Control system, replacing


421-068 5.50 Transmission, removing (upwards)
421-069 5.50 Transmission, installing (from above)
421-070 7.00 Transmission, removing
421-072 8.00 Transmission, installing
421-078 2.00 Transmission, remove and fitting from a non
mounted engine
421-079 0.25 Transmission, replacing breather filter

43 GEARBOX,
434-002 2.00 Dropbox, replacing seal for front otput shaft
434-004 2.00 Dropbox, replacing seal for rear output shaft
434-015 4.00 Dropbox, replacing seal for input shaft
434-016 1.00 Dropbox, oil pump, replacing
434-061 0.75 Differential lock longitudinal, adjusting
engagement
434-073 4.50 Dropbox, installing
434-074 4.00 Dropbox, removing

45 PROPELLER SHAFT
451-004 1.50 Propeller shaft, rear, replacing
451-005 1.00 Propeller shaft for rear boggie axel, replacing
451-007 0.75 Propeller shaft, in frame joint, replacing
451-010 0.75 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning
451-014 3.50 Propeller shaft between transmission and
dropbox, replacing

46 FRONT AXLE; REAR AXLE


461-043 4.00 Hub, replacing seal
468-005 0.50 Differential lock rear, adjusting engagement

5 BRAKE
51 WHEEL BRAKE
510-001 1.50 Brake linings, checking wear
510-002 0.25 Brake disc for service brake, checking
511-001 0.50 Brake pads for service brake, checking
511-002 4.50 Brake disc, replacing one
511-004 3.00 Brake pads, replacing on both sides of axel
511-005 1.50 Brake pads, replacing (one wheel, front axle)
511-045 2.00 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-001 0.50 Brake linings, checking wear rear axle
512-002 4.50 Brake disc, replacing one

52 Volvo Construction Equipment 7/11/2012


A30C
Op.no. time (h) Notes

512-004 3.00 Brake pads, replacing on both sides of axle


512-005 1.50 Brake pads, replacing (one wheel, first boggie
axle)
512-045 2.50 Brake caliper, replacing one
512-081 1.00 Brake caliper, removed, reconditioning

52 HYDRAULIC BRAKE SYSTEM


520-037 1.00 Brake system, bleeding

55 PARKING BRAKE
550-002 0.50 Parking brake, adjusting
550-005 2.50 Parking brake, replacing brake disc
550-009 0.50 Spring brake cylinder, replacing
550-010 1.00 Spring brake cylinder removed, reconditioning
550-012 1.00 Parking brake , replacing brake caliper
550-013 0.75 Parking brake caliper (air), removed
reconditioning
550-014 1.00 Parking brake, replacing brake pads
551-003 1.00 Parking brake, (removed) reconditioning of brake
caliper

56 COMPRESSED-AIR BRAKE
561-004 1.00 Compressor, replacing
561-022 0.25 Pressure regulator, adjusting
563-010 1.00 Relay valve (load unit), reconditioning incl.
removing and fitting
563-073 1.00 Foot brake valve (pneumatic) removed,
reconditioning

6 STEERING
64 STEERING
642-026 3.00 Steering gear, replacing
643-010 3.50 Steering linkage, checking and adjusting
645-001 0.50 Steering cylinder bearing, checking clearanse
645-003 0.50 Steering system working pressure, checking
645-006 5.00 Steering cylinder, replacing
645-054 1.00 Steering cylinder, replacing bearings
645-060 3.00 Steering cylinder, repacking in machine
645-080 2.00 Steering valve neutral position and valve spool
end float, checking
645-081 3.00 Steering valve removed, reconditioning
645-082 3.00 Steering valve, replacing
645-084 0.50 Damping cylinder, checking spring force
645-085 1.00 Damping cylinder, changing seal

7/11/2012 Volvo Construction Equipment 53


A30C
Op.no. time (h) Notes

647-093 2.00 Auxiliary steering, replacing hydraulic pump


647-095 0.50 Auxiliary steering, adjusting working- and stand-by
pressure

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
711-020 3.00 Load unit frame, checking measurements

72 SUSPENSION
727-001 5.00 Spring element front, replacing all

74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-006 4.00 Frame joint, measuring and adjusting clearence
741-036 2.00 Frame joint, replacing bearings
742-007 10.00 Frame joint, replacing hitch
742-038 1.50 Articulated joint, checking clearence
742-040 9.00 Steering joint, replacing bearings
742-044 1.00 Articulated joint, replacing bushing
742-046 1.50 Frame joint, changing metallic bearing (machine
separated)

75 AXLE SUSPENSION
754-010 3.00 Replacing link bearing (rubber bearing), front axle
754-021 1.00 Front bogie axle cross stay, adjusting
754-031 1.00 Rear bogie axle cross stay, adjusting
756-011 6.00 Bogie member, replacing rubber bearing (one
side)
756-012 1.00 Cross stay rubber bushing (bearing), replacing
(front)
756-014 1.00 Cross stay rubber bushing (bearing), replacing,
(rear)
756-015 3.00 Cross stay, checking and adjusting
756-024 1.00 Bogie beam, changing rubber spring, one side
(front)
756-026 3.00 Bogie, replacing all rubber elements both sides

76 SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL /


SIDE CONTROL
761-001 2.00 Shock absorber front, replacing all

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.50 Wheel, removing and fitting one

54 Volvo Construction Equipment 7/11/2012


A30C
Op.no. time (h) Notes

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
843-002 1.00 Windscreen, replacing
843-012 1.50 Rear window, replacing
843-013 1.00 Side window, replacing
843-048 1.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-002 1.00 Air suspension for operators seat, changing

87 AIR CONDITIONING UNIT


873-004 1.50 Heater core, replacing
873-006 1.50 Fan motor, replacing
873-008 1.00 Heat control valve, replacing
874-002 1.50 Refrigerant, draining
874-003 0.50 Cooling unit, performance test
874-005 2.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
913-003 0.50 Hydraulic pump, checking and adjusting standby
pressure
913-004 0.50 Hydraulic pump, checking and adjusting max
working pressure
913-008 2.00 Hydraulic pump, ground dependent, changing

95 LOAD CARRIER
951-001 0.50 Tipping control, adjusting
951-002 2.00 Tipping valve, changing wire
951-003 0.50 Dump body position indicator, adjusting
951-004 5.00 Hoist cylinder, changing
951-006 3.50 Hoist cylinder removed, reconditioning
951-010 2.00 Tipping valve, replacing
951-040 3.00 Dump body joint, changing tipping bearing
951-041 1.50 Dump body, adjusting against frame

7/11/2012 Volvo Construction Equipment 55


56 Volvo Construction Equipment 7/11/2012
A30D
Op.no. time (h) Notes

0 GENERAL
09 MISCELLANEOUS
090-001 0.70 Engine, basic check

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
170-005 0.25 Start of VCADS Pro computer and reading
machine data
171-001 1.00 Arrival inspection, according to programme
171-002 1.00 Delivery inspection, according to programme
172-002 3.50 Warranty inspection 100 hours
172-004 13.00 Warranty inspection 1000 hours 10000 - 19999
172-004 7.50 Warranty inspection 1000 hours 10000 - 19999
173-002 0.30 Maintenance service, daily
173-004 0.50 Maintenance service, every 50 hours
173-007 1.00 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 6.00 Maintenance service, every 1000 hours
173-014 11.00 Maintenance service, every 2000 hours

19 GENERAL
191-021 0.20 Service position 1

2 ENGINE WITH MOUNTING AND EQUIPMENT


20 GENERAL
200-068 1.00 E-ECU, MID 128, changing non-programmed 12001 - 14311
ECU 73001 - 74088
200-068 0.90 E-ECU, MID 128, changing non-programmed 10001 - 10682
ECU 60001 - 60093
70001 - 72999
200-068 1.25 E-ECU, MID 128, changing non-programmed 14001 - 19999
ECU 74001 - 79999
200-070 0.90 E-ECU, MID 128, changing pre-programmed ECU12001 - 19999
73001 - 79999
200-070 0.90 E-ECU, MID 128, changing pre-programmed ECU14001 - 19999
74001 - 79999
200-070 0.80 E-ECU, MID 128, changing pre-programmed ECU10001 - 10682
60001 - 60093
70001 - 72999

7/11/2012 Volvo Construction Equipment 57


A30D
Op.no. time (h) Notes

21 ENGINE
210-002 2.50 Compression test 60000 - 60093
10000 - 11999
70000 - 72999
210-002 5.50 Compression test 14000 - 19999
74000 - 79999
210-070 10.00 Engine, removing
210-072 11.00 Engine, installing
210-073 8.50 Engine and transmission, removing
210-074 8.50 Engine and transmission, mounting
212-051 1.00 Flywheel housing with power take-off (PTO),
removing from engine (out of machine)
212-052 1.50 Flywheel housing with power take-off (PTO),
mounting on engine (out of machine)
214-012 5.50 Valves, adjusting 14000 - 19999
74000 - 79999
214-012 5.50 Valves, adjusting 14000 - 19999
74000 - 79999
215-042 6.50 Camshaft, replacing
215-043 3.00 Camshaft setting, checking 12001 - 19999
73001 - 79999
216-014 3.00 Crankshaft, replacing front oil seal
216-014 1.75 Crankshaft, replacing front oil seal
216-018 24.00 Crankshaft, replacing rear oil seal 12000 - 19999
73000 - 79999
217-004 4.00 Oil sump gasket, changing
217-005 4.50 Oil level sensor, changing
218-001 1.50 Rubber cushion, replacing
218-007 4.00 Engine mounting rear, changing

22 LUBRICATING SYSTEM
221-022 0.60 Lubrication oil pressure, checking with pressure 10000 - 19999
gauge 70000 - 79999
223-006 5.00 Oil cooler, replacing

23 FUEL SYSTEM
230-001 0.50 Carbon monoxide in fuel system, check
233-001 0.70 Fuel system, bleeding 14000 - 19999
74000 - 79999
233-004 0.70 Feed pump, checking feed pressure 14001 - 19999
74001 - 79999
233-004 0.70 Feed pump, checking feed pressure 10001 - 10682
60001 - 60093
70001 - 72999
233-004 0.70 Feed pump, checking feed pressure 12001 - 14311
73001 - 74088
233-010 2.00 Fuel pump, inspection 10001 - 10682

58 Volvo Construction Equipment 7/11/2012


A30D
Op.no. time (h) Notes

60001 - 60093
70001 - 72999
236-002 0.90 Stall speed, checking
237-002 2.00 Injectors, replacing all
237-012 5.50 Unit injector, replacing 14000 - 19999
74000 - 79999
237-016 11.00 Injectors, replacing copper sleeve in machine 14000 - 19999
74000 - 79999
237-123 0.70 Injector shut off, manual

25 INLET SYSTEM; EXHAUST SYSTEM


255-002 1.25 Turbocharger, inspection
255-071 2.50 Turbocharger, replacing
256-006 0.70 Preheating coil, replacing
258-002 3.00 Intercooler, replacing
258-016 0.70 Cooling fan motor, intercooler, checking/adjusting
low rpm
258-017 0.80 Cooling fan motor, intercooler, checking/adjusting
high rpm

26 COOLING SYSTEM
260-002 5.50 Cooling system, flushing
261-004 0.90 Coolant, changing 12001 - 19999
73001 - 79999
261-004 0.90 Coolant, changing 10000 - 11999
60000 - 60093
70000 - 72999
261-004 0.90 Coolant, changing 10000 - 11999
60000 - 60093
70000 - 72999
261-004 0.90 Coolant, changing 12001 - 19999
73001 - 79999
261-011 1.50 Radiator, removing
261-013 2.00 Radiator, installing
262-002 2.00 Coolant pump, replacing
262-002 2.50 Coolant pump, replacing 10000 - 11999
60000 - 60093
70000 - 72999
262-071 0.90 Coolant pump removed, reconditioning
262-098 1.25 Thermostat, replacing 12001 - 19999
73001 - 79999
263-063 0.70 Cooling fan motor, radiator, checking/adjusting
low rpm
263-064 0.80 Cooling fan motor, radiator, checking/adjusting
high rpm

7/11/2012 Volvo Construction Equipment 59


A30D
Op.no. time (h) Notes

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
30 GENERAL
300-072 0.60 I-ECU, MID 140, changing non-programmed ECU
300-074 0.40 I-ECU, MID 140, changing pre-programmed ECU

31 BATTERY
311-002 0.90 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 0.90 Alternator, replacing incl function check 12001 - 19999
73001 - 79999
321-002 0.40 Alternator, replacing incl function check 10001 - 10682
60001 - 60093
70001 - 72999

33 STARTING SYSTEM
331-018 1.75 Starter motor, replacing 10001 - 10682
60001 - 60093
70001 - 72999
331-018 0.90 Starter motor, replacing 12001 - 19999
73001 - 79999

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.75 Headlight, complete, changing (high beam 1 pc.)
incl. setting
352-060 0.75 Headlight, complete, changing (low beam 1 pc.)
incl. setting/adjustment
353-016 0.50 Rear lamp, replacing one
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


360-001 0.75 Combination control (by steering wheel), changing
361-002 1.00 Flasher unit, replacing relay
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-900 1.00 Rotating beacon, installing new
363-002 1.25 Windscreen wiper front, replacing motor
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
366-060 0.70 C-ECU, MID178, changing non-programmed ECU10001 - 12473
60001 - 60093
70001 - 73152
366-062 0.70 C-ECU, MID178, changing pre-programmed ECU10001 - 12473

60 Volvo Construction Equipment 7/11/2012


A30D
Op.no. time (h) Notes

60001 - 60093
70001 - 73152
366-064 1.00 V-ECU, MID 187, changing non-programmed 12474 - 19999
ECU 73153 - 79999
366-064 1.50 V-ECU, MID 187, changing non-programmed 10001 - 12473
ECU 60001 - 60093
70001 - 73152
366-066 0.90 V-ECU, MID 187, changing pre-programmed ECU12474 - 19999
73153 - 79999
366-066 1.25 V-ECU, MID 187, changing pre-programmed ECU10001 - 12473
60001 - 60093
70001 - 73152

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-008 0.60 Engine rotation speed sensor, replacing 12001 - 19999
73001 - 79999
386-088 0.80 Engine rotation speed sensor (camshaft), 14001 - 19999
replacing 74001 - 79999

39 MISCELLANEOUS
390-902 2.00 CareTrack, installing new

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-001 1.75 Checking of main, torque converter and lubricating
oil pressure
421-002 1.75 Transmission, check oil pressure
421-047 0.50 Gear selector, replacing
421-054 2.00 Seal for rear output shaft, replacing 12001 - 19999
73000 - 79999
421-057 3.00 Retarder valve, replacing of seal
421-062 1.50 Induction sensor for turbine speed, changing
421-070 10.00 Transmission, removing 12001 - 19999
73001 - 79999
421-072 11.00 Transmission, installing 12001 - 19999
73001 - 79999
421-083 1.25 Transmission, remove from a non mounted engine
421-084 1.00 Transmission, fitting on a non mounted engine

43 GEARBOX,
432-076 0.70 T-ECU, MID 130, changing non-programmed
ECU
432-078 0.60 T-ECU, MID 130, changing pre-programmed ECU
434-064 0.50 Differential lock longitudinal, adjustment of sender
unit
434-073 4.00 Dropbox, installing

7/11/2012 Volvo Construction Equipment 61


A30D
Op.no. time (h) Notes

434-074 3.00 Dropbox, removing

45 PROPELLER SHAFT
451-006 6.50 Intermediate shaft and/or bearing, replacing (in 14418 - 19999
frame joint) 74213 - 79999

46 FRONT AXLE; REAR AXLE


461-011 8.00 Centre gear , removing and fitting
461-011 8.00 Centre gear , removing and fitting
461-037 4.00 Hub reduction, removing
461-038 2.50 Hub reduction, installing
463-006 9.00 Spindle, replacing one side
463-011 8.00 Centre gear, removing and fitting
463-016 0.50 Dog clutch 6x6, checking and adjusting
463-079 2.00 Output shaft 6-wheel drive bearing, replacing
464-011 8.00 Centre gear, removing and fitting
464-084 9.50 Spindle, replacing one side
468-005 0.50 Differential lock rear, adjusting engagement
468-062 0.50 Transverse differential lock/axle, checking and
adjusting

48 POWER TAKE OFF


482-004 8.00 Power take-off, between engine and gearbox, 14001 - 19999
reconditioning 74001 - 79999

49 MISCELLANEOUS
491-006 1.25 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
511-002 4.00 Brake disc, replacing one
511-005 1.75 Brake pads, replacing (one wheel, front axle)
511-045 4.00 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-002 4.00 Brake disc, replacing one
512-005 1.75 Brake pads, replacing (one wheel, first boggie
axle)
512-045 4.00 Brake caliper, replacing one
512-045 4.00 Brake caliper, replacing one
513-005 1.75 Brake pads, replacing (one wheel, 2:d boggie axle)

52 HYDRAULIC BRAKE SYSTEM


520-037 1.00 Brake system, bleeding

62 Volvo Construction Equipment 7/11/2012


A30D
Op.no. time (h) Notes

55 PARKING BRAKE
550-005 3.00 Parking brake, replacing brake disc
550-009 1.00 Spring brake cylinder, replacing
550-012 2.00 Parking brake , replacing brake caliper
550-014 1.75 Parking brake, replacing brake pads
550-014 1.50 Parking brake, replacing brake pads
550-015 0.50 Manual release of parking brake
550-016 0.50 Parking brake lever, changing
553-000 0.40 Load and dump brake, working pressure, checking
and adjusting

56 COMPRESSED-AIR BRAKE
560-002 1.25 Compressed air brake, function check
560-003 0.10 Brake system, relieve pressure
561-004 2.50 Compressor, replacing 12001 - 19999
73001 - 79999
561-023 0.30 Relief/Cut-in pressure, check
561-024 0.30 Relief/Cut-in pressure, adjusting 12001 - 19999
73001 - 79999
563-004 1.75 Foot brake valve (pneum), replacing 10369 - 19999
70001 - 79999

6 STEERING
64 STEERING
642-026 3.00 Steering gear, replacing
642-058 1.00 Steering gear, check.and adj.
643-010 2.00 Steering linkage, checking and adjusting 10000 - 14399
70000 - 74165
643-010 1.50 Steering linkage, checking and adjusting 14400 - 19999
74196 - 79999
643-012 0.40 Steering angle, checking and adjusting 14400 - 19999
74196 - 79999
643-013 0.80 Steering times, checking and adjusting 14400 - 19999
74196 - 79999
643-014 1.00 Steering valve, neutral position, checking and 14400 - 19999
adjusting 74196 - 79999
643-017 2.50 Lever bracket, steering bearing, replacing 14400 - 19999
74196 - 79999
645-004 1.00 Steering cylinder, removing
645-005 1.25 Steering cylinder, installing
645-054 2.50 Steering cylinder, replacing bearings
645-054 0.60 Steering cylinder, replacing bearings 14213 - 19999
74072 - 79999
645-054 0.50 Steering cylinder, replacing bearings 10000 - 14212

7/11/2012 Volvo Construction Equipment 63


A30D
Op.no. time (h) Notes

70000 - 74071
645-060 2.00 Steering cylinder, repacking in machine
645-077 1.00 Steering cylinder removed, reconditioning incl
replacing bearings
645-084 1.00 Damping cylinder, checking spring force
645-085 1.25 Damping cylinder, changing seal
647-095 1.00 Auxiliary steering, adjusting working- and stand-by
pressure
647-096 1.00 Auxiliary steering, hydraulic pump, removing
647-097 2.00 Auxiliary steering, hydraulic pump, installation

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
715-015 0.90 Protecting plate, removal
715-016 1.50 Protecting plate, installation

74 FRAME LINK
741-001 7.50 Frame joint, separating machine 14418 - 19999
74213 - 79999
741-036 2.00 Frame joint, replacing bearings
741-041 1.50 Frame joint, changing bearing, machine separated14418 - 19999
(on load unit frame) 74213 - 79999
742-040 8.00 Steering joint, replacing bearings

75 AXLE SUSPENSION
754-010 1.50 Replacing link bearing (rubber bearing), front axle
756-011 5.50 Bogie member, replacing rubber bearing (one
side)
756-024 2.00 Bogie beam, changing rubber spring, one side
(front)
756-027 2.00 A-frame bushing, front on load unit, changing
756-028 2.50 A-frame bushing, rear on load unit, changing
756-029 0.90 Bogie beam, changing rubber bushing on
removed beam
756-030 7.00 Bogie beam, changing

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.60 Wheel, removing and fitting one

64 Volvo Construction Equipment 7/11/2012


A30D
Op.no. time (h) Notes

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 4.00 Cab, removing
810-002 4.50 Cab, installing

82 ENGINE HOOD; MUDGUARD; FOOT STEP


821-002 0.60 Engine hood, installing
821-060 0.50 Electric hood pump, changing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.00 Door, replacing 60000 - 60093
10000 - 19999
70000 - 79999
831-006 0.60 Door lock, replacing
831-052 0.60 Cab door, removing door catch 60000 - 60093
10000 - 19999
70000 - 79999
831-053 0.30 Cab door, installing door catch 60000 - 60093
10000 - 19999
70000 - 79999

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 3.00 Windscreen, replacing
843-012 3.00 Rear window, replacing
843-013 2.50 Side window, replacing
843-048 2.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-002 1.00 Air suspension for operators seat, changing
852-003 0.80 Operator's seat, removing
852-004 0.40 Operator's seat, installing

87 AIR CONDITIONING UNIT


873-004 3.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.90 Heat control valve, replacing
873-009 0.90 Heat control, replacing
874-002 1.50 Refrigerant, draining
874-003 0.80 Cooling unit, performance test
874-008 2.50 Refrigerant, filling incl vacuum pumping
874-010 4.00 Condenser, replacing incl draining and filling
874-011 4.00 Receiver, replacing incl draining and filling
874-012 5.00 Evaporator, replacing incl draining and filling
874-014 1.75 Thermostat, replacing

7/11/2012 Volvo Construction Equipment 65


A30D
Op.no. time (h) Notes

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 0.40 Hydraulic system, bleeding 10369 - 19999
70001 - 79999
900-003 0.10 Hydraulic system, relieve pressure
900-005 0.30 Vacuum pump, connection
900-006 0.20 Vacuum pump, disconnection

91 WORKING HYDRAULICS; SERVO HYDRAULICS


912-078 0.60 Dump lever, changing
912-079 10.00 Steering and tipping valve, replacing
912-080 3.00 Steering and dumping valve (removed),
reconditioning
912-115 5.00 Steering and tipping valve, removal
912-116 5.00 Steering and tipping valve, installation
913-003 0.90 Hydraulic pump, checking and adjusting standby 70001 - 79999
pressure 10369 - 19999
913-004 0.80 Hydraulic pump, checking and adjusting max 10369 - 19999
working pressure 70001 - 79999
913-007 0.30 Hydraulic pump (removed), changing shaft seal
913-010 2.50 Hydraulic pump, replacing 10369 - 19999
70001 - 79999
913-010 2.50 Hydraulic pump, replacing 10000 - 10368
60000 - 60093
913-043 0.70 Torque limiting valve, checking and adjusting
913-068 1.50 Pump regulator, checking
914-095 0.90 Dumping lever, checking pressure

95 LOAD CARRIER
951-003 0.30 Dump body position indicator, adjusting
951-004 2.00 Hoist cylinder, changing
951-005 1.00 Hoist cylinder bearing, changing
951-005 0.90 Hoist cylinder bearing, changing
951-006 3.00 Hoist cylinder removed, reconditioning
951-007 1.00 Hoist cylinder, removal
951-008 1.00 Hoist cylinder, installation
951-011 0.30 Cylinder, rear flap, gas pressure, checking and
adjusting
951-030 0.40 Dump body alternative, lowering
951-040 2.50 Dump body joint, changing tipping bearing
951-041 2.50 Dump body, adjusting against frame

66 Volvo Construction Equipment 7/11/2012


A35C
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
171-001 1.00 Arrival inspection, according to programme
171-002 1.25 Delivery inspection, according to programme
172-002 7.00 Warranty inspection 100 hours
172-004 10.00 Warranty inspection 1000 hours
173-002 0.50 Maintenance service, daily
173-004 1.25 Maintenance service, every 50 hours
173-007 4.00 Maintenance service, every 250 hours
173-010 4.00 Maintenance service, every 500 hours
173-012 7.00 Maintenance service, every 1000 hours
173-014 16.00 Maintenance service, every 2000 hours
173-059 2.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-066 1.00 Drop box, changing oil/cleaning suction strainer
173-074 1.00 Hydraulic oil tank, changing oil and filter
173-075 1.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank
173-085 3.00 Brake system, changing oil/fluid and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 2.00 Compression test
210-070 8.50 Engine, removing
210-071 48.00 Engine removed, general overhaul
210-072 10.00 Engine, installing
210-073 8.00 Engine and transmission, removing
210-074 9.00 Engine and transmission, mounting
214-012 1.50 Valves, adjusting
214-096 1.50 Valve cap, changing

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-004 0.75 Feed pump, checking feed pressure
236-001 0.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
236-003 0.25 Idling speed, checking
236-004 0.25 Iow idling speed, checking and adjusting
236-030 1.50 Injection timing, checking and adjusting
236-031 1.00 Injection timing adjuster, checking

7/11/2012 Volvo Construction Equipment 67


A35C
Op.no. time (h) Notes

237-002 2.00 Injectors, replacing all

25 INLET SYSTEM; EXHAUST SYSTEM


255-070 0.50 Turbocharger, removing
255-071 1.50 Turbocharger, replacing
255-072 1.00 Turbocharger, installing
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.50 Air cleaner, primary filter replacing
256-004 0.50 Air cleaner, secondary filter replacing
258-002 1.50 Intercooler, replacing

26 COOLING SYSTEM
261-002 0.25 Coolant, checking anti-freeze resistance
261-004 1.50 Coolant, changing
261-008 2.50 Radiator, replacing
261-010 1.00 Radiator, adjusting
261-072 0.50 Coolant filter, changing
262-071 2.00 Coolant pump removed, reconditioning
263-001 1.00 Fan motor, removing
263-002 1.00 Fan motor, changing piston rings
263-003 1.00 Fan motor, installing
263-004 1.00 Fan motor, checking working pressure
263-005 0.25 Fan motor, adjusting working pressure
263-006 1.00 Fan hydraulically driven, removing pump
263-007 1.00 Fan hydraulically driven, fitting pump
263-009 0.75 Fan hydraulically driven, replacing oil return filter
263-012 0.50 Fan belt and/or alternator belt, replacing
263-013 0.50 Fan belt and/or alternator belt, checking and
adjusting tension
263-022 0.50 Fan belt and/or alternator-, compressor belt,
replacing all belts

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.50 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check

33 STARTING SYSTEM
331-018 1.25 Starter motor, replacing

68 Volvo Construction Equipment 7/11/2012


A35C
Op.no. time (h) Notes

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-008 0.50 Headlamp reflector and/or glass, replacing one
incl adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.50 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.50 Flasher unit, replacing relay
361-010 0.50 Flasher switch, replacing
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-016 0.50 Horn switch, replacing
363-002 1.50 Windscreen wiper front, replacing motor
363-003 0.50 Windscreen wiper, replacing switch
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.50 Switch, replacing
364-008 0.50 Brake light switch, replacing
367-020 0.50 ECU, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-001 1.75 Checking of main, torque converter and lubricating
oil pressure
421-050 0.75 Transmission, resistance measuring of
cableharness
421-051 0.50 Transmission, resistance measuring of solenoides
421-054 4.00 Seal for rear output shaft, replacing
421-057 0.50 Retarder valve, replacing of seal
421-059 0.50 Transmission retarder valve, adjusting air
pressure
421-060 0.50 Transmission, resistans measuring control system
421-061 1.00 Induction sensor for output shaft, changing
421-062 0.75 Induction sensor for turbine speed, changing
421-065 5.00 Control system, replacing
421-068 5.50 Transmission, removing (upwards)
421-069 5.50 Transmission, installing (from above)
421-070 7.00 Transmission, removing

7/11/2012 Volvo Construction Equipment 69


A35C
Op.no. time (h) Notes

421-072 9.00 Transmission, installing


421-078 2.00 Transmission, remove and fitting from a non
mounted engine
421-079 0.25 Transmission, replacing breather filter

43 GEARBOX,
434-002 2.00 Dropbox, replacing seal for front otput shaft
434-004 2.00 Dropbox, replacing seal for rear output shaft
434-015 4.00 Dropbox, replacing seal for input shaft
434-016 1.00 Dropbox, oil pump, replacing
434-060 1.00 Dropbox, adjusting control for high and low gear
434-061 0.50 Differential lock longitudinal, adjusting
engagement
434-063 1.00 Adjustment of sender units SE54 and SE55
434-073 4.50 Dropbox, installing
434-074 4.00 Dropbox, removing

45 PROPELLER SHAFT
451-004 1.50 Propeller shaft, rear, replacing
451-005 1.00 Propeller shaft for rear boggie axel, replacing
451-007 0.75 Propeller shaft, in frame joint, replacing
451-010 0.75 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning
451-014 3.50 Propeller shaft between transmission and
dropbox, replacing

46 FRONT AXLE; REAR AXLE


461-043 4.00 Hub, replacing seal
468-005 0.50 Differential lock rear, adjusting engagement

5 BRAKE
51 WHEEL BRAKE
510-001 2.00 Brake linings, checking wear
510-002 0.25 Brake disc for service brake, checking
511-001 1.00 Brake pads for service brake, checking
511-002 4.50 Brake disc, replacing one
511-004 3.00 Brake pads, replacing on both sides of axel
511-005 1.50 Brake pads, replacing (one wheel, front axle)
511-045 3.00 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-001 1.00 Brake linings, checking wear rear axle
512-002 4.50 Brake disc, replacing one
512-004 3.00 Brake pads, replacing on both sides of axle

70 Volvo Construction Equipment 7/11/2012


A35C
Op.no. time (h) Notes

512-005 1.50 Brake pads, replacing (one wheel, first boggie


axle)
512-045 2.50 Brake caliper, replacing one
512-081 0.75 Brake caliper, removed, reconditioning

52 HYDRAULIC BRAKE SYSTEM


520-001 0.75 Brake system, checking function, hydraulic
520-006 2.50 Brake pads for service brake, checking complete
machine
520-037 3.50 Brake system, bleeding
525-002 1.50 Unloading valve, removing and fitting
525-008 3.00 Foot brake valve, replacing
525-009 0.75 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure
527-004 1.50 Hydraulic pump, replacing
527-005 2.50 Hydraulic pump, reconditioning incl removing and
fitting
527-007 1.00 Brake oil pump, piston ring, changing

55 PARKING BRAKE
550-002 0.50 Parking brake, adjusting
550-005 2.50 Parking brake, replacing brake disc
550-009 0.50 Spring brake cylinder, replacing
550-010 1.00 Spring brake cylinder removed, reconditioning
550-012 2.00 Parking brake , replacing brake caliper
550-013 0.75 Parking brake caliper (air), removed
reconditioning
550-014 2.00 Parking brake, replacing brake pads
551-003 1.00 Parking brake, (removed) reconditioning of brake
caliper

56 COMPRESSED-AIR BRAKE
561-004 1.00 Compressor, replacing
561-022 0.25 Pressure regulator, adjusting

6 STEERING
64 STEERING
642-026 3.00 Steering gear, replacing
643-010 3.50 Steering linkage, checking and adjusting
645-001 0.50 Steering cylinder bearing, checking clearanse
645-003 0.50 Steering system working pressure, checking
645-006 5.00 Steering cylinder, replacing
645-054 1.00 Steering cylinder, replacing bearings

7/11/2012 Volvo Construction Equipment 71


A35C
Op.no. time (h) Notes

645-060 3.00 Steering cylinder, repacking in machine


645-080 2.00 Steering valve neutral position and valve spool
end float, checking
645-081 3.00 Steering valve removed, reconditioning
645-082 3.00 Steering valve, replacing
645-084 0.50 Damping cylinder, checking spring force
645-085 1.00 Damping cylinder, changing seal
647-093 3.00 Auxiliary steering, replacing hydraulic pump
647-095 0.50 Auxiliary steering, adjusting working- and stand-by
pressure

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
711-020 3.00 Load unit frame, checking measurements

72 SUSPENSION
727-001 6.00 Spring element front, replacing all

74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-006 4.00 Frame joint, measuring and adjusting clearence
741-036 2.00 Frame joint, replacing bearings
742-007 10.50 Frame joint, replacing hitch
742-038 1.50 Articulated joint, checking clearence
742-040 15.00 Steering joint, replacing bearings
742-044 1.00 Articulated joint, replacing bushing
742-046 1.50 Frame joint, changing metallic bearing (machine
separated)

75 AXLE SUSPENSION
754-021 1.00 Front bogie axle cross stay, adjusting
754-031 1.00 Rear bogie axle cross stay, adjusting
756-011 7.00 Bogie member, replacing rubber bearing (one
side)
756-012 1.00 Cross stay rubber bushing (bearing), replacing
(front)
756-014 1.00 Cross stay rubber bushing (bearing), replacing,
(rear)
756-015 3.00 Cross stay, checking and adjusting
756-024 1.00 Bogie beam, changing rubber spring, one side
(front)
756-026 3.00 Bogie, replacing all rubber elements both sides

72 Volvo Construction Equipment 7/11/2012


A35C
Op.no. time (h) Notes

76 SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL /


SIDE CONTROL
761-001 2.00 Shock absorber front, replacing all

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.50 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
843-002 1.00 Windscreen, replacing
843-012 1.50 Rear window, replacing
843-013 1.00 Side window, replacing
843-048 1.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-002 1.00 Air suspension for operators seat, changing

87 AIR CONDITIONING UNIT


873-004 1.50 Heater core, replacing
873-006 1.50 Fan motor, replacing
873-008 1.00 Heat control valve, replacing
874-002 1.50 Refrigerant, draining
874-003 0.50 Cooling unit, performance test
874-005 2.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
912-080 2.00 Steering and dumping valve (removed),
reconditioning
913-001 0.50 Hydraulic pump, checking and adjusting standby
pressure and working pressure
913-003 0.50 Hydraulic pump, checking and adjusting standby
pressure
913-008 3.00 Hydraulic pump, ground dependent, changing

94 UNIT, LOAD HANDLING


945-010 1.50 Tilt cylinder removed, repacking

7/11/2012 Volvo Construction Equipment 73


A35C
Op.no. time (h) Notes

95 LOAD CARRIER
951-001 0.50 Tipping control, adjusting
951-002 2.00 Tipping valve, changing wire
951-003 0.50 Dump body position indicator, adjusting
951-004 4.00 Hoist cylinder, changing
951-006 4.00 Hoist cylinder removed, reconditioning
951-010 2.00 Tipping valve, replacing
951-040 3.00 Dump body joint, changing tipping bearing
951-041 1.50 Dump body, adjusting against frame

74 Volvo Construction Equipment 7/11/2012


A35D
Op.no. time (h) Notes

0 GENERAL
09 MISCELLANEOUS
090-001 0.70 Engine, basic check

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
170-005 0.25 Start of VCADS Pro computer and reading
machine data
171-001 1.00 Arrival inspection, according to programme
171-002 1.25 Delivery inspection, according to programme
172-002 3.50 Warranty inspection 100 hours
172-004 8.00 Warranty inspection 1000 hours 11000 - 19999
172-004 14.00 Warranty inspection 1000 hours 11000 - 19999
173-002 0.30 Maintenance service, daily
173-004 0.30 Maintenance service, every 50 hours
173-007 1.00 Maintenance service, every 250 hours
173-010 2.50 Maintenance service, every 500 hours
173-012 5.50 Maintenance service, every 1000 hours
173-014 13.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.25 Transmission, changing oil and filter
173-066 1.00 Drop box, changing oil/cleaning suction strainer
173-070 3.00 Axles, changing oil
173-074 1.00 Hydraulic oil tank, changing oil and filter
173-075 3.00 Hydraulic oil tank, changing oil and filter
incl.cleaning tank
173-083 0.50 Frame joint, changing oil

19 GENERAL
191-021 0.20 Service position 1

2 ENGINE WITH MOUNTING AND EQUIPMENT


20 GENERAL
200-068 1.25 E-ECU, MID 128, changing non-programmed 11001 - 19999
ECU 72001 - 79999
200-070 0.80 E-ECU, MID 128, changing pre-programmed ECU11001 - 13521
61001 - 61303
71001 - 72280
200-070 0.90 E-ECU, MID 128, changing pre-programmed ECU11001 - 19999
72001 - 79999

7/11/2012 Volvo Construction Equipment 75


A35D
Op.no. time (h) Notes

21 ENGINE
210-002 7.00 Compression test
210-070 8.50 Engine, removing
210-072 10.00 Engine, installing
210-073 6.50 Engine and transmission, removing
210-074 11.00 Engine and transmission, mounting
214-012 5.50 Valves, adjusting 11000 - 12999
61000 - 61303
71000 - 71999
214-012 5.50 Valves, adjusting 13000 - 19999
72000 - 79999
215-032 7.50 Timing gear case, fitting new gasket in machine 13001 - 19999
72001 - 79999
215-042 7.00 Camshaft, replacing 13001 - 19999
72001 - 79999
215-043 4.00 Camshaft setting, checking 13001 - 19999
72001 - 79999
216-018 3.50 Crankshaft, replacing rear oil seal
217-004 3.50 Oil sump gasket, changing
217-005 4.00 Oil level sensor, changing
218-001 1.50 Rubber cushion, replacing
218-007 4.00 Engine mounting rear, changing

22 LUBRICATING SYSTEM
223-006 4.50 Oil cooler, replacing

23 FUEL SYSTEM
230-001 0.50 Carbon monoxide in fuel system, check 13001 - 19999
71000 - 79999
233-001 0.70 Fuel system, bleeding 61000 - 61303
11000 - 12999
71000 - 71999
233-001 0.70 Fuel system, bleeding 13001 - 19999
72001 - 79999
233-004 0.70 Feed pump, checking feed pressure
233-009 0.20 Fuel pump (valves), inspection
233-010 2.00 Fuel pump, inspection
236-002 0.80 Stall speed, checking
236-004 0.25 Iow idling speed, checking and adjusting
237-012 5.00 Unit injector, replacing
237-016 10.00 Injectors, replacing copper sleeve in machine
237-123 0.70 Injector shut off, manual

25 INLET SYSTEM; EXHAUST SYSTEM


255-002 1.25 Turbocharger, inspection
255-071 2.00 Turbocharger, replacing

76 Volvo Construction Equipment 7/11/2012


A35D
Op.no. time (h) Notes

256-001 0.50 Air cleaner, cleaning filter element


256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.70 Preheating coil, replacing
258-002 3.50 Intercooler, replacing
258-016 0.80 Cooling fan motor, intercooler, checking/adjusting
low rpm
258-017 0.80 Cooling fan motor, intercooler, checking/adjusting
high rpm

26 COOLING SYSTEM
260-002 5.50 Cooling system, flushing
261-002 0.25 Coolant, checking anti-freeze resistance
261-004 1.50 Coolant, changing
261-011 1.75 Radiator, removing
261-013 2.50 Radiator, installing
261-072 0.50 Coolant filter, changing
262-071 0.90 Coolant pump removed, reconditioning
263-001 1.00 Fan motor, removing
263-003 1.00 Fan motor, installing
263-004 1.00 Fan motor, checking working pressure
263-005 0.25 Fan motor, adjusting working pressure
263-006 1.00 Fan hydraulically driven, removing pump
263-007 1.50 Fan hydraulically driven, fitting pump
263-009 0.50 Fan hydraulically driven, replacing oil return filter
263-012 1.00 Fan belt and/or alternator belt, replacing
263-013 0.70 Fan belt and/or alternator belt, checking and 13000 - 19999
adjusting tension 72000 - 79999
263-013 0.70 Fan belt and/or alternator belt, checking and 11000 - 12999
adjusting tension 61000 - 61303
71000 - 71999
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts
263-063 0.80 Cooling fan motor, radiator, checking/adjusting
low rpm
263-064 0.80 Cooling fan motor, radiator, checking/adjusting
high rpm

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
30 GENERAL
300-072 0.60 I-ECU, MID 140, changing non-programmed ECU
300-074 0.40 I-ECU, MID 140, changing pre-programmed ECU

7/11/2012 Volvo Construction Equipment 77


A35D
Op.no. time (h) Notes

31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.25 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check 13001 - 19999
72001 - 79999

33 STARTING SYSTEM
331-018 0.75 Starter motor, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.75 Headlight, complete, changing (high beam 1 pc.)
incl. setting
352-060 0.75 Headlight, complete, changing (low beam 1 pc.)
incl. setting/adjustment
353-016 0.50 Rear lamp, replacing one
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


360-001 0.75 Combination control (by steering wheel), changing
361-002 1.00 Flasher unit, replacing relay
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-900 1.00 Rotating beacon, installing new
363-002 1.25 Windscreen wiper front, replacing motor
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
366-060 0.70 C-ECU, MID178, changing non-programmed ECU11001 - 12999
61001 - 61303
71001 - 71999
366-062 0.70 C-ECU, MID178, changing pre-programmed ECU11001 - 12999
61001 - 61303
71001 - 71999
366-064 1.50 V-ECU, MID 187, changing non-programmed 11001 - 12999
ECU 61001 - 61303
71001 - 71999
366-064 1.00 V-ECU, MID 187, changing non-programmed 13001 - 19999
ECU 72001 - 79999
366-066 1.25 V-ECU, MID 187, changing pre-programmed ECU11001 - 12999
61001 - 61303
71001 - 71999
366-066 0.90 V-ECU, MID 187, changing pre-programmed ECU13001 - 19999
72001 - 79999

78 Volvo Construction Equipment 7/11/2012


A35D
Op.no. time (h) Notes

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-038 1.00 Engine rotation speed sensor, replacing
386-088 2.00 Engine rotation speed sensor (camshaft),
replacing

39 MISCELLANEOUS
390-902 2.00 CareTrack, installing new

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-001 0.70 Checking of main, torque converter and lubricating
oil pressure
421-002 1.75 Transmission, check oil pressure
421-047 0.50 Gear selector, replacing
421-050 0.75 Transmission, resistance measuring of
cableharness
421-051 0.50 Transmission, resistance measuring of solenoides
421-054 2.00 Seal for rear output shaft, replacing 11593 - 19999
61276 - 61303
71017 - 79999
421-057 1.50 Retarder valve, replacing of seal
421-060 0.50 Transmission, resistans measuring control system
421-062 1.50 Induction sensor for turbine speed, changing
421-068 5.50 Transmission, removing (upwards)
421-069 5.50 Transmission, installing (from above)
421-070 6.00 Transmission, removing
421-072 7.00 Transmission, installing
421-079 0.25 Transmission, replacing breather filter
421-083 1.00 Transmission, remove from a non mounted engine
421-084 1.50 Transmission, fitting on a non mounted engine

43 GEARBOX,
432-076 0.70 T-ECU, MID 130, changing non-programmed
ECU
432-078 0.60 T-ECU, MID 130, changing pre-programmed ECU
434-002 2.00 Dropbox, replacing seal for front otput shaft
434-004 2.00 Dropbox, replacing seal for rear output shaft
434-015 4.00 Dropbox, replacing seal for input shaft
434-016 1.00 Dropbox, oil pump, replacing
434-061 0.50 Differential lock longitudinal, adjusting
engagement
434-063 1.00 Adjustment of sender units SE54 and SE55
434-073 4.50 Dropbox, installing

7/11/2012 Volvo Construction Equipment 79


A35D
Op.no. time (h) Notes

434-074 4.00 Dropbox, removing

45 PROPELLER SHAFT
451-005 1.00 Propeller shaft for rear boggie axel, replacing
451-006 6.00 Intermediate shaft and/or bearing, replacing (in
frame joint)
451-007 1.50 Propeller shaft, in frame joint, replacing
451-008 1.50 Propellershaft for front boggie axel, replacing
451-010 1.00 Propeller shaft, front, replacing
451-014 3.50 Propeller shaft between transmission and
dropbox, replacing

46 FRONT AXLE; REAR AXLE


461-006 5.00 Spindle, replacing one side
461-043 4.00 Hub, replacing seal
463-016 0.50 Dog clutch 6x6, checking and adjusting
468-005 0.50 Differential lock rear, adjusting engagement
468-062 0.50 Transverse differential lock/axle, checking and
adjusting

48 POWER TAKE OFF


482-004 7.00 Power take-off, between engine and gearbox, 13001 - 19999
reconditioning 72001 - 79999

49 MISCELLANEOUS
491-006 1.25 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
510-001 2.00 Brake linings, checking wear
510-002 0.50 Brake disc for service brake, checking
511-001 1.00 Brake pads for service brake, checking
511-002 4.50 Brake disc, replacing one
511-004 3.00 Brake pads, replacing on both sides of axel
511-005 1.50 Brake pads, replacing (one wheel, front axle)
511-045 3.00 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-001 1.00 Brake linings, checking wear rear axle
512-002 4.50 Brake disc, replacing one
512-004 3.00 Brake pads, replacing on both sides of axle
512-005 1.50 Brake pads, replacing (one wheel, first boggie
axle)
512-045 3.00 Brake caliper, replacing one
512-081 1.00 Brake caliper, removed, reconditioning

80 Volvo Construction Equipment 7/11/2012


A35D
Op.no. time (h) Notes

52 HYDRAULIC BRAKE SYSTEM


520-001 0.75 Brake system, checking function, hydraulic
520-010 0.10 Brake system, relieve pressure
520-037 2.50 Brake system, bleeding
525-008 3.50 Foot brake valve, replacing
527-001 0.50 Accumulator removed, checking charging
pressure
527-004 2.50 Hydraulic pump, replacing

55 PARKING BRAKE
550-005 3.00 Parking brake, replacing brake disc
550-009 1.00 Spring brake cylinder, replacing
550-012 2.00 Parking brake , replacing brake caliper
550-014 1.00 Parking brake, replacing brake pads
550-016 0.50 Parking brake lever, changing
553-000 0.40 Load and dump brake, working pressure, checking
and adjusting

56 COMPRESSED-AIR BRAKE
561-004 2.00 Compressor, replacing 11794 - 19999
71153 - 79999
561-022 0.25 Pressure regulator, adjusting

6 STEERING
64 STEERING
642-026 2.50 Steering gear, replacing
642-058 2.00 Steering gear, check.and adj.
643-010 1.75 Steering linkage, checking and adjusting 13540 - 19999
72370 - 79999
643-012 0.40 Steering angle, checking and adjusting 13540 - 19999
72370 - 79999
643-013 0.80 Steering times, checking and adjusting 13540 - 19999
72370 - 79999
643-014 1.00 Steering valve, neutral position, checking and 13540 - 19999
adjusting 72370 - 79999
645-001 0.50 Steering cylinder bearing, checking clearanse
645-006 2.00 Steering cylinder, replacing
645-054 2.00 Steering cylinder, replacing bearings
645-060 3.00 Steering cylinder, repacking in machine
645-084 1.00 Damping cylinder, checking spring force
645-085 1.25 Damping cylinder, changing seal
647-093 3.00 Auxiliary steering, replacing hydraulic pump
647-095 1.00 Auxiliary steering, adjusting working- and stand-by
pressure

7/11/2012 Volvo Construction Equipment 81


A35D
Op.no. time (h) Notes

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
72 SUSPENSION
727-001 6.00 Spring element front, replacing all

74 FRAME LINK
741-001 7.00 Frame joint, separating machine
741-005 0.50 Frame joint, checking clearance
741-036 2.00 Frame joint, replacing bearings
741-041 2.00 Frame joint, changing bearing, machine separated
(on load unit frame)
742-038 0.80 Articulated joint, checking clearence
742-040 8.00 Steering joint, replacing bearings

75 AXLE SUSPENSION
754-021 1.00 Front bogie axle cross stay, adjusting
754-031 1.00 Rear bogie axle cross stay, adjusting
756-011 7.00 Bogie member, replacing rubber bearing (one
side)
756-012 2.00 Cross stay rubber bushing (bearing), replacing
(front)
756-024 1.00 Bogie beam, changing rubber spring, one side
(front)

76 SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL /


SIDE CONTROL
761-001 4.00 Shock absorber front, replacing all

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.60 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 4.00 Cab, removing
810-002 4.50 Cab, installing

82 ENGINE HOOD; MUDGUARD; FOOT STEP


821-002 0.60 Engine hood, installing
821-060 0.50 Electric hood pump, changing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.00 Door, replacing 61000 - 61303
11000 - 19999
71000 - 79999

82 Volvo Construction Equipment 7/11/2012


A35D
Op.no. time (h) Notes

831-006 0.60 Door lock, replacing


831-052 0.60 Cab door, removing door catch 61000 - 61303
11000 - 19999
71000 - 79999
831-053 0.30 Cab door, installing door catch 61000 - 61303
11000 - 19999
71000 - 79999

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 3.00 Windscreen, replacing
843-012 3.00 Rear window, replacing
843-013 2.50 Side window, replacing
843-048 2.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-002 1.00 Air suspension for operators seat, changing
852-003 0.80 Operator's seat, removing
852-004 0.40 Operator's seat, installing

87 AIR CONDITIONING UNIT


873-004 3.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.90 Heat control valve, replacing
873-009 0.90 Heat control, replacing
874-002 1.50 Refrigerant, draining
874-003 0.80 Cooling unit, performance test
874-006 4.00 Compressor, replacing incl draining and filling
874-008 2.50 Refrigerant, filling incl vacuum pumping
874-011 4.00 Receiver, replacing incl draining and filling
874-012 5.00 Evaporator, replacing incl draining and filling
874-014 1.75 Thermostat, replacing

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 1.00 Hydraulic system, bleeding
900-003 0.10 Hydraulic system, relieve pressure
900-005 0.30 Vacuum pump, connection
900-006 0.20 Vacuum pump, disconnection

91 WORKING HYDRAULICS; SERVO HYDRAULICS


912-078 0.60 Dump lever, changing
912-079 7.00 Steering and tipping valve, replacing

7/11/2012 Volvo Construction Equipment 83


A35D
Op.no. time (h) Notes

912-080 3.00 Steering and dumping valve (removed),


reconditioning
912-115 3.00 Steering and tipping valve, removal 13540 - 19999
72370 - 79999
912-116 3.00 Steering and tipping valve, installation 13540 - 19999
72370 - 79999
913-003 1.50 Hydraulic pump, checking and adjusting standby
pressure
913-004 1.50 Hydraulic pump, checking and adjusting max
working pressure
913-007 0.30 Hydraulic pump (removed), changing shaft seal
913-010 2.50 Hydraulic pump, replacing 11000 - 11917
71000 - 71195
913-010 2.50 Hydraulic pump, replacing 11918 - 19999
71196 - 79999
913-042 0.50 Working pumps, checking function
913-068 1.50 Pump regulator, checking
914-095 0.90 Dumping lever, checking pressure

95 LOAD CARRIER
951-003 0.30 Dump body position indicator, adjusting
951-004 3.00 Hoist cylinder, changing
951-005 1.00 Hoist cylinder bearing, changing
951-005 0.90 Hoist cylinder bearing, changing
951-006 3.00 Hoist cylinder removed, reconditioning
951-007 1.25 Hoist cylinder, removal
951-008 1.25 Hoist cylinder, installation
951-011 0.30 Cylinder, rear flap, gas pressure, checking and
adjusting
951-030 0.40 Dump body alternative, lowering
951-040 2.50 Dump body joint, changing tipping bearing
951-041 2.50 Dump body, adjusting against frame

84 Volvo Construction Equipment 7/11/2012


A40
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
171-001 1.00 Arrival inspection, according to programme
171-002 1.25 Delivery inspection, according to programme
172-002 7.00 Warranty inspection 100 hours
172-004 10.00 Warranty inspection 1000 hours
173-002 0.50 Maintenance service, daily
173-004 1.50 Maintenance service, every 50 hours
173-007 4.00 Maintenance service, every 250 hours
173-010 4.50 Maintenance service, every 500 hours
173-012 7.00 Maintenance service, every 1000 hours
173-014 16.00 Maintenance service, every 2000 hours
173-059 2.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-066 1.00 Drop box, changing oil/cleaning suction strainer
173-074 1.00 Hydraulic oil tank, changing oil and filter
173-075 1.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 2.00 Compression test
210-070 8.50 Engine, removing
210-071 48.00 Engine removed, general overhaul
210-072 10.00 Engine, installing
210-073 8.00 Engine and transmission, removing
210-074 9.00 Engine and transmission, mounting
214-012 1.50 Valves, adjusting
214-096 1.50 Valve cap, changing

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-004 0.75 Feed pump, checking feed pressure
236-030 1.50 Injection timing, checking and adjusting
236-031 1.00 Injection timing adjuster, checking
237-002 2.00 Injectors, replacing all

25 INLET SYSTEM; EXHAUST SYSTEM


255-070 0.50 Turbocharger, removing
255-071 1.50 Turbocharger, replacing
255-072 1.00 Turbocharger, installing

7/11/2012 Volvo Construction Equipment 85


A40
Op.no. time (h) Notes

256-001 0.50 Air cleaner, cleaning filter element


256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.50 Air cleaner, primary filter replacing
256-004 0.50 Air cleaner, secondary filter replacing
258-002 1.50 Intercooler, replacing

26 COOLING SYSTEM
261-002 0.25 Coolant, checking anti-freeze resistance
261-004 1.50 Coolant, changing
261-008 2.50 Radiator, replacing
261-010 1.00 Radiator, adjusting
261-072 0.50 Coolant filter, changing
263-001 1.00 Fan motor, removing
263-002 1.00 Fan motor, changing piston rings
263-003 1.00 Fan motor, installing
263-004 1.00 Fan motor, checking working pressure
263-005 0.25 Fan motor, adjusting working pressure
263-006 1.50 Fan hydraulically driven, removing pump
263-007 1.50 Fan hydraulically driven, fitting pump
263-009 0.75 Fan hydraulically driven, replacing oil return filter
263-012 0.50 Fan belt and/or alternator belt, replacing
263-013 0.50 Fan belt and/or alternator belt, checking and
adjusting tension
263-022 0.50 Fan belt and/or alternator-, compressor belt,
replacing all belts

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.50 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check

33 STARTING SYSTEM
331-018 1.25 Starter motor, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-008 0.50 Headlamp reflector and/or glass, replacing one
incl adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting

86 Volvo Construction Equipment 7/11/2012


A40
Op.no. time (h) Notes

353-016 0.50 Rear lamp, replacing one


353-018 0.50 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.50 Flasher unit, replacing relay
361-010 0.50 Flasher switch, replacing
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-016 0.50 Horn switch, replacing
362-900 1.00 Rotating beacon, installing new
363-002 1.50 Windscreen wiper front, replacing motor
363-003 0.50 Windscreen wiper, replacing switch
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.50 Switch, replacing
364-008 0.50 Brake light switch, replacing
367-020 0.50 ECU, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-001 1.75 Checking of main, torque converter and lubricating
oil pressure
421-050 0.75 Transmission, resistance measuring of
cableharness
421-051 0.50 Transmission, resistance measuring of solenoides
421-054 4.00 Seal for rear output shaft, replacing
421-057 0.50 Retarder valve, replacing of seal
421-059 0.50 Transmission retarder valve, adjusting air
pressure
421-060 0.50 Transmission, resistans measuring control system
421-061 1.00 Induction sensor for output shaft, changing
421-062 0.75 Induction sensor for turbine speed, changing
421-065 5.00 Control system, replacing
421-068 5.50 Transmission, removing (upwards)
421-069 5.50 Transmission, installing (from above)
421-070 7.00 Transmission, removing
421-072 9.00 Transmission, installing
421-078 2.00 Transmission, remove and fitting from a non
mounted engine
421-079 0.25 Transmission, replacing breather filter

7/11/2012 Volvo Construction Equipment 87


A40
Op.no. time (h) Notes

43 GEARBOX,
434-002 2.00 Dropbox, replacing seal for front otput shaft
434-004 2.00 Dropbox, replacing seal for rear output shaft
434-015 4.00 Dropbox, replacing seal for input shaft
434-060 1.00 Dropbox, adjusting control for high and low gear
434-061 0.75 Differential lock longitudinal, adjusting
engagement
434-063 1.00 Adjustment of sender units SE54 and SE55
434-073 4.50 Dropbox, installing
434-074 4.00 Dropbox, removing

45 PROPELLER SHAFT
451-004 1.50 Propeller shaft, rear, replacing
451-005 1.00 Propeller shaft for rear boggie axel, replacing
451-007 0.75 Propeller shaft, in frame joint, replacing
451-010 0.75 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning
451-014 3.50 Propeller shaft between transmission and
dropbox, replacing

46 FRONT AXLE; REAR AXLE


461-043 4.00 Hub, replacing seal
468-005 0.50 Differential lock rear, adjusting engagement

5 BRAKE
51 WHEEL BRAKE
516-004 7.00 Brake discs, replacing on both sides
516-010 9.00 Wheel brake, replacing

52 HYDRAULIC BRAKE SYSTEM


520-001 0.75 Brake system, checking function, hydraulic
520-037 1.00 Brake system, bleeding
527-001 0.50 Accumulator removed, checking charging
pressure

55 PARKING BRAKE
550-002 0.50 Parking brake, adjusting
550-003 0.50 Parking brake, control valve (removed)
reconditioning
550-005 2.50 Parking brake, replacing brake disc
550-009 0.50 Spring brake cylinder, replacing
550-010 1.00 Spring brake cylinder removed, reconditioning
550-012 2.00 Parking brake , replacing brake caliper

88 Volvo Construction Equipment 7/11/2012


A40
Op.no. time (h) Notes

550-013 0.75 Parking brake caliper (air), removed


reconditioning
550-014 2.00 Parking brake, replacing brake pads
551-003 1.00 Parking brake, (removed) reconditioning of brake
caliper

56 COMPRESSED-AIR BRAKE
561-004 1.00 Compressor, replacing
561-022 0.25 Pressure regulator, adjusting

6 STEERING
64 STEERING
642-026 3.00 Steering gear, replacing
643-010 3.50 Steering linkage, checking and adjusting
645-001 0.50 Steering cylinder bearing, checking clearanse
645-003 5.00 Steering system working pressure, checking
645-006 5.00 Steering cylinder, replacing
645-054 1.00 Steering cylinder, replacing bearings
645-060 3.00 Steering cylinder, repacking in machine
645-080 2.00 Steering valve neutral position and valve spool
end float, checking
645-081 3.00 Steering valve removed, reconditioning
645-082 3.00 Steering valve, replacing
645-084 0.50 Damping cylinder, checking spring force
645-085 1.00 Damping cylinder, changing seal
647-093 3.00 Auxiliary steering, replacing hydraulic pump
647-095 0.50 Auxiliary steering, adjusting working- and stand-by
pressure

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
711-020 3.00 Load unit frame, checking measurements

72 SUSPENSION
727-001 6.50 Spring element front, replacing all

74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 2.00 Frame joint, replacing bearings
742-007 10.50 Frame joint, replacing hitch
742-040 15.00 Steering joint, replacing bearings

7/11/2012 Volvo Construction Equipment 89


A40
Op.no. time (h) Notes

742-044 1.00 Articulated joint, replacing bushing

75 AXLE SUSPENSION
754-021 1.00 Front bogie axle cross stay, adjusting
754-031 1.00 Rear bogie axle cross stay, adjusting
756-012 1.00 Cross stay rubber bushing (bearing), replacing
(front)
756-014 1.00 Cross stay rubber bushing (bearing), replacing,
(rear)
756-015 3.00 Cross stay, checking and adjusting
756-024 1.00 Bogie beam, changing rubber spring, one side
(front)
756-026 3.00 Bogie, replacing all rubber elements both sides

76 SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL /


SIDE CONTROL
761-001 2.00 Shock absorber front, replacing all

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.50 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
843-002 1.00 Windscreen, replacing
843-012 1.50 Rear window, replacing
843-013 1.00 Side window, replacing
843-048 1.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-002 1.00 Air suspension for operators seat, changing

87 AIR CONDITIONING UNIT


873-004 1.50 Heater core, replacing
873-006 1.50 Fan motor, replacing
873-008 1.00 Heat control valve, replacing
874-002 1.50 Refrigerant, draining
874-003 0.50 Cooling unit, performance test
874-005 2.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling

90 Volvo Construction Equipment 7/11/2012


A40
Op.no. time (h) Notes

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
913-003 0.50 Hydraulic pump, checking and adjusting standby
pressure
913-008 3.00 Hydraulic pump, ground dependent, changing

94 UNIT, LOAD HANDLING


945-010 1.50 Tilt cylinder removed, repacking

95 LOAD CARRIER
951-001 0.50 Tipping control, adjusting
951-002 2.00 Tipping valve, changing wire
951-003 0.50 Dump body position indicator, adjusting
951-004 5.00 Hoist cylinder, changing
951-006 4.00 Hoist cylinder removed, reconditioning
951-011 0.30 Cylinder, rear flap, gas pressure, checking and
adjusting
951-030 0.50 Dump body alternative, lowering
951-040 3.50 Dump body joint, changing tipping bearing
951-041 1.50 Dump body, adjusting against frame

7/11/2012 Volvo Construction Equipment 91


92 Volvo Construction Equipment 7/11/2012
A40D
Op.no. time (h) Notes

0 GENERAL
09 MISCELLANEOUS
090-001 0.70 Engine, basic check

1 STANDARD PARTS, SERVICE


17 SERVICE
170-001 0.75 Washing, external cleaning
170-005 0.25 Start of VCADS Pro computer and reading
machine data
171-001 1.00 Arrival inspection, according to programme
171-002 1.25 Delivery inspection, according to programme
172-002 3.50 Warranty inspection 100 hours
172-004 8.00 Warranty inspection 1000 hours 10000 - 19999
172-004 14.00 Warranty inspection 1000 hours
173-002 0.30 Maintenance service, daily
173-004 0.30 Maintenance service, every 50 hours
173-007 1.00 Maintenance service, every 250 hours
173-010 2.50 Maintenance service, every 500 hours
173-012 5.50 Maintenance service, every 1000 hours
173-014 13.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.25 Transmission, changing oil and filter
173-066 1.00 Drop box, changing oil/cleaning suction strainer
173-070 3.00 Axles, changing oil
173-074 1.00 Hydraulic oil tank, changing oil and filter
173-075 3.00 Hydraulic oil tank, changing oil and filter
incl.cleaning tank
173-083 0.50 Frame joint, changing oil

19 GENERAL
191-021 0.20 Service position 1

2 ENGINE WITH MOUNTING AND EQUIPMENT


20 GENERAL
200-068 1.25 E-ECU, MID 128, changing non-programmed 12001 - 19999
ECU 70001 - 79999
200-070 0.80 E-ECU, MID 128, changing pre-programmed ECU10001 - 12996
60001 - 60286
200-070 0.90 E-ECU, MID 128, changing pre-programmed ECU12001 - 19999
70001 - 79999

7/11/2012 Volvo Construction Equipment 93


A40D
Op.no. time (h) Notes

21 ENGINE
210-002 7.00 Compression test
210-070 8.50 Engine, removing
210-072 10.00 Engine, installing
210-073 6.50 Engine and transmission, removing
210-074 11.00 Engine and transmission, mounting
214-012 5.50 Valves, adjusting 10000 - 11999
60000 - 60286
214-012 5.50 Valves, adjusting 12000 - 19999
70000 - 79999
215-032 7.50 Timing gear case, fitting new gasket in machine 12001 - 19999
70001 - 79999
215-042 7.00 Camshaft, replacing 12001 - 19999
70001 - 79999
215-043 4.00 Camshaft setting, checking 12001 - 19999
70001 - 79999
216-018 3.50 Crankshaft, replacing rear oil seal
217-004 3.50 Oil sump gasket, changing
217-005 4.00 Oil level sensor, changing
218-001 1.50 Rubber cushion, replacing
218-007 4.00 Engine mounting rear, changing

22 LUBRICATING SYSTEM
223-006 4.50 Oil cooler, replacing

23 FUEL SYSTEM
230-001 0.50 Carbon monoxide in fuel system, check 13001 - 19999
72001 - 79999
233-001 0.70 Fuel system, bleeding 10000 - 11999
60000 - 60286
233-001 0.70 Fuel system, bleeding 12001 - 19999
70001 - 79999
233-004 0.70 Feed pump, checking feed pressure
233-009 0.20 Fuel pump (valves), inspection
233-010 2.00 Fuel pump, inspection
236-002 0.80 Stall speed, checking
236-004 0.25 Iow idling speed, checking and adjusting
237-012 5.00 Unit injector, replacing
237-016 10.00 Injectors, replacing copper sleeve in machine
237-123 0.70 Injector shut off, manual

25 INLET SYSTEM; EXHAUST SYSTEM


255-002 1.25 Turbocharger, inspection
255-071 2.00 Turbocharger, replacing
256-001 0.50 Air cleaner, cleaning filter element
256-003 0.25 Air cleaner, primary filter replacing

94 Volvo Construction Equipment 7/11/2012


A40D
Op.no. time (h) Notes

256-004 0.25 Air cleaner, secondary filter replacing


256-006 0.70 Preheating coil, replacing
258-002 3.50 Intercooler, replacing
258-016 0.80 Cooling fan motor, intercooler, checking/adjusting
low rpm
258-017 0.80 Cooling fan motor, intercooler, checking/adjusting
high rpm

26 COOLING SYSTEM
260-002 5.50 Cooling system, flushing
261-002 0.25 Coolant, checking anti-freeze resistance
261-004 1.50 Coolant, changing
261-011 1.75 Radiator, removing
261-013 2.50 Radiator, installing
261-072 0.50 Coolant filter, changing
262-071 0.90 Coolant pump removed, reconditioning
263-001 1.00 Fan motor, removing
263-003 1.00 Fan motor, installing
263-006 1.00 Fan hydraulically driven, removing pump
263-007 1.50 Fan hydraulically driven, fitting pump
263-009 0.50 Fan hydraulically driven, replacing oil return filter
263-012 1.00 Fan belt and/or alternator belt, replacing
263-013 0.70 Fan belt and/or alternator belt, checking and 12000 - 19999
adjusting tension 70000 - 79999
263-013 0.70 Fan belt and/or alternator belt, checking and 10000 - 11999
adjusting tension 60000 - 60286
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts
263-063 0.80 Cooling fan motor, radiator, checking/adjusting
low rpm
263-064 0.80 Cooling fan motor, radiator, checking/adjusting
high rpm

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
30 GENERAL
300-072 0.60 I-ECU, MID 140, changing non-programmed ECU
300-074 0.40 I-ECU, MID 140, changing pre-programmed ECU

31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.25 Batteries, replacing

7/11/2012 Volvo Construction Equipment 95


A40D
Op.no. time (h) Notes

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check 12001 - 19999
70001 - 79999

33 STARTING SYSTEM
331-018 0.75 Starter motor, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.75 Headlight, complete, changing (high beam 1 pc.)
incl. setting
352-060 0.75 Headlight, complete, changing (low beam 1 pc.)
incl. setting/adjustment
353-016 0.50 Rear lamp, replacing one
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


360-001 0.75 Combination control (by steering wheel), changing
361-002 1.00 Flasher unit, replacing relay
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.50 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-900 1.00 Rotating beacon, installing new
363-002 1.25 Windscreen wiper front, replacing motor
363-004 0.50 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
366-060 0.70 C-ECU, MID178, changing non-programmed ECU10001 - 11999
60001 - 60286
366-062 0.70 C-ECU, MID178, changing pre-programmed ECU10001 - 11999
60001 - 60286
366-064 1.50 V-ECU, MID 187, changing non-programmed 10001 - 11999
ECU 60001 - 60286
366-064 1.00 V-ECU, MID 187, changing non-programmed 12001 - 19999
ECU 70001 - 79999
366-066 1.25 V-ECU, MID 187, changing pre-programmed ECU10001 - 11999
60001 - 60286
366-066 0.90 V-ECU, MID 187, changing pre-programmed ECU12001 - 19999
70001 - 79999

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-038 1.00 Engine rotation speed sensor, replacing
386-088 2.00 Engine rotation speed sensor (camshaft),
replacing

39 MISCELLANEOUS
390-902 2.00 CareTrack, installing new

96 Volvo Construction Equipment 7/11/2012


A40D
Op.no. time (h) Notes

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-001 0.70 Checking of main, torque converter and lubricating
oil pressure
421-002 1.75 Transmission, check oil pressure
421-047 0.50 Gear selector, replacing
421-050 0.75 Transmission, resistance measuring of
cableharness
421-051 0.50 Transmission, resistance measuring of solenoides
421-054 2.00 Seal for rear output shaft, replacing 10509 - 19999
60236 - 60286
421-057 1.50 Retarder valve, replacing of seal
421-060 0.50 Transmission, resistans measuring control system
421-062 1.50 Induction sensor for turbine speed, changing
421-068 5.50 Transmission, removing (upwards)
421-069 5.50 Transmission, installing (from above)
421-070 6.00 Transmission, removing
421-072 7.00 Transmission, installing
421-079 0.25 Transmission, replacing breather filter
421-083 1.00 Transmission, remove from a non mounted engine
421-084 1.50 Transmission, fitting on a non mounted engine

43 GEARBOX,
432-076 0.70 T-ECU, MID 130, changing non-programmed
ECU
432-078 0.60 T-ECU, MID 130, changing pre-programmed ECU
434-002 2.00 Dropbox, replacing seal for front otput shaft
434-004 2.00 Dropbox, replacing seal for rear output shaft
434-015 4.00 Dropbox, replacing seal for input shaft
434-016 1.00 Dropbox, oil pump, replacing
434-061 0.50 Differential lock longitudinal, adjusting
engagement
434-063 1.00 Adjustment of sender units SE54 and SE55
434-073 4.50 Dropbox, installing
434-074 4.00 Dropbox, removing

45 PROPELLER SHAFT
451-005 1.00 Propeller shaft for rear boggie axel, replacing
451-006 6.00 Intermediate shaft and/or bearing, replacing (in
frame joint)
451-007 1.50 Propeller shaft, in frame joint, replacing
451-008 1.50 Propellershaft for front boggie axel, replacing
451-010 1.00 Propeller shaft, front, replacing
451-014 3.50 Propeller shaft between transmission and
dropbox, replacing

7/11/2012 Volvo Construction Equipment 97


A40D
Op.no. time (h) Notes

46 FRONT AXLE; REAR AXLE


461-006 5.00 Spindle, replacing one side
463-016 0.50 Dog clutch 6x6, checking and adjusting
468-005 0.50 Differential lock rear, adjusting engagement
468-062 0.50 Transverse differential lock/axle, checking and
adjusting

48 POWER TAKE OFF


482-004 7.00 Power take-off, between engine and gearbox, 13001 - 19999
reconditioning 72001 - 79999

49 MISCELLANEOUS
491-006 1.25 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-004 7.00 Brake discs, replacing on both sides
516-010 9.00 Wheel brake, replacing

52 HYDRAULIC BRAKE SYSTEM


520-001 0.75 Brake system, checking function, hydraulic
520-010 0.10 Brake system, relieve pressure
520-037 1.00 Brake system, bleeding
525-008 3.50 Foot brake valve, replacing
527-001 0.50 Accumulator removed, checking charging
pressure
527-004 2.50 Hydraulic pump, replacing

55 PARKING BRAKE
550-005 3.00 Parking brake, replacing brake disc
550-009 1.00 Spring brake cylinder, replacing
550-012 2.00 Parking brake , replacing brake caliper
550-013 1.00 Parking brake caliper (air), removed
reconditioning
550-014 1.00 Parking brake, replacing brake pads
550-016 0.50 Parking brake lever, changing
553-000 0.40 Load and dump brake, working pressure, checking
and adjusting

56 COMPRESSED-AIR BRAKE
561-004 2.00 Compressor, replacing 10949 - 10955
561-004 2.00 Compressor, replacing 10958 - 19999
561-022 0.25 Pressure regulator, adjusting

98 Volvo Construction Equipment 7/11/2012


A40D
Op.no. time (h) Notes

6 STEERING
64 STEERING
642-026 2.50 Steering gear, replacing
642-058 2.00 Steering gear, check.and adj.
643-010 1.75 Steering linkage, checking and adjusting 13144 - 19999
70158 - 79999
643-012 0.40 Steering angle, checking and adjusting 13144 - 19999
70158 - 79999
643-013 0.80 Steering times, checking and adjusting 13144 - 19999
70158 - 79999
643-014 1.00 Steering valve, neutral position, checking and 13144 - 19999
adjusting 70158 - 79999
645-001 0.50 Steering cylinder bearing, checking clearanse
645-006 2.00 Steering cylinder, replacing
645-054 2.00 Steering cylinder, replacing bearings
645-060 3.00 Steering cylinder, repacking in machine
645-084 1.00 Damping cylinder, checking spring force
645-085 1.25 Damping cylinder, changing seal
647-093 3.00 Auxiliary steering, replacing hydraulic pump
647-095 1.00 Auxiliary steering, adjusting working- and stand-by
pressure

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
72 SUSPENSION
727-001 6.50 Spring element front, replacing all

74 FRAME LINK
741-001 7.00 Frame joint, separating machine
741-005 0.50 Frame joint, checking clearance
741-036 2.00 Frame joint, replacing bearings
741-041 2.00 Frame joint, changing bearing, machine separated
(on load unit frame)
742-038 0.80 Articulated joint, checking clearence
742-040 8.00 Steering joint, replacing bearings

75 AXLE SUSPENSION
754-021 1.00 Front bogie axle cross stay, adjusting
754-031 1.00 Rear bogie axle cross stay, adjusting
756-011 7.00 Bogie member, replacing rubber bearing (one
side)
756-012 2.00 Cross stay rubber bushing (bearing), replacing
(front)

7/11/2012 Volvo Construction Equipment 99


A40D
Op.no. time (h) Notes

756-024 1.00 Bogie beam, changing rubber spring, one side


(front)

76 SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL /


SIDE CONTROL
761-001 4.00 Shock absorber front, replacing all

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.60 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 4.00 Cab, removing
810-002 4.50 Cab, installing

82 ENGINE HOOD; MUDGUARD; FOOT STEP


821-002 0.60 Engine hood, installing
821-060 0.50 Electric hood pump, changing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.00 Door, replacing 60000 - 60286
10000 - 19999
70000 - 79999
831-006 0.60 Door lock, replacing
831-052 0.60 Cab door, removing door catch 60000 - 60286
10000 - 19999
70000 - 79999
831-053 0.30 Cab door, installing door catch 60000 - 60286
10000 - 19999
70000 - 79999

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 3.00 Windscreen, replacing
843-012 3.00 Rear window, replacing
843-013 2.50 Side window, replacing
843-048 2.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-002 1.00 Air suspension for operators seat, changing
852-003 0.80 Operator's seat, removing
852-004 0.40 Operator's seat, installing

87 AIR CONDITIONING UNIT


873-004 3.00 Heater core, replacing
873-006 1.00 Fan motor, replacing

100 Volvo Construction Equipment 7/11/2012


A40D
Op.no. time (h) Notes

873-008 0.90 Heat control valve, replacing


873-009 0.90 Heat control, replacing
874-002 1.50 Refrigerant, draining
874-003 0.80 Cooling unit, performance test
874-006 4.00 Compressor, replacing incl draining and filling
874-008 2.50 Refrigerant, filling incl vacuum pumping
874-011 4.00 Receiver, replacing incl draining and filling
874-012 5.00 Evaporator, replacing incl draining and filling
874-014 1.75 Thermostat, replacing

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 1.00 Hydraulic system, bleeding
900-003 0.10 Hydraulic system, relieve pressure
900-005 0.30 Vacuum pump, connection
900-006 0.20 Vacuum pump, disconnection

91 WORKING HYDRAULICS; SERVO HYDRAULICS


912-078 0.60 Dump lever, changing
912-079 7.00 Steering and tipping valve, replacing
912-080 3.00 Steering and dumping valve (removed),
reconditioning
912-115 3.00 Steering and tipping valve, removal 13144 - 19999
70158 - 79999
912-116 3.00 Steering and tipping valve, installation 13144 - 19999
70158 - 79999
913-003 1.50 Hydraulic pump, checking and adjusting standby
pressure
913-004 1.50 Hydraulic pump, checking and adjusting max
working pressure
913-007 0.30 Hydraulic pump (removed), changing shaft seal
913-010 2.50 Hydraulic pump, replacing 10000 - 11101
913-010 2.50 Hydraulic pump, replacing 11102 - 19999
913-042 0.50 Working pumps, checking function
913-068 1.50 Pump regulator, checking
914-095 0.90 Dumping lever, checking pressure

95 LOAD CARRIER
951-003 0.30 Dump body position indicator, adjusting
951-004 3.00 Hoist cylinder, changing
951-005 1.00 Hoist cylinder bearing, changing
951-005 0.90 Hoist cylinder bearing, changing
951-006 3.00 Hoist cylinder removed, reconditioning

7/11/2012 Volvo Construction Equipment 101


A40D
Op.no. time (h) Notes

951-007 1.25 Hoist cylinder, removal


951-008 1.25 Hoist cylinder, installation
951-011 0.30 Cylinder, rear flap, gas pressure, checking and
adjusting
951-030 0.40 Dump body alternative, lowering
951-040 2.50 Dump body joint, changing tipping bearing
951-041 2.50 Dump body, adjusting against frame

102 Volvo Construction Equipment 7/11/2012


EL70
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 5.00 Warranty inspection 100 hours
172-004 8.00 Warranty inspection 1000 hours
173-007 2.00 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 7.00 Maintenance service, every 1000 hours
173-014 10.00 Maintenance service, every 2000 hours
173-061 2.00 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.50 Hydraulic oil tank, changing oil and filter
173-075 2.00 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.50 Compression test
210-070 3.00 Engine, removing
210-071 32.00 Engine removed, general overhaul
210-072 5.00 Engine, installing
211-002 7.00 Cylinder head, replacing gasket
211-008 1.50 Cylinder heads all, retightening incl. adjusting
valves
211-068 3.00 Cylinder heads all removed, decarbonizing and
grinding in valves
211-080 2.00 Cylinder heads all, removing
211-082 5.00 Cylinder heads all, fitting
212-007 3.00 Cylinder block, liners removed, milling of all liner
locations
213-010 14.00 Cylinder liner and piston, replacing one
213-018 18.00 Cylinder liners and pistons, replacing all
214-012 1.50 Valves, adjusting
214-021 0.50 Valve cover, fitting new gasket each
215-002 6.50 Timing gear cover, fitting new gasket in machine
215-032 12.00 Timing gear case, fitting new gasket in machine
216-014 2.00 Crankshaft, replacing front oil seal
216-018 9.00 Crankshaft, replacing rear oil seal
216-040 12.00 Flywheel housing and sump gasket, replacing
216-048 6.00 Balance unit, removing and fitting
217-002 6.00 Sump gasket, replacing incl cleaning oil strainer

7/11/2012 Volvo Construction Equipment 103


EL70
Op.no. time (h) Notes

22 LUBRICATING SYSTEM
221-006 0.75 Oil pressure relief valve, replacing
223-006 0.75 Oil cooler, replacing

23 FUEL SYSTEM
233-001 0.25 Fuel system, bleeding
233-002 0.50 Feed pump, replacing
233-004 0.50 Feed pump, checking feed pressure
233-007 0.50 Feed pump, cleaning glass bowl and strainer
233-014 0.75 Fuel filters, replacing
233-097 0.75 Feed pump removed, reconditioning
236-001 1.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
236-030 2.00 Injection timing, checking and adjusting
236-044 1.50 Injection timing, checking
236-070 2.00 Injection pump, removing
236-072 3.00 Injection pump, fitting incl setting injection timing
237-001 2.00 Injectors cylinder head removed, replacing copper
sleeve
237-002 1.50 Injectors, replacing all
237-004 1.00 Injector, replacing one
237-007 0.25 Overflow valve, replacing
237-016 2.00 Injectors, replacing copper sleeve in machine
237-018 0.50 Delivery pipe, replacing one
237-020 0.50 Pressure equalizer, replacing
237-074 4.00 Injectors all, testing and adjusting incl removing
and fitting
237-080 2.00 Injectors removed, reconditioning all

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 1.00 Exhaust manifold, replacing gasket
252-020 0.50 Silencer, replacing
255-070 0.75 Turbocharger, removing
255-072 0.75 Turbocharger, installing
255-073 2.00 Turbocharger removed, reconditioning
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.50 Preheating coil, replacing
256-007 1.00 Preheating coil, replacing inlet manifold
258-002 1.25 Intercooler, replacing

104 Volvo Construction Equipment 7/11/2012


EL70
Op.no. time (h) Notes

26 COOLING SYSTEM
261-001 0.50 Radiator, pressure testing
261-004 0.75 Coolant, changing
261-008 2.00 Radiator, replacing
262-002 2.00 Coolant pump, replacing
262-071 1.50 Coolant pump removed, reconditioning
262-098 0.75 Thermostat, replacing
263-012 0.75 Fan belt and/or alternator belt, replacing
263-013 0.50 Fan belt and/or alternator belt, checking and
adjusting tension
263-022 0.75 Fan belt and/or alternator-, compressor belt,
replacing all belts

27 ENGINE CONTROL
273-022 0.75 Stop cable control, replacing
275-001 0.50 Automatic speed control, check and adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.25 Battery charging capacity, checking
311-002 0.75 Batteries, replacing
311-014 1.50 Batteries, checking charging incl cleaning and
painting battery boxes

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.75 Alternator, replacing carbon brush kit in machine
321-074 1.50 Charging test in machine (with measuring
instrument)
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 0.75 Starter motor, replacing
331-099 0.50 Starter motor removed, replacing carbon brush kit

35 LIGHTING
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

7/11/2012 Volvo Construction Equipment 105


EL70
Op.no. time (h) Notes

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-016 0.75 Horn switch, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.50 Windscreen wiper front, replacing motor
363-003 0.75 Windscreen wiper, replacing switch
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
364-024 0.75 Main switch, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-005 0.50 Transmission, revolution sensor, replacing
386-011 0.75 Fuel level sender, replacing
387-020 0.50 Tachometer, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 1.50 Transmission, check oil pressure
421-004 2.00 Oil pump, replacing
421-005 1.00 Oil pump removed, reconditioning
421-008 2.00 Gear selector valve, replacing
421-009 1.50 Gear selector valve removed, reconditioning
421-011 1.00 Converter removed, reconditioning
421-018 12.00 Converter, replacing
421-023 2.00 Lubrication and converter pressure valve,
replacing
421-047 0.75 Gear selector, replacing
421-048 0.50 Gear selector valve, replacing one solenoid
421-052 1.50 Seal for front output shaft, replacing
421-054 1.50 Seal for rear output shaft, replacing
421-071 30.00 Transmission removed, reconditioning
421-073 6.00 Transmission, removing (together with engine)
421-074 8.00 Transmission, installing (together with engine)
421-075 2.00 Clutch shaft removed, reconditioning
421-077 0.75 Oil filter, replacing
421-079 0.25 Transmission, replacing breather filter

106 Volvo Construction Equipment 7/11/2012


EL70
Op.no. time (h) Notes

45 PROPELLER SHAFT
451-010 1.00 Propeller shaft, front, replacing
451-013 1.00 Propeller shaft, removed reconditioning

46 FRONT AXLE; REAR AXLE


461-002 1.50 Axle, removing
461-003 2.00 Axle, installing
461-011 4.00 Centre gear , removing and fitting
461-012 5.00 Centre gear removed, reconditioning
461-014 1.50 Pinion front, fitting new gasket
461-041 3.00 Hub reduction gear, removed, reconditioning
461-043 3.00 Hub, replacing seal
461-051 9.00 Differential lock, replacing selector fork and clutch
sleeves and adjusting
461-052 0.25 Differential lock front, repacking excl adjusting
461-053 0.50 Differential lock, adjusting engagement
463-002 3.00 Axle, removing
463-003 3.00 Axle, installing
463-005 1.00 Drive shaft, replacing one side
463-012 5.00 Centre gear removed, reconditioning
463-014 1.50 Pinion rear, fitting new gasket
463-041 3.00 Hub reduction gear removed, reconditioning
463-043 3.00 Hub, replacing seal

49 MISCELLANEOUS
491-006 1.50 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
511-002 3.00 Brake disc, replacing one
511-045 1.50 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-002 3.00 Brake disc, replacing one
512-045 1.50 Brake caliper, replacing one
512-081 1.00 Brake caliper, removed, reconditioning
516-004 0.75 Brake discs, replacing on both sides
517-004 0.75 Brake disc, replacing both sides

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-004 0.75 Brake system, adjusting unloading pressure
520-032 0.25 Brake system, replacing breathing filter
520-037 1.00 Brake system, bleeding

7/11/2012 Volvo Construction Equipment 107


EL70
Op.no. time (h) Notes

525-002 2.00 Unloading valve, removing and fitting


525-008 3.00 Foot brake valve, replacing
525-009 0.75 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure
527-002 0.50 Accumulator, replacing
527-003 1.25 Accumulators, checking in machine
527-004 1.50 Hydraulic pump, replacing
527-005 3.00 Hydraulic pump, reconditioning incl removing and
fitting
527-006 2.00 Hydraulic pump, replacing seal for pump shaft

55 PARKING BRAKE
550-001 1.00 Parking brake, replacing control cable
550-002 0.75 Parking brake, adjusting
550-004 1.50 Parking brake mechanical, replacing brake caliper
550-005 1.00 Parking brake, replacing brake disc
550-009 1.00 Spring brake cylinder, replacing
550-010 1.00 Spring brake cylinder removed, reconditioning
550-011 1.50 Parking brake (hydraulic), replacing brake caliper
550-014 1.00 Parking brake, replacing brake pads

6 STEERING
64 STEERING
645-003 0.50 Steering system working pressure, checking
645-006 2.00 Steering cylinder, replacing
645-007 0.50 Steering cylinder shock valve (proportional),
adjusting
645-015 0.50 Steering system, checking and adjusting standby
pressure
645-020 1.00 Steering system, checking and adjusting shock
and anti-cavitation-valve
645-021 1.00 Valve block, replacing
645-028 1.00 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 1.75 Steering cylinder, repacking in machine
645-077 1.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
647-091 0.50 Secondary steering pump, checking and adjusting
working pressure

108 Volvo Construction Equipment 7/11/2012


EL70
Op.no. time (h) Notes

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.75 Frame joint, checking clearance
741-036 14.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.25 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
83 DOORS; HATCH; COVER PLATE, (all)
831-004 1.50 Door, replacing
831-006 0.50 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 3.00 Windscreen, replacing
843-011 0.75 Gas suspension rear window, replacing
843-012 1.00 Rear window, replacing
843-013 0.75 Side window, replacing
843-048 0.75 Door window, replacing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 2.00 Heater core, replacing
873-006 1.50 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.50 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 1.50 Belt, changing
874-010 3.50 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 3.50 Evaporator, replacing incl draining and filling
874-013 3.00 Expansion valve, replacing incl draining and filling
874-014 1.00 Thermostat, replacing
874-015 0.75 Compressor, replacing shaft seal (compressor
removed)

7/11/2012 Volvo Construction Equipment 109


EL70
Op.no. time (h) Notes

874-016 0.75 Compressor, replacing magnetic clutch


(compressor removed)
874-017 1.50 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-005 3.00 Vacuum pump, connection
900-006 1.00 Vacuum pump, disconnection

91 WORKING HYDRAULICS; SERVO HYDRAULICS


910-002 4.00 Hydraulic system, bleeding air
910-004 4.00 Hydraulic pressure, adjusting
911-001 0.50 Oil return filter, replacing
911-002 0.25 Ventilation filter, replacing
911-038 2.00 Hydraulic oil tank, replacing
911-039 4.00 Hydraulic oil tank, replacin incl rebuilding
attachment
911-040 4.00 Hydraulic oil tank, vacuum-pumping, connecting
and disconnecting pump
912-003 1.50 Control valve, repacking all slides
912-009 1.00 Shock valve, tilt function, checking and adjusting
912-012 0.75 Shock and anti-cavitation valve, checking and
adjusting
912-016 0.50 Shock- and anti-cavitation valve (dvl 1), checking
912-017 2.50 Control valve (dvl 2), proportionally controlled,
replacing
912-042 1.50 Main valve block, installation
912-043 0.75 Control valve block assembly (intermediate),
replacing
912-045 2.00 Main valve block, loader, installation
912-060 4.00 Dipper arm valve, reconditioning
912-061 1.00 Control valve, repacking slide in machine
912-062 5.00 Control valve, servo assisted system, replacing
912-064 0.75 Control valve, shock and anti-cavitation valve,
checking
912-065 1.50 Control valve, shock- and anti-cavitation valve,
replacing
912-072 1.75 Implement attachment, shock valve, check and
adjusting

110 Volvo Construction Equipment 7/11/2012


EL70
Op.no. time (h) Notes

913-001 1.50 Hydraulic pump, checking and adjusting standby


pressure and working pressure
913-003 0.75 Hydraulic pump, checking and adjusting standby
pressure
913-004 0.50 Hydraulic pump, checking and adjusting max
working pressure
913-010 3.00 Hydraulic pump, replacing
913-011 1.50 Hydraulic pump removed, reconditioning
913-015 0.75 Hydraulic pump, airing LS system
913-017 0.75 Oil return pressure, checking and adjusting
913-022 1.00 Pump, fixed, installation
914-051 1.00 Accumulator, replacing
914-052 3.00 Accumulator, checking (pressure back-up for
servo circuit)
914-053 1.25 Servo valve, electrically controlled, reconditioning
914-056 0.50 Servo pressure (dvl 2), check
914-057 0.50 Servo pressure, check
916-972 0.75 Boom suspension system, installing new

94 UNIT, LOAD HANDLING


945-002 2.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 3.00 Lift cylinder, repacking in machine
945-007 0.50 Tilt cylinder removed, replacing bearings "E-F"
945-008 2.00 Tilt cylinder, replacing
945-009 2.00 Tilt cylinder, repacking in machine
945-011 1.00 Implemental attachment, replacing hydraulic
cylinder
945-012 0.50 Lift cylinder removed, replacing bearings "C-P"
945-016 4.00 Lift frame, replacing bearing in upper mounting "O"
945-045 1.00 Implemental attachment/bucket attachment,
replacing bushes "A"
945-054 2.00 Implement attachment, replacing
945-056 0.75 Implement attachment, repacking removed
hydraulic cylinder
945-066 0.75 Tilt link, replacing "GH"
945-069 2.00 Tilt arm, replacing "GDF"

97 UNIT, DIGGING
970-001 3.00 Excavating unit, measuring axial and radial
clearence in joints
971-090 14.00 Slewing post, replacing

7/11/2012 Volvo Construction Equipment 111


EL70
Op.no. time (h) Notes

971-091 12.00 Slewing post-slewing post shaft, replacing


bearings
971-094 5.00 Slewing cylinder, replacing
971-095 3.00 Slewing cylinder, repacking in machine
971-097 4.00 Slewing cylinder, replacing bearings and/or
bushes
972-071 1.50 Support leg, replacing
972-072 1.00 Support leg, replacing bushes in machine
972-081 1.50 Support leg cylinder, replacing
972-083 2.00 Support leg cylinder, repacking in machine
972-084 0.50 Support leg cylinder removed, replacing bearings
and/or bushes
974-010 10.00 Boom, replacing
974-011 2.00 Boom-slewing post, replacing bearings
974-012 7.00 Intermediate link, boom-dipper arm, replacing
bushes
974-021 2.00 Boom cylinder, replacing
974-022 1.50 Boom cylinder removed, repacking
974-024 1.00 Boom cylinder removed, replacing bearings
and/or bushes
974-025 3.00 Boom cylinder, repacking in machine
975-030 0.50 Lateral angulation cyl. shock valve proport.
controlled, adjusting
975-031 1.50 Side-angling cylinder, replacing
975-033 2.00 Side-angling cylinder, repacking in machine
975-034 0.50 Side-angling cylinder removed, replacing bearings
and/or bushes
975-036 4.00 Dipper arm-intermediate link, replacing bushes
975-037 2.00 Universal joint link for dipper arm cylinder,
replacing
975-038 3.00 Universal joint link for dipper arm cylinder,
replacing bushes
975-039 7.00 Dipper arm, replacing
975-041 2.00 Dipper arm cylinder, replacing
975-043 3.00 Dipper arm cylinder, repacking in machine
975-044 1.00 Dipper arm cylinder removed, replacing bearings
and/or bushes
975-046 2.00 Dipper arm-toggle arm, replacing bushes
975-047 5.00 Dipper arm telescopic, replacing bearing plates
975-050 2.00 Implement attachment, replacing
975-051 3.00 Implement attachment incl links, replacing bushes
975-053 1.75 Implement attachment, replacing locking cylinder
975-055 1.50 Implement attachment, repacking removed
locking cylinder
975-060 4.00 Bucket link, replacing bearing
975-061 3.00 Bucket cylinder, replacing

112 Volvo Construction Equipment 7/11/2012


EL70
Op.no. time (h) Notes

975-063 3.00 Bucket cylinder, repacking in machine


975-064 4.00 Bucket cylinder, replacing link bearings
975-079 4.00 Telescopic dipper arm cylinder, replacing
975-080 4.00 Telescopic dipper arm cylinder, repacking in
machine

7/11/2012 Volvo Construction Equipment 113


114 Volvo Construction Equipment 7/11/2012
EL70C
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 5.00 Warranty inspection 100 hours
172-004 8.00 Warranty inspection 1000 hours
173-007 2.00 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 7.00 Maintenance service, every 1000 hours
173-014 10.00 Maintenance service, every 2000 hours
173-061 2.00 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.50 Hydraulic oil tank, changing oil and filter
173-075 2.00 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-070 3.00 Engine, removing
210-072 5.00 Engine, installing
216-014 2.00 Crankshaft, replacing front oil seal
217-002 6.00 Sump gasket, replacing incl cleaning oil strainer

23 FUEL SYSTEM
233-002 0.50 Feed pump, replacing
236-001 1.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
236-011 1.50 Fuel pump element, replacing
237-004 1.00 Injector, replacing one
238-041 3.00 Regulator, replacing

25 INLET SYSTEM; EXHAUST SYSTEM


256-006 1.00 Preheating coil, replacing

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.25 Battery charging capacity, checking
311-002 0.75 Batteries, replacing

7/11/2012 Volvo Construction Equipment 115


EL70C
Op.no. time (h) Notes

311-014 1.50 Batteries, checking charging incl cleaning and


painting battery boxes

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.75 Alternator, replacing carbon brush kit in machine
321-074 1.50 Charging test in machine (with measuring
instrument)
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 0.75 Starter motor, replacing
331-099 0.50 Starter motor removed, replacing carbon brush kit

35 LIGHTING
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy
356-057 0.50 Work lighting, replacing one insert

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-016 0.75 Horn switch, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.50 Windscreen wiper front, replacing motor
363-003 0.75 Windscreen wiper, replacing switch
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
364-024 0.75 Main switch, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-005 0.50 Transmission, revolution sensor, replacing
386-011 0.75 Fuel level sender, replacing
387-020 0.50 Tachometer, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 1.50 Transmission, check oil pressure
421-004 2.00 Oil pump, replacing

116 Volvo Construction Equipment 7/11/2012


EL70C
Op.no. time (h) Notes

421-005 1.00 Oil pump removed, reconditioning


421-008 2.00 Gear selector valve, replacing
421-009 1.50 Gear selector valve removed, reconditioning
421-011 1.00 Converter removed, reconditioning
421-018 12.00 Converter, replacing
421-023 2.00 Lubrication and converter pressure valve,
replacing
421-047 0.75 Gear selector, replacing
421-048 0.50 Gear selector valve, replacing one solenoid
421-052 1.50 Seal for front output shaft, replacing
421-054 1.50 Seal for rear output shaft, replacing
421-071 30.00 Transmission removed, reconditioning
421-073 6.00 Transmission, removing (together with engine)
421-074 8.00 Transmission, installing (together with engine)
421-075 2.00 Clutch shaft removed, reconditioning
421-077 0.75 Oil filter, replacing
421-079 0.25 Transmission, replacing breather filter

45 PROPELLER SHAFT
451-010 1.00 Propeller shaft, front, replacing
451-013 1.00 Propeller shaft, removed reconditioning

46 FRONT AXLE; REAR AXLE


461-002 1.50 Axle, removing
461-003 2.00 Axle, installing
461-011 4.00 Centre gear , removing and fitting
461-012 5.00 Centre gear removed, reconditioning
461-014 1.50 Pinion front, fitting new gasket
461-041 3.00 Hub reduction gear, removed, reconditioning
461-043 3.00 Hub, replacing seal
461-051 9.00 Differential lock, replacing selector fork and clutch
sleeves and adjusting
461-052 0.25 Differential lock front, repacking excl adjusting
461-053 0.50 Differential lock, adjusting engagement
463-002 3.00 Axle, removing
463-003 3.00 Axle, installing
463-005 1.00 Drive shaft, replacing one side
463-012 5.00 Centre gear removed, reconditioning
463-014 1.50 Pinion rear, fitting new gasket
463-041 3.00 Hub reduction gear removed, reconditioning
463-043 3.00 Hub, replacing seal

49 MISCELLANEOUS
491-006 1.50 Oil cooler, replacing

7/11/2012 Volvo Construction Equipment 117


EL70C
Op.no. time (h) Notes

5 BRAKE
51 WHEEL BRAKE
511-002 3.00 Brake disc, replacing one
511-045 1.50 Brake calliper, replacing one
511-081 1.00 Brake calliper removed, reconditioning
512-002 3.00 Brake disc, replacing one
512-045 1.50 Brake caliper, replacing one
512-081 1.00 Brake caliper, removed, reconditioning
516-004 0.75 Brake discs, replacing on both sides
517-004 0.75 Brake disc, replacing both sides

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-004 0.75 Brake system, adjusting unloading pressure
520-032 0.25 Brake system, replacing breathing filter
520-037 1.00 Brake system, bleeding
525-002 2.00 Unloading valve, removing and fitting
525-008 3.00 Foot brake valve, replacing
525-009 0.75 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure
527-002 0.50 Accumulator, replacing
527-003 1.25 Accumulators, checking in machine
527-004 1.50 Hydraulic pump, replacing
527-005 3.00 Hydraulic pump, reconditioning incl removing and
fitting
527-006 2.00 Hydraulic pump, replacing seal for pump shaft

55 PARKING BRAKE
550-001 1.00 Parking brake, replacing control cable
550-002 0.75 Parking brake, adjusting
550-004 1.50 Parking brake mechanical, replacing brake caliper
550-005 1.00 Parking brake, replacing brake disc
550-009 1.00 Spring brake cylinder, replacing
550-010 1.00 Spring brake cylinder removed, reconditioning
550-011 1.50 Parking brake (hydraulic), replacing brake caliper
550-014 1.00 Parking brake, replacing brake pads

6 STEERING
64 STEERING
645-003 0.50 Steering system working pressure, checking
645-006 2.00 Steering cylinder, replacing

118 Volvo Construction Equipment 7/11/2012


EL70C
Op.no. time (h) Notes

645-007 0.50 Steering cylinder shock valve (proportional),


adjusting
645-015 0.50 Steering system, checking and adjusting standby
pressure
645-020 1.00 Steering system, checking and adjusting shock
and anti-cavitation-valve
645-021 1.00 Valve block, replacing
645-028 1.00 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 1.75 Steering cylinder, repacking in machine
645-077 1.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
647-091 0.50 Secondary steering pump, checking and adjusting
working pressure

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.75 Frame joint, checking clearance
741-036 14.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.25 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
83 DOORS; HATCH; COVER PLATE, (all)
831-004 1.50 Door, replacing
831-006 0.50 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 3.00 Windscreen, replacing
843-011 0.75 Gas suspension rear window, replacing
843-012 1.00 Rear window, replacing
843-013 0.75 Side window, replacing
843-048 0.75 Door window, replacing

7/11/2012 Volvo Construction Equipment 119


EL70C
Op.no. time (h) Notes

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 2.00 Heater core, replacing
873-006 1.50 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.50 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 1.50 Belt, changing
874-010 3.50 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 3.50 Evaporator, replacing incl draining and filling
874-013 3.00 Expansion valve, replacing incl draining and filling
874-014 1.00 Thermostat, replacing
874-015 0.75 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-017 1.50 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-005 3.00 Vacuum pump, connection
900-006 1.00 Vacuum pump, disconnection

91 WORKING HYDRAULICS; SERVO HYDRAULICS


910-002 4.00 Hydraulic system, bleeding air
910-004 4.00 Hydraulic pressure, adjusting
911-001 0.50 Oil return filter, replacing
911-002 0.25 Ventilation filter, replacing
911-038 2.00 Hydraulic oil tank, replacing
911-039 4.00 Hydraulic oil tank, replacin incl rebuilding
attachment
911-040 4.00 Hydraulic oil tank, vacuum-pumping, connecting
and disconnecting pump
912-003 1.50 Control valve, repacking all slides
912-009 1.00 Shock valve, tilt function, checking and adjusting

120 Volvo Construction Equipment 7/11/2012


EL70C
Op.no. time (h) Notes

912-012 0.75 Shock and anti-cavitation valve, checking and


adjusting
912-016 0.50 Shock- and anti-cavitation valve (dvl 1), checking
912-017 2.50 Control valve (dvl 2), proportionally controlled,
replacing
912-042 1.50 Main valve block, installation
912-043 0.75 Control valve block assembly (intermediate),
replacing
912-045 2.00 Main valve block, loader, installation
912-060 4.00 Dipper arm valve, reconditioning
912-061 1.00 Control valve, repacking slide in machine
912-062 5.00 Control valve, servo assisted system, replacing
912-064 0.75 Control valve, shock and anti-cavitation valve,
checking
912-065 1.50 Control valve, shock- and anti-cavitation valve,
replacing
912-072 1.75 Implement attachment, shock valve, check and
adjusting
913-001 1.50 Hydraulic pump, checking and adjusting standby
pressure and working pressure
913-003 0.75 Hydraulic pump, checking and adjusting standby
pressure
913-004 0.50 Hydraulic pump, checking and adjusting max
working pressure
913-010 3.00 Hydraulic pump, replacing
913-011 1.50 Hydraulic pump removed, reconditioning
913-015 0.75 Hydraulic pump, airing LS system
913-017 0.75 Oil return pressure, checking and adjusting
913-022 1.00 Pump, fixed, installation
914-051 1.00 Accumulator, replacing
914-052 3.00 Accumulator, checking (pressure back-up for
servo circuit)
914-053 1.25 Servo valve, electrically controlled, reconditioning
914-056 0.50 Servo pressure (dvl 2), check
914-057 0.50 Servo pressure, check
916-972 0.75 Boom suspension system, installing new

94 UNIT, LOAD HANDLING


945-002 2.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 3.00 Lift cylinder, repacking in machine
945-007 0.50 Tilt cylinder removed, replacing bearings "E-F"
945-008 2.00 Tilt cylinder, replacing

7/11/2012 Volvo Construction Equipment 121


EL70C
Op.no. time (h) Notes

945-009 2.00 Tilt cylinder, repacking in machine


945-011 1.00 Implemental attachment, replacing hydraulic
cylinder
945-012 0.50 Lift cylinder removed, replacing bearings "C-P"
945-016 4.00 Lift frame, replacing bearing in upper mounting "O"
945-045 1.00 Implemental attachment/bucket attachment,
replacing bushes "A"
945-054 2.00 Implement attachment, replacing
945-056 0.75 Implement attachment, repacking removed
hydraulic cylinder
945-066 0.75 Tilt link, replacing "GH"
945-069 2.00 Tilt arm, replacing "GDF"

97 UNIT, DIGGING
970-001 3.00 Excavating unit, measuring axial and radial
clearence in joints
971-090 14.00 Slewing post, replacing
971-091 12.00 Slewing post-slewing post shaft, replacing
bearings
971-094 5.00 Slewing cylinder, replacing
971-095 3.00 Slewing cylinder, repacking in machine
971-097 4.00 Slewing cylinder, replacing bearings and/or
bushes
972-071 1.50 Support leg, replacing
972-072 1.00 Support leg, replacing bushes in machine
972-081 1.50 Support leg cylinder, replacing
972-083 2.00 Support leg cylinder, repacking in machine
972-084 0.50 Support leg cylinder removed, replacing bearings
and/or bushes
974-010 10.00 Boom, replacing
974-011 2.00 Boom-slewing post, replacing bearings
974-012 7.00 Intermediate link, boom-dipper arm, replacing
bushes
974-021 2.00 Boom cylinder, replacing
974-022 1.50 Boom cylinder removed, repacking
974-024 1.00 Boom cylinder removed, replacing bearings
and/or bushes
974-025 3.00 Boom cylinder, repacking in machine
975-030 0.50 Lateral angulation cyl. shock valve proport.
controlled, adjusting
975-031 1.50 Side-angling cylinder, replacing
975-033 2.00 Side-angling cylinder, repacking in machine
975-034 0.50 Side-angling cylinder removed, replacing bearings
and/or bushes
975-036 4.00 Dipper arm-intermediate link, replacing bushes

122 Volvo Construction Equipment 7/11/2012


EL70C
Op.no. time (h) Notes

975-037 2.00 Universal joint link for dipper arm cylinder,


replacing
975-038 3.00 Universal joint link for dipper arm cylinder,
replacing bushes
975-039 7.00 Dipper arm, replacing
975-041 2.00 Dipper arm cylinder, replacing
975-043 3.00 Dipper arm cylinder, repacking in machine
975-044 1.00 Dipper arm cylinder removed, replacing bearings
and/or bushes
975-046 2.00 Dipper arm-toggle arm, replacing bushes
975-047 5.00 Dipper arm telescopic, replacing bearing plates
975-050 2.00 Implement attachment, replacing
975-051 3.00 Implement attachment incl links, replacing bushes
975-053 1.75 Implement attachment, replacing locking cylinder
975-055 1.50 Implement attachment, repacking removed
locking cylinder
975-060 4.00 Bucket link, replacing bearing
975-061 3.00 Bucket cylinder, replacing
975-063 3.00 Bucket cylinder, repacking in machine
975-064 4.00 Bucket cylinder, replacing link bearings
975-079 4.00 Telescopic dipper arm cylinder, replacing
975-080 4.00 Telescopic dipper arm cylinder, repacking in
machine

7/11/2012 Volvo Construction Equipment 123


124 Volvo Construction Equipment 7/11/2012
EW140B
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
172-002 3.50 Warranty inspection 100 hours
172-004 8.00 Warranty inspection 1000 hours
173-002 1.00 Maintenance service, daily
173-004 1.50 Maintenance service, every 50 hours
173-007 2.50 Maintenance service, every 250 hours
173-010 5.00 Maintenance service, every 500 hours
173-012 6.00 Maintenance service, every 1000 hours
173-014 8.00 Maintenance service, every 2000 hours
173-018 10.00 Maintenance service, every 4000 hours

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
216-014 3.00 Crankshaft, replacing front oil seal
216-018 9.00 Crankshaft, replacing rear oil seal
217-003 4.00 Oil sump, replacing

23 FUEL SYSTEM
233-002 0.70 Feed pump, replacing
236-076 1.25 Injection pump, one changing

25 INLET SYSTEM; EXHAUST SYSTEM


252-020 0.80 Silencer, replacing

26 COOLING SYSTEM
262-002 1.25 Coolant pump, replacing
262-098 0.80 Thermostat, replacing

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
30 GENERAL
300-072 0.60 I-ECU, MID 140, changing non-programmed ECU
300-074 0.30 I-ECU, MID 140, changing pre-programmed ECU

31 BATTERY
311-002 0.40 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 0.60 Alternator, replacing incl function check

7/11/2012 Volvo Construction Equipment 125


EW140B
Op.no. time (h) Notes

36 OTHER ELECTRICAL EQUIPMENT


366-064 0.70 V-ECU, MID 187, changing non-programmed
ECU
366-066 0.50 V-ECU, MID 187, changing pre-programmed ECU

4 POWER TRANSMISSION
43 GEARBOX,
432-076 0.40 T-ECU, MID 130, changing non-programmed
ECU
432-078 0.30 T-ECU, MID 130, changing pre-programmed ECU

44 HYDROSTATIC DRIVE
441-021 3.50 Swing motor, replacing
443-033 1.25 Center passage, disassembly and assembly

6 STEERING
64 STEERING
640-001 0.50 Steering system, adjustment
645-060 3.00 Steering cylinder, repacking in machine

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
77 WHEELS; TRACKS; TYRE; HUB; DRUM
774-001 0.60 Stone protection ring, removing
774-002 0.70 Stone protection ring, installing

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
87 AIR CONDITIONING UNIT
874-006 2.50 Compressor, replacing incl draining and filling
874-010 2.00 Condenser, replacing incl draining and filling
874-012 3.50 Evaporator, replacing incl draining and filling

126 Volvo Construction Equipment 7/11/2012


EW140B
Op.no. time (h) Notes

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
912-019 0.40 Shock valve removed, checking
912-091 1.25 Main control valve, removal
912-092 3.00 Main control valve, installation

7/11/2012 Volvo Construction Equipment 127


128 Volvo Construction Equipment 7/11/2012
EW160B
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
172-004 8.00 Warranty inspection 1000 hours
173-002 1.00 Maintenance service, daily
173-004 1.50 Maintenance service, every 50 hours
173-007 2.50 Maintenance service, every 250 hours
173-010 5.00 Maintenance service, every 500 hours
173-012 6.00 Maintenance service, every 1000 hours
173-014 8.00 Maintenance service, every 2000 hours
173-018 10.00 Maintenance service, every 4000 hours

2 ENGINE WITH MOUNTING AND EQUIPMENT


20 GENERAL
200-068 0.70 E-ECU, MID 128, changing non-programmed
ECU
200-070 0.50 E-ECU, MID 128, changing pre-programmed ECU

21 ENGINE
216-014 3.00 Crankshaft, replacing front oil seal
216-018 9.00 Crankshaft, replacing rear oil seal
217-003 4.00 Oil sump, replacing

22 LUBRICATING SYSTEM
221-006 1.25 Oil pressure relief valve, replacing

23 FUEL SYSTEM
233-002 0.70 Feed pump, replacing

25 INLET SYSTEM; EXHAUST SYSTEM


252-020 0.80 Silencer, replacing

26 COOLING SYSTEM
262-002 1.25 Coolant pump, replacing
262-098 0.80 Thermostat, replacing

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
30 GENERAL
300-072 0.60 I-ECU, MID 140, changing non-programmed ECU
300-074 0.30 I-ECU, MID 140, changing pre-programmed ECU

7/11/2012 Volvo Construction Equipment 129


EW160B
Op.no. time (h) Notes

31 BATTERY
311-002 0.40 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 0.60 Alternator, replacing incl function check

36 OTHER ELECTRICAL EQUIPMENT


366-064 0.70 V-ECU, MID 187, changing non-programmed
ECU
366-066 0.50 V-ECU, MID 187, changing pre-programmed ECU

4 POWER TRANSMISSION
43 GEARBOX,
431-012 3.50 Travel gearbox, removal
431-013 4.00 Travel gearbox, installation
432-076 0.40 T-ECU, MID 130, changing non-programmed
ECU
432-078 0.30 T-ECU, MID 130, changing pre-programmed ECU

44 HYDROSTATIC DRIVE
441-024 0.90 Swing motor, replacing plate (brake)
443-033 1.25 Center passage, disassembly and assembly

6 STEERING
64 STEERING
640-001 0.50 Steering system, adjustment
645-060 3.00 Steering cylinder, repacking in machine

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
77 WHEELS; TRACKS; TYRE; HUB; DRUM
774-001 0.60 Stone protection ring, removing
774-002 0.70 Stone protection ring, installing

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
912-019 0.40 Shock valve removed, checking

130 Volvo Construction Equipment 7/11/2012


EW160B
Op.no. time (h) Notes

92 MECHANICAL EQUIPMENT/ATTACHMENT
924-034 0.90 Attachment bracket cylinder, reconditioning

7/11/2012 Volvo Construction Equipment 131


132 Volvo Construction Equipment 7/11/2012
EW180B
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
172-004 8.00 Warranty inspection 1000 hours
173-002 1.00 Maintenance service, daily
173-004 1.50 Maintenance service, every 50 hours
173-007 2.50 Maintenance service, every 250 hours
173-010 5.00 Maintenance service, every 500 hours
173-012 6.00 Maintenance service, every 1000 hours
173-014 8.00 Maintenance service, every 2000 hours
173-018 10.00 Maintenance service, every 4000 hours

2 ENGINE WITH MOUNTING AND EQUIPMENT


20 GENERAL
200-068 0.70 E-ECU, MID 128, changing non-programmed
ECU
200-070 0.50 E-ECU, MID 128, changing pre-programmed ECU

21 ENGINE
216-014 3.00 Crankshaft, replacing front oil seal
216-018 9.00 Crankshaft, replacing rear oil seal
217-003 4.00 Oil sump, replacing

22 LUBRICATING SYSTEM
221-006 1.25 Oil pressure relief valve, replacing

23 FUEL SYSTEM
233-002 0.70 Feed pump, replacing

25 INLET SYSTEM; EXHAUST SYSTEM


252-020 0.80 Silencer, replacing

26 COOLING SYSTEM
262-002 1.25 Coolant pump, replacing
262-098 0.80 Thermostat, replacing

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
30 GENERAL
300-072 0.60 I-ECU, MID 140, changing non-programmed ECU
300-074 0.30 I-ECU, MID 140, changing pre-programmed ECU

7/11/2012 Volvo Construction Equipment 133


EW180B
Op.no. time (h) Notes

31 BATTERY
311-002 0.40 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 0.60 Alternator, replacing incl function check

36 OTHER ELECTRICAL EQUIPMENT


366-064 0.70 V-ECU, MID 187, changing non-programmed
ECU
366-066 0.50 V-ECU, MID 187, changing pre-programmed ECU

4 POWER TRANSMISSION
43 GEARBOX,
432-076 0.40 T-ECU, MID 130, changing non-programmed
ECU
432-078 0.30 T-ECU, MID 130, changing pre-programmed ECU

44 HYDROSTATIC DRIVE
441-024 0.90 Swing motor, replacing plate (brake)
443-033 1.25 Center passage, disassembly and assembly

6 STEERING
64 STEERING
640-001 0.50 Steering system, adjustment
645-060 3.00 Steering cylinder, repacking in machine

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
77 WHEELS; TRACKS; TYRE; HUB; DRUM
774-001 0.60 Stone protection ring, removing
774-002 0.70 Stone protection ring, installing

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
912-019 0.40 Shock valve removed, checking
912-091 1.75 Main control valve, removal
912-092 3.50 Main control valve, installation

134 Volvo Construction Equipment 7/11/2012


EW180B
Op.no. time (h) Notes

92 MECHANICAL EQUIPMENT/ATTACHMENT
924-034 0.90 Attachment bracket cylinder, reconditioning

7/11/2012 Volvo Construction Equipment 135


136 Volvo Construction Equipment 7/11/2012
EW200B
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
172-004 8.00 Warranty inspection 1000 hours
173-002 1.00 Maintenance service, daily
173-004 1.50 Maintenance service, every 50 hours
173-007 2.50 Maintenance service, every 250 hours
173-010 5.00 Maintenance service, every 500 hours
173-012 6.00 Maintenance service, every 1000 hours
173-014 8.00 Maintenance service, every 2000 hours
173-018 10.00 Maintenance service, every 4000 hours

2 ENGINE WITH MOUNTING AND EQUIPMENT


20 GENERAL
200-068 0.70 E-ECU, MID 128, changing non-programmed
ECU
200-070 0.50 E-ECU, MID 128, changing pre-programmed ECU

21 ENGINE
216-014 3.00 Crankshaft, replacing front oil seal
216-018 9.00 Crankshaft, replacing rear oil seal
217-003 4.00 Oil sump, replacing

22 LUBRICATING SYSTEM
221-006 1.25 Oil pressure relief valve, replacing

23 FUEL SYSTEM
233-002 0.70 Feed pump, replacing

25 INLET SYSTEM; EXHAUST SYSTEM


252-020 0.80 Silencer, replacing

26 COOLING SYSTEM
262-002 1.25 Coolant pump, replacing
262-098 0.80 Thermostat, replacing

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
30 GENERAL
300-072 0.60 I-ECU, MID 140, changing non-programmed ECU
300-074 0.30 I-ECU, MID 140, changing pre-programmed ECU

7/11/2012 Volvo Construction Equipment 137


EW200B
Op.no. time (h) Notes

31 BATTERY
311-002 0.40 Batteries, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 0.60 Alternator, replacing incl function check

36 OTHER ELECTRICAL EQUIPMENT


366-064 0.70 V-ECU, MID 187, changing non-programmed
ECU
366-066 0.50 V-ECU, MID 187, changing pre-programmed ECU

4 POWER TRANSMISSION
43 GEARBOX,
432-076 0.40 T-ECU, MID 130, changing non-programmed
ECU
432-078 0.30 T-ECU, MID 130, changing pre-programmed ECU

44 HYDROSTATIC DRIVE
441-021 3.50 Swing motor, replacing
441-024 0.90 Swing motor, replacing plate (brake)
443-033 1.25 Center passage, disassembly and assembly

6 STEERING
64 STEERING
640-001 0.50 Steering system, adjustment
645-060 3.00 Steering cylinder, repacking in machine

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
77 WHEELS; TRACKS; TYRE; HUB; DRUM
774-001 0.60 Stone protection ring, removing
774-002 0.70 Stone protection ring, installing

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
87 AIR CONDITIONING UNIT
874-006 2.50 Compressor, replacing incl draining and filling
874-010 2.00 Condenser, replacing incl draining and filling

138 Volvo Construction Equipment 7/11/2012


EW200B
Op.no. time (h) Notes

874-012 3.50 Evaporator, replacing incl draining and filling

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
912-091 1.75 Main control valve, removal
912-092 3.50 Main control valve, installation

92 MECHANICAL EQUIPMENT/ATTACHMENT
924-034 0.90 Attachment bracket cylinder, reconditioning

7/11/2012 Volvo Construction Equipment 139


140 Volvo Construction Equipment 7/11/2012
G710B
Op.no. time (h) Notes

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 8.00 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 8.00 Engine, installing
211-002 10.00 Cylinder head, replacing gasket
213-010 2.00 Cylinder liner and piston, replacing one
214-005 0.50 Valve seat insert cylinder head removed, replacing
each
214-030 1.50 Valves, decarbonizing and grinding
214-036 1.00 Valve covers, fitting new gasket
215-002 1.50 Timing gear cover, fitting new gasket in machine
216-014 4.00 Crankshaft, replacing front oil seal
216-018 4.00 Crankshaft, replacing rear oil seal
216-034 0.50 Big- end bearing shells, replacing in machine
216-041 5.00 Flywheel housing with power take-off, removing
216-042 5.50 Flywheel housing with power take-off, installing
216-046 2.50 Vibration damper, removal
217-003 4.00 Oil sump, replacing
217-004 2.00 Oil sump gasket, changing
218-001 1.00 Rubber cushion, replacing
218-003 2.00 Engine mount, right rear, changing
218-004 1.50 Engine mount, left rear, changing
218-005 2.00 Engine mount, right front, changing
218-006 1.50 Engine mount, left front, changing

22 LUBRICATING SYSTEM
222-011 0.50 Oil filter, replacing
223-006 6.00 Oil cooler, replacing

23 FUEL SYSTEM
233-002 2.00 Feed pump, replacing
233-011 1.00 Fuel pump, removing
233-012 1.50 Fuel pump, installing
233-014 0.75 Fuel filters, replacing
233-041 1.50 Fuel strainer, changing
234-010 6.00 Fuel tank, replacing
234-091 1.00 Fuel shut-off valve, changing
236-030 0.50 Injection timing, checking and adjusting
236-076 2.50 Injection pump, one changing
237-018 1.00 Delivery pipe, replacing one

7/11/2012 Volvo Construction Equipment 141


G710B
Op.no. time (h) Notes

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 0.75 Exhaust manifold, replacing gasket
252-020 4.00 Silencer, replacing
252-022 1.50 Exhaust pipe, changing pipe between silencer and
turbocharger
255-071 4.00 Turbocharger, replacing
255-072 2.00 Turbocharger, installing

6 STEERING
62 STEERING AXLE
622-011 2.00 Steering spindle, changing
622-031 2.00 Steering spindle, changing king pin bearing
622-041 2.00 Steering spindle, changing king pin bearing seal
622-051 1.00 Preparation and Wheel Removal
622-052 2.00 Wheel Hub - Removal
622-053 2.00 Steering Cylinder - Removal
622-054 1.00 Drag link, removing
622-055 1.50 Pivot block, removing and disassembling
622-056 3.00 Spindle - Removal and Disassembly
622-057 2.00 Wheel Lean Cylinder - Removal
622-058 2.50 Tie bar, removing
622-059 2.00 Knuckle, removing
622-060 2.00 Front axle frame, removing
622-061 2.00 Front axle frame, installing
622-062 2.00 Knuckle, installing
622-063 1.50 Tie bar, installing
622-064 1.00 Wheel Lean Cylinder - Installation
622-065 1.00 Spindle - Assembly and Installation
622-066 1.50 Pivot Block - Assembly and Installation
622-067 1.50 Drag link, installing
622-068 1.00 Steering Cylinder - Installation
622-069 1.00 Wheel Hub - Installation
622-070 0.50 Wheel - Installation
622-071 0.50 Toe - in, adjustment
622-072 1.50 Front Axle Pivot Pin Bearings - Disassembly
622-073 1.50 Front Axle Pivot Pin Bearings - Assembly
622-074 1.50 King Pin Bearings and Spindle Thrust Bearing -
Disassembly
622-075 1.50 King Pin Bearings and Spindle Thrust Bearing -
Assembly
622-078 0.50 Pivot Block Adjustments

142 Volvo Construction Equipment 7/11/2012


G710B
Op.no. time (h) Notes

622-081 10.00 Front axle, overhaul

64 STEERING
645-004 1.00 Steering cylinder, removing
645-005 1.00 Steering cylinder, installing
645-021 1.50 Valve block, replacing
645-031 1.00 Steering control unit, removing
645-032 1.00 Steering Control Unit - Disassembly
645-033 0.50 Steering Control Unit - Cleaning and Inspection
645-034 1.50 Steering Control Unit - Assembly
645-052 1.50 Steering cylinder removed, reconditioning excl
replacing bearings
645-077 2.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
647-089 0.50 Secondary steering relief valve, adjusting
647-992 2.00 Secondary steering system, installing new
648-001 1.00 Wheel lean cylinder, removing
648-002 1.00 Wheel lean cylinder, installing

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-036 4.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one
771-002 0.50 Front wheel, removal
771-003 0.50 Front wheel, installation
771-004 0.50 Rear wheel, removal
771-005 0.50 Rear wheel, installation
771-006 0.50 Tyres, checking pressure
771-007 1.00 Wheel, installing

7/11/2012 Volvo Construction Equipment 143


144 Volvo Construction Equipment 7/11/2012
G720B
Op.no. time (h) Notes

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 8.00 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 8.00 Engine, installing
211-002 10.00 Cylinder head, replacing gasket
213-010 2.00 Cylinder liner and piston, replacing one
214-005 0.50 Valve seat insert cylinder head removed, replacing
each
214-030 1.50 Valves, decarbonizing and grinding
214-036 1.00 Valve covers, fitting new gasket
215-002 1.50 Timing gear cover, fitting new gasket in machine
216-014 4.00 Crankshaft, replacing front oil seal
216-018 4.00 Crankshaft, replacing rear oil seal
216-034 0.50 Big- end bearing shells, replacing in machine
216-041 5.00 Flywheel housing with power take-off, removing
216-042 5.50 Flywheel housing with power take-off, installing
216-046 2.50 Vibration damper, removal
217-003 4.00 Oil sump, replacing
217-004 2.00 Oil sump gasket, changing
218-001 1.00 Rubber cushion, replacing
218-003 2.00 Engine mount, right rear, changing
218-004 1.50 Engine mount, left rear, changing
218-005 2.00 Engine mount, right front, changing
218-006 1.50 Engine mount, left front, changing

22 LUBRICATING SYSTEM
222-011 0.50 Oil filter, replacing
223-006 6.00 Oil cooler, replacing

23 FUEL SYSTEM
233-002 2.00 Feed pump, replacing
233-011 1.00 Fuel pump, removing
233-012 1.50 Fuel pump, installing
233-014 0.75 Fuel filters, replacing
233-041 1.50 Fuel strainer, changing
234-010 6.00 Fuel tank, replacing
234-091 1.00 Fuel shut-off valve, changing
236-030 0.50 Injection timing, checking and adjusting
236-076 2.50 Injection pump, one changing
237-018 1.00 Delivery pipe, replacing one

7/11/2012 Volvo Construction Equipment 145


G720B
Op.no. time (h) Notes

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 0.75 Exhaust manifold, replacing gasket
252-020 4.00 Silencer, replacing
252-022 1.50 Exhaust pipe, changing pipe between silencer and
turbocharger
255-071 4.00 Turbocharger, replacing
255-072 2.00 Turbocharger, installing

6 STEERING
62 STEERING AXLE
622-011 2.00 Steering spindle, changing
622-031 2.00 Steering spindle, changing king pin bearing
622-041 2.00 Steering spindle, changing king pin bearing seal
622-051 1.00 Preparation and Wheel Removal
622-052 2.00 Wheel Hub - Removal
622-053 2.00 Steering Cylinder - Removal
622-054 1.00 Drag link, removing
622-055 1.50 Pivot block, removing and disassembling
622-056 3.00 Spindle - Removal and Disassembly
622-057 2.00 Wheel Lean Cylinder - Removal
622-058 2.50 Tie bar, removing
622-059 2.00 Knuckle, removing
622-060 2.00 Front axle frame, removing
622-061 2.00 Front axle frame, installing
622-062 2.00 Knuckle, installing
622-063 1.50 Tie bar, installing
622-064 1.00 Wheel Lean Cylinder - Installation
622-065 1.00 Spindle - Assembly and Installation
622-066 1.50 Pivot Block - Assembly and Installation
622-067 1.50 Drag link, installing
622-068 1.00 Steering Cylinder - Installation
622-069 1.00 Wheel Hub - Installation
622-070 0.50 Wheel - Installation
622-071 0.50 Toe - in, adjustment
622-072 1.50 Front Axle Pivot Pin Bearings - Disassembly
622-073 1.50 Front Axle Pivot Pin Bearings - Assembly
622-074 1.50 King Pin Bearings and Spindle Thrust Bearing -
Disassembly
622-075 1.50 King Pin Bearings and Spindle Thrust Bearing -
Assembly
622-078 0.50 Pivot Block Adjustments

146 Volvo Construction Equipment 7/11/2012


G720B
Op.no. time (h) Notes

622-081 10.00 Front axle, overhaul

64 STEERING
645-004 1.00 Steering cylinder, removing
645-005 1.00 Steering cylinder, installing
645-021 1.50 Valve block, replacing
645-031 1.00 Steering control unit, removing
645-032 1.00 Steering Control Unit - Disassembly
645-033 0.50 Steering Control Unit - Cleaning and Inspection
645-034 1.50 Steering Control Unit - Assembly
645-052 1.50 Steering cylinder removed, reconditioning excl
replacing bearings
645-077 2.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
647-089 0.50 Secondary steering relief valve, adjusting
647-992 2.00 Secondary steering system, installing new
648-001 1.00 Wheel lean cylinder, removing
648-002 1.00 Wheel lean cylinder, installing

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-036 4.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one
771-002 0.50 Front wheel, removal
771-003 0.50 Front wheel, installation
771-004 0.50 Rear wheel, removal
771-005 0.50 Rear wheel, installation
771-006 0.50 Tyres, checking pressure
771-007 1.00 Wheel, installing

7/11/2012 Volvo Construction Equipment 147


148 Volvo Construction Equipment 7/11/2012
G726B
Op.no. time (h) Notes

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 8.00 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 8.00 Engine, installing
211-002 10.00 Cylinder head, replacing gasket
213-010 2.00 Cylinder liner and piston, replacing one
214-005 0.50 Valve seat insert cylinder head removed, replacing
each
214-030 1.50 Valves, decarbonizing and grinding
214-036 1.00 Valve covers, fitting new gasket
215-002 1.50 Timing gear cover, fitting new gasket in machine
216-014 4.00 Crankshaft, replacing front oil seal
216-018 4.00 Crankshaft, replacing rear oil seal
216-034 0.50 Big- end bearing shells, replacing in machine
216-041 5.00 Flywheel housing with power take-off, removing
216-042 5.50 Flywheel housing with power take-off, installing
216-046 2.50 Vibration damper, removal
217-003 4.00 Oil sump, replacing
217-004 2.00 Oil sump gasket, changing
218-001 1.00 Rubber cushion, replacing
218-003 2.00 Engine mount, right rear, changing
218-004 1.50 Engine mount, left rear, changing
218-005 2.00 Engine mount, right front, changing
218-006 1.50 Engine mount, left front, changing

22 LUBRICATING SYSTEM
222-011 0.50 Oil filter, replacing
223-006 6.00 Oil cooler, replacing

23 FUEL SYSTEM
233-002 2.00 Feed pump, replacing
233-011 1.00 Fuel pump, removing
233-012 1.50 Fuel pump, installing
233-014 0.75 Fuel filters, replacing
233-041 1.50 Fuel strainer, changing
234-010 6.00 Fuel tank, replacing
234-091 1.00 Fuel shut-off valve, changing
236-030 0.50 Injection timing, checking and adjusting
236-076 2.50 Injection pump, one changing
237-018 1.00 Delivery pipe, replacing one

7/11/2012 Volvo Construction Equipment 149


G726B
Op.no. time (h) Notes

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 0.75 Exhaust manifold, replacing gasket
252-020 4.00 Silencer, replacing
252-022 1.50 Exhaust pipe, changing pipe between silencer and
turbocharger
255-071 4.00 Turbocharger, replacing
255-072 2.00 Turbocharger, installing

6 STEERING
62 STEERING AXLE
622-011 2.00 Steering spindle, changing
622-031 2.00 Steering spindle, changing king pin bearing
622-041 2.00 Steering spindle, changing king pin bearing seal
622-051 1.00 Preparation and Wheel Removal
622-052 2.00 Wheel Hub - Removal
622-053 2.00 Steering Cylinder - Removal
622-054 1.00 Drag link, removing
622-055 1.50 Pivot block, removing and disassembling
622-056 3.00 Spindle - Removal and Disassembly
622-057 2.00 Wheel Lean Cylinder - Removal
622-058 2.50 Tie bar, removing
622-059 2.00 Knuckle, removing
622-060 2.00 Front axle frame, removing
622-061 2.00 Front axle frame, installing
622-062 2.00 Knuckle, installing
622-063 1.50 Tie bar, installing
622-064 1.00 Wheel Lean Cylinder - Installation
622-065 1.00 Spindle - Assembly and Installation
622-066 1.50 Pivot Block - Assembly and Installation
622-067 1.50 Drag link, installing
622-068 1.00 Steering Cylinder - Installation
622-069 1.00 Wheel Hub - Installation
622-070 0.50 Wheel - Installation
622-071 0.50 Toe - in, adjustment
622-072 1.50 Front Axle Pivot Pin Bearings - Disassembly
622-073 1.50 Front Axle Pivot Pin Bearings - Assembly
622-074 1.50 King Pin Bearings and Spindle Thrust Bearing -
Disassembly
622-075 1.50 King Pin Bearings and Spindle Thrust Bearing -
Assembly
622-078 0.50 Pivot Block Adjustments

150 Volvo Construction Equipment 7/11/2012


G726B
Op.no. time (h) Notes

622-081 10.00 Front axle, overhaul

64 STEERING
645-004 1.00 Steering cylinder, removing
645-005 1.00 Steering cylinder, installing
645-021 1.50 Valve block, replacing
645-031 1.00 Steering control unit, removing
645-032 1.00 Steering Control Unit - Disassembly
645-033 0.50 Steering Control Unit - Cleaning and Inspection
645-034 1.50 Steering Control Unit - Assembly
645-052 1.50 Steering cylinder removed, reconditioning excl
replacing bearings
645-077 2.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
647-089 0.50 Secondary steering relief valve, adjusting
647-992 2.00 Secondary steering system, installing new
648-001 1.00 Wheel lean cylinder, removing
648-002 1.00 Wheel lean cylinder, installing

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-036 4.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one
771-002 0.50 Front wheel, removal
771-003 0.50 Front wheel, installation
771-004 0.50 Rear wheel, removal
771-005 0.50 Rear wheel, installation
771-006 0.50 Tyres, checking pressure
771-007 1.00 Wheel, installing

7/11/2012 Volvo Construction Equipment 151


152 Volvo Construction Equipment 7/11/2012
G730B
Op.no. time (h) Notes

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 8.00 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 8.00 Engine, installing
211-002 10.00 Cylinder head, replacing gasket
213-010 2.00 Cylinder liner and piston, replacing one
214-005 0.50 Valve seat insert cylinder head removed, replacing
each
214-030 1.50 Valves, decarbonizing and grinding
214-036 1.00 Valve covers, fitting new gasket
215-002 1.50 Timing gear cover, fitting new gasket in machine
216-014 4.00 Crankshaft, replacing front oil seal
216-018 4.00 Crankshaft, replacing rear oil seal
216-034 0.50 Big- end bearing shells, replacing in machine
216-041 5.00 Flywheel housing with power take-off, removing
216-042 5.50 Flywheel housing with power take-off, installing
216-046 2.50 Vibration damper, removal
217-003 4.00 Oil sump, replacing
217-004 2.00 Oil sump gasket, changing
218-001 1.00 Rubber cushion, replacing
218-003 2.00 Engine mount, right rear, changing
218-004 1.50 Engine mount, left rear, changing
218-005 2.00 Engine mount, right front, changing
218-006 1.50 Engine mount, left front, changing

22 LUBRICATING SYSTEM
222-011 0.50 Oil filter, replacing
223-006 6.00 Oil cooler, replacing

23 FUEL SYSTEM
233-002 2.00 Feed pump, replacing
233-011 1.00 Fuel pump, removing
233-012 1.50 Fuel pump, installing
233-014 0.75 Fuel filters, replacing
233-041 1.50 Fuel strainer, changing
234-010 6.00 Fuel tank, replacing
234-091 1.00 Fuel shut-off valve, changing
236-030 0.50 Injection timing, checking and adjusting
236-076 2.50 Injection pump, one changing
237-018 1.00 Delivery pipe, replacing one

7/11/2012 Volvo Construction Equipment 153


G730B
Op.no. time (h) Notes

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 0.75 Exhaust manifold, replacing gasket
252-020 4.00 Silencer, replacing
252-022 1.50 Exhaust pipe, changing pipe between silencer and
turbocharger
255-071 4.00 Turbocharger, replacing
255-072 2.00 Turbocharger, installing

6 STEERING
62 STEERING AXLE
622-011 2.00 Steering spindle, changing
622-031 2.00 Steering spindle, changing king pin bearing
622-041 2.00 Steering spindle, changing king pin bearing seal
622-051 1.00 Preparation and Wheel Removal
622-052 2.00 Wheel Hub - Removal
622-053 2.00 Steering Cylinder - Removal
622-054 1.00 Drag link, removing
622-055 1.50 Pivot block, removing and disassembling
622-056 3.00 Spindle - Removal and Disassembly
622-057 2.00 Wheel Lean Cylinder - Removal
622-058 2.50 Tie bar, removing
622-059 2.00 Knuckle, removing
622-060 2.00 Front axle frame, removing
622-061 2.00 Front axle frame, installing
622-062 2.00 Knuckle, installing
622-063 1.50 Tie bar, installing
622-064 1.00 Wheel Lean Cylinder - Installation
622-065 1.00 Spindle - Assembly and Installation
622-066 1.50 Pivot Block - Assembly and Installation
622-067 1.50 Drag link, installing
622-068 1.00 Steering Cylinder - Installation
622-069 1.00 Wheel Hub - Installation
622-070 0.50 Wheel - Installation
622-071 0.50 Toe - in, adjustment
622-072 1.50 Front Axle Pivot Pin Bearings - Disassembly
622-073 1.50 Front Axle Pivot Pin Bearings - Assembly
622-074 1.50 King Pin Bearings and Spindle Thrust Bearing -
Disassembly
622-075 1.50 King Pin Bearings and Spindle Thrust Bearing -
Assembly
622-078 0.50 Pivot Block Adjustments

154 Volvo Construction Equipment 7/11/2012


G730B
Op.no. time (h) Notes

622-081 10.00 Front axle, overhaul

64 STEERING
645-004 1.00 Steering cylinder, removing
645-005 1.00 Steering cylinder, installing
645-021 1.50 Valve block, replacing
645-031 1.00 Steering control unit, removing
645-032 1.00 Steering Control Unit - Disassembly
645-033 0.50 Steering Control Unit - Cleaning and Inspection
645-034 1.50 Steering Control Unit - Assembly
645-052 1.50 Steering cylinder removed, reconditioning excl
replacing bearings
645-077 2.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
647-089 0.50 Secondary steering relief valve, adjusting
647-992 2.00 Secondary steering system, installing new
648-001 1.00 Wheel lean cylinder, removing
648-002 1.00 Wheel lean cylinder, installing

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-036 4.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one
771-002 0.50 Front wheel, removal
771-003 0.50 Front wheel, installation
771-004 0.50 Rear wheel, removal
771-005 0.50 Rear wheel, installation
771-006 0.50 Tyres, checking pressure
771-007 1.00 Wheel, installing

7/11/2012 Volvo Construction Equipment 155


156 Volvo Construction Equipment 7/11/2012
G740B
Op.no. time (h) Notes

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 8.00 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 8.00 Engine, installing
211-002 10.00 Cylinder head, replacing gasket
213-010 2.50 Cylinder liner and piston, replacing one
214-005 0.75 Valve seat insert cylinder head removed, replacing
each
214-021 0.50 Valve cover, fitting new gasket each
214-030 1.50 Valves, decarbonizing and grinding
215-002 2.00 Timing gear cover, fitting new gasket in machine
216-014 3.50 Crankshaft, replacing front oil seal
216-018 3.50 Crankshaft, replacing rear oil seal
216-034 0.50 Big- end bearing shells, replacing in machine
216-041 5.00 Flywheel housing with power take-off, removing
216-042 5.50 Flywheel housing with power take-off, installing
216-046 2.50 Vibration damper, removal
217-003 4.00 Oil sump, replacing
217-004 2.00 Oil sump gasket, changing
218-001 1.00 Rubber cushion, replacing
218-003 2.50 Engine mount, right rear, changing
218-004 2.00 Engine mount, left rear, changing
218-005 2.50 Engine mount, right front, changing
218-006 2.00 Engine mount, left front, changing

22 LUBRICATING SYSTEM
222-011 0.50 Oil filter, replacing
223-006 6.00 Oil cooler, replacing

23 FUEL SYSTEM
233-002 2.00 Feed pump, replacing
233-011 1.00 Fuel pump, removing
233-012 1.50 Fuel pump, installing
233-014 0.75 Fuel filters, replacing
233-015 0.75 Fuel filter extra, replacing
234-010 6.00 Fuel tank, replacing
234-091 1.00 Fuel shut-off valve, changing
236-044 1.00 Injection timing, checking
236-076 4.00 Injection pump, one changing
237-004 2.50 Injector, replacing one
237-018 1.00 Delivery pipe, replacing one

7/11/2012 Volvo Construction Equipment 157


G740B
Op.no. time (h) Notes

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 0.75 Exhaust manifold, replacing gasket
252-020 4.00 Silencer, replacing
252-022 2.00 Exhaust pipe, changing pipe between silencer and
turbocharger
255-071 4.00 Turbocharger, replacing
255-072 3.00 Turbocharger, installing

6 STEERING
62 STEERING AXLE
622-011 2.00 Steering spindle, changing
622-031 2.00 Steering spindle, changing king pin bearing
622-041 2.00 Steering spindle, changing king pin bearing seal
622-051 1.00 Preparation and Wheel Removal
622-052 2.00 Wheel Hub - Removal
622-053 2.00 Steering Cylinder - Removal
622-054 1.00 Drag link, removing
622-055 1.50 Pivot block, removing and disassembling
622-056 3.00 Spindle - Removal and Disassembly
622-057 2.00 Wheel Lean Cylinder - Removal
622-058 2.50 Tie bar, removing
622-059 2.00 Knuckle, removing
622-060 2.00 Front axle frame, removing
622-061 2.00 Front axle frame, installing
622-062 2.00 Knuckle, installing
622-063 1.50 Tie bar, installing
622-064 1.00 Wheel Lean Cylinder - Installation
622-065 1.00 Spindle - Assembly and Installation
622-066 1.50 Pivot Block - Assembly and Installation
622-067 1.50 Drag link, installing
622-068 1.00 Steering Cylinder - Installation
622-069 1.00 Wheel Hub - Installation
622-070 0.50 Wheel - Installation
622-071 0.50 Toe - in, adjustment
622-072 1.50 Front Axle Pivot Pin Bearings - Disassembly
622-073 1.50 Front Axle Pivot Pin Bearings - Assembly
622-074 1.50 King Pin Bearings and Spindle Thrust Bearing -
Disassembly
622-075 1.50 King Pin Bearings and Spindle Thrust Bearing -
Assembly
622-078 0.50 Pivot Block Adjustments

158 Volvo Construction Equipment 7/11/2012


G740B
Op.no. time (h) Notes

622-081 10.00 Front axle, overhaul

64 STEERING
645-004 1.00 Steering cylinder, removing
645-005 1.00 Steering cylinder, installing
645-021 1.50 Valve block, replacing
645-031 1.00 Steering control unit, removing
645-032 1.00 Steering Control Unit - Disassembly
645-033 0.50 Steering Control Unit - Cleaning and Inspection
645-034 1.50 Steering Control Unit - Assembly
645-052 1.50 Steering cylinder removed, reconditioning excl
replacing bearings
645-077 2.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
647-089 0.50 Secondary steering relief valve, adjusting
647-992 2.00 Secondary steering system, installing new
648-001 1.00 Wheel lean cylinder, removing
648-002 1.00 Wheel lean cylinder, installing

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-036 4.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one
771-002 0.50 Front wheel, removal
771-003 0.50 Front wheel, installation
771-004 0.50 Rear wheel, removal
771-005 0.50 Rear wheel, installation
771-006 0.50 Tyres, checking pressure
771-007 1.00 Wheel, installing

7/11/2012 Volvo Construction Equipment 159


160 Volvo Construction Equipment 7/11/2012
G746B
Op.no. time (h) Notes

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 8.00 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 8.00 Engine, installing
211-002 10.00 Cylinder head, replacing gasket
213-010 2.50 Cylinder liner and piston, replacing one
214-005 0.75 Valve seat insert cylinder head removed, replacing
each
214-021 0.50 Valve cover, fitting new gasket each
214-030 1.50 Valves, decarbonizing and grinding
215-002 2.00 Timing gear cover, fitting new gasket in machine
216-014 3.50 Crankshaft, replacing front oil seal
216-018 3.50 Crankshaft, replacing rear oil seal
216-034 0.50 Big- end bearing shells, replacing in machine
216-041 5.00 Flywheel housing with power take-off, removing
216-042 5.50 Flywheel housing with power take-off, installing
216-046 2.50 Vibration damper, removal
217-003 4.00 Oil sump, replacing
217-004 2.00 Oil sump gasket, changing
218-001 1.00 Rubber cushion, replacing
218-003 2.50 Engine mount, right rear, changing
218-004 2.00 Engine mount, left rear, changing
218-005 2.50 Engine mount, right front, changing
218-006 2.00 Engine mount, left front, changing

22 LUBRICATING SYSTEM
222-011 0.50 Oil filter, replacing
223-006 6.00 Oil cooler, replacing

23 FUEL SYSTEM
233-002 2.00 Feed pump, replacing
233-011 1.00 Fuel pump, removing
233-012 1.50 Fuel pump, installing
233-014 0.75 Fuel filters, replacing
233-015 0.75 Fuel filter extra, replacing
234-010 6.00 Fuel tank, replacing
234-091 1.00 Fuel shut-off valve, changing
236-044 1.00 Injection timing, checking
236-076 4.00 Injection pump, one changing
237-004 2.50 Injector, replacing one
237-018 1.00 Delivery pipe, replacing one

7/11/2012 Volvo Construction Equipment 161


G746B
Op.no. time (h) Notes

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 0.75 Exhaust manifold, replacing gasket
252-020 4.00 Silencer, replacing
252-022 2.00 Exhaust pipe, changing pipe between silencer and
turbocharger
255-071 4.00 Turbocharger, replacing
255-072 3.00 Turbocharger, installing

6 STEERING
62 STEERING AXLE
622-011 2.00 Steering spindle, changing
622-031 2.00 Steering spindle, changing king pin bearing
622-041 2.00 Steering spindle, changing king pin bearing seal
622-051 1.00 Preparation and Wheel Removal
622-052 2.00 Wheel Hub - Removal
622-053 2.00 Steering Cylinder - Removal
622-054 1.00 Drag link, removing
622-055 1.50 Pivot block, removing and disassembling
622-056 3.00 Spindle - Removal and Disassembly
622-057 2.00 Wheel Lean Cylinder - Removal
622-058 2.50 Tie bar, removing
622-059 2.00 Knuckle, removing
622-060 2.00 Front axle frame, removing
622-061 2.00 Front axle frame, installing
622-062 2.00 Knuckle, installing
622-063 1.50 Tie bar, installing
622-064 1.00 Wheel Lean Cylinder - Installation
622-065 1.00 Spindle - Assembly and Installation
622-066 1.50 Pivot Block - Assembly and Installation
622-067 1.50 Drag link, installing
622-068 1.00 Steering Cylinder - Installation
622-069 1.00 Wheel Hub - Installation
622-070 0.50 Wheel - Installation
622-071 0.50 Toe - in, adjustment
622-072 1.50 Front Axle Pivot Pin Bearings - Disassembly
622-073 1.50 Front Axle Pivot Pin Bearings - Assembly
622-074 1.50 King Pin Bearings and Spindle Thrust Bearing -
Disassembly
622-075 1.50 King Pin Bearings and Spindle Thrust Bearing -
Assembly
622-078 0.50 Pivot Block Adjustments

162 Volvo Construction Equipment 7/11/2012


G746B
Op.no. time (h) Notes

622-081 10.00 Front axle, overhaul

64 STEERING
645-004 1.00 Steering cylinder, removing
645-005 1.00 Steering cylinder, installing
645-021 1.50 Valve block, replacing
645-031 1.00 Steering control unit, removing
645-032 1.00 Steering Control Unit - Disassembly
645-033 0.50 Steering Control Unit - Cleaning and Inspection
645-034 1.50 Steering Control Unit - Assembly
645-052 1.50 Steering cylinder removed, reconditioning excl
replacing bearings
645-077 2.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
647-089 0.50 Secondary steering relief valve, adjusting
647-992 2.00 Secondary steering system, installing new
648-001 1.00 Wheel lean cylinder, removing
648-002 1.00 Wheel lean cylinder, installing

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-036 4.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one
771-002 0.50 Front wheel, removal
771-003 0.50 Front wheel, installation
771-004 0.50 Rear wheel, removal
771-005 0.50 Rear wheel, installation
771-006 0.50 Tyres, checking pressure
771-007 1.00 Wheel, installing

7/11/2012 Volvo Construction Equipment 163


164 Volvo Construction Equipment 7/11/2012
G780B
Op.no. time (h) Notes

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 8.00 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 8.00 Engine, installing
211-002 10.00 Cylinder head, replacing gasket
213-010 2.50 Cylinder liner and piston, replacing one
214-005 0.75 Valve seat insert cylinder head removed, replacing
each
214-021 0.50 Valve cover, fitting new gasket each
214-030 1.50 Valves, decarbonizing and grinding
215-002 2.00 Timing gear cover, fitting new gasket in machine
216-014 3.50 Crankshaft, replacing front oil seal
216-018 3.50 Crankshaft, replacing rear oil seal
216-034 0.50 Big- end bearing shells, replacing in machine
216-041 5.00 Flywheel housing with power take-off, removing
216-042 5.50 Flywheel housing with power take-off, installing
216-046 2.50 Vibration damper, removal
217-003 4.00 Oil sump, replacing
217-004 2.00 Oil sump gasket, changing
218-001 1.00 Rubber cushion, replacing
218-003 2.50 Engine mount, right rear, changing
218-004 2.00 Engine mount, left rear, changing
218-005 2.50 Engine mount, right front, changing
218-006 2.00 Engine mount, left front, changing

22 LUBRICATING SYSTEM
222-011 0.50 Oil filter, replacing
223-006 6.00 Oil cooler, replacing

23 FUEL SYSTEM
233-002 2.00 Feed pump, replacing
233-011 1.00 Fuel pump, removing
233-012 1.50 Fuel pump, installing
233-014 0.75 Fuel filters, replacing
233-015 0.75 Fuel filter extra, replacing
234-010 6.00 Fuel tank, replacing
234-091 1.00 Fuel shut-off valve, changing
236-044 1.00 Injection timing, checking
236-076 4.00 Injection pump, one changing
237-004 2.50 Injector, replacing one
237-018 1.00 Delivery pipe, replacing one

7/11/2012 Volvo Construction Equipment 165


G780B
Op.no. time (h) Notes

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 0.75 Exhaust manifold, replacing gasket
252-020 4.00 Silencer, replacing
252-022 2.00 Exhaust pipe, changing pipe between silencer and
turbocharger
255-071 4.00 Turbocharger, replacing
255-072 3.00 Turbocharger, installing

6 STEERING
62 STEERING AXLE
622-011 2.00 Steering spindle, changing
622-031 2.00 Steering spindle, changing king pin bearing
622-041 2.00 Steering spindle, changing king pin bearing seal
622-051 1.00 Preparation and Wheel Removal
622-052 2.00 Wheel Hub - Removal
622-053 2.00 Steering Cylinder - Removal
622-054 1.00 Drag link, removing
622-055 1.50 Pivot block, removing and disassembling
622-056 3.00 Spindle - Removal and Disassembly
622-057 2.00 Wheel Lean Cylinder - Removal
622-058 2.50 Tie bar, removing
622-059 2.00 Knuckle, removing
622-060 2.00 Front axle frame, removing
622-061 2.00 Front axle frame, installing
622-062 2.00 Knuckle, installing
622-063 1.50 Tie bar, installing
622-064 1.00 Wheel Lean Cylinder - Installation
622-065 1.00 Spindle - Assembly and Installation
622-066 1.50 Pivot Block - Assembly and Installation
622-067 1.50 Drag link, installing
622-068 1.00 Steering Cylinder - Installation
622-069 1.00 Wheel Hub - Installation
622-070 0.50 Wheel - Installation
622-071 0.50 Toe - in, adjustment
622-072 1.50 Front Axle Pivot Pin Bearings - Disassembly
622-073 1.50 Front Axle Pivot Pin Bearings - Assembly
622-074 1.50 King Pin Bearings and Spindle Thrust Bearing -
Disassembly
622-075 1.50 King Pin Bearings and Spindle Thrust Bearing -
Assembly
622-078 0.50 Pivot Block Adjustments

166 Volvo Construction Equipment 7/11/2012


G780B
Op.no. time (h) Notes

622-081 10.00 Front axle, overhaul

64 STEERING
645-004 1.00 Steering cylinder, removing
645-005 1.00 Steering cylinder, installing
645-021 1.50 Valve block, replacing
645-031 1.00 Steering control unit, removing
645-032 1.00 Steering Control Unit - Disassembly
645-033 0.50 Steering Control Unit - Cleaning and Inspection
645-034 1.50 Steering Control Unit - Assembly
645-052 1.50 Steering cylinder removed, reconditioning excl
replacing bearings
645-077 2.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
647-089 0.50 Secondary steering relief valve, adjusting
647-992 2.00 Secondary steering system, installing new
648-001 1.00 Wheel lean cylinder, removing
648-002 1.00 Wheel lean cylinder, installing

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-036 4.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one
771-002 0.50 Front wheel, removal
771-003 0.50 Front wheel, installation
771-004 0.50 Rear wheel, removal
771-005 0.50 Rear wheel, installation
771-006 0.50 Tyres, checking pressure
771-007 1.00 Wheel, installing

7/11/2012 Volvo Construction Equipment 167


168 Volvo Construction Equipment 7/11/2012
L110E
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
172-002 3.50 Warranty inspection 100 hours
172-004 9.00 Warranty inspection 1000 hours
173-002 0.40 Maintenance service, daily
173-004 1.00 Maintenance service, every 50 hours
173-007 1.50 Maintenance service, every 250 hours
173-010 4.50 Maintenance service, every 500 hours
173-012 9.50 Maintenance service, every 1000 hours 1001 - 3499
60001 - 69999
70201 - 79999
173-014 11.00 Maintenance service, every 2000 hours 1001 - 2165
60001 - 69999
70201 - 79999
173-016 10.00 Maintenance service, every 3000 hours 1001 - 3499
60001 - 69999
70201 - 79999
173-018 11.00 Maintenance service, every 4000 hours 1001 - 2165
60001 - 69999
70201 - 79999
173-022 0.50 Maintenance service, every 6000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 3.00 Compression test 2201 - 3499
61001 - 69999
70401 - 79999
210-070 6.00 Engine, removing 2201 - 3499
61001 - 69999
70401 - 79999
210-072 8.00 Engine, installing
210-090 0.30 Camshaft and flywheel signals, checking with 1001 - 2165
VCADS Pro and oscilloscope 60001 - 60631
70201 - 70257
210-090 0.30 Camshaft and flywheel signals, checking with 2201 - 3499
VCADS Pro and oscilloscope 61001 - 69999
70401 - 79999
214-012 4.50 Valves, adjusting 2202 - 3499
61001 - 69999
70401 - 79999

7/11/2012 Volvo Construction Equipment 169


L110E
Op.no. time (h) Notes

216-014 2.00 Crankshaft, replacing front oil seal 1001 - 2165


60001 - 60999
70201 - 70201
216-014 2.00 Crankshaft, replacing front oil seal 2202 - 3499
61001 - 69999
70401 - 79999
217-002 4.00 Sump gasket, replacing incl cleaning oil strainer
218-001 3.00 Rubber cushion, replacing

22 LUBRICATING SYSTEM
221-021 1.00 Lubrication oil pressure, check

23 FUEL SYSTEM
233-001 0.40 Fuel system, bleeding 1001 - 2165
60001 - 60999
70201 - 70399
233-001 0.70 Fuel system, bleeding 2202 - 3499
61001 - 69999
70401 - 79999
233-004 0.80 Feed pump, checking feed pressure 2202 - 3499
60001 - 69999
70201 - 79999
233-020 0.10 Fuel filter, checking
236-002 0.50 Stall speed, checking
236-076 1.25 Injection pump, one changing
236-077 1.00 Injection pump, one removing and refitting
236-078 0.25 Injection pump, each additional removing and
refitting
237-004 2.00 Injector, replacing one
237-030 1.00 High pressure fuel pump, checking 2201 - 3499
61001 - 69999
70401 - 79999
237-032 2.00 High pressure fuel pump, replacing 2201 - 3499
61001 - 69999
70401 - 79999
237-033 1.25 Fuel control valve (FCV), replacing
237-034 0.30 Pressure relief valve (PRV), replacing 2201 - 3499
61001 - 69999
70401 - 79999
237-035 0.30 Fuel rail pressure sensor, replacing 2201 - 3499
61001 - 69999
70401 - 79999
237-036 0.70 Pressure relief valve (PRV), checking 2201 - 3499
61001 - 69999
70401 - 79999
237-038 0.70 Fuel control valve (FCV), checking 2201 - 3499
61001 - 69999
70401 - 79999

170 Volvo Construction Equipment 7/11/2012


L110E
Op.no. time (h) Notes

25 INLET SYSTEM; EXHAUST SYSTEM


252-021 0.50 Exhaust pipe, flexible tube, replacing
255-002 0.80 Turbocharger, inspection

26 COOLING SYSTEM
261-011 2.50 Radiator, removing 2002 - 3499
61001 - 69999
70401 - 79999
261-013 4.00 Radiator, installing 2202 - 3499
61001 - 69999
70401 - 79999
263-010 0.40 Pump 3 (P3) standby pressure, checking
263-016 0.50 Maximum fan speed, checking
263-051 1.50 Cooling fan hydraulics, funktion check
263-062 2.50 Cooling fan motor, changing 2201 - 3499
61001 - 69999
70401 - 79999

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
36 OTHER ELECTRICAL EQUIPMENT
367-052 1.00 V-ECU, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
390-902 2.00 CareTrack, installing new

4 POWER TRANSMISSION
41 CLUTCH; TORQUE CONVERTER
414-003 2.00 Converter, replacing (engine removed)

42 TRANSMISSION, HYDRAULIC CONTROL


421-002 0.70 Transmission, check oil pressure 70225 - 79999
60270 - 69999
1511 - 3499
421-002 0.70 Transmission, check oil pressure 70201 - 70224
60001 - 60269
1001 - 1510
421-008 3.00 Gear selector valve, replacing
421-009 1.00 Gear selector valve removed, reconditioning
421-051 0.25 Transmission, resistance measuring of solenoides
421-068 12.00 Transmission, removing (upwards)
421-069 14.00 Transmission, installing (from above)

7/11/2012 Volvo Construction Equipment 171


L110E
Op.no. time (h) Notes

421-071 32.00 Transmission removed, reconditioning

46 FRONT AXLE; REAR AXLE


461-002 1.75 Axle, removing
461-003 2.00 Axle, installing
461-005 3.50 Drive shaft, replacing one side
463-002 4.50 Axle, removing
463-003 4.50 Axle, installing
463-043 4.00 Hub, replacing seal

5 BRAKE
51 WHEEL BRAKE
517-001 0.50 Brake linings, checking wear
517-004 4.50 Brake disc, replacing both sides

52 HYDRAULIC BRAKE SYSTEM


520-001 0.75 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-009 0.50 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure

6 STEERING
64 STEERING
645-006 3.00 Steering cylinder, replacing
645-028 0.50 Steering system, checking and adjusting working
pressure
645-081 1.50 Steering valve removed, reconditioning
645-082 1.50 Steering valve, replacing

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed
660-005 1.25 CDC, checking lever signals

172 Volvo Construction Equipment 7/11/2012


L110E
Op.no. time (h) Notes

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
716-001 1.75 Counterweight, removing
716-002 1.75 Counterweight, fitting

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.75 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing
818-020 1.75 Viscous cab suspension, changing one unit

82 ENGINE HOOD; MUDGUARD; FOOT STEP


821-001 0.90 Engine hood, removing 2202 - 3499
66001 - 69999
71401 - 79999
821-002 2.00 Engine hood, installing 2202 - 3499
61001 - 69999
70401 - 79999

87 AIR CONDITIONING UNIT


873-004 2.00 Heater core, replacing
873-006 1.25 Fan motor, replacing
873-008 1.00 Heat control valve, replacing
874-003 0.75 Cooling unit, performance test
874-059 1.25 Evaporator, cleaning

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 3.00 Hydraulic system, bleeding

91 WORKING HYDRAULICS; SERVO HYDRAULICS


911-040 0.25 Hydraulic oil tank, vacuum-pumping, connecting
and disconnecting pump
912-019 0.50 Shock valve removed, checking
912-021 0.30 Shock valve, tilt function, checking
912-023 0.70 Shock valve lift function, checking

7/11/2012 Volvo Construction Equipment 173


L110E
Op.no. time (h) Notes

913-003 1.25 Hydraulic pump, checking and adjusting standby


pressure
913-004 1.00 Hydraulic pump, checking and adjusting max
working pressure
913-005 0.50 Hydraulic pump, flow control
913-006 0.75 LS (load sense) pressure, checking
914-055 0.50 Servo pressure, checking and adjusting
914-058 3.50 Servo valve, replacing
916-003 1.00 Boom suspension accumulator, reconditioning
916-006 0.50 Boom suspension system, pressure reduction,
safety valve, checking and adjusting
916-019 0.25 3rd/4th hydraulic function, pressure check
916-070 0.10 Boom suspension system, hydraulic oil pressure
in accumulators, depressurizing
916-071 2.50 Boom suspension system, changing accumulator
916-074 0.30 Boom suspension system, test drive with load

94 UNIT, LOAD HANDLING


945-002 3.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 4.00 Lift cylinder, repacking in machine
945-006 3.00 Lift cylinder removed, repacking
945-008 3.00 Tilt cylinder, replacing
945-009 5.00 Tilt cylinder, repacking in machine
945-010 3.50 Tilt cylinder removed, repacking
945-011 2.00 Implemental attachment, replacing hydraulic
cylinder
945-016 5.00 Lift frame, replacing bearing in upper mounting "O"
945-054 1.75 Implement attachment, replacing
945-056 1.00 Implement attachment, repacking removed
hydraulic cylinder
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 2.00 T-link, lower, replacing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.00 Tilt arm, replacing bearing "GDF"
945-069 3.00 Tilt arm, replacing "GDF"

174 Volvo Construction Equipment 7/11/2012


L120D
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 4.50 Warranty inspection 100 hours
172-004 12.00 Warranty inspection 1000 hours
173-007 1.25 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 7.50 Maintenance service, every 1000 hours
173-014 12.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 1.50 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter
173-075 3.00 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 7.50 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 8.50 Engine, installing
211-002 8.00 Cylinder head, replacing gasket
211-018 10.00 Cylinder heads all, replacing gaskets
211-068 4.00 Cylinder heads all removed, decarbonizing and
grinding in valves
211-071 0.50 Cylinder head removed, pressure testing each
211-080 4.50 Cylinder heads all, removing
211-082 7.00 Cylinder heads all, fitting
212-007 4.00 Cylinder block, liners removed, milling of all liner
locations
212-011 0.50 Cylinder, cylinder heads removed, measuring
wear in all cylinders
213-010 14.00 Cylinder liner and piston, replacing one
213-018 24.00 Cylinder liners and pistons, replacing all
214-012 1.50 Valves, adjusting
214-027 0.50 Inspection cover, fitting new gasket
214-093 0.50 Rocker arm mechanism removed, reconditioning
215-002 6.00 Timing gear cover, fitting new gasket in machine
215-030 8.00 Timing gear, replacing in machine
215-032 9.00 Timing gear case, fitting new gasket in machine

7/11/2012 Volvo Construction Equipment 175


L120D
Op.no. time (h) Notes

215-040 2.00 Injection pump, drive shaft, replacing seal


216-014 3.00 Crankshaft, replacing front oil seal
216-018 13.00 Crankshaft, replacing rear oil seal
217-002 5.00 Sump gasket, replacing incl cleaning oil strainer

22 LUBRICATING SYSTEM
221-006 0.25 Oil pressure relief valve, replacing
221-014 6.00 Oil pump, replacing
223-006 3.00 Oil cooler, replacing

23 FUEL SYSTEM
233-001 0.25 Fuel system, bleeding
233-002 0.75 Feed pump, replacing
233-004 0.50 Feed pump, checking feed pressure
233-014 0.50 Fuel filters, replacing
233-015 0.25 Fuel filter extra, replacing
234-010 4.00 Fuel tank, replacing
236-001 0.50 Idling speed, checking and adjusting
236-002 0.25 Stall speed, checking
236-030 1.50 Injection timing, checking and adjusting
236-044 1.00 Injection timing, checking
236-073 2.00 Injection pump, replacing incl setting injection
timing
237-002 1.50 Injectors, replacing all
237-004 0.75 Injector, replacing one
237-007 0.25 Overflow valve, replacing
237-016 1.50 Injectors, replacing copper sleeve in machine
237-018 0.50 Delivery pipe, replacing one
237-020 0.50 Pressure equalizer, replacing
237-080 2.00 Injectors removed, reconditioning all

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 2.00 Exhaust manifold, replacing gasket
252-019 1.25 Silencer, rubber cuchion replacing
252-020 1.50 Silencer, replacing
252-021 0.50 Exhaust pipe, flexible tube, replacing
255-071 1.00 Turbocharger, replacing
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 2.00 Preheating coil, replacing

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 3.00 Radiator, replacing

176 Volvo Construction Equipment 7/11/2012


L120D
Op.no. time (h) Notes

261-012 1.00 Radiator hose upper, replacing


261-014 1.00 Radiator hoses lower, replacing
261-018 1.00 Expansion tank, replacing
262-002 1.50 Coolant pump, replacing
262-071 1.50 Coolant pump removed, reconditioning
262-098 1.00 Thermostat, replacing
263-012 0.75 Fan belt and/or alternator belt, replacing
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts

27 ENGINE CONTROL
273-021 0.75 Stop magnet, replacing
273-023 0.50 Electrical engine shut down, check and adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 1.00 Battery charging capacity, checking
311-003 0.50 Main switch, replacing
311-006 0.50 Earth lead to battery, replacing
311-008 1.00 Starter motor lead to battery, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 0.75 Starter motor, replacing

35 LIGHTING
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor

7/11/2012 Volvo Construction Equipment 177


L120D
Op.no. time (h) Notes

363-004 0.25 Windscreen flusher pump, replacing


364-004 0.50 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

37 CABLE; FUSE; RELAY


372-031 1.00 Relay CU201, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 0.50 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-011 1.00 Fuel level sender, replacing
386-035 0.75 Induction sensor (lifting cylinder) replacing
386-036 1.00 Induction sensor (tilt cylinder) replacing
387-004 0.50 Transmission temperature gauge, replacing
387-005 0.50 Information display, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
420-012 2.00 Oil draining pipe, replacing
421-002 0.75 Transmission, check oil pressure
421-008 3.00 Gear selector valve, replacing
421-009 1.75 Gear selector valve removed, reconditioning
421-018 17.00 Converter, replacing
421-023 1.00 Lubrication and converter pressure valve,
replacing
421-047 0.75 Gear selector, replacing
421-048 0.75 Gear selector valve, replacing one solenoid
421-068 9.00 Transmission, removing (upwards)
421-069 10.00 Transmission, installing (from above)
421-071 32.00 Transmission removed, reconditioning

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-004 1.50 Propeller shaft, rear, replacing

178 Volvo Construction Equipment 7/11/2012


L120D
Op.no. time (h) Notes

451-007 1.50 Propeller shaft, in frame joint, replacing


451-010 2.00 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning

46 FRONT AXLE; REAR AXLE


460-001 0.75 Axle suspension, measuring axial and radial
clearanse
460-002 1.00 Axle suspension, adjusting axial clearance
461-001 4.00 Axle, replacing
461-011 5.00 Centre gear , removing and fitting
461-012 6.00 Centre gear removed, reconditioning
461-014 2.00 Pinion front, fitting new gasket
461-042 6.00 Hub reduction gear, reconditioning one side
461-043 4.00 Hub, replacing seal
461-052 0.25 Differential lock front, repacking excl adjusting
461-053 1.00 Differential lock, adjusting engagement
463-001 5.00 Axle, replacing
463-005 2.00 Drive shaft, replacing one side
463-012 6.00 Centre gear removed, reconditioning
463-014 2.00 Pinion rear, fitting new gasket
463-042 6.00 Hub reduction gear, reconditioning one side
463-043 4.00 Hub, replacing seal

49 MISCELLANEOUS
491-006 1.50 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
517-001 0.50 Brake linings, checking wear
517-004 4.00 Brake disc, replacing both sides
517-050 3.00 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-004 0.50 Brake system, adjusting unloading pressure
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-008 1.75 Foot brake valve, replacing
525-009 1.25 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure

7/11/2012 Volvo Construction Equipment 179


L120D
Op.no. time (h) Notes

527-002 0.50 Accumulator, replacing


527-004 2.00 Hydraulic pump, replacing

55 PARKING BRAKE
550-006 4.50 Parking brake, replacing discs and seals
550-008 1.00 Parking brake, replacing control valve

6 STEERING
64 STEERING
641-021 1.50 Adjustable steering column, replacing
645-003 0.25 Steering system working pressure, checking
645-006 1.75 Steering cylinder, replacing
645-010 2.00 Hydraulic pump, replacing
645-015 0.50 Steering system, checking and adjusting standby
pressure
645-020 1.75 Steering system, checking and adjusting shock
and anti-cavitation-valve
645-021 1.50 Valve block, replacing
645-028 0.75 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 3.00 Steering cylinder, repacking in machine
645-073 2.00 Hydraulic pump removed, reconditioning
645-077 1.75 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 12.00 Frame joint, replacing bearings

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing

180 Volvo Construction Equipment 7/11/2012


L120D
Op.no. time (h) Notes

818-015 1.75 Cab suspension, rubber element replacing

82 ENGINE HOOD; MUDGUARD; FOOT STEP


823-001 0.25 Gas spring (radiator casing), replacing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 4.50 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-006 1.25 Operators seat, air suspensioned, control,
replacing
852-007 1.25 Operators seat (air suspensioned), backrest
replacing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 1.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 0.50 Belt, changing
874-010 4.00 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 0.75 Thermostat, replacing
874-015 0.75 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-017 1.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

7/11/2012 Volvo Construction Equipment 181


L120D
Op.no. time (h) Notes

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-005 2.00 Pump suction hose and pipe, replacing
911-011 2.00 Oil cooler, replacing
911-038 5.00 Hydraulic oil tank, replacing
912-001 2.00 Control valve, replacing
912-002 4.00 Control valve removed, reconditioning
912-004 0.75 Control valve, low pressure valve, replacing
912-009 0.50 Shock valve, tilt function, checking and adjusting
913-002 1.00 Hydraulic pump, checking and adjusting unloading
pressure
913-004 1.00 Hydraulic pump, checking and adjusting max
working pressure
913-010 5.00 Hydraulic pump, replacing
913-011 1.75 Hydraulic pump removed, reconditioning
914-054 1.75 Servo valve, adjusting control
914-055 0.50 Servo pressure, checking and adjusting
914-057 0.50 Servo pressure, check
914-058 3.00 Servo valve, replacing
914-060 2.00 Servo pump, replacing
914-062 0.50 Pressure limiting valve, replacing
914-063 0.50 Servo pressure, checking at the spool in control
valve
914-075 2.00 Servo valve removed, reconditioning
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 0.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-004 1.50 Boom suspension system, checking closing
pressure
916-005 1.00 Boom suspension system, checking opening
pressure
916-071 2.50 Boom suspension system, changing accumulator
916-073 2.50 Boom suspension system, changing valve

94 UNIT, LOAD HANDLING


945-002 3.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 4.00 Lift cylinder, repacking in machine

182 Volvo Construction Equipment 7/11/2012


L120D
Op.no. time (h) Notes

945-006 3.00 Lift cylinder removed, repacking


945-008 3.00 Tilt cylinder, replacing
945-009 5.00 Tilt cylinder, repacking in machine
945-010 3.50 Tilt cylinder removed, repacking
945-011 2.00 Implemental attachment, replacing hydraulic
cylinder
945-016 5.00 Lift frame, replacing bearing in upper mounting "O"
945-054 1.75 Implement attachment, replacing
945-056 1.00 Implement attachment, repacking removed
hydraulic cylinder
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 2.00 T-link, lower, replacing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.00 Tilt arm, replacing bearing "GDF"
945-069 3.00 Tilt arm, replacing "GDF"

7/11/2012 Volvo Construction Equipment 183


184 Volvo Construction Equipment 7/11/2012
L120E
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
172-002 3.50 Warranty inspection 100 hours
172-004 9.00 Warranty inspection 1000 hours
173-002 0.40 Maintenance service, daily
173-004 1.00 Maintenance service, every 50 hours
173-007 1.50 Maintenance service, every 250 hours
173-010 4.50 Maintenance service, every 500 hours
173-012 9.50 Maintenance service, every 1000 hours 16001 - 19668
64001 - 65999
70701 - 71399
173-014 11.00 Maintenance service, every 2000 hours 16001 - 19668
64001 - 64001
70701 - 71399
173-016 10.00 Maintenance service, every 3000 hours
173-018 11.00 Maintenance service, every 4000 hours 16001 - 19668
70701 - 79999
64001 - 69999
173-022 0.50 Maintenance service, every 6000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 1.50 Axles, changing oil

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 3.00 Compression test 19801 - 22999
71401 - 79999
66001 - 69999
210-070 6.00 Engine, removing 19801 - 22999
71401 - 79999
66001 - 69999
210-072 8.00 Engine, installing
210-090 0.30 Camshaft and flywheel signals, checking with 16001 - 19668
VCADS Pro and oscilloscope 70701 - 71050
64001 - 64958
210-090 0.30 Camshaft and flywheel signals, checking with 19804 - 22999
VCADS Pro and oscilloscope 71401 - 79999
66001 - 69999
214-012 4.50 Valves, adjusting 19804 - 22999
71401 - 79999
66001 - 69999
214-036 1.50 Valve covers, fitting new gasket

7/11/2012 Volvo Construction Equipment 185


L120E
Op.no. time (h) Notes

216-014 2.00 Crankshaft, replacing front oil seal 16001 - 19668


70701 - 71399
64001 - 65999
216-014 2.00 Crankshaft, replacing front oil seal 19804 - 22999
71401 - 79999
66001 - 69999
216-018 16.00 Crankshaft, replacing rear oil seal
217-002 4.00 Sump gasket, replacing incl cleaning oil strainer
218-001 3.00 Rubber cushion, replacing

22 LUBRICATING SYSTEM
221-021 1.00 Lubrication oil pressure, check

23 FUEL SYSTEM
233-001 0.40 Fuel system, bleeding 16001 - 19668
70701 - 71399
64001 - 65999
233-001 0.70 Fuel system, bleeding 19804 - 22999
71401 - 79999
66001 - 69999
233-002 0.50 Feed pump, replacing
233-004 0.80 Feed pump, checking feed pressure 19804 - 22999
71401 - 79999
66001 - 69999
233-014 0.50 Fuel filters, replacing
233-020 0.10 Fuel filter, checking
236-002 0.50 Stall speed, checking
237-004 2.00 Injector, replacing one
237-018 1.25 Delivery pipe, replacing one
237-030 1.00 High pressure fuel pump, checking 19801 - 22999
71401 - 79999
66001 - 69999
237-032 2.00 High pressure fuel pump, replacing 19801 - 22999
71401 - 79999
66001 - 69999
237-033 1.25 Fuel control valve (FCV), replacing
237-034 0.30 Pressure relief valve (PRV), replacing 19804 - 22999
71401 - 79999
66001 - 69999
237-035 0.30 Fuel rail pressure sensor, replacing 19801 - 22999
71401 - 79999
66001 - 69999
237-036 0.70 Pressure relief valve (PRV), checking 19801 - 22999
71401 - 79999
66001 - 69999
237-038 0.70 Fuel control valve (FCV), checking 19801 - 22999
71401 - 79999
66001 - 69999

186 Volvo Construction Equipment 7/11/2012


L120E
Op.no. time (h) Notes

25 INLET SYSTEM; EXHAUST SYSTEM


252-021 0.50 Exhaust pipe, flexible tube, replacing
255-002 0.80 Turbocharger, inspection
258-002 3.00 Intercooler, replacing

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-011 2.50 Radiator, removing 19804 - 22999
70701 - 79999
64002 - 69999
261-013 4.00 Radiator, installing 19804 - 22999
71401 - 79999
66001 - 69999
262-002 2.00 Coolant pump, replacing
262-098 1.00 Thermostat, replacing
263-010 0.40 Pump 3 (P3) standby pressure, checking
263-012 0.50 Fan belt and/or alternator belt, replacing
263-016 0.50 Maximum fan speed, checking
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts
263-051 1.50 Cooling fan hydraulics, funktion check
263-062 2.50 Cooling fan motor, changing 19804 - 22999
71401 - 79999
66001 - 69999

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
33 STARTING SYSTEM
331-018 0.75 Starter motor, replacing

36 OTHER ELECTRICAL EQUIPMENT


367-052 1.00 V-ECU, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
390-902 2.00 CareTrack, installing new

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 0.70 Transmission, check oil pressure 64544 - 69999
70856 - 79999
18192 - 22999
421-002 0.70 Transmission, check oil pressure 64001 - 64543

7/11/2012 Volvo Construction Equipment 187


L120E
Op.no. time (h) Notes

70701 - 70855
16001 - 18191
421-008 3.00 Gear selector valve, replacing
421-009 1.00 Gear selector valve removed, reconditioning
421-051 0.25 Transmission, resistance measuring of solenoides
421-068 12.00 Transmission, removing (upwards)
421-069 14.00 Transmission, installing (from above)
421-071 32.00 Transmission removed, reconditioning

45 PROPELLER SHAFT
451-004 1.00 Propeller shaft, rear, replacing
451-010 1.00 Propeller shaft, front, replacing

46 FRONT AXLE; REAR AXLE


460-001 1.00 Axle suspension, measuring axial and radial
clearanse
461-002 1.75 Axle, removing
461-003 2.00 Axle, installing
461-005 3.50 Drive shaft, replacing one side
463-002 4.50 Axle, removing
463-003 4.50 Axle, installing
463-043 4.00 Hub, replacing seal

5 BRAKE
51 WHEEL BRAKE
517-001 0.50 Brake linings, checking wear
517-004 4.50 Brake disc, replacing both sides

52 HYDRAULIC BRAKE SYSTEM


520-001 0.75 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-009 0.50 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure

6 STEERING
64 STEERING
645-006 3.00 Steering cylinder, replacing
645-028 0.50 Steering system, checking and adjusting working
pressure

188 Volvo Construction Equipment 7/11/2012


L120E
Op.no. time (h) Notes

645-081 1.50 Steering valve removed, reconditioning


645-082 1.50 Steering valve, replacing

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed
660-005 1.25 CDC, checking lever signals

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
716-001 1.75 Counterweight, removing
716-002 1.75 Counterweight, fitting

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.75 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing
818-020 1.75 Viscous cab suspension, changing one unit

82 ENGINE HOOD; MUDGUARD; FOOT STEP


821-001 0.90 Engine hood, removing 19804 - 22999
66001 - 69999
71401 - 79999
821-002 2.00 Engine hood, installing 19804 - 22999
66001 - 69999
71401 - 79999

87 AIR CONDITIONING UNIT


873-004 2.00 Heater core, replacing
873-006 1.25 Fan motor, replacing
873-008 1.00 Heat control valve, replacing
874-007 0.25 Belt, changing

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 3.00 Hydraulic system, bleeding

7/11/2012 Volvo Construction Equipment 189


L120E
Op.no. time (h) Notes

91 WORKING HYDRAULICS; SERVO HYDRAULICS


911-040 0.25 Hydraulic oil tank, vacuum-pumping, connecting
and disconnecting pump
912-019 0.50 Shock valve removed, checking
912-021 0.30 Shock valve, tilt function, checking
912-023 0.70 Shock valve lift function, checking
913-003 1.25 Hydraulic pump, checking and adjusting standby
pressure
913-004 1.00 Hydraulic pump, checking and adjusting max
working pressure
913-005 0.50 Hydraulic pump, flow control
913-006 0.75 LS (load sense) pressure, checking
914-055 0.50 Servo pressure, checking and adjusting
914-058 3.50 Servo valve, replacing
916-003 1.00 Boom suspension accumulator, reconditioning
916-006 0.50 Boom suspension system, pressure reduction,
safety valve, checking and adjusting
916-019 0.25 3rd/4th hydraulic function, pressure check
916-070 0.10 Boom suspension system, hydraulic oil pressure
in accumulators, depressurizing
916-071 2.50 Boom suspension system, changing accumulator
916-074 0.30 Boom suspension system, test drive with load

94 UNIT, LOAD HANDLING


945-002 3.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 4.00 Lift cylinder, repacking in machine
945-006 3.00 Lift cylinder removed, repacking
945-008 3.00 Tilt cylinder, replacing
945-009 5.00 Tilt cylinder, repacking in machine
945-010 3.50 Tilt cylinder removed, repacking
945-011 2.00 Implemental attachment, replacing hydraulic
cylinder
945-016 5.00 Lift frame, replacing bearing in upper mounting "O"
945-054 1.75 Implement attachment, replacing
945-056 1.00 Implement attachment, repacking removed
hydraulic cylinder
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 2.00 T-link, lower, replacing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"

190 Volvo Construction Equipment 7/11/2012


L120E
Op.no. time (h) Notes

945-068 3.00 Tilt arm, replacing bearing "GDF"


945-069 3.00 Tilt arm, replacing "GDF"

7/11/2012 Volvo Construction Equipment 191


192 Volvo Construction Equipment 7/11/2012
L150D
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 5.00 Warranty inspection 100 hours
172-004 12.00 Warranty inspection 1000 hours
173-007 1.75 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 7.00 Maintenance service, every 1000 hours
173-014 12.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter
173-075 2.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 9.50 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 11.00 Engine, installing
211-002 7.00 Cylinder head, replacing gasket
211-018 12.00 Cylinder heads all, replacing gaskets
211-068 4.00 Cylinder heads all removed, decarbonizing and
grinding in valves
211-071 0.50 Cylinder head removed, pressure testing each
212-007 4.00 Cylinder block, liners removed, milling of all liner
locations
212-011 0.50 Cylinder, cylinder heads removed, measuring
wear in all cylinders
213-010 16.00 Cylinder liner and piston, replacing one
213-018 24.00 Cylinder liners and pistons, replacing all
214-012 1.50 Valves, adjusting
214-027 0.50 Inspection cover, fitting new gasket
214-030 16.00 Valves, decarbonizing and grinding
214-036 1.00 Valve covers, fitting new gasket
215-002 6.00 Timing gear cover, fitting new gasket in machine
215-030 7.00 Timing gear, replacing in machine
215-032 8.00 Timing gear case, fitting new gasket in machine
216-014 3.00 Crankshaft, replacing front oil seal

7/11/2012 Volvo Construction Equipment 193


L150D
Op.no. time (h) Notes

216-018 20.00 Crankshaft, replacing rear oil seal


217-002 6.50 Sump gasket, replacing incl cleaning oil strainer

22 LUBRICATING SYSTEM
221-006 1.00 Oil pressure relief valve, replacing
221-014 7.00 Oil pump, replacing
223-006 2.00 Oil cooler, replacing

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-002 0.75 Feed pump, replacing
233-004 0.50 Feed pump, checking feed pressure
233-014 0.50 Fuel filters, replacing
233-097 0.25 Feed pump removed, reconditioning
234-010 5.00 Fuel tank, replacing
236-001 0.50 Idling speed, checking and adjusting
236-002 0.25 Stall speed, checking
236-030 1.50 Injection timing, checking and adjusting
236-044 1.00 Injection timing, checking
236-073 3.00 Injection pump, replacing incl setting injection
timing
237-002 2.00 Injectors, replacing all
237-004 0.75 Injector, replacing one
237-007 0.25 Overflow valve, replacing
237-016 1.50 Injectors, replacing copper sleeve in machine
237-018 0.75 Delivery pipe, replacing one
237-019 1.00 Fuel line, leak-off pipe, replacing
237-080 2.00 Injectors removed, reconditioning all

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 2.00 Exhaust manifold, replacing gasket
252-019 1.25 Silencer, rubber cuchion replacing
252-020 1.50 Silencer, replacing
252-021 0.75 Exhaust pipe, flexible tube, replacing
255-071 1.50 Turbocharger, replacing
255-073 2.00 Turbocharger removed, reconditioning
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.75 Preheating coil, replacing

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 3.00 Radiator, replacing

194 Volvo Construction Equipment 7/11/2012


L150D
Op.no. time (h) Notes

261-012 1.50 Radiator hose upper, replacing


261-014 2.50 Radiator hoses lower, replacing
261-018 1.00 Expansion tank, replacing
262-002 1.50 Coolant pump, replacing
262-071 1.50 Coolant pump removed, reconditioning
262-098 1.00 Thermostat, replacing
263-012 0.50 Fan belt and/or alternator belt, replacing
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts

27 ENGINE CONTROL
273-021 0.75 Stop magnet, replacing
273-023 0.50 Electrical engine shut down, check and adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing
334-001 0.50 Starter lock, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing

7/11/2012 Volvo Construction Equipment 195


L150D
Op.no. time (h) Notes

362-016 0.75 Horn switch, replacing


363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

37 CABLE; FUSE; RELAY


372-031 1.00 Relay CU201, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 1.50 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-011 1.00 Fuel level sender, replacing
386-032 0.75 Sensor unit (differential lock), replacing
386-035 0.75 Induction sensor (lifting cylinder) replacing
386-036 1.00 Induction sensor (tilt cylinder) replacing
387-005 0.50 Information display, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 0.75 Transmission, check oil pressure
421-008 2.00 Gear selector valve, replacing
421-009 1.75 Gear selector valve removed, reconditioning
421-018 18.00 Converter, replacing
421-024 2.00 Lubrication oil valve, replacing
421-047 0.75 Gear selector, replacing
421-048 0.75 Gear selector valve, replacing one solenoid
421-052 3.00 Seal for front output shaft, replacing
421-054 3.00 Seal for rear output shaft, replacing
421-070 11.00 Transmission, removing
421-071 32.00 Transmission removed, reconditioning
421-072 12.00 Transmission, installing

196 Volvo Construction Equipment 7/11/2012


L150D
Op.no. time (h) Notes

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-004 1.50 Propeller shaft, rear, replacing
451-007 1.50 Propeller shaft, in frame joint, replacing
451-010 2.00 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning

46 FRONT AXLE; REAR AXLE


460-001 0.75 Axle suspension, measuring axial and radial
clearanse
460-002 1.50 Axle suspension, adjusting axial clearance
460-003 13.00 Axle suspension, replacing bushes/bearings and
seals
461-001 7.00 Axle, replacing
461-011 10.00 Centre gear , removing and fitting
461-012 10.00 Centre gear removed, reconditioning
461-013 13.00 Centre gear, axle removed, reconditioning
461-014 1.50 Pinion front, fitting new gasket
461-018 1.50 Oil cooler, replacing
461-019 2.00 Oil pump, replacing
461-040 3.00 Hub reduction gear, replacing
461-041 6.50 Hub reduction gear, removed, reconditioning
461-043 4.50 Hub, replacing seal
461-052 0.25 Differential lock front, repacking excl adjusting
461-053 0.75 Differential lock, adjusting engagement
463-001 9.00 Axle, replacing
463-002 4.50 Axle, removing
463-003 4.50 Axle, installing
463-011 11.00 Centre gear, removing and fitting
463-012 10.00 Centre gear removed, reconditioning
463-013 13.00 Centre gear, axle removed, reconditioning
463-014 1.50 Pinion rear, fitting new gasket
463-018 1.50 Oil cooler, replacing
463-019 2.00 Oil pump, replacing
463-040 3.00 Hub reduction gear, replacing
463-041 6.50 Hub reduction gear removed, reconditioning
463-043 4.50 Hub, replacing seal

49 MISCELLANEOUS
491-006 3.50 Oil cooler, replacing

7/11/2012 Volvo Construction Equipment 197


L150D
Op.no. time (h) Notes

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 4.50 Brake discs, replacing on both sides
516-050 3.50 Brake piston, replacing seals
517-001 0.50 Brake linings, checking wear
517-004 5.00 Brake disc, replacing both sides
517-050 4.00 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-004 0.50 Brake system, adjusting unloading pressure
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-008 2.00 Foot brake valve, replacing
525-009 2.50 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure
527-002 0.50 Accumulator, replacing
527-004 3.00 Hydraulic pump, replacing

55 PARKING BRAKE
550-006 5.00 Parking brake, replacing discs and seals
550-008 1.00 Parking brake, replacing control valve

6 STEERING
64 STEERING
641-021 1.50 Adjustable steering column, replacing
645-006 1.75 Steering cylinder, replacing
645-010 6.00 Hydraulic pump, replacing
645-015 0.50 Steering system, checking and adjusting standby
pressure
645-020 2.50 Steering system, checking and adjusting shock
and anti-cavitation-valve
645-021 1.50 Valve block, replacing
645-028 0.75 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 2.50 Steering cylinder, repacking in machine
645-073 2.50 Hydraulic pump removed, reconditioning

198 Volvo Construction Equipment 7/11/2012


L150D
Op.no. time (h) Notes

645-077 1.75 Steering cylinder removed, reconditioning incl


replacing bearings
645-079 2.50 Shift valve, replacing
645-081 1.50 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

66 LEVER STEERING
660-902 7.00 Lever steering (CDC), hydraulic, installing new

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 17.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.75 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
818-015 1.75 Cab suspension, rubber element replacing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-006 1.25 Operators seat, air suspensioned, control,
replacing
852-007 1.25 Operators seat (air suspensioned), backrest
replacing

86 PROTECTIVE EQUIPMENT, not specified in a special group


865-001 1.00 Engine compartment fan, replacing

7/11/2012 Volvo Construction Equipment 199


L150D
Op.no. time (h) Notes

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 1.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 0.50 Belt, changing
874-010 4.00 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 0.75 Thermostat, replacing
874-015 1.50 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-017 0.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-001 0.50 Oil return filter, replacing
911-005 2.00 Pump suction hose and pipe, replacing
911-011 1.00 Oil cooler, replacing
911-038 5.00 Hydraulic oil tank, replacing
912-001 5.00 Control valve, replacing
912-002 4.00 Control valve removed, reconditioning
912-004 0.75 Control valve, low pressure valve, replacing
912-009 0.50 Shock valve, tilt function, checking and adjusting
912-010 1.00 Shock valve, lowering function, checking and
adjusting
912-011 0.75 Shock valve lift function, adjusting
912-030 2.50 Central valve, replacing
913-002 1.00 Hydraulic pump, checking and adjusting unloading
pressure

200 Volvo Construction Equipment 7/11/2012


L150D
Op.no. time (h) Notes

913-004 0.50 Hydraulic pump, checking and adjusting max


working pressure
913-010 3.50 Hydraulic pump, replacing
913-011 1.75 Hydraulic pump removed, reconditioning
913-013 4.00 Hydraulic pump, replacing seal for input shaft
913-016 1.00 Hydraulic pump, (pump 2) checking and adjusting
working pressure.
913-019 4.50 Hydraulic pump, compensator replacing
914-054 1.75 Servo valve, adjusting control
914-055 1.00 Servo pressure, checking and adjusting
914-057 0.50 Servo pressure, check
914-058 3.00 Servo valve, replacing
914-060 2.50 Servo pump, replacing
914-062 0.50 Pressure limiting valve, replacing
914-063 1.75 Servo pressure, checking at the spool in control
valve
914-075 2.00 Servo valve removed, reconditioning
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 1.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-004 1.50 Boom suspension system, checking closing
pressure
916-005 1.00 Boom suspension system, checking opening
pressure
916-071 2.50 Boom suspension system, changing accumulator
916-073 3.00 Boom suspension system, changing valve
916-908 2.00 Return pipe for optional hydraulic function, new
installation

94 UNIT, LOAD HANDLING


945-002 4.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.50 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 5.50 Lift cylinder, repacking in machine
945-006 3.00 Lift cylinder removed, repacking
945-007 0.75 Tilt cylinder removed, replacing bearings "E-F"
945-008 5.00 Tilt cylinder, replacing
945-009 8.00 Tilt cylinder, repacking in machine
945-010 4.00 Tilt cylinder removed, repacking
945-012 1.00 Lift cylinder removed, replacing bearings "C-P"
945-013 3.00 Lift cylinder, rear bearing replacing
945-014 4.00 Lift cylinder, front bearing replacing

7/11/2012 Volvo Construction Equipment 201


L150D
Op.no. time (h) Notes

945-016 6.00 Lift frame, replacing bearing in upper mounting "O"


945-024 4.00 Tilting cylinder, changing bearing 'E-F' in machine
945-054 3.00 Implement attachment, replacing
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 3.00 T-link, lower, replacing "IB"
945-065 2.00 T-link lower removed, replacing bearing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.50 Tilt arm, replacing bearing "GDF"
945-069 4.00 Tilt arm, replacing "GDF"
945-070 1.75 Tilt arm removed, replacing bearing "GDF"

99 MISCELLANEOUS
993-021 2.50 Automatic lubrication pump, replacing

202 Volvo Construction Equipment 7/11/2012


L150E
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 5.00 Warranty inspection 100 hours 63001 - 65200
6101 - 7549
172-002 5.00 Warranty inspection 100 hours 8004 - 9455
172-004 10.00 Warranty inspection 1000 hours 63001 - 69999
6101 - 7549
172-004 11.00 Warranty inspection 1000 hours 8001 - 9455
173-002 0.40 Maintenance service, daily
173-004 0.80 Maintenance service, every 50 hours
173-007 1.50 Maintenance service, every 250 hours
173-010 5.00 Maintenance service, every 500 hours 6101 - 7549
63001 - 69999
173-010 5.50 Maintenance service, every 500 hours 8001 - 9455
173-012 7.50 Maintenance service, every 1000 hours 6101 - 7549
63001 - 69999
173-012 8.00 Maintenance service, every 1000 hours 8001 - 9455
173-014 9.00 Maintenance service, every 2000 hours 8001 - 9455
173-014 11.00 Maintenance service, every 2000 hours 6101 - 7549
63001 - 69999
173-018 12.00 Maintenance service, every 4000 hours 6101 - 7549
63001 - 69999
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-063 1.50 Transmission, oil filter, changing
173-070 2.00 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 7.00 Compression test 10001 - 12999
210-070 7.50 Engine, removing 8001 - 9455
210-070 4.50 Engine, removing 10001 - 12999
210-072 6.00 Engine, installing 10001 - 12999
210-072 8.00 Engine, installing 8001 - 9455
211-002 7.00 Cylinder head, replacing gasket
214-012 4.00 Valves, adjusting 8001 - 9455
214-012 4.00 Valves, adjusting 10001 - 12999

7/11/2012 Volvo Construction Equipment 203


L150E
Op.no. time (h) Notes

214-036 1.50 Valve covers, fitting new gasket


216-014 2.00 Crankshaft, replacing front oil seal 8001 - 9455
216-018 19.00 Crankshaft, replacing rear oil seal
217-002 7.50 Sump gasket, replacing incl cleaning oil strainer
218-001 4.00 Rubber cushion, replacing 6105 - 7549
63001 - 69999
218-001 4.00 Rubber cushion, replacing 8004 - 9463

22 LUBRICATING SYSTEM
221-014 8.50 Oil pump, replacing
221-021 0.40 Lubrication oil pressure, check 6101 - 7549
63001 - 69999
221-022 0.60 Lubrication oil pressure, checking with pressure 8001 - 9455
gauge
221-022 0.20 Lubrication oil pressure, checking with pressure 10001 - 12999
gauge
223-006 1.50 Oil cooler, replacing 6101 - 7549
63001 - 69999
223-006 7.50 Oil cooler, replacing 8001 - 9463
223-006 3.00 Oil cooler, replacing 10001 - 12999

23 FUEL SYSTEM
233-001 0.40 Fuel system, bleeding 8001 - 9463
233-001 0.30 Fuel system, bleeding 10001 - 12999
233-002 1.25 Feed pump, replacing 6101 - 7549
63001 - 69999
233-002 1.25 Feed pump, replacing 8001 - 9463
233-004 0.40 Feed pump, checking feed pressure 8001 - 9455
233-009 0.20 Fuel pump (valves), inspection 10001 - 12999
233-010 0.90 Fuel pump, inspection 10001 - 12999
233-014 0.75 Fuel filters, replacing
233-020 0.10 Fuel filter, checking 10001 - 12999
233-097 0.25 Feed pump removed, reconditioning
234-010 4.00 Fuel tank, replacing
237-012 5.50 Unit injector, replacing 8001 - 9999
237-012 5.50 Unit injector, replacing 10001 - 12999

25 INLET SYSTEM; EXHAUST SYSTEM


250-901 2.00 Insulation for exhaust system, installation
251-002 1.00 Induction manifold, replacing gasket
251-004 2.00 Exhaust manifold, replacing gasket
252-020 1.00 Silencer, replacing
252-021 0.75 Exhaust pipe, flexible tube, replacing
255-002 0.80 Turbocharger, inspection
255-071 1.75 Turbocharger, replacing 6101 - 7549
63001 - 69999

204 Volvo Construction Equipment 7/11/2012


L150E
Op.no. time (h) Notes

255-071 1.75 Turbocharger, replacing 8001 - 9463


256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.75 Preheating coil, replacing
258-002 4.00 Intercooler, replacing 6001 - 9455
63001 - 69999
258-030 0.80 Charge air system, inspection 10001 - 12999

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 6.00 Radiator, replacing 10001 - 12999
261-008 5.50 Radiator, replacing 8002 - 9999
261-012 1.00 Radiator hose upper, replacing
261-014 3.00 Radiator hoses lower, replacing
262-002 1.75 Coolant pump, replacing 8001 - 9455
262-071 1.50 Coolant pump removed, reconditioning
262-098 1.00 Thermostat, replacing
263-004 0.75 Fan motor, checking working pressure
263-010 0.50 Pump 3 (P3) standby pressure, checking
263-011 0.10 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)
263-011 0.40 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)
263-051 1.50 Cooling fan hydraulics, funktion check
263-062 2.50 Cooling fan motor, changing 8001 - 9455
263-062 4.50 Cooling fan motor, changing 10001 - 12999
263-065 3.00 Cooling fan motor, changing non-return valve

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing

7/11/2012 Volvo Construction Equipment 205


L150E
Op.no. time (h) Notes

334-001 0.25 Starter lock, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.25 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 1.00 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-008 0.60 Engine rotation speed sensor, replacing 10002 - 12999
386-008 0.60 Engine rotation speed sensor, replacing
386-011 1.00 Fuel level sender, replacing
386-088 0.70 Engine rotation speed sensor (camshaft), 10002 - 12999
replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
390-902 2.00 CareTrack, installing new
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
41 CLUTCH; TORQUE CONVERTER
414-003 2.00 Converter, replacing (engine removed)

206 Volvo Construction Equipment 7/11/2012


L150E
Op.no. time (h) Notes

42 TRANSMISSION, HYDRAULIC CONTROL


421-002 0.70 Transmission, check oil pressure 6001 - 8157
421-002 0.70 Transmission, check oil pressure 8158 - 12999
421-008 3.00 Gear selector valve, replacing
421-009 1.00 Gear selector valve removed, reconditioning
421-018 19.00 Converter, replacing
421-024 1.50 Lubrication oil valve, replacing
421-047 0.75 Gear selector, replacing
421-048 1.50 Gear selector valve, replacing one solenoid
421-052 3.00 Seal for front output shaft, replacing
421-054 2.50 Seal for rear output shaft, replacing
421-068 10.00 Transmission, removing (upwards)
421-069 15.00 Transmission, installing (from above)
421-071 32.00 Transmission removed, reconditioning

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-004 1.50 Propeller shaft, rear, replacing
451-007 1.50 Propeller shaft, in frame joint, replacing
451-010 2.00 Propeller shaft, front, replacing

46 FRONT AXLE; REAR AXLE


460-001 0.75 Axle suspension, measuring axial and radial
clearanse
460-002 1.50 Axle suspension, adjusting axial clearance
460-003 13.00 Axle suspension, replacing bushes/bearings and
seals
461-001 7.00 Axle, replacing
461-011 10.00 Centre gear , removing and fitting
461-012 10.00 Centre gear removed, reconditioning
461-013 11.00 Centre gear, axle removed, reconditioning
461-040 3.00 Hub reduction gear, replacing
461-041 6.50 Hub reduction gear, removed, reconditioning
461-043 4.50 Hub, replacing seal
463-001 9.00 Axle, replacing
463-002 4.50 Axle, removing
463-003 4.50 Axle, installing
463-011 11.00 Centre gear, removing and fitting
463-012 10.00 Centre gear removed, reconditioning
463-013 13.00 Centre gear, axle removed, reconditioning
463-040 3.00 Hub reduction gear, replacing
463-041 6.50 Hub reduction gear removed, reconditioning

7/11/2012 Volvo Construction Equipment 207


L150E
Op.no. time (h) Notes

463-043 4.50 Hub, replacing seal

49 MISCELLANEOUS
491-006 4.00 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 4.50 Brake discs, replacing on both sides
516-050 3.50 Brake piston, replacing seals
517-001 0.50 Brake linings, checking wear
517-004 5.00 Brake disc, replacing both sides
517-050 4.00 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.90 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-005 0.60 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-009 0.50 Foot brake valve removed, reconditioning
527-002 0.50 Accumulator, replacing

6 STEERING
64 STEERING
645-006 1.75 Steering cylinder, replacing
645-021 1.50 Valve block, replacing
645-028 0.10 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 2.50 Steering cylinder, repacking in machine
645-077 1.75 Steering cylinder removed, reconditioning incl
replacing bearings
645-078 1.50 Shift valve removed, reconditioning
645-079 2.50 Shift valve, replacing
645-081 1.50 Steering valve removed, reconditioning
645-082 1.50 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed
660-005 1.25 CDC, checking lever signals

208 Volvo Construction Equipment 7/11/2012


L150E
Op.no. time (h) Notes

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.30 Frame joint, checking clearance
741-036 19.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing
818-015 1.75 Cab suspension, rubber element replacing
818-020 1.75 Viscous cab suspension, changing one unit

82 ENGINE HOOD; MUDGUARD; FOOT STEP


821-001 0.70 Engine hood, removing 10002 - 12999
821-001 0.70 Engine hood, removing 10001 - 12999
821-001 0.70 Engine hood, removing 6001 - 9455
63001 - 69999
821-002 0.70 Engine hood, installing 6001 - 9455
63001 - 69999
821-002 1.00 Engine hood, installing 10002 - 12999
821-002 0.80 Engine hood, installing 10001 - 12999

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 2.00 Heater core, replacing
873-006 1.25 Fan motor, replacing
873-008 1.00 Heat control valve, replacing

7/11/2012 Volvo Construction Equipment 209


L150E
Op.no. time (h) Notes

873-009 0.75 Heat control, replacing


874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 0.50 Belt, changing
874-010 3.00 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 0.75 Thermostat, replacing
874-015 1.50 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-017 0.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)
874-059 1.25 Evaporator, cleaning

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 3.00 Hydraulic system, bleeding

91 WORKING HYDRAULICS; SERVO HYDRAULICS


911-001 0.75 Oil return filter, replacing
911-005 2.00 Pump suction hose and pipe, replacing
911-011 4.00 Oil cooler, replacing
911-036 3.00 Hydraulic oil tank, removing
911-037 4.50 Hydraulic oil tank, installing
911-038 8.00 Hydraulic oil tank, replacing
912-001 6.50 Control valve, replacing
912-002 4.00 Control valve removed, reconditioning
912-018 0.20 Back-up valve, checking and adjusting
912-019 0.50 Shock valve removed, checking
912-021 0.30 Shock valve, tilt function, checking
912-023 0.70 Shock valve lift function, checking
912-030 7.50 Central valve, replacing
913-003 0.20 Hydraulic pump, checking and adjusting standby
pressure

210 Volvo Construction Equipment 7/11/2012


L150E
Op.no. time (h) Notes

913-004 0.20 Hydraulic pump, checking and adjusting max


working pressure
913-034 0.40 Lifting time, checking
913-037 6.00 Hydraulic pump P1, replacing
913-037 6.00 Hydraulic pump P1, replacing
913-039 5.00 Hydraulic pump P3, replacing
913-040 6.50 Hydraulic pumps P2 and P3, replacing
914-054 1.75 Servo valve, adjusting control
914-055 0.25 Servo pressure, checking and adjusting
914-058 3.50 Servo valve, replacing
914-075 2.00 Servo valve removed, reconditioning
916-001 0.50 Boom suspension system, functional check
916-002 1.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-006 0.50 Boom suspension system, pressure reduction,
safety valve, checking and adjusting
916-019 0.50 3rd/4th hydraulic function, pressure check
916-070 0.10 Boom suspension system, hydraulic oil pressure
in accumulators, depressurizing
916-071 2.50 Boom suspension system, changing accumulator
916-074 0.30 Boom suspension system, test drive with load
916-075 0.70 Boom Suspension System, valve block V1,
removing
916-076 1.25 Boom Suspension System, valve block V1,
installing
916-077 0.40 Boom Suspension System, valve block V2,
removing
916-078 1.25 Boom Suspension System, valve block V2,
installing

94 UNIT, LOAD HANDLING


945-002 4.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 4.50 Lift cylinder, repacking in machine
945-006 3.00 Lift cylinder removed, repacking
945-007 0.50 Tilt cylinder removed, replacing bearings "E-F"
945-008 4.00 Tilt cylinder, replacing
945-009 5.00 Tilt cylinder, repacking in machine
945-010 4.00 Tilt cylinder removed, repacking
945-012 0.70 Lift cylinder removed, replacing bearings "C-P"
945-013 3.00 Lift cylinder, rear bearing replacing
945-014 4.00 Lift cylinder, front bearing replacing

7/11/2012 Volvo Construction Equipment 211


L150E
Op.no. time (h) Notes

945-016 6.00 Lift frame, replacing bearing in upper mounting "O"


945-023 1.25 Tilting cylinder, replacing bearing 'E' in machine
945-024 4.00 Tilting cylinder, changing bearing 'E-F' in machine
945-054 3.00 Implement attachment, replacing
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 3.00 T-link, lower, replacing "IB"
945-065 2.00 T-link lower removed, replacing bearing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.50 Tilt arm, replacing bearing "GDF"
945-069 4.00 Tilt arm, replacing "GDF"
945-070 1.75 Tilt arm removed, replacing bearing "GDF"

212 Volvo Construction Equipment 7/11/2012


L180D
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 5.00 Warranty inspection 100 hours
172-004 12.00 Warranty inspection 1000 hours
173-007 1.25 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 8.00 Maintenance service, every 1000 hours
173-014 12.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter
173-075 2.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 10.00 Engine, removing
210-071 48.00 Engine removed, general overhaul
210-072 11.00 Engine, installing
211-002 7.00 Cylinder head, replacing gasket
211-018 13.00 Cylinder heads all, replacing gaskets
211-068 4.00 Cylinder heads all removed, decarbonizing and
grinding in valves
211-071 0.50 Cylinder head removed, pressure testing each
212-007 4.00 Cylinder block, liners removed, milling of all liner
locations
212-011 0.50 Cylinder, cylinder heads removed, measuring
wear in all cylinders
213-010 16.00 Cylinder liner and piston, replacing one
213-018 26.00 Cylinder liners and pistons, replacing all
214-012 1.50 Valves, adjusting
214-027 0.50 Inspection cover, fitting new gasket
214-030 16.00 Valves, decarbonizing and grinding
214-036 1.00 Valve covers, fitting new gasket
215-002 6.00 Timing gear cover, fitting new gasket in machine
215-030 7.00 Timing gear, replacing in machine
215-032 8.00 Timing gear case, fitting new gasket in machine
216-014 3.50 Crankshaft, replacing front oil seal

7/11/2012 Volvo Construction Equipment 213


L180D
Op.no. time (h) Notes

216-018 20.00 Crankshaft, replacing rear oil seal


217-002 8.50 Sump gasket, replacing incl cleaning oil strainer

22 LUBRICATING SYSTEM
221-006 1.00 Oil pressure relief valve, replacing
221-014 10.00 Oil pump, replacing
223-006 2.00 Oil cooler, replacing

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-002 0.75 Feed pump, replacing
233-004 0.50 Feed pump, checking feed pressure
233-014 0.50 Fuel filters, replacing
233-097 0.25 Feed pump removed, reconditioning
234-010 5.00 Fuel tank, replacing
236-001 0.50 Idling speed, checking and adjusting
236-002 0.25 Stall speed, checking
236-030 2.00 Injection timing, checking and adjusting
236-044 1.00 Injection timing, checking
236-073 3.50 Injection pump, replacing incl setting injection
timing
237-002 2.00 Injectors, replacing all
237-004 0.75 Injector, replacing one
237-007 0.25 Overflow valve, replacing
237-016 2.00 Injectors, replacing copper sleeve in machine
237-018 0.75 Delivery pipe, replacing one
237-019 1.00 Fuel line, leak-off pipe, replacing
237-080 2.00 Injectors removed, reconditioning all

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 2.00 Exhaust manifold, replacing gasket
252-019 1.25 Silencer, rubber cuchion replacing
252-020 1.50 Silencer, replacing
252-021 0.75 Exhaust pipe, flexible tube, replacing
255-071 1.50 Turbocharger, replacing
255-073 2.00 Turbocharger removed, reconditioning
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.75 Preheating coil, replacing

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 3.50 Radiator, replacing

214 Volvo Construction Equipment 7/11/2012


L180D
Op.no. time (h) Notes

261-012 1.50 Radiator hose upper, replacing


261-014 2.50 Radiator hoses lower, replacing
261-018 1.00 Expansion tank, replacing
262-002 1.50 Coolant pump, replacing
262-071 1.50 Coolant pump removed, reconditioning
262-098 1.50 Thermostat, replacing
263-006 1.25 Fan hydraulically driven, removing pump
263-007 1.25 Fan hydraulically driven, fitting pump
263-012 0.50 Fan belt and/or alternator belt, replacing
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts
263-080 2.50 Fan hydraulically driven, replacing pump

27 ENGINE CONTROL
273-021 0.75 Stop magnet, replacing
273-023 0.50 Electrical engine shut down, check and adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing
334-001 0.50 Starter lock, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing

7/11/2012 Volvo Construction Equipment 215


L180D
Op.no. time (h) Notes

361-017 0.25 Flasher lamp, replacing glass or bulb


362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-016 0.75 Horn switch, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

37 CABLE; FUSE; RELAY


372-031 1.00 Relay CU201, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 0.50 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-011 1.00 Fuel level sender, replacing
386-032 0.75 Sensor unit (differential lock), replacing
386-035 0.75 Induction sensor (lifting cylinder) replacing
386-036 1.00 Induction sensor (tilt cylinder) replacing
387-005 0.50 Information display, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 1.00 Transmission, check oil pressure
421-008 2.00 Gear selector valve, replacing
421-009 1.75 Gear selector valve removed, reconditioning
421-018 18.00 Converter, replacing
421-024 2.00 Lubrication oil valve, replacing
421-047 0.75 Gear selector, replacing
421-048 0.75 Gear selector valve, replacing one solenoid
421-052 3.00 Seal for front output shaft, replacing
421-054 3.00 Seal for rear output shaft, replacing
421-070 11.00 Transmission, removing
421-071 32.00 Transmission removed, reconditioning

216 Volvo Construction Equipment 7/11/2012


L180D
Op.no. time (h) Notes

421-072 12.00 Transmission, installing

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-004 1.50 Propeller shaft, rear, replacing
451-007 1.50 Propeller shaft, in frame joint, replacing
451-010 2.00 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning

46 FRONT AXLE; REAR AXLE


460-001 0.75 Axle suspension, measuring axial and radial
clearanse
460-002 1.50 Axle suspension, adjusting axial clearance
460-003 13.00 Axle suspension, replacing bushes/bearings and
seals
461-001 7.00 Axle, replacing
461-011 10.00 Centre gear , removing and fitting
461-012 10.00 Centre gear removed, reconditioning
461-013 13.00 Centre gear, axle removed, reconditioning
461-014 1.50 Pinion front, fitting new gasket
461-018 1.50 Oil cooler, replacing
461-019 2.00 Oil pump, replacing
461-040 3.00 Hub reduction gear, replacing
461-041 6.50 Hub reduction gear, removed, reconditioning
461-043 4.50 Hub, replacing seal
461-052 0.25 Differential lock front, repacking excl adjusting
461-053 0.75 Differential lock, adjusting engagement
463-001 9.00 Axle, replacing
463-002 4.50 Axle, removing
463-003 4.50 Axle, installing
463-011 11.00 Centre gear, removing and fitting
463-012 10.00 Centre gear removed, reconditioning
463-013 13.00 Centre gear, axle removed, reconditioning
463-014 1.50 Pinion rear, fitting new gasket
463-018 1.50 Oil cooler, replacing
463-019 2.00 Oil pump, replacing
463-040 3.00 Hub reduction gear, replacing
463-041 6.50 Hub reduction gear removed, reconditioning
463-043 4.50 Hub, replacing seal

49 MISCELLANEOUS
491-006 3.50 Oil cooler, replacing

7/11/2012 Volvo Construction Equipment 217


L180D
Op.no. time (h) Notes

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 4.50 Brake discs, replacing on both sides
516-050 3.50 Brake piston, replacing seals
517-001 0.50 Brake linings, checking wear
517-004 5.00 Brake disc, replacing both sides
517-050 4.00 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-004 0.50 Brake system, adjusting unloading pressure
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-008 2.00 Foot brake valve, replacing
525-009 2.50 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure
527-002 0.50 Accumulator, replacing
527-004 3.00 Hydraulic pump, replacing

55 PARKING BRAKE
550-006 5.00 Parking brake, replacing discs and seals
550-008 1.00 Parking brake, replacing control valve

6 STEERING
64 STEERING
641-021 1.50 Adjustable steering column, replacing
645-006 1.75 Steering cylinder, replacing
645-010 6.00 Hydraulic pump, replacing
645-015 0.50 Steering system, checking and adjusting standby
pressure
645-020 2.50 Steering system, checking and adjusting shock
and anti-cavitation-valve
645-021 1.50 Valve block, replacing
645-028 0.50 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 2.50 Steering cylinder, repacking in machine
645-073 3.00 Hydraulic pump removed, reconditioning

218 Volvo Construction Equipment 7/11/2012


L180D
Op.no. time (h) Notes

645-077 1.75 Steering cylinder removed, reconditioning incl


replacing bearings
645-079 2.50 Shift valve, replacing
645-081 1.50 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed
660-005 1.25 CDC, checking lever signals
660-902 7.00 Lever steering (CDC), hydraulic, installing new

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 17.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
818-015 1.75 Cab suspension, rubber element replacing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-006 1.25 Operators seat, air suspensioned, control,
replacing
852-007 1.25 Operators seat (air suspensioned), backrest
replacing

7/11/2012 Volvo Construction Equipment 219


L180D
Op.no. time (h) Notes

86 PROTECTIVE EQUIPMENT, not specified in a special group


865-001 1.00 Engine compartment fan, replacing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 1.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 0.50 Belt, changing
874-010 4.00 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 0.75 Thermostat, replacing
874-015 1.50 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-017 0.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-001 0.50 Oil return filter, replacing
911-005 2.00 Pump suction hose and pipe, replacing
911-011 1.00 Oil cooler, replacing
911-038 5.00 Hydraulic oil tank, replacing
912-001 5.00 Control valve, replacing
912-002 4.00 Control valve removed, reconditioning
912-004 0.75 Control valve, low pressure valve, replacing
912-009 0.50 Shock valve, tilt function, checking and adjusting
912-010 1.00 Shock valve, lowering function, checking and
adjusting
912-011 0.75 Shock valve lift function, adjusting
912-030 2.50 Central valve, replacing

220 Volvo Construction Equipment 7/11/2012


L180D
Op.no. time (h) Notes

913-002 1.00 Hydraulic pump, checking and adjusting unloading


pressure
913-004 0.50 Hydraulic pump, checking and adjusting max
working pressure
913-010 3.50 Hydraulic pump, replacing
913-011 2.00 Hydraulic pump removed, reconditioning
913-016 1.00 Hydraulic pump, (pump 2) checking and adjusting
working pressure.
913-019 4.50 Hydraulic pump, compensator replacing
913-027 3.00 Relief valve, replacing
914-054 1.75 Servo valve, adjusting control
914-055 1.00 Servo pressure, checking and adjusting
914-057 0.50 Servo pressure, check
914-058 3.00 Servo valve, replacing
914-060 3.00 Servo pump, replacing
914-063 1.75 Servo pressure, checking at the spool in control
valve
914-075 2.00 Servo valve removed, reconditioning
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 1.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-004 1.50 Boom suspension system, checking closing
pressure
916-005 1.00 Boom suspension system, checking opening
pressure
916-071 2.50 Boom suspension system, changing accumulator
916-073 3.00 Boom suspension system, changing valve
916-908 2.00 Return pipe for optional hydraulic function, new
installation

94 UNIT, LOAD HANDLING


945-002 4.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.50 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 5.50 Lift cylinder, repacking in machine
945-006 3.00 Lift cylinder removed, repacking
945-007 0.75 Tilt cylinder removed, replacing bearings "E-F"
945-008 4.00 Tilt cylinder, replacing
945-009 8.00 Tilt cylinder, repacking in machine
945-010 4.00 Tilt cylinder removed, repacking
945-012 1.00 Lift cylinder removed, replacing bearings "C-P"
945-013 3.00 Lift cylinder, rear bearing replacing

7/11/2012 Volvo Construction Equipment 221


L180D
Op.no. time (h) Notes

945-014 4.00 Lift cylinder, front bearing replacing


945-016 6.00 Lift frame, replacing bearing in upper mounting "O"
945-024 4.00 Tilting cylinder, changing bearing 'E-F' in machine
945-054 3.00 Implement attachment, replacing
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 3.00 T-link, lower, replacing "IB"
945-065 2.00 T-link lower removed, replacing bearing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.50 Tilt arm, replacing bearing "GDF"
945-069 4.00 Tilt arm, replacing "GDF"
945-070 1.75 Tilt arm removed, replacing bearing "GDF"

99 MISCELLANEOUS
993-021 2.50 Automatic lubrication pump, replacing

222 Volvo Construction Equipment 7/11/2012


L180D HL
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 5.00 Warranty inspection 100 hours
172-004 12.00 Warranty inspection 1000 hours
173-007 1.25 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 8.00 Maintenance service, every 1000 hours
173-014 12.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter
173-075 2.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 10.00 Engine, removing
210-071 48.00 Engine removed, general overhaul
210-072 11.00 Engine, installing
211-002 7.00 Cylinder head, replacing gasket
211-018 13.00 Cylinder heads all, replacing gaskets
211-068 4.00 Cylinder heads all removed, decarbonizing and
grinding in valves
211-071 0.50 Cylinder head removed, pressure testing each
212-007 4.00 Cylinder block, liners removed, milling of all liner
locations
212-011 0.50 Cylinder, cylinder heads removed, measuring
wear in all cylinders
213-010 16.00 Cylinder liner and piston, replacing one
213-018 26.00 Cylinder liners and pistons, replacing all
214-012 1.50 Valves, adjusting
214-027 0.50 Inspection cover, fitting new gasket
214-030 16.00 Valves, decarbonizing and grinding
214-036 1.00 Valve covers, fitting new gasket
215-002 6.00 Timing gear cover, fitting new gasket in machine
215-030 7.00 Timing gear, replacing in machine
215-032 8.00 Timing gear case, fitting new gasket in machine
216-014 3.50 Crankshaft, replacing front oil seal

7/11/2012 Volvo Construction Equipment 223


L180D HL
Op.no. time (h) Notes

216-018 20.00 Crankshaft, replacing rear oil seal


217-002 8.50 Sump gasket, replacing incl cleaning oil strainer

22 LUBRICATING SYSTEM
221-006 1.00 Oil pressure relief valve, replacing
221-014 10.00 Oil pump, replacing
223-006 2.00 Oil cooler, replacing

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-002 0.75 Feed pump, replacing
233-004 0.50 Feed pump, checking feed pressure
233-014 0.50 Fuel filters, replacing
233-097 0.25 Feed pump removed, reconditioning
234-010 5.00 Fuel tank, replacing
236-001 0.50 Idling speed, checking and adjusting
236-002 0.25 Stall speed, checking
236-030 2.00 Injection timing, checking and adjusting
236-044 1.00 Injection timing, checking
236-073 3.50 Injection pump, replacing incl setting injection
timing
237-002 2.00 Injectors, replacing all
237-004 0.75 Injector, replacing one
237-007 0.25 Overflow valve, replacing
237-016 2.00 Injectors, replacing copper sleeve in machine
237-018 0.75 Delivery pipe, replacing one
237-019 1.00 Fuel line, leak-off pipe, replacing
237-080 2.00 Injectors removed, reconditioning all

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 2.00 Exhaust manifold, replacing gasket
252-019 1.25 Silencer, rubber cuchion replacing
252-020 1.50 Silencer, replacing
252-021 0.75 Exhaust pipe, flexible tube, replacing
255-071 1.50 Turbocharger, replacing
255-073 2.00 Turbocharger removed, reconditioning
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.75 Preheating coil, replacing

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 3.50 Radiator, replacing

224 Volvo Construction Equipment 7/11/2012


L180D HL
Op.no. time (h) Notes

261-012 1.50 Radiator hose upper, replacing


261-014 2.50 Radiator hoses lower, replacing
261-018 1.00 Expansion tank, replacing
262-002 1.50 Coolant pump, replacing
262-071 1.50 Coolant pump removed, reconditioning
262-098 1.50 Thermostat, replacing
263-006 1.25 Fan hydraulically driven, removing pump
263-007 1.25 Fan hydraulically driven, fitting pump
263-012 0.50 Fan belt and/or alternator belt, replacing
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts
263-080 2.50 Fan hydraulically driven, replacing pump

27 ENGINE CONTROL
273-021 0.75 Stop magnet, replacing
273-023 0.50 Electrical engine shut down, check and adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing
334-001 0.50 Starter lock, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing

7/11/2012 Volvo Construction Equipment 225


L180D HL
Op.no. time (h) Notes

361-017 0.25 Flasher lamp, replacing glass or bulb


362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-016 0.75 Horn switch, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

37 CABLE; FUSE; RELAY


372-031 1.00 Relay CU201, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 0.50 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-011 1.00 Fuel level sender, replacing
386-032 0.75 Sensor unit (differential lock), replacing
386-035 0.75 Induction sensor (lifting cylinder) replacing
386-036 1.00 Induction sensor (tilt cylinder) replacing
387-005 0.50 Information display, replacing

39 MISCELLANEOUS
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 1.00 Transmission, check oil pressure
421-008 2.00 Gear selector valve, replacing
421-009 1.75 Gear selector valve removed, reconditioning
421-018 18.00 Converter, replacing
421-024 2.00 Lubrication oil valve, replacing
421-047 0.75 Gear selector, replacing
421-048 0.75 Gear selector valve, replacing one solenoid
421-052 3.00 Seal for front output shaft, replacing
421-054 3.00 Seal for rear output shaft, replacing
421-070 11.00 Transmission, removing
421-071 32.00 Transmission removed, reconditioning
421-072 12.00 Transmission, installing

226 Volvo Construction Equipment 7/11/2012


L180D HL
Op.no. time (h) Notes

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-004 1.50 Propeller shaft, rear, replacing
451-007 1.50 Propeller shaft, in frame joint, replacing
451-010 2.00 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning

46 FRONT AXLE; REAR AXLE


460-001 0.75 Axle suspension, measuring axial and radial
clearanse
460-002 1.50 Axle suspension, adjusting axial clearance
460-003 13.00 Axle suspension, replacing bushes/bearings and
seals
461-001 7.00 Axle, replacing
461-011 10.00 Centre gear , removing and fitting
461-012 10.00 Centre gear removed, reconditioning
461-013 13.00 Centre gear, axle removed, reconditioning
461-014 1.50 Pinion front, fitting new gasket
461-018 1.50 Oil cooler, replacing
461-019 2.00 Oil pump, replacing
461-040 3.00 Hub reduction gear, replacing
461-041 6.50 Hub reduction gear, removed, reconditioning
461-043 4.50 Hub, replacing seal
461-052 0.25 Differential lock front, repacking excl adjusting
461-053 0.75 Differential lock, adjusting engagement
463-001 9.00 Axle, replacing
463-002 4.50 Axle, removing
463-003 4.50 Axle, installing
463-011 11.00 Centre gear, removing and fitting
463-012 10.00 Centre gear removed, reconditioning
463-013 13.00 Centre gear, axle removed, reconditioning
463-014 1.50 Pinion rear, fitting new gasket
463-018 1.50 Oil cooler, replacing
463-019 2.00 Oil pump, replacing
463-040 3.00 Hub reduction gear, replacing
463-041 6.50 Hub reduction gear removed, reconditioning
463-043 4.50 Hub, replacing seal

49 MISCELLANEOUS
491-006 3.50 Oil cooler, replacing

7/11/2012 Volvo Construction Equipment 227


L180D HL
Op.no. time (h) Notes

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 4.50 Brake discs, replacing on both sides
516-050 3.50 Brake piston, replacing seals
517-001 0.50 Brake linings, checking wear
517-004 5.00 Brake disc, replacing both sides
517-050 4.00 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-004 0.50 Brake system, adjusting unloading pressure
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-008 2.00 Foot brake valve, replacing
525-009 2.50 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure
527-002 0.50 Accumulator, replacing
527-004 3.00 Hydraulic pump, replacing

55 PARKING BRAKE
550-006 5.00 Parking brake, replacing discs and seals
550-008 1.00 Parking brake, replacing control valve

6 STEERING
64 STEERING
641-021 1.50 Adjustable steering column, replacing
645-006 1.75 Steering cylinder, replacing
645-010 6.00 Hydraulic pump, replacing
645-015 0.50 Steering system, checking and adjusting standby
pressure
645-020 2.50 Steering system, checking and adjusting shock
and anti-cavitation-valve
645-021 1.50 Valve block, replacing
645-028 0.50 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 2.50 Steering cylinder, repacking in machine
645-073 3.00 Hydraulic pump removed, reconditioning

228 Volvo Construction Equipment 7/11/2012


L180D HL
Op.no. time (h) Notes

645-077 1.75 Steering cylinder removed, reconditioning incl


replacing bearings
645-079 2.50 Shift valve, replacing
645-081 1.50 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed
660-005 1.25 CDC, checking lever signals
660-902 7.00 Lever steering (CDC), hydraulic, installing new

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 17.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
818-015 1.75 Cab suspension, rubber element replacing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-006 1.25 Operators seat, air suspensioned, control,
replacing
852-007 1.25 Operators seat (air suspensioned), backrest
replacing

7/11/2012 Volvo Construction Equipment 229


L180D HL
Op.no. time (h) Notes

86 PROTECTIVE EQUIPMENT, not specified in a special group


865-001 1.00 Engine compartment fan, replacing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 1.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 0.50 Belt, changing
874-010 4.00 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 0.75 Thermostat, replacing
874-015 1.50 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-017 0.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-001 0.50 Oil return filter, replacing
911-005 2.00 Pump suction hose and pipe, replacing
911-011 1.00 Oil cooler, replacing
911-038 5.00 Hydraulic oil tank, replacing
912-001 5.00 Control valve, replacing
912-002 4.00 Control valve removed, reconditioning
912-004 0.75 Control valve, low pressure valve, replacing
912-009 0.50 Shock valve, tilt function, checking and adjusting
912-010 1.00 Shock valve, lowering function, checking and
adjusting
912-011 0.75 Shock valve lift function, adjusting
912-030 2.50 Central valve, replacing

230 Volvo Construction Equipment 7/11/2012


L180D HL
Op.no. time (h) Notes

913-002 1.00 Hydraulic pump, checking and adjusting unloading


pressure
913-004 0.50 Hydraulic pump, checking and adjusting max
working pressure
913-010 3.50 Hydraulic pump, replacing
913-011 2.00 Hydraulic pump removed, reconditioning
913-016 1.00 Hydraulic pump, (pump 2) checking and adjusting
working pressure.
913-019 4.50 Hydraulic pump, compensator replacing
913-027 3.00 Relief valve, replacing
914-054 1.75 Servo valve, adjusting control
914-055 1.00 Servo pressure, checking and adjusting
914-057 0.50 Servo pressure, check
914-058 3.00 Servo valve, replacing
914-060 3.00 Servo pump, replacing
914-063 1.75 Servo pressure, checking at the spool in control
valve
914-075 2.00 Servo valve removed, reconditioning
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 1.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-004 1.50 Boom suspension system, checking closing
pressure
916-005 1.00 Boom suspension system, checking opening
pressure
916-071 2.50 Boom suspension system, changing accumulator
916-073 3.00 Boom suspension system, changing valve
916-908 2.00 Return pipe for optional hydraulic function, new
installation

94 UNIT, LOAD HANDLING


945-002 4.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.50 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 5.50 Lift cylinder, repacking in machine
945-006 3.00 Lift cylinder removed, repacking
945-007 0.75 Tilt cylinder removed, replacing bearings "E-F"
945-008 5.00 Tilt cylinder, replacing
945-009 8.00 Tilt cylinder, repacking in machine
945-010 4.00 Tilt cylinder removed, repacking
945-012 1.00 Lift cylinder removed, replacing bearings "C-P"
945-013 3.00 Lift cylinder, rear bearing replacing

7/11/2012 Volvo Construction Equipment 231


L180D HL
Op.no. time (h) Notes

945-014 4.00 Lift cylinder, front bearing replacing


945-016 6.00 Lift frame, replacing bearing in upper mounting "O"
945-024 4.00 Tilting cylinder, changing bearing 'E-F' in machine
945-054 3.00 Implement attachment, replacing
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 3.00 T-link, lower, replacing "IB"
945-065 2.00 T-link lower removed, replacing bearing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.50 Tilt arm, replacing bearing "GDF"
945-069 4.00 Tilt arm, replacing "GDF"
945-070 1.75 Tilt arm removed, replacing bearing "GDF"

99 MISCELLANEOUS
993-021 2.50 Automatic lubrication pump, replacing

232 Volvo Construction Equipment 7/11/2012


L180E
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 5.00 Warranty inspection 100 hours
172-004 11.00 Warranty inspection 1000 hours
173-002 0.40 Maintenance service, daily
173-004 0.70 Maintenance service, every 50 hours
173-007 1.50 Maintenance service, every 250 hours
173-010 5.50 Maintenance service, every 500 hours
173-012 8.00 Maintenance service, every 1000 hours
173-014 9.00 Maintenance service, every 2000 hours
173-018 14.00 Maintenance service, every 4000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 7.50 Compression test 5001 - 7398
62501 - 69999
210-002 7.00 Compression test 8001 - 10999
210-070 4.50 Engine, removing 8001 - 10999
210-072 6.00 Engine, installing 8001 - 10999
210-090 0.30 Camshaft and flywheel signals, checking with
VCADS Pro and oscilloscope
211-002 16.00 Cylinder head, replacing gasket
214-012 4.00 Valves, adjusting 8002 - 10999
214-012 4.00 Valves, adjusting 5001 - 7398
62501 - 69999
214-036 2.50 Valve covers, fitting new gasket
215-032 13.00 Timing gear case, fitting new gasket in machine 5001 - 7398
62501 - 69999
216-018 19.00 Crankshaft, replacing rear oil seal
217-002 7.50 Sump gasket, replacing incl cleaning oil strainer
218-001 2.50 Rubber cushion, replacing

22 LUBRICATING SYSTEM
221-014 8.50 Oil pump, replacing

7/11/2012 Volvo Construction Equipment 233


L180E
Op.no. time (h) Notes

221-022 0.20 Lubrication oil pressure, checking with pressure 8001 - 10999
gauge
223-006 3.00 Oil cooler, replacing

23 FUEL SYSTEM
233-001 0.30 Fuel system, bleeding
233-001 0.30 Fuel system, bleeding 8002 - 10999
233-002 1.50 Feed pump, replacing
233-004 0.40 Feed pump, checking feed pressure 5001 - 7398
62501 - 69999
233-009 0.20 Fuel pump (valves), inspection
233-010 0.90 Fuel pump, inspection
233-014 0.75 Fuel filters, replacing
233-020 0.10 Fuel filter, checking
233-097 0.75 Feed pump removed, reconditioning
234-010 4.00 Fuel tank, replacing
236-002 0.50 Stall speed, checking 5001 - 7398
62501 - 69999
237-012 5.50 Unit injector, replacing 8002 - 10999

25 INLET SYSTEM; EXHAUST SYSTEM


250-901 2.00 Insulation for exhaust system, installation
251-002 1.00 Induction manifold, replacing gasket
251-004 2.00 Exhaust manifold, replacing gasket
252-020 1.00 Silencer, replacing
252-021 0.75 Exhaust pipe, flexible tube, replacing
255-002 0.80 Turbocharger, inspection
255-071 1.50 Turbocharger, replacing
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.75 Preheating coil, replacing
258-002 4.00 Intercooler, replacing 62501 - 69999
5001 - 7398
258-030 0.80 Charge air system, inspection

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 6.00 Radiator, replacing 8002 - 10999
261-012 1.00 Radiator hose upper, replacing
261-014 3.00 Radiator hoses lower, replacing
262-002 2.00 Coolant pump, replacing
262-071 1.50 Coolant pump removed, reconditioning
262-098 1.75 Thermostat, replacing
263-004 0.75 Fan motor, checking working pressure

234 Volvo Construction Equipment 7/11/2012


L180E
Op.no. time (h) Notes

263-010 0.50 Pump 3 (P3) standby pressure, checking


263-011 0.10 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)
263-011 0.40 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)
263-051 1.50 Cooling fan hydraulics, funktion check
263-062 4.50 Cooling fan motor, changing 8001 - 10999

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing
334-001 0.25 Starter lock, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.25 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

7/11/2012 Volvo Construction Equipment 235


L180E
Op.no. time (h) Notes

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 1.00 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-008 0.60 Engine rotation speed sensor, replacing 8001 - 10999
386-011 1.00 Fuel level sender, replacing
386-088 0.70 Engine rotation speed sensor (camshaft), 8001 - 10999
replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
390-902 2.00 CareTrack, installing new
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
41 CLUTCH; TORQUE CONVERTER
414-003 2.00 Converter, replacing (engine removed)

42 TRANSMISSION, HYDRAULIC CONTROL


421-002 0.70 Transmission, check oil pressure 6302 - 10999
421-002 0.70 Transmission, check oil pressure 5001 - 6301
421-008 3.00 Gear selector valve, replacing
421-009 1.00 Gear selector valve removed, reconditioning
421-018 20.00 Converter, replacing
421-024 1.50 Lubrication oil valve, replacing
421-047 0.75 Gear selector, replacing
421-048 1.50 Gear selector valve, replacing one solenoid
421-052 3.00 Seal for front output shaft, replacing
421-054 2.50 Seal for rear output shaft, replacing
421-068 10.00 Transmission, removing (upwards)
421-069 15.00 Transmission, installing (from above)
421-071 32.00 Transmission removed, reconditioning

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-004 1.50 Propeller shaft, rear, replacing
451-007 1.50 Propeller shaft, in frame joint, replacing
451-010 2.00 Propeller shaft, front, replacing

236 Volvo Construction Equipment 7/11/2012


L180E
Op.no. time (h) Notes

46 FRONT AXLE; REAR AXLE


460-001 0.75 Axle suspension, measuring axial and radial
clearanse
460-002 1.50 Axle suspension, adjusting axial clearance
460-003 13.00 Axle suspension, replacing bushes/bearings and
seals
461-001 7.00 Axle, replacing
461-011 10.00 Centre gear , removing and fitting
461-012 10.00 Centre gear removed, reconditioning
461-013 11.00 Centre gear, axle removed, reconditioning
461-040 3.00 Hub reduction gear, replacing
461-041 11.00 Hub reduction gear, removed, reconditioning
461-043 4.50 Hub, replacing seal
463-001 9.00 Axle, replacing
463-002 4.50 Axle, removing
463-003 4.50 Axle, installing
463-011 11.00 Centre gear, removing and fitting
463-012 10.00 Centre gear removed, reconditioning
463-013 13.00 Centre gear, axle removed, reconditioning
463-040 3.00 Hub reduction gear, replacing
463-041 6.50 Hub reduction gear removed, reconditioning
463-043 4.50 Hub, replacing seal

49 MISCELLANEOUS
491-006 4.00 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 5.50 Brake discs, replacing on both sides
516-050 3.50 Brake piston, replacing seals
517-001 0.50 Brake linings, checking wear
517-004 5.50 Brake disc, replacing both sides
517-050 3.50 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.90 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-005 0.60 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-009 0.50 Foot brake valve removed, reconditioning
527-002 0.50 Accumulator, replacing

7/11/2012 Volvo Construction Equipment 237


L180E
Op.no. time (h) Notes

6 STEERING
64 STEERING
645-006 1.75 Steering cylinder, replacing
645-021 1.50 Valve block, replacing
645-028 0.10 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 2.50 Steering cylinder, repacking in machine
645-077 1.75 Steering cylinder removed, reconditioning incl
replacing bearings
645-078 1.50 Shift valve removed, reconditioning
645-079 2.50 Shift valve, replacing
645-081 1.50 Steering valve removed, reconditioning
645-082 1.50 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.30 Frame joint, checking clearance
741-036 19.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing
818-015 1.75 Cab suspension, rubber element replacing
818-020 1.75 Viscous cab suspension, changing one unit

82 ENGINE HOOD; MUDGUARD; FOOT STEP


821-001 0.70 Engine hood, removing 62501 - 69999
5001 - 7398
821-001 0.70 Engine hood, removing 8002 - 10999
821-001 0.70 Engine hood, removing 8001 - 10999

238 Volvo Construction Equipment 7/11/2012


L180E
Op.no. time (h) Notes

821-002 0.70 Engine hood, installing 5001 - 7398


62501 - 69999
821-002 1.00 Engine hood, installing 8002 - 10999
821-002 0.80 Engine hood, installing 8001 - 10999

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 2.00 Heater core, replacing
873-006 1.25 Fan motor, replacing
873-008 1.00 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 0.50 Belt, changing
874-010 3.00 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 0.75 Thermostat, replacing
874-015 1.50 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-017 0.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)
874-059 1.25 Evaporator, cleaning

7/11/2012 Volvo Construction Equipment 239


L180E
Op.no. time (h) Notes

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 3.00 Hydraulic system, bleeding

91 WORKING HYDRAULICS; SERVO HYDRAULICS


911-001 0.75 Oil return filter, replacing
911-005 2.00 Pump suction hose and pipe, replacing
911-011 4.00 Oil cooler, replacing
911-036 3.00 Hydraulic oil tank, removing
911-037 4.50 Hydraulic oil tank, installing
911-038 8.00 Hydraulic oil tank, replacing
912-001 6.50 Control valve, replacing
912-002 4.00 Control valve removed, reconditioning
912-018 0.20 Back-up valve, checking and adjusting
912-021 0.30 Shock valve, tilt function, checking
912-023 0.70 Shock valve lift function, checking
912-030 7.50 Central valve, replacing
913-003 0.20 Hydraulic pump, checking and adjusting standby
pressure
913-004 0.20 Hydraulic pump, checking and adjusting max
working pressure
913-034 0.40 Lifting time, checking
913-037 6.00 Hydraulic pump P1, replacing
913-037 6.00 Hydraulic pump P1, replacing
913-039 5.00 Hydraulic pump P3, replacing
913-040 6.50 Hydraulic pumps P2 and P3, replacing
914-054 1.75 Servo valve, adjusting control
914-055 0.25 Servo pressure, checking and adjusting
914-058 3.50 Servo valve, replacing
914-075 2.00 Servo valve removed, reconditioning
916-001 0.50 Boom suspension system, functional check
916-002 1.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-006 0.50 Boom suspension system, pressure reduction,
safety valve, checking and adjusting
916-019 0.50 3rd/4th hydraulic function, pressure check
916-070 0.10 Boom suspension system, hydraulic oil pressure
in accumulators, depressurizing
916-074 0.30 Boom suspension system, test drive with load
916-075 0.70 Boom Suspension System, valve block V1,
removing

240 Volvo Construction Equipment 7/11/2012


L180E
Op.no. time (h) Notes

916-076 1.25 Boom Suspension System, valve block V1,


installing
916-077 0.40 Boom Suspension System, valve block V2,
removing
916-078 1.25 Boom Suspension System, valve block V2,
installing

94 UNIT, LOAD HANDLING


945-002 4.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 4.50 Lift cylinder, repacking in machine
945-006 3.00 Lift cylinder removed, repacking
945-007 0.50 Tilt cylinder removed, replacing bearings "E-F"
945-008 4.00 Tilt cylinder, replacing
945-009 5.00 Tilt cylinder, repacking in machine
945-010 4.00 Tilt cylinder removed, repacking
945-012 0.70 Lift cylinder removed, replacing bearings "C-P"
945-013 3.00 Lift cylinder, rear bearing replacing
945-014 4.00 Lift cylinder, front bearing replacing
945-016 6.00 Lift frame, replacing bearing in upper mounting "O"
945-023 1.25 Tilting cylinder, replacing bearing 'E' in machine
945-024 4.00 Tilting cylinder, changing bearing 'E-F' in machine
945-054 3.00 Implement attachment, replacing
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 3.00 T-link, lower, replacing "IB"
945-065 2.00 T-link lower removed, replacing bearing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.50 Tilt arm, replacing bearing "GDF"
945-069 4.00 Tilt arm, replacing "GDF"
945-070 1.75 Tilt arm removed, replacing bearing "GDF"

7/11/2012 Volvo Construction Equipment 241


242 Volvo Construction Equipment 7/11/2012
L180E HL
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 5.00 Warranty inspection 100 hours
172-004 12.00 Warranty inspection 1000 hours
173-010 2.50 Maintenance service, every 500 hours
173-012 7.00 Maintenance service, every 1000 hours
173-014 10.00 Maintenance service, every 2000 hours
173-018 13.00 Maintenance service, every 4000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-070 4.50 Engine, removing 8001 - 10999
210-072 9.00 Engine, installing
211-002 16.00 Cylinder head, replacing gasket
214-036 2.50 Valve covers, fitting new gasket
216-018 19.00 Crankshaft, replacing rear oil seal
217-002 7.50 Sump gasket, replacing incl cleaning oil strainer
218-001 2.50 Rubber cushion, replacing

22 LUBRICATING SYSTEM
221-014 8.50 Oil pump, replacing

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-002 1.50 Feed pump, replacing
233-014 0.75 Fuel filters, replacing
233-097 0.75 Feed pump removed, reconditioning
234-010 4.00 Fuel tank, replacing

25 INLET SYSTEM; EXHAUST SYSTEM


250-901 2.00 Insulation for exhaust system, installation
251-002 1.00 Induction manifold, replacing gasket
251-004 2.00 Exhaust manifold, replacing gasket
252-020 1.00 Silencer, replacing
252-021 0.75 Exhaust pipe, flexible tube, replacing
255-071 1.50 Turbocharger, replacing

7/11/2012 Volvo Construction Equipment 243


L180E HL
Op.no. time (h) Notes

256-001 0.50 Air cleaner, cleaning filter element


256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.75 Preheating coil, replacing

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 5.00 Radiator, replacing
261-012 1.00 Radiator hose upper, replacing
261-014 3.00 Radiator hoses lower, replacing
262-071 1.50 Coolant pump removed, reconditioning
263-004 0.75 Fan motor, checking working pressure
263-010 0.50 Pump 3 (P3) standby pressure, checking
263-011 1.25 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing
334-001 0.25 Starter lock, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.25 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing

244 Volvo Construction Equipment 7/11/2012


L180E HL
Op.no. time (h) Notes

361-017 0.25 Flasher lamp, replacing glass or bulb


362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 1.00 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-011 1.00 Fuel level sender, replacing

39 MISCELLANEOUS
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
41 CLUTCH; TORQUE CONVERTER
414-003 2.00 Converter, replacing (engine removed)

42 TRANSMISSION, HYDRAULIC CONTROL


421-002 1.00 Transmission, check oil pressure
421-008 3.00 Gear selector valve, replacing
421-009 1.00 Gear selector valve removed, reconditioning
421-018 20.00 Converter, replacing
421-024 1.50 Lubrication oil valve, replacing
421-047 0.75 Gear selector, replacing
421-048 1.50 Gear selector valve, replacing one solenoid
421-052 3.00 Seal for front output shaft, replacing
421-054 3.00 Seal for rear output shaft, replacing
421-068 13.00 Transmission, removing (upwards)
421-069 14.00 Transmission, installing (from above)
421-071 32.00 Transmission removed, reconditioning

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-004 1.50 Propeller shaft, rear, replacing

7/11/2012 Volvo Construction Equipment 245


L180E HL
Op.no. time (h) Notes

451-007 1.50 Propeller shaft, in frame joint, replacing


451-010 2.00 Propeller shaft, front, replacing

46 FRONT AXLE; REAR AXLE


460-001 0.75 Axle suspension, measuring axial and radial
clearanse
460-002 1.50 Axle suspension, adjusting axial clearance
460-003 13.00 Axle suspension, replacing bushes/bearings and
seals
461-001 7.00 Axle, replacing
461-011 10.00 Centre gear , removing and fitting
461-012 10.00 Centre gear removed, reconditioning
461-013 11.00 Centre gear, axle removed, reconditioning
461-040 3.00 Hub reduction gear, replacing
461-041 11.00 Hub reduction gear, removed, reconditioning
461-043 4.50 Hub, replacing seal
463-001 9.00 Axle, replacing
463-002 4.50 Axle, removing
463-003 4.50 Axle, installing
463-011 11.00 Centre gear, removing and fitting
463-012 10.00 Centre gear removed, reconditioning
463-013 13.00 Centre gear, axle removed, reconditioning
463-040 3.00 Hub reduction gear, replacing
463-041 6.50 Hub reduction gear removed, reconditioning
463-043 4.50 Hub, replacing seal

49 MISCELLANEOUS
491-006 4.00 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 5.50 Brake discs, replacing on both sides
516-050 3.50 Brake piston, replacing seals
517-001 0.50 Brake linings, checking wear
517-004 5.50 Brake disc, replacing both sides
517-050 3.50 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.75 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding

246 Volvo Construction Equipment 7/11/2012


L180E HL
Op.no. time (h) Notes

527-002 0.50 Accumulator, replacing

6 STEERING
64 STEERING
645-006 1.75 Steering cylinder, replacing
645-021 1.50 Valve block, replacing
645-054 2.00 Steering cylinder, replacing bearings
645-060 2.50 Steering cylinder, repacking in machine
645-077 1.75 Steering cylinder removed, reconditioning incl
replacing bearings
645-078 1.50 Shift valve removed, reconditioning
645-079 2.50 Shift valve, replacing
645-081 1.50 Steering valve removed, reconditioning
647-093 1.00 Auxiliary steering, replacing hydraulic pump

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-036 19.00 Frame joint, replacing bearings

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing
818-015 1.75 Cab suspension, rubber element replacing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing

7/11/2012 Volvo Construction Equipment 247


L180E HL
Op.no. time (h) Notes

843-012 5.00 Rear window, replacing


843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 2.00 Heater core, replacing
873-006 1.25 Fan motor, replacing
873-008 1.00 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 0.50 Belt, changing
874-010 3.00 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 0.75 Thermostat, replacing
874-015 1.50 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-017 0.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)
874-059 1.25 Evaporator, cleaning

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 3.00 Hydraulic system, bleeding

91 WORKING HYDRAULICS; SERVO HYDRAULICS


911-001 0.75 Oil return filter, replacing
911-005 2.00 Pump suction hose and pipe, replacing
911-011 4.00 Oil cooler, replacing
911-038 8.00 Hydraulic oil tank, replacing
912-002 4.00 Control valve removed, reconditioning
912-023 0.70 Shock valve lift function, checking
914-054 1.75 Servo valve, adjusting control

248 Volvo Construction Equipment 7/11/2012


L180E HL
Op.no. time (h) Notes

914-055 0.25 Servo pressure, checking and adjusting


914-075 2.00 Servo valve removed, reconditioning
916-001 0.50 Boom suspension system, functional check
916-002 1.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-006 0.50 Boom suspension system, pressure reduction,
safety valve, checking and adjusting
916-019 0.50 3rd/4th hydraulic function, pressure check

94 UNIT, LOAD HANDLING


945-002 4.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-006 3.00 Lift cylinder removed, repacking
945-010 4.00 Tilt cylinder removed, repacking
945-013 3.00 Lift cylinder, rear bearing replacing
945-014 4.00 Lift cylinder, front bearing replacing
945-016 6.00 Lift frame, replacing bearing in upper mounting "O"
945-024 4.00 Tilting cylinder, changing bearing 'E-F' in machine
945-054 3.00 Implement attachment, replacing
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 3.00 T-link, lower, replacing "IB"
945-065 2.00 T-link lower removed, replacing bearing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.50 Tilt arm, replacing bearing "GDF"
945-069 4.00 Tilt arm, replacing "GDF"
945-070 1.75 Tilt arm removed, replacing bearing "GDF"

7/11/2012 Volvo Construction Equipment 249


250 Volvo Construction Equipment 7/11/2012
L220D
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 5.00 Warranty inspection 100 hours
172-004 12.00 Warranty inspection 1000 hours
173-007 1.75 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 9.00 Maintenance service, every 1000 hours
173-014 12.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter
173-075 2.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 10.00 Engine, removing
210-071 48.00 Engine removed, general overhaul
210-072 10.00 Engine, installing
211-002 7.00 Cylinder head, replacing gasket
211-018 13.00 Cylinder heads all, replacing gaskets
211-068 4.00 Cylinder heads all removed, decarbonizing and
grinding in valves
211-071 0.50 Cylinder head removed, pressure testing each
212-007 4.00 Cylinder block, liners removed, milling of all liner
locations
212-011 0.50 Cylinder, cylinder heads removed, measuring
wear in all cylinders
213-010 16.00 Cylinder liner and piston, replacing one
213-018 26.00 Cylinder liners and pistons, replacing all
214-012 1.50 Valves, adjusting
214-027 0.50 Inspection cover, fitting new gasket
214-030 16.00 Valves, decarbonizing and grinding
214-036 1.00 Valve covers, fitting new gasket
215-002 6.00 Timing gear cover, fitting new gasket in machine
215-030 7.00 Timing gear, replacing in machine
215-032 8.00 Timing gear case, fitting new gasket in machine
216-003 3.00 Main bearing shells, replacing, removed sump

7/11/2012 Volvo Construction Equipment 251


L220D
Op.no. time (h) Notes

216-014 3.50 Crankshaft, replacing front oil seal


216-015 7.50 Crankshaft engine removed, replacing
216-018 21.00 Crankshaft, replacing rear oil seal
217-002 9.00 Sump gasket, replacing incl cleaning oil strainer

22 LUBRICATING SYSTEM
221-006 1.00 Oil pressure relief valve, replacing
221-014 10.00 Oil pump, replacing
223-006 2.00 Oil cooler, replacing

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-002 0.75 Feed pump, replacing
233-004 0.50 Feed pump, checking feed pressure
233-014 0.50 Fuel filters, replacing
233-097 0.25 Feed pump removed, reconditioning
234-010 5.00 Fuel tank, replacing
236-001 0.50 Idling speed, checking and adjusting
236-002 0.25 Stall speed, checking
236-030 2.00 Injection timing, checking and adjusting
236-044 1.00 Injection timing, checking
236-073 3.50 Injection pump, replacing incl setting injection
timing
237-002 2.00 Injectors, replacing all
237-004 0.75 Injector, replacing one
237-007 0.25 Overflow valve, replacing
237-016 2.00 Injectors, replacing copper sleeve in machine
237-018 0.75 Delivery pipe, replacing one
237-019 1.00 Fuel line, leak-off pipe, replacing
237-080 2.00 Injectors removed, reconditioning all

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 2.00 Exhaust manifold, replacing gasket
252-019 1.25 Silencer, rubber cuchion replacing
252-020 1.50 Silencer, replacing
252-021 0.75 Exhaust pipe, flexible tube, replacing
255-071 1.50 Turbocharger, replacing
255-073 2.00 Turbocharger removed, reconditioning
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.75 Preheating coil, replacing
258-002 5.00 Intercooler, replacing

252 Volvo Construction Equipment 7/11/2012


L220D
Op.no. time (h) Notes

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 3.50 Radiator, replacing
261-012 1.50 Radiator hose upper, replacing
261-014 2.50 Radiator hoses lower, replacing
261-018 1.00 Expansion tank, replacing
262-002 1.50 Coolant pump, replacing
262-071 1.50 Coolant pump removed, reconditioning
262-098 1.50 Thermostat, replacing
263-004 0.75 Fan motor, checking working pressure
263-006 1.50 Fan hydraulically driven, removing pump
263-007 1.50 Fan hydraulically driven, fitting pump
263-010 0.50 Pump 3 (P3) standby pressure, checking
263-011 1.25 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)
263-012 0.50 Fan belt and/or alternator belt, replacing
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts

27 ENGINE CONTROL
273-021 0.75 Stop magnet, replacing
273-023 0.50 Electrical engine shut down, check and adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing
334-001 0.25 Starter lock, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.25 Rear lamp, replacing one

7/11/2012 Volvo Construction Equipment 253


L220D
Op.no. time (h) Notes

353-018 0.25 Rear lamp, replacing glass or bulb


356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

37 CABLE; FUSE; RELAY


372-031 1.00 Relay CU201, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 0.50 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-011 1.00 Fuel level sender, replacing
386-032 0.75 Sensor unit (differential lock), replacing
386-035 0.75 Induction sensor (lifting cylinder) replacing
386-036 1.00 Induction sensor (tilt cylinder) replacing
387-005 0.50 Information display, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
41 CLUTCH; TORQUE CONVERTER
414-003 2.00 Converter, replacing (engine removed)

42 TRANSMISSION, HYDRAULIC CONTROL


421-002 1.00 Transmission, check oil pressure
421-008 3.00 Gear selector valve, replacing
421-009 1.00 Gear selector valve removed, reconditioning
421-018 22.00 Converter, replacing

254 Volvo Construction Equipment 7/11/2012


L220D
Op.no. time (h) Notes

421-024 1.50 Lubrication oil valve, replacing


421-047 0.75 Gear selector, replacing
421-048 1.50 Gear selector valve, replacing one solenoid
421-052 3.00 Seal for front output shaft, replacing
421-054 3.00 Seal for rear output shaft, replacing
421-068 13.00 Transmission, removing (upwards)
421-069 14.00 Transmission, installing (from above)
421-071 32.00 Transmission removed, reconditioning

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-004 1.50 Propeller shaft, rear, replacing
451-007 1.50 Propeller shaft, in frame joint, replacing
451-010 2.00 Propeller shaft, front, replacing
451-013 1.50 Propeller shaft, removed reconditioning

46 FRONT AXLE; REAR AXLE


460-001 0.75 Axle suspension, measuring axial and radial
clearanse
460-003 11.00 Axle suspension, replacing bushes/bearings and
seals
461-001 7.00 Axle, replacing
461-011 10.00 Centre gear , removing and fitting
461-012 10.00 Centre gear removed, reconditioning
461-013 11.00 Centre gear, axle removed, reconditioning
461-014 1.50 Pinion front, fitting new gasket
461-040 3.00 Hub reduction gear, replacing
461-041 11.00 Hub reduction gear, removed, reconditioning
461-043 4.50 Hub, replacing seal
461-052 0.25 Differential lock front, repacking excl adjusting
461-053 0.75 Differential lock, adjusting engagement
463-001 8.00 Axle, replacing
463-002 4.50 Axle, removing
463-003 4.50 Axle, installing
463-011 11.00 Centre gear, removing and fitting
463-012 10.00 Centre gear removed, reconditioning
463-013 13.00 Centre gear, axle removed, reconditioning
463-014 1.50 Pinion rear, fitting new gasket
463-040 3.00 Hub reduction gear, replacing
463-041 6.50 Hub reduction gear removed, reconditioning
463-043 4.50 Hub, replacing seal

7/11/2012 Volvo Construction Equipment 255


L220D
Op.no. time (h) Notes

49 MISCELLANEOUS
491-006 3.00 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 4.50 Brake discs, replacing on both sides
516-050 3.50 Brake piston, replacing seals
517-001 0.50 Brake linings, checking wear
517-004 4.50 Brake disc, replacing both sides
517-050 3.50 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
523-041 2.50 Axle oil cooler (front) replacing
525-008 2.00 Foot brake valve, replacing
525-009 2.50 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure
527-002 0.50 Accumulator, replacing
527-004 2.50 Hydraulic pump, replacing

55 PARKING BRAKE
550-006 3.50 Parking brake, replacing discs and seals
550-008 1.00 Parking brake, replacing control valve

6 STEERING
64 STEERING
641-021 1.50 Adjustable steering column, replacing
645-006 1.75 Steering cylinder, replacing
645-010 6.00 Hydraulic pump, replacing
645-021 1.50 Valve block, replacing
645-028 0.50 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 2.50 Steering cylinder, repacking in machine

256 Volvo Construction Equipment 7/11/2012


L220D
Op.no. time (h) Notes

645-077 1.75 Steering cylinder removed, reconditioning incl


replacing bearings
645-079 2.50 Shift valve, replacing
645-081 1.50 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed
660-005 1.25 CDC, checking lever signals

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 19.00 Frame joint, replacing bearings

75 AXLE SUSPENSION
755-003 7.00 Axle suspension, replacing bushes and seals

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing
818-015 1.75 Cab suspension, rubber element replacing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

7/11/2012 Volvo Construction Equipment 257


L220D
Op.no. time (h) Notes

85 CAB INTERIOR/UPHOLSTERY
852-006 1.25 Operators seat, air suspensioned, control,
replacing
852-007 1.25 Operators seat (air suspensioned), backrest
replacing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 1.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-010 4.00 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 0.75 Thermostat, replacing
874-015 1.50 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-019 0.50 Compressor, replacing valve plate (compressor
removed)
874-059 1.25 Evaporator, cleaning

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-001 0.75 Oil return filter, replacing
911-005 2.00 Pump suction hose and pipe, replacing
911-011 3.50 Oil cooler, replacing
911-021 3.00 Feedline from pumps to valve body, pipe replacing
911-038 5.00 Hydraulic oil tank, replacing
912-001 6.00 Control valve, replacing
912-002 4.00 Control valve removed, reconditioning
912-004 0.75 Control valve, low pressure valve, replacing
912-009 0.50 Shock valve, tilt function, checking and adjusting
912-030 2.50 Central valve, replacing

258 Volvo Construction Equipment 7/11/2012


L220D
Op.no. time (h) Notes

913-003 0.75 Hydraulic pump, checking and adjusting standby


pressure
913-004 0.50 Hydraulic pump, checking and adjusting max
working pressure
913-010 4.50 Hydraulic pump, replacing
913-011 2.00 Hydraulic pump removed, reconditioning
913-019 4.50 Hydraulic pump, compensator replacing
914-054 1.75 Servo valve, adjusting control
914-055 0.75 Servo pressure, checking and adjusting
914-057 0.50 Servo pressure, check
914-058 3.00 Servo valve, replacing
914-075 2.00 Servo valve removed, reconditioning
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 1.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-006 0.50 Boom suspension system, pressure reduction,
safety valve, checking and adjusting
916-019 0.50 3rd/4th hydraulic function, pressure check
916-071 2.50 Boom suspension system, changing accumulator
916-073 3.00 Boom suspension system, changing valve

94 UNIT, LOAD HANDLING


945-002 4.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 5.50 Lift cylinder, repacking in machine
945-006 3.00 Lift cylinder removed, repacking
945-007 0.75 Tilt cylinder removed, replacing bearings "E-F"
945-008 5.00 Tilt cylinder, replacing
945-009 8.00 Tilt cylinder, repacking in machine
945-010 4.00 Tilt cylinder removed, repacking
945-012 1.00 Lift cylinder removed, replacing bearings "C-P"
945-013 3.00 Lift cylinder, rear bearing replacing
945-014 4.00 Lift cylinder, front bearing replacing
945-016 6.00 Lift frame, replacing bearing in upper mounting "O"
945-024 4.00 Tilting cylinder, changing bearing 'E-F' in machine
945-054 3.00 Implement attachment, replacing
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 3.00 T-link, lower, replacing "IB"
945-065 2.00 T-link lower removed, replacing bearing "IB"

7/11/2012 Volvo Construction Equipment 259


L220D
Op.no. time (h) Notes

945-066 2.00 Tilt link, replacing "GH"


945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.50 Tilt arm, replacing bearing "GDF"
945-069 4.00 Tilt arm, replacing "GDF"
945-070 1.75 Tilt arm removed, replacing bearing "GDF"

99 MISCELLANEOUS
993-021 2.50 Automatic lubrication pump, replacing

260 Volvo Construction Equipment 7/11/2012


L220E
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 5.50 Warranty inspection 100 hours
172-004 11.00 Warranty inspection 1000 hours
173-002 0.40 Maintenance service, daily
173-004 0.80 Maintenance service, every 50 hours
173-007 1.50 Maintenance service, every 250 hours
173-010 6.00 Maintenance service, every 500 hours
173-012 8.50 Maintenance service, every 1000 hours
173-014 9.50 Maintenance service, every 2000 hours
173-018 13.00 Maintenance service, every 4000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 7.50 Compression test 2001 - 3566
210-002 7.00 Compression test 4001 - 5999
210-070 4.50 Engine, removing 4001 - 5999
210-072 6.00 Engine, installing 4001 - 5999
210-090 0.30 Camshaft and flywheel signals, checking with
VCADS Pro and oscilloscope
211-002 16.00 Cylinder head, replacing gasket
214-012 4.00 Valves, adjusting 4008 - 5999
214-012 4.00 Valves, adjusting 2005 - 3566
214-036 2.50 Valve covers, fitting new gasket
215-032 13.00 Timing gear case, fitting new gasket in machine 2001 - 3566
216-018 19.00 Crankshaft, replacing rear oil seal
217-002 7.50 Sump gasket, replacing incl cleaning oil strainer
218-001 2.50 Rubber cushion, replacing

22 LUBRICATING SYSTEM
221-014 8.50 Oil pump, replacing
221-022 0.20 Lubrication oil pressure, checking with pressure 4001 - 5999
gauge
223-006 3.00 Oil cooler, replacing

7/11/2012 Volvo Construction Equipment 261


L220E
Op.no. time (h) Notes

23 FUEL SYSTEM
233-001 0.30 Fuel system, bleeding
233-001 0.30 Fuel system, bleeding 4003 - 5999
233-002 1.50 Feed pump, replacing
233-009 0.20 Fuel pump (valves), inspection
233-010 0.90 Fuel pump, inspection
233-014 0.75 Fuel filters, replacing
233-020 0.10 Fuel filter, checking
233-097 0.75 Feed pump removed, reconditioning
234-010 4.00 Fuel tank, replacing
237-012 5.50 Unit injector, replacing 4003 - 5999

25 INLET SYSTEM; EXHAUST SYSTEM


250-901 2.00 Insulation for exhaust system, installation
251-002 1.00 Induction manifold, replacing gasket
251-004 2.00 Exhaust manifold, replacing gasket
252-020 1.00 Silencer, replacing
252-021 0.75 Exhaust pipe, flexible tube, replacing
255-002 0.80 Turbocharger, inspection
255-071 1.50 Turbocharger, replacing
256-001 0.50 Air cleaner, cleaning filter element
256-002 0.25 Air cleaner, checking prssure drop indicator
256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.75 Preheating coil, replacing
258-002 4.00 Intercooler, replacing 2001 - 3566
258-030 0.80 Charge air system, inspection

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 6.00 Radiator, replacing 4003 - 5999
261-012 1.00 Radiator hose upper, replacing
261-014 3.00 Radiator hoses lower, replacing
262-002 2.00 Coolant pump, replacing
262-071 1.50 Coolant pump removed, reconditioning
262-098 1.75 Thermostat, replacing
263-004 0.75 Fan motor, checking working pressure
263-010 0.50 Pump 3 (P3) standby pressure, checking
263-011 0.10 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)
263-011 0.40 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)
263-051 1.50 Cooling fan hydraulics, funktion check
263-062 4.50 Cooling fan motor, changing 4003 - 5999

262 Volvo Construction Equipment 7/11/2012


L220E
Op.no. time (h) Notes

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing
334-001 0.25 Starter lock, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.25 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 1.00 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-008 0.60 Engine rotation speed sensor, replacing 4001 - 5999
386-011 1.00 Fuel level sender, replacing

7/11/2012 Volvo Construction Equipment 263


L220E
Op.no. time (h) Notes

386-088 0.70 Engine rotation speed sensor (camshaft), 4001 - 5999


replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
390-902 2.00 CareTrack, installing new
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
41 CLUTCH; TORQUE CONVERTER
414-003 2.00 Converter, replacing (engine removed)

42 TRANSMISSION, HYDRAULIC CONTROL


421-002 0.70 Transmission, check oil pressure 3018 - 5999
421-002 0.70 Transmission, check oil pressure 2001 - 3017
421-008 3.00 Gear selector valve, replacing
421-009 1.00 Gear selector valve removed, reconditioning
421-018 19.00 Converter, replacing
421-024 1.50 Lubrication oil valve, replacing
421-047 0.75 Gear selector, replacing
421-048 1.50 Gear selector valve, replacing one solenoid
421-052 3.00 Seal for front output shaft, replacing
421-054 3.00 Seal for rear output shaft, replacing
421-068 10.00 Transmission, removing (upwards)
421-069 15.00 Transmission, installing (from above)
421-071 32.00 Transmission removed, reconditioning

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-004 1.50 Propeller shaft, rear, replacing
451-007 1.50 Propeller shaft, in frame joint, replacing
451-010 2.00 Propeller shaft, front, replacing

46 FRONT AXLE; REAR AXLE


460-001 0.75 Axle suspension, measuring axial and radial
clearanse
460-003 11.00 Axle suspension, replacing bushes/bearings and
seals
461-001 7.00 Axle, replacing
461-011 10.00 Centre gear , removing and fitting
461-012 10.00 Centre gear removed, reconditioning
461-013 11.00 Centre gear, axle removed, reconditioning

264 Volvo Construction Equipment 7/11/2012


L220E
Op.no. time (h) Notes

461-040 3.00 Hub reduction gear, replacing


461-041 11.00 Hub reduction gear, removed, reconditioning
461-043 4.50 Hub, replacing seal
463-001 9.00 Axle, replacing
463-002 4.50 Axle, removing
463-003 4.50 Axle, installing
463-011 11.00 Centre gear, removing and fitting
463-012 10.00 Centre gear removed, reconditioning
463-013 13.00 Centre gear, axle removed, reconditioning
463-040 3.00 Hub reduction gear, replacing
463-041 6.50 Hub reduction gear removed, reconditioning
463-043 4.50 Hub, replacing seal

49 MISCELLANEOUS
491-006 4.00 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
517-001 0.50 Brake linings, checking wear
517-004 5.50 Brake disc, replacing both sides
517-050 3.50 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.90 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-005 0.60 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-009 0.50 Foot brake valve removed, reconditioning
527-002 0.50 Accumulator, replacing

6 STEERING
64 STEERING
645-006 1.75 Steering cylinder, replacing
645-021 1.50 Valve block, replacing
645-028 0.10 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 2.50 Steering cylinder, repacking in machine
645-077 1.75 Steering cylinder removed, reconditioning incl
replacing bearings

7/11/2012 Volvo Construction Equipment 265


L220E
Op.no. time (h) Notes

645-078 1.50 Shift valve removed, reconditioning


645-079 2.50 Shift valve, replacing
645-081 1.50 Steering valve removed, reconditioning
645-082 1.50 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed
660-005 1.25 CDC, checking lever signals

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.30 Frame joint, checking clearance
741-036 19.00 Frame joint, replacing bearings

75 AXLE SUSPENSION
755-003 7.00 Axle suspension, replacing bushes and seals

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 1.00 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing
818-015 1.75 Cab suspension, rubber element replacing
818-020 1.75 Viscous cab suspension, changing one unit

82 ENGINE HOOD; MUDGUARD; FOOT STEP


821-001 0.70 Engine hood, removing 2001 - 3566
821-001 0.70 Engine hood, removing 4001 - 5999
821-001 0.70 Engine hood, removing 4001 - 5999
821-002 0.70 Engine hood, installing 2001 - 3566
821-002 1.00 Engine hood, installing 4001 - 5999
821-002 0.80 Engine hood, installing 4001 - 5999

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

266 Volvo Construction Equipment 7/11/2012


L220E
Op.no. time (h) Notes

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 2.00 Heater core, replacing
873-006 1.25 Fan motor, replacing
873-008 1.00 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 0.50 Belt, changing
874-010 3.00 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 0.75 Thermostat, replacing
874-015 1.50 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-017 0.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)
874-059 1.25 Evaporator, cleaning

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 3.00 Hydraulic system, bleeding

91 WORKING HYDRAULICS; SERVO HYDRAULICS


911-001 0.75 Oil return filter, replacing
911-005 2.00 Pump suction hose and pipe, replacing
911-011 4.00 Oil cooler, replacing
911-036 3.00 Hydraulic oil tank, removing
911-037 4.50 Hydraulic oil tank, installing

7/11/2012 Volvo Construction Equipment 267


L220E
Op.no. time (h) Notes

911-038 8.00 Hydraulic oil tank, replacing


912-001 6.50 Control valve, replacing
912-002 4.00 Control valve removed, reconditioning
912-018 0.20 Back-up valve, checking and adjusting
912-019 0.50 Shock valve removed, checking
912-021 0.30 Shock valve, tilt function, checking
912-023 0.70 Shock valve lift function, checking
912-030 7.50 Central valve, replacing
913-003 0.20 Hydraulic pump, checking and adjusting standby
pressure
913-004 0.20 Hydraulic pump, checking and adjusting max
working pressure
913-034 0.40 Lifting time, checking
913-037 6.00 Hydraulic pump P1, replacing
913-039 5.00 Hydraulic pump P3, replacing
913-040 6.50 Hydraulic pumps P2 and P3, replacing
914-054 1.75 Servo valve, adjusting control
914-055 0.25 Servo pressure, checking and adjusting
914-058 3.50 Servo valve, replacing
914-075 2.00 Servo valve removed, reconditioning
916-001 0.50 Boom suspension system, functional check
916-002 1.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-006 0.50 Boom suspension system, pressure reduction,
safety valve, checking and adjusting
916-019 0.50 3rd/4th hydraulic function, pressure check
916-070 0.10 Boom suspension system, hydraulic oil pressure
in accumulators, depressurizing
916-074 0.30 Boom suspension system, test drive with load
916-075 0.70 Boom Suspension System, valve block V1,
removing
916-076 1.25 Boom Suspension System, valve block V1,
installing
916-077 0.40 Boom Suspension System, valve block V2,
removing
916-078 1.25 Boom Suspension System, valve block V2,
installing

94 UNIT, LOAD HANDLING


945-002 4.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 4.50 Lift cylinder, repacking in machine

268 Volvo Construction Equipment 7/11/2012


L220E
Op.no. time (h) Notes

945-006 3.00 Lift cylinder removed, repacking


945-007 0.50 Tilt cylinder removed, replacing bearings "E-F"
945-008 4.00 Tilt cylinder, replacing
945-009 5.00 Tilt cylinder, repacking in machine
945-010 4.00 Tilt cylinder removed, repacking
945-012 0.70 Lift cylinder removed, replacing bearings "C-P"
945-013 3.00 Lift cylinder, rear bearing replacing
945-014 4.00 Lift cylinder, front bearing replacing
945-016 6.00 Lift frame, replacing bearing in upper mounting "O"
945-023 1.25 Tilting cylinder, replacing bearing 'E' in machine
945-024 4.00 Tilting cylinder, changing bearing 'E-F' in machine
945-054 3.00 Implement attachment, replacing
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 3.00 T-link, lower, replacing "IB"
945-065 2.00 T-link lower removed, replacing bearing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.50 Tilt arm, replacing bearing "GDF"
945-069 4.00 Tilt arm, replacing "GDF"
945-070 1.75 Tilt arm removed, replacing bearing "GDF"

7/11/2012 Volvo Construction Equipment 269


270 Volvo Construction Equipment 7/11/2012
L330D
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
172-002 5.50 Warranty inspection 100 hours
172-004 13.00 Warranty inspection 1000 hours
173-007 1.75 Maintenance service, every 250 hours
173-010 4.00 Maintenance service, every 500 hours
173-012 8.00 Maintenance service, every 1000 hours
173-014 13.00 Maintenance service, every 2000 hours
173-059 1.25 Engine, changing oil and filter
173-061 2.00 Transmission, changing oil and filter
173-070 3.00 Axles, changing oil
173-074 2.00 Hydraulic oil tank, changing oil and filter
173-075 3.00 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-070 10.00 Engine, removing
210-071 55.00 Engine removed, general overhaul
210-072 10.00 Engine, installing
217-002 8.00 Sump gasket, replacing incl cleaning oil strainer

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
234-010 5.00 Fuel tank, replacing
236-001 0.25 Idling speed, checking and adjusting
236-002 0.25 Stall speed, checking
236-011 2.50 Fuel pump element, replacing
236-030 2.00 Injection timing, checking and adjusting
236-031 1.25 Injection timing adjuster, checking
236-044 1.00 Injection timing, checking

25 INLET SYSTEM; EXHAUST SYSTEM


252-020 2.00 Silencer, replacing
252-021 1.00 Exhaust pipe, flexible tube, replacing

26 COOLING SYSTEM
261-008 8.00 Radiator, replacing
262-002 3.50 Coolant pump, replacing
262-003 2.00 Coolant pump (intercooler), replacing
263-001 1.50 Fan motor, removing
263-003 1.50 Fan motor, installing

7/11/2012 Volvo Construction Equipment 271


L330D
Op.no. time (h) Notes

263-004 0.50 Fan motor, checking working pressure


263-005 1.00 Fan motor, adjusting working pressure
263-006 2.00 Fan hydraulically driven, removing pump
263-007 2.00 Fan hydraulically driven, fitting pump
263-010 0.75 Pump 3 (P3) standby pressure, checking
263-011 1.00 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)
263-016 0.75 Maximum fan speed, checking

27 ENGINE CONTROL
273-021 0.75 Stop magnet, replacing
273-023 0.25 Electrical engine shut down, check and adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-001 0.50 Battery charging capacity, checking
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine

33 STARTING SYSTEM
331-018 1.25 Starter motor, replacing
334-001 0.25 Starter lock, replacing

35 LIGHTING
352-002 0.50 Headlights, adjusting
352-024 0.75 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 1.00 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing

272 Volvo Construction Equipment 7/11/2012


L330D
Op.no. time (h) Notes

364-004 0.25 Switch, replacing


364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

37 CABLE; FUSE; RELAY


372-031 1.00 Relay CU201, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-011 1.00 Fuel level sender, replacing
387-005 0.50 Information display, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 0.70 Transmission, check oil pressure
421-018 24.00 Converter, replacing
421-047 0.75 Gear selector, replacing
421-068 20.00 Transmission, removing (upwards)
421-069 22.00 Transmission, installing (from above)
421-070 18.00 Transmission, removing
421-071 36.00 Transmission removed, reconditioning
421-072 18.00 Transmission, installing
421-076 5.50 Clutch disk, replacing in machine, 1:st and 2:nd
421-080 3.00 Clutch discs, forward - reverse or 3rd - 4th,
changing in machine
421-081 8.00 Clutch drum bearings, 1st or 2nd, changing in
machine
421-082 6.00 Clutch drum bearings, forward, reverse, 3rd or 4th,
changing in machine

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-003 4.00 Midmont bearing removed, reconditioning
451-004 0.75 Propeller shaft, rear, replacing
451-007 0.75 Propeller shaft, in frame joint, replacing
451-010 0.75 Propeller shaft, front, replacing

46 FRONT AXLE; REAR AXLE


461-005 4.00 Drive shaft, replacing one side
461-006 15.00 Spindle, replacing one side

7/11/2012 Volvo Construction Equipment 273


L330D
Op.no. time (h) Notes

461-007 9.00 Hub bearing, replacing


461-011 16.00 Centre gear , removing and fitting
461-012 10.00 Centre gear removed, reconditioning
461-041 11.00 Hub reduction gear, removed, reconditioning
461-043 9.00 Hub, replacing seal
463-001 13.00 Axle, replacing
463-002 6.00 Axle, removing
463-003 7.00 Axle, installing
463-005 4.00 Drive shaft, replacing one side
463-006 15.00 Spindle, replacing one side
463-007 9.00 Hub bearing, replacing
463-011 18.00 Centre gear, removing and fitting
463-013 11.00 Centre gear, axle removed, reconditioning
463-041 11.00 Hub reduction gear removed, reconditioning
463-043 9.00 Hub, replacing seal

49 MISCELLANEOUS
491-006 3.00 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 12.00 Brake discs, replacing on both sides
516-005 8.00 Brake disc, replacing
517-001 0.50 Brake linings, checking wear
517-004 12.00 Brake disc, replacing both sides
517-005 8.00 Brake disc, replacing

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-005 0.50 Brake system, check and adjusting pressure in
circuit
523-001 2.50 Oil pump, replacing
527-002 2.50 Accumulator, replacing
527-004 4.00 Hydraulic pump, replacing
527-009 1.00 Accumulator, check
527-010 1.50 Accumulator, check and adjusting
527-011 1.00 Accumulator, reconditioning

55 PARKING BRAKE
550-002 0.75 Parking brake, adjusting

274 Volvo Construction Equipment 7/11/2012


L330D
Op.no. time (h) Notes

6 STEERING
64 STEERING
641-021 2.00 Adjustable steering column, replacing
645-006 5.00 Steering cylinder, replacing
645-010 12.00 Hydraulic pump, replacing
645-028 1.00 Steering system, checking and adjusting working
pressure
645-054 4.00 Steering cylinder, replacing bearings
645-077 4.00 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
645-089 4.00 Flow amplifier, replacing
645-090 3.00 Flow amplifier removed, reconditioning

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.75 Frame joint, checking clearance
741-036 27.00 Frame joint, replacing bearings

75 AXLE SUSPENSION
755-001 1.00 Axle suspension, measuring axial and radial
clearanse
755-002 2.50 Axle suspension, adjusting axial clearance
755-003 25.00 Axle suspension, replacing bushes and seals

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 2.50 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 5.00 Cab, removing
810-002 6.00 Cab, installing
818-015 2.00 Cab suspension, rubber element replacing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

7/11/2012 Volvo Construction Equipment 275


L330D
Op.no. time (h) Notes

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-007 1.25 Operators seat (air suspensioned), backrest
replacing

86 PROTECTIVE EQUIPMENT, not specified in a special group


860-001 3.00 Roll-over bar ROPS, fitting
860-002 2.50 Roll-over bar ROPS, removing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 1.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 0.75 Cooling unit, performance test
874-005 1.00 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-010 4.00 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 0.75 Thermostat, replacing
874-015 1.50 Compressor, replacing shaft seal (compressor
removed)
874-016 0.75 Compressor, replacing magnetic clutch
(compressor removed)
874-017 0.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-001 1.00 Oil return filter, replacing
911-005 4.00 Pump suction hose and pipe, replacing

276 Volvo Construction Equipment 7/11/2012


L330D
Op.no. time (h) Notes

911-038 8.00 Hydraulic oil tank, replacing


912-001 5.00 Control valve, replacing
912-009 1.00 Shock valve, tilt function, checking and adjusting
912-019 0.50 Shock valve removed, checking
913-003 1.50 Hydraulic pump, checking and adjusting standby
pressure
913-004 1.00 Hydraulic pump, checking and adjusting max
working pressure
913-010 11.00 Hydraulic pump, replacing
914-054 1.75 Servo valve, adjusting control
914-055 0.60 Servo pressure, checking and adjusting
914-057 0.25 Servo pressure, check
916-001 0.75 Boom suspension system, functional check
916-002 1.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning

94 UNIT, LOAD HANDLING


945-002 7.00 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-004 5.50 Lift cylinder, replacing
945-005 6.50 Lift cylinder, repacking in machine
945-008 4.00 Tilt cylinder, replacing
945-009 6.00 Tilt cylinder, repacking in machine
945-013 7.00 Lift cylinder, rear bearing replacing
945-014 3.00 Lift cylinder, front bearing replacing
945-024 5.50 Tilting cylinder, changing bearing 'E-F' in machine
945-066 2.50 Tilt link, replacing "GH"
945-067 1.75 Tilt link removed, replacing bearings "GH"
945-068 5.00 Tilt arm, replacing bearing "GDF"

7/11/2012 Volvo Construction Equipment 277


278 Volvo Construction Equipment 7/11/2012
L50D
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 4.50 Warranty inspection 100 hours
172-004 11.00 Warranty inspection 1000 hours
173-007 1.75 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 7.50 Maintenance service, every 1000 hours
173-014 12.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.00 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter
173-075 2.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 8.00 Engine, removing
210-071 30.00 Engine removed, general overhaul
210-072 9.00 Engine, installing
211-002 7.00 Cylinder head, replacing gasket
211-068 3.00 Cylinder heads all removed, decarbonizing and
grinding in valves
211-071 1.00 Cylinder head removed, pressure testing each
212-011 0.50 Cylinder, cylinder heads removed, measuring
wear in all cylinders
213-010 14.00 Cylinder liner and piston, replacing one
213-018 18.00 Cylinder liners and pistons, replacing all
214-012 1.50 Valves, adjusting
215-002 3.00 Timing gear cover, fitting new gasket in machine
215-030 4.00 Timing gear, replacing in machine
215-032 5.00 Timing gear case, fitting new gasket in machine
216-014 2.00 Crankshaft, replacing front oil seal
216-018 8.00 Crankshaft, replacing rear oil seal
217-002 3.50 Sump gasket, replacing incl cleaning oil strainer

22 LUBRICATING SYSTEM
221-006 4.00 Oil pressure relief valve, replacing
223-006 1.00 Oil cooler, replacing

7/11/2012 Volvo Construction Equipment 279


L50D
Op.no. time (h) Notes

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-002 0.50 Feed pump, replacing
233-004 0.50 Feed pump, checking feed pressure
233-014 0.50 Fuel filters, replacing
233-097 0.50 Feed pump removed, reconditioning
234-010 3.00 Fuel tank, replacing
236-001 0.75 Idling speed, checking and adjusting
236-030 1.50 Injection timing, checking and adjusting
236-070 3.00 Injection pump, removing
236-072 4.50 Injection pump, fitting incl setting injection timing
236-073 3.00 Injection pump, replacing incl setting injection
timing
236-075 6.50 Injection pump, replacing incl setting injection
timing (low emission)
237-002 2.00 Injectors, replacing all
237-004 0.50 Injector, replacing one
237-018 0.50 Delivery pipe, replacing one
237-080 1.50 Injectors removed, reconditioning all

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.25 Induction manifold, replacing gasket
251-004 1.50 Exhaust manifold, replacing gasket
252-020 1.25 Silencer, replacing
252-021 0.50 Exhaust pipe, flexible tube, replacing
255-071 1.25 Turbocharger, replacing
255-073 2.00 Turbocharger removed, reconditioning
256-002 0.50 Air cleaner, checking prssure drop indicator
256-006 0.50 Preheating coil, replacing

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 1.50 Radiator, replacing
261-012 1.00 Radiator hose upper, replacing
261-014 1.00 Radiator hoses lower, replacing
262-002 2.00 Coolant pump, replacing
262-071 1.00 Coolant pump removed, reconditioning
262-098 1.25 Thermostat, replacing
263-001 1.75 Fan motor, removing
263-003 2.00 Fan motor, installing
263-012 0.50 Fan belt and/or alternator belt, replacing
263-013 0.25 Fan belt and/or alternator belt, checking and
adjusting tension
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts

280 Volvo Construction Equipment 7/11/2012


L50D
Op.no. time (h) Notes

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing
311-006 0.50 Earth lead to battery, replacing
311-008 1.00 Starter motor lead to battery, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 0.75 Starter motor, replacing
334-001 0.50 Starter lock, replacing

35 LIGHTING
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.50 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 0.50 Transmission oil pressure sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-011 1.25 Fuel level sender, replacing
386-013 0.50 Hydrostatic system temperature sensor, replacing
386-014 0.50 Hydrostatic system oil pressure sensor, replacing
386-016 1.00 Temperature sensor cooling system, replacing

7/11/2012 Volvo Construction Equipment 281


L50D
Op.no. time (h) Notes

387-005 0.50 Information display, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 0.75 Transmission, check oil pressure
421-004 1.00 Oil pump, replacing
421-025 2.00 Transmission, replacing solenoid
421-047 0.75 Gear selector, replacing
421-052 1.00 Seal for front output shaft, replacing
421-054 1.00 Seal for rear output shaft, replacing
421-070 7.00 Transmission, removing
421-071 12.00 Transmission removed, reconditioning
421-072 7.50 Transmission, installing

44 HYDROSTATIC DRIVE
441-001 1.00 Hydrostatic system, checking oil pressure
441-002 6.00 Hydraulic motor, replacing
441-004 1.50 Hydraulic engine solenoid valve, replacing
442-001 7.00 Hydraulic pump, replacing
442-003 1.50 Hydraulic pump solenoid replacing

45 PROPELLER SHAFT
451-002 1.50 Support or intermediate bearing, replacing
451-004 1.00 Propeller shaft, rear, replacing
451-007 1.00 Propeller shaft, in frame joint, replacing
451-010 1.00 Propeller shaft, front, replacing
451-013 1.00 Propeller shaft, removed reconditioning

46 FRONT AXLE; REAR AXLE


461-001 4.00 Axle, replacing
461-002 1.75 Axle, removing
461-003 2.00 Axle, installing
461-005 1.50 Drive shaft, replacing one side
461-013 15.00 Centre gear, axle removed, reconditioning
461-014 1.75 Pinion front, fitting new gasket
461-040 1.00 Hub reduction gear, replacing
461-041 4.50 Hub reduction gear, removed, reconditioning
461-042 3.50 Hub reduction gear, reconditioning one side
461-043 2.50 Hub, replacing seal
463-001 8.00 Axle, replacing

282 Volvo Construction Equipment 7/11/2012


L50D
Op.no. time (h) Notes

463-002 3.50 Axle, removing


463-003 4.50 Axle, installing
463-005 3.50 Drive shaft, replacing one side
463-013 15.00 Centre gear, axle removed, reconditioning
463-014 1.50 Pinion rear, fitting new gasket
463-040 1.00 Hub reduction gear, replacing
463-041 4.50 Hub reduction gear removed, reconditioning
463-042 3.50 Hub reduction gear, reconditioning one side
463-043 2.50 Hub, replacing seal

49 MISCELLANEOUS
491-006 2.50 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 3.00 Brake discs, replacing on both sides
516-050 1.50 Brake piston, replacing seals
517-001 0.50 Brake linings, checking wear
517-004 3.00 Brake disc, replacing both sides
517-050 1.50 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.75 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-004 0.50 Brake system, adjusting unloading pressure
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-008 1.75 Foot brake valve, replacing
525-009 1.25 Foot brake valve removed, reconditioning
527-003 1.25 Accumulators, checking in machine

55 PARKING BRAKE
550-002 0.50 Parking brake, adjusting

6 STEERING
64 STEERING
641-021 1.50 Adjustable steering column, replacing
645-006 3.00 Steering cylinder, replacing
645-015 0.50 Steering system, checking and adjusting standby
pressure

7/11/2012 Volvo Construction Equipment 283


L50D
Op.no. time (h) Notes

645-028 0.75 Steering system, checking and adjusting working


pressure
645-054 3.50 Steering cylinder, replacing bearings
645-060 2.00 Steering cylinder, repacking in machine
645-073 3.00 Hydraulic pump removed, reconditioning
645-077 1.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.75 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

66 LEVER STEERING
660-902 8.00 Lever steering (CDC), hydraulic, installing new

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 12.00 Frame joint, replacing bearings

75 AXLE SUSPENSION
755-001 1.00 Axle suspension, measuring axial and radial
clearanse
755-002 1.00 Axle suspension, adjusting axial clearance
755-003 9.50 Axle suspension, replacing bushes and seals

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.50 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
818-015 1.00 Cab suspension, rubber element replacing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.50 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing

284 Volvo Construction Equipment 7/11/2012


L50D
Op.no. time (h) Notes

843-048 5.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-007 1.25 Operators seat (air suspensioned), backrest
replacing

87 AIR CONDITIONING UNIT


873-004 1.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 1.00 Cooling unit, performance test
874-005 1.75 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 1.00 Belt, changing
874-010 3.50 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 1.00 Thermostat, replacing
874-015 1.00 Compressor, replacing shaft seal (compressor
removed)
874-016 1.00 Compressor, replacing magnetic clutch
(compressor removed)
874-017 1.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-005 3.00 Pump suction hose and pipe, replacing
911-011 1.25 Oil cooler, replacing
911-038 5.00 Hydraulic oil tank, replacing
912-001 3.00 Control valve, replacing
912-002 2.00 Control valve removed, reconditioning
912-009 1.00 Shock valve, tilt function, checking and adjusting
912-011 1.00 Shock valve lift function, adjusting
912-030 3.00 Central valve, replacing
913-003 0.25 Hydraulic pump, checking and adjusting standby
pressure

7/11/2012 Volvo Construction Equipment 285


L50D
Op.no. time (h) Notes

913-004 0.25 Hydraulic pump, checking and adjusting max


working pressure
913-010 4.00 Hydraulic pump, replacing
913-011 3.00 Hydraulic pump removed, reconditioning
914-054 0.50 Servo valve, adjusting control
914-055 0.50 Servo pressure, checking and adjusting
914-058 1.00 Servo valve, replacing
914-063 0.50 Servo pressure, checking at the spool in control
valve
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 0.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-004 1.50 Boom suspension system, checking closing
pressure
916-005 1.00 Boom suspension system, checking opening
pressure

94 UNIT, LOAD HANDLING


945-002 1.00 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.50 Implement attachment, measuring clearence of
lower bearing
945-004 2.00 Lift cylinder, replacing
945-005 3.00 Lift cylinder, repacking in machine
945-006 2.00 Lift cylinder removed, repacking
945-007 0.75 Tilt cylinder removed, replacing bearings "E-F"
945-008 2.00 Tilt cylinder, replacing
945-009 2.00 Tilt cylinder, repacking in machine
945-010 1.00 Tilt cylinder removed, repacking
945-011 1.75 Implemental attachment, replacing hydraulic
cylinder
945-012 1.00 Lift cylinder removed, replacing bearings "C-P"
945-016 4.00 Lift frame, replacing bearing in upper mounting "O"
945-024 1.50 Tilting cylinder, changing bearing 'E-F' in machine
945-045 1.00 Implemental attachment/bucket attachment,
replacing bushes "A"
945-054 0.75 Implement attachment, replacing
945-056 1.00 Implement attachment, repacking removed
hydraulic cylinder
945-062 1.00 T-link upper, replacing "HIJ"
945-064 1.50 T-link, lower, replacing "IB"
945-065 1.00 T-link lower removed, replacing bearing "IB"
945-066 1.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"

286 Volvo Construction Equipment 7/11/2012


L50D
Op.no. time (h) Notes

945-068 3.00 Tilt arm, replacing bearing "GDF"


945-069 2.00 Tilt arm, replacing "GDF"
945-070 0.75 Tilt arm removed, replacing bearing "GDF"

7/11/2012 Volvo Construction Equipment 287


288 Volvo Construction Equipment 7/11/2012
L50E
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
172-010 0.00 Out of warranty inspection

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-070 6.00 Engine, removing
210-072 7.50 Engine, installing
214-012 2.00 Valves, adjusting 71650 - 79999
214-012 2.00 Valves, adjusting
216-014 2.50 Crankshaft, replacing front oil seal

23 FUEL SYSTEM
233-001 0.30 Fuel system, bleeding
233-004 0.50 Feed pump, checking feed pressure
234-010 3.00 Fuel tank, replacing
236-001 0.50 Idling speed, checking and adjusting
236-076 1.25 Injection pump, one changing

25 INLET SYSTEM; EXHAUST SYSTEM


252-020 1.25 Silencer, replacing
252-021 0.50 Exhaust pipe, flexible tube, replacing

26 COOLING SYSTEM
262-098 0.90 Thermostat, replacing
263-001 1.50 Fan motor, removing
263-003 0.90 Fan motor, installing

27 ENGINE CONTROL
272-010 1.25 Accelerator control cable, changing

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
36 OTHER ELECTRICAL EQUIPMENT
364-008 0.25 Brake light switch, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
390-902 2.00 CareTrack, installing new

7/11/2012 Volvo Construction Equipment 289


L50E
Op.no. time (h) Notes

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 0.75 Transmission, check oil pressure

43 GEARBOX,
434-029 12.00 Dropbox removed, reconditioning
434-073 7.50 Dropbox, installing
434-074 7.00 Dropbox, removing

44 HYDROSTATIC DRIVE
441-001 1.00 Hydrostatic system, checking oil pressure
441-002 6.00 Hydraulic motor, replacing
441-004 1.50 Hydraulic engine solenoid valve, replacing
442-001 7.00 Hydraulic pump, replacing
442-003 1.50 Hydraulic pump solenoid replacing

45 PROPELLER SHAFT
451-002 1.50 Support or intermediate bearing, replacing
451-004 1.00 Propeller shaft, rear, replacing
451-007 1.00 Propeller shaft, in frame joint, replacing
451-010 1.00 Propeller shaft, front, replacing
451-013 1.00 Propeller shaft, removed reconditioning

46 FRONT AXLE; REAR AXLE


461-002 1.75 Axle, removing
461-003 2.00 Axle, installing
461-043 2.50 Hub, replacing seal
461-053 1.00 Differential lock, adjusting engagement
463-002 3.50 Axle, removing
463-003 4.50 Axle, installing
463-043 2.50 Hub, replacing seal
468-005 1.00 Differential lock rear, adjusting engagement

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 3.00 Brake discs, replacing on both sides
517-001 0.50 Brake linings, checking wear
517-004 3.00 Brake disc, replacing both sides

52 HYDRAULIC BRAKE SYSTEM


520-001 0.75 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation

290 Volvo Construction Equipment 7/11/2012


L50E
Op.no. time (h) Notes

520-005 0.50 Brake system, check and adjusting pressure in


circuit
520-037 1.00 Brake system, bleeding
525-009 0.50 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure

55 PARKING BRAKE
550-002 0.50 Parking brake, adjusting

6 STEERING
64 STEERING
645-006 3.00 Steering cylinder, replacing
645-028 0.75 Steering system, checking and adjusting working
pressure
645-077 1.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.75 Steering valve removed, reconditioning

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed
660-004 0.50 CDC, checking and adjusting control valve
660-005 1.25 CDC, checking lever signals

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-036 12.00 Frame joint, replacing bearings

75 AXLE SUSPENSION
755-001 1.00 Axle suspension, measuring axial and radial
clearanse

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing

87 AIR CONDITIONING UNIT


873-004 2.00 Heater core, replacing

7/11/2012 Volvo Construction Equipment 291


L50E
Op.no. time (h) Notes

873-006 1.25 Fan motor, replacing


873-008 1.00 Heat control valve, replacing
874-003 1.00 Cooling unit, performance test

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
912-011 1.00 Shock valve lift function, adjusting
913-003 0.25 Hydraulic pump, checking and adjusting standby
pressure
913-004 0.25 Hydraulic pump, checking and adjusting max
working pressure
913-010 4.00 Hydraulic pump, replacing
914-054 0.50 Servo valve, adjusting control
914-055 0.50 Servo pressure, checking and adjusting
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 0.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-006 0.50 Boom suspension system, pressure reduction,
safety valve, checking and adjusting
916-007 0.25 Boom suspension system, hydraulic pressure in
accumulator(s), releasing

94 UNIT, LOAD HANDLING


945-002 1.00 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-004 2.00 Lift cylinder, replacing
945-008 2.00 Tilt cylinder, replacing
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-066 1.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.00 Tilt arm, replacing bearing "GDF"

292 Volvo Construction Equipment 7/11/2012


L60E
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
172-002 3.00 Warranty inspection 100 hours
172-004 8.00 Warranty inspection 1000 hours
173-002 0.40 Maintenance service, daily
173-004 1.00 Maintenance service, every 50 hours
173-007 1.50 Maintenance service, every 250 hours
173-010 4.00 Maintenance service, every 500 hours
173-012 8.50 Maintenance service, every 1000 hours
173-014 9.50 Maintenance service, every 2000 hours
173-016 8.50 Maintenance service, every 3000 hours
173-018 9.50 Maintenance service, every 4000 hours
173-022 0.50 Maintenance service, every 6000 hours

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-070 6.50 Engine, removing
210-072 8.50 Engine, installing
210-090 0.30 Camshaft and flywheel signals, checking with
VCADS Pro and oscilloscope
214-012 4.50 Valves, adjusting 2928 - 3999
61006 - 69999
70434 - 79999
214-093 4.00 Rocker arm mechanism removed, reconditioning
216-014 2.50 Crankshaft, replacing front oil seal
218-001 3.00 Rubber cushion, replacing

22 LUBRICATING SYSTEM
221-021 0.50 Lubrication oil pressure, check

23 FUEL SYSTEM
233-001 0.40 Fuel system, bleeding
233-004 0.50 Feed pump, checking feed pressure
233-014 0.50 Fuel filters, replacing
234-010 4.00 Fuel tank, replacing
236-001 0.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
237-002 2.50 Injectors, replacing all
237-007 0.25 Overflow valve, replacing

7/11/2012 Volvo Construction Equipment 293


L60E
Op.no. time (h) Notes

25 INLET SYSTEM; EXHAUST SYSTEM


252-021 0.50 Exhaust pipe, flexible tube, replacing
255-002 0.80 Turbocharger, inspection
256-002 0.50 Air cleaner, checking prssure drop indicator

26 COOLING SYSTEM
261-004 0.50 Coolant, changing
261-012 1.00 Radiator hose upper, replacing
261-014 1.00 Radiator hoses lower, replacing
261-016 2.00 Radiator hoses all, replacing
261-018 0.75 Expansion tank, replacing
262-098 1.00 Thermostat, replacing
263-001 1.25 Fan motor, removing
263-003 1.25 Fan motor, installing
263-010 0.40 Pump 3 (P3) standby pressure, checking
263-018 0.25 Hydraulic cooling fan, revolution sensor replacing
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts
263-051 1.50 Cooling fan hydraulics, funktion check
263-080 2.50 Fan hydraulically driven, replacing pump

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing
311-006 1.00 Earth lead to battery, replacing
311-008 1.50 Starter motor lead to battery, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.50 Alternator, replacing incl function check

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing

35 LIGHTING
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb

36 OTHER ELECTRICAL EQUIPMENT


367-052 1.25 V-ECU, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-007 0.50 Engine oil pressure sensor, replacing

294 Volvo Construction Equipment 7/11/2012


L60E
Op.no. time (h) Notes

386-011 3.00 Fuel level sender, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
390-902 2.00 CareTrack, installing new

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 1.25 Transmission, check oil pressure
421-047 1.00 Gear selector, replacing
421-048 0.75 Gear selector valve, replacing one solenoid
421-051 0.75 Transmission, resistance measuring of solenoides
421-068 12.00 Transmission, removing (upwards)
421-069 14.00 Transmission, installing (from above)
421-071 32.00 Transmission removed, reconditioning

45 PROPELLER SHAFT
451-002 1.50 Support or intermediate bearing, replacing
451-004 1.00 Propeller shaft, rear, replacing
451-007 1.00 Propeller shaft, in frame joint, replacing
451-010 1.50 Propeller shaft, front, replacing

46 FRONT AXLE; REAR AXLE


461-002 2.50 Axle, removing
461-003 3.50 Axle, installing
461-005 2.00 Drive shaft, replacing one side
461-014 2.50 Pinion front, fitting new gasket
461-037 0.80 Hub reduction, removing 1001 - 3999
60001 - 69999
70001 - 79999
461-038 1.75 Hub reduction, installing 1001 - 3999
60001 - 69999
70001 - 79999
461-040 2.00 Hub reduction gear, replacing
461-041 4.50 Hub reduction gear, removed, reconditioning
461-043 2.50 Hub, replacing seal
461-053 1.00 Differential lock, adjusting engagement
463-002 1.00 Axle, removing
463-003 1.50 Axle, installing
463-005 2.00 Drive shaft, replacing one side
463-014 2.00 Pinion rear, fitting new gasket
463-040 2.00 Hub reduction gear, replacing
463-041 4.50 Hub reduction gear removed, reconditioning
463-043 3.00 Hub, replacing seal

7/11/2012 Volvo Construction Equipment 295


L60E
Op.no. time (h) Notes

49 MISCELLANEOUS
491-006 2.00 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-005 3.00 Brake disc, replacing 70001 - 79999
60001 - 69999
1001 - 3999
516-050 3.50 Brake piston, replacing seals 1001 - 3999
60001 - 69999
70001 - 79999
517-001 0.50 Brake linings, checking wear

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-008 1.75 Foot brake valve, replacing
525-009 0.50 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure

55 PARKING BRAKE
550-014 1.25 Parking brake, replacing brake pads

6 STEERING
64 STEERING
645-006 6.00 Steering cylinder, replacing
645-015 0.50 Steering system, checking and adjusting standby
pressure
645-028 0.75 Steering system, checking and adjusting working
pressure
645-077 1.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
645-082 1.50 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

296 Volvo Construction Equipment 7/11/2012


L60E
Op.no. time (h) Notes

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
716-001 2.50 Counterweight, removing
716-002 2.00 Counterweight, fitting

74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 12.00 Frame joint, replacing bearings

75 AXLE SUSPENSION
755-001 1.00 Axle suspension, measuring axial and radial
clearanse

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.75 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
818-015 1.00 Cab suspension, rubber element replacing

87 AIR CONDITIONING UNIT


873-004 2.00 Heater core, replacing
873-006 1.25 Fan motor, replacing
873-008 1.00 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 1.00 Cooling unit, performance test
874-005 1.75 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 1.00 Belt, changing
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-005 3.00 Pump suction hose and pipe, replacing
911-011 1.00 Oil cooler, replacing
911-038 5.00 Hydraulic oil tank, replacing

7/11/2012 Volvo Construction Equipment 297


L60E
Op.no. time (h) Notes

912-001 8.00 Control valve, replacing


912-018 0.20 Back-up valve, checking and adjusting
912-021 0.30 Shock valve, tilt function, checking
912-023 0.60 Shock valve lift function, checking
912-030 4.50 Central valve, replacing
913-003 1.00 Hydraulic pump, checking and adjusting standby
pressure
913-004 1.00 Hydraulic pump, checking and adjusting max
working pressure
914-054 0.50 Servo valve, adjusting control
914-055 0.10 Servo pressure, checking and adjusting
914-058 3.50 Servo valve, replacing
914-063 1.00 Servo pressure, checking at the spool in control
valve
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 0.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-070 0.10 Boom suspension system, hydraulic oil pressure
in accumulators, depressurizing
916-071 2.00 Boom suspension system, changing accumulator
916-074 0.30 Boom suspension system, test drive with load

298 Volvo Construction Equipment 7/11/2012


L70D
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 4.50 Warranty inspection 100 hours
172-004 12.00 Warranty inspection 1000 hours
173-007 1.75 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 7.50 Maintenance service, every 1000 hours
173-014 12.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 2.00 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter
173-075 2.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 7.00 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 7.50 Engine, installing
211-002 8.00 Cylinder head, replacing gasket
211-068 3.00 Cylinder heads all removed, decarbonizing and
grinding in valves
211-071 0.75 Cylinder head removed, pressure testing each
212-011 0.50 Cylinder, cylinder heads removed, measuring
wear in all cylinders
213-010 15.00 Cylinder liner and piston, replacing one
213-018 25.00 Cylinder liners and pistons, replacing all
214-012 3.00 Valves, adjusting
214-036 2.00 Valve covers, fitting new gasket
215-002 6.00 Timing gear cover, fitting new gasket in machine
215-030 7.00 Timing gear, replacing in machine
215-032 8.00 Timing gear case, fitting new gasket in machine
216-014 2.50 Crankshaft, replacing front oil seal

22 LUBRICATING SYSTEM
221-006 0.25 Oil pressure relief valve, replacing
223-006 1.50 Oil cooler, replacing

7/11/2012 Volvo Construction Equipment 299


L70D
Op.no. time (h) Notes

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-014 0.50 Fuel filters, replacing
233-015 0.50 Fuel filter extra, replacing
234-010 3.00 Fuel tank, replacing
236-001 0.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
236-030 1.50 Injection timing, checking and adjusting
236-044 1.50 Injection timing, checking
236-073 3.00 Injection pump, replacing incl setting injection
timing
237-002 2.50 Injectors, replacing all
237-007 0.25 Overflow valve, replacing
237-016 2.00 Injectors, replacing copper sleeve in machine
237-018 0.50 Delivery pipe, replacing one
237-020 0.50 Pressure equalizer, replacing
237-080 2.00 Injectors removed, reconditioning all

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.50 Induction manifold, replacing gasket
251-004 1.50 Exhaust manifold, replacing gasket
252-020 1.00 Silencer, replacing
252-021 0.50 Exhaust pipe, flexible tube, replacing
255-071 1.25 Turbocharger, replacing
255-073 2.00 Turbocharger removed, reconditioning
256-002 0.50 Air cleaner, checking prssure drop indicator
256-006 0.75 Preheating coil, replacing

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 2.50 Radiator, replacing
261-012 1.00 Radiator hose upper, replacing
261-014 1.00 Radiator hoses lower, replacing
261-016 2.00 Radiator hoses all, replacing
261-018 1.00 Expansion tank, replacing
262-002 2.00 Coolant pump, replacing
262-071 2.00 Coolant pump removed, reconditioning
262-098 0.75 Thermostat, replacing
263-001 1.25 Fan motor, removing
263-003 1.25 Fan motor, installing
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts
263-080 1.75 Fan hydraulically driven, replacing pump

300 Volvo Construction Equipment 7/11/2012


L70D
Op.no. time (h) Notes

27 ENGINE CONTROL
273-021 1.00 Stop magnet, replacing
273-022 0.75 Stop cable control, replacing
273-023 0.50 Electrical engine shut down, check and adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing
311-006 0.50 Earth lead to battery, replacing
311-008 1.00 Starter motor lead to battery, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 0.75 Starter motor, replacing
334-001 0.50 Starter lock, replacing

35 LIGHTING
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.50 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.50 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

37 CABLE; FUSE; RELAY


372-031 0.75 Relay CU201, replacing

7/11/2012 Volvo Construction Equipment 301


L70D
Op.no. time (h) Notes

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 0.50 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.50 Engine oil pressure sensor, replacing
386-011 1.25 Fuel level sender, replacing
387-004 0.50 Transmission temperature gauge, replacing
387-005 0.50 Information display, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 0.75 Transmission, check oil pressure
421-047 1.00 Gear selector, replacing
421-048 1.00 Gear selector valve, replacing one solenoid
421-052 1.00 Seal for front output shaft, replacing
421-054 1.00 Seal for rear output shaft, replacing
421-070 6.00 Transmission, removing
421-071 40.00 Transmission removed, reconditioning
421-072 8.00 Transmission, installing

45 PROPELLER SHAFT
451-002 1.50 Support or intermediate bearing, replacing
451-004 1.00 Propeller shaft, rear, replacing
451-007 1.00 Propeller shaft, in frame joint, replacing
451-013 1.00 Propeller shaft, removed reconditioning

46 FRONT AXLE; REAR AXLE


461-001 5.00 Axle, replacing
461-003 2.50 Axle, installing
461-005 1.50 Drive shaft, replacing one side
461-013 15.00 Centre gear, axle removed, reconditioning
461-014 1.75 Pinion front, fitting new gasket
461-040 1.00 Hub reduction gear, replacing
461-041 4.50 Hub reduction gear, removed, reconditioning
461-042 3.50 Hub reduction gear, reconditioning one side
461-043 2.50 Hub, replacing seal
461-052 0.25 Differential lock front, repacking excl adjusting
461-053 0.75 Differential lock, adjusting engagement

302 Volvo Construction Equipment 7/11/2012


L70D
Op.no. time (h) Notes

463-001 5.00 Axle, replacing


463-005 1.50 Drive shaft, replacing one side
463-013 15.00 Centre gear, axle removed, reconditioning
463-014 1.50 Pinion rear, fitting new gasket
463-040 1.00 Hub reduction gear, replacing
463-041 4.50 Hub reduction gear removed, reconditioning
463-043 2.50 Hub, replacing seal

49 MISCELLANEOUS
491-006 2.00 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 3.00 Brake discs, replacing on both sides
516-050 1.50 Brake piston, replacing seals
517-001 0.50 Brake linings, checking wear
517-004 3.00 Brake disc, replacing both sides
517-050 1.50 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-004 0.50 Brake system, adjusting unloading pressure
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-008 1.75 Foot brake valve, replacing
525-009 1.25 Foot brake valve removed, reconditioning

55 PARKING BRAKE
550-002 0.50 Parking brake, adjusting

6 STEERING
64 STEERING
641-021 1.50 Adjustable steering column, replacing
645-015 0.50 Steering system, checking and adjusting standby
pressure
645-028 0.50 Steering system, checking and adjusting working
pressure
645-060 2.00 Steering cylinder, repacking in machine

7/11/2012 Volvo Construction Equipment 303


L70D
Op.no. time (h) Notes

645-077 1.50 Steering cylinder removed, reconditioning incl


replacing bearings
645-081 1.75 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

66 LEVER STEERING
660-902 8.00 Lever steering (CDC), hydraulic, installing new

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 12.00 Frame joint, replacing bearings

75 AXLE SUSPENSION
755-001 1.00 Axle suspension, measuring axial and radial
clearanse
755-002 1.00 Axle suspension, adjusting axial clearance

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.50 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
818-015 1.00 Cab suspension, rubber element replacing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.75 Door, replacing
831-006 0.50 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing
843-013 5.00 Side window, replacing
843-048 5.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-007 1.25 Operators seat (air suspensioned), backrest
replacing

304 Volvo Construction Equipment 7/11/2012


L70D
Op.no. time (h) Notes

87 AIR CONDITIONING UNIT


873-004 1.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 1.00 Cooling unit, performance test
874-005 1.75 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 1.00 Belt, changing
874-010 3.50 Condenser, replacing incl draining and filling
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 1.00 Thermostat, replacing
874-015 1.00 Compressor, replacing shaft seal (compressor
removed)
874-016 1.00 Compressor, replacing magnetic clutch
(compressor removed)
874-017 1.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-005 3.00 Pump suction hose and pipe, replacing
911-011 1.00 Oil cooler, replacing
911-038 5.00 Hydraulic oil tank, replacing
912-001 3.00 Control valve, replacing
912-009 1.00 Shock valve, tilt function, checking and adjusting
912-011 1.00 Shock valve lift function, adjusting
912-030 2.00 Central valve, replacing
912-061 2.00 Control valve, repacking slide in machine
913-003 0.25 Hydraulic pump, checking and adjusting standby
pressure
913-004 0.50 Hydraulic pump, checking and adjusting max
working pressure
913-010 3.00 Hydraulic pump, replacing
913-011 3.00 Hydraulic pump removed, reconditioning
914-054 0.50 Servo valve, adjusting control

7/11/2012 Volvo Construction Equipment 305


L70D
Op.no. time (h) Notes

914-055 0.50 Servo pressure, checking and adjusting


914-058 3.00 Servo valve, replacing
914-063 0.50 Servo pressure, checking at the spool in control
valve
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 0.75 Boom suspension accumulator, check and
adjusting
916-004 1.50 Boom suspension system, checking closing
pressure
916-005 1.00 Boom suspension system, checking opening
pressure
916-071 2.00 Boom suspension system, changing accumulator
916-073 2.50 Boom suspension system, changing valve
916-950 10.00 Attachment locking, installing new
916-972 16.00 Boom suspension system, installing new

94 UNIT, LOAD HANDLING


945-002 1.00 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.50 Implement attachment, measuring clearence of
lower bearing
945-004 2.00 Lift cylinder, replacing
945-005 3.00 Lift cylinder, repacking in machine
945-006 2.00 Lift cylinder removed, repacking
945-007 0.75 Tilt cylinder removed, replacing bearings "E-F"
945-008 2.00 Tilt cylinder, replacing
945-009 2.00 Tilt cylinder, repacking in machine
945-010 1.50 Tilt cylinder removed, repacking
945-011 2.00 Implemental attachment, replacing hydraulic
cylinder
945-012 1.00 Lift cylinder removed, replacing bearings "C-P"
945-016 4.00 Lift frame, replacing bearing in upper mounting "O"
945-045 1.00 Implemental attachment/bucket attachment,
replacing bushes "A"
945-054 0.75 Implement attachment, replacing
945-056 1.00 Implement attachment, repacking removed
hydraulic cylinder
945-062 1.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 1.50 T-link, lower, replacing "IB"
945-065 1.00 T-link lower removed, replacing bearing "IB"
945-066 1.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.00 Tilt arm, replacing bearing "GDF"
945-069 2.00 Tilt arm, replacing "GDF"

306 Volvo Construction Equipment 7/11/2012


L70D
Op.no. time (h) Notes

945-070 0.75 Tilt arm removed, replacing bearing "GDF"

7/11/2012 Volvo Construction Equipment 307


308 Volvo Construction Equipment 7/11/2012
L70E
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
172-002 3.50 Warranty inspection 100 hours
172-004 8.50 Warranty inspection 1000 hours 60001 - 69999
21001 - 23999
173-002 0.40 Maintenance service, daily
173-004 1.00 Maintenance service, every 50 hours
173-007 1.50 Maintenance service, every 250 hours
173-010 4.50 Maintenance service, every 500 hours
173-012 8.50 Maintenance service, every 1000 hours
173-014 10.00 Maintenance service, every 2000 hours
173-016 9.00 Maintenance service, every 3000 hours
173-018 10.00 Maintenance service, every 4000 hours
173-022 0.50 Maintenance service, every 6000 hours
173-061 0.75 Transmission, changing oil and filter
173-070 1.25 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-070 6.50 Engine, removing
210-072 8.50 Engine, installing
210-090 0.30 Camshaft and flywheel signals, checking with
VCADS Pro and oscilloscope
214-012 4.50 Valves, adjusting 22527 - 23999
61247 - 69999
214-093 4.00 Rocker arm mechanism removed, reconditioning
216-014 2.50 Crankshaft, replacing front oil seal
217-002 5.00 Sump gasket, replacing incl cleaning oil strainer
218-001 3.50 Rubber cushion, replacing

22 LUBRICATING SYSTEM
223-006 1.00 Oil cooler, replacing

23 FUEL SYSTEM
233-001 0.40 Fuel system, bleeding
233-014 0.50 Fuel filters, replacing
234-010 4.00 Fuel tank, replacing
236-001 0.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking

7/11/2012 Volvo Construction Equipment 309


L70E
Op.no. time (h) Notes

237-002 2.50 Injectors, replacing all


237-007 0.25 Overflow valve, replacing

25 INLET SYSTEM; EXHAUST SYSTEM


252-021 0.50 Exhaust pipe, flexible tube, replacing
255-002 0.80 Turbocharger, inspection
256-002 0.50 Air cleaner, checking prssure drop indicator

26 COOLING SYSTEM
261-004 0.50 Coolant, changing
261-012 1.00 Radiator hose upper, replacing
261-014 1.00 Radiator hoses lower, replacing
261-016 2.00 Radiator hoses all, replacing
261-018 0.75 Expansion tank, replacing
262-098 1.00 Thermostat, replacing
263-001 1.25 Fan motor, removing
263-003 1.25 Fan motor, installing
263-010 0.40 Pump 3 (P3) standby pressure, checking
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts
263-051 1.50 Cooling fan hydraulics, funktion check
263-080 2.50 Fan hydraulically driven, replacing pump

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing
311-006 1.00 Earth lead to battery, replacing
311-008 1.50 Starter motor lead to battery, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.50 Alternator, replacing incl function check

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing

35 LIGHTING
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb

36 OTHER ELECTRICAL EQUIPMENT


367-052 1.25 V-ECU, replacing

310 Volvo Construction Equipment 7/11/2012


L70E
Op.no. time (h) Notes

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-007 0.50 Engine oil pressure sensor, replacing
386-011 3.00 Fuel level sender, replacing
386-031 0.75 Sensor unit (differential lock) adjusting

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
390-902 2.00 CareTrack, installing new

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 1.25 Transmission, check oil pressure
421-008 3.00 Gear selector valve, replacing
421-047 1.00 Gear selector, replacing
421-048 0.75 Gear selector valve, replacing one solenoid
421-051 0.75 Transmission, resistance measuring of solenoides
421-068 12.00 Transmission, removing (upwards)
421-069 14.00 Transmission, installing (from above)
421-071 32.00 Transmission removed, reconditioning

45 PROPELLER SHAFT
451-002 1.50 Support or intermediate bearing, replacing
451-004 1.00 Propeller shaft, rear, replacing
451-007 1.00 Propeller shaft, in frame joint, replacing
451-010 1.50 Propeller shaft, front, replacing

46 FRONT AXLE; REAR AXLE


461-002 2.50 Axle, removing
461-003 3.50 Axle, installing
461-005 2.00 Drive shaft, replacing one side
461-014 2.50 Pinion front, fitting new gasket
461-037 0.80 Hub reduction, removing 60001 - 69999
21001 - 23999
461-038 1.75 Hub reduction, installing 21001 - 23999
60001 - 69999
461-040 2.00 Hub reduction gear, replacing
461-041 4.50 Hub reduction gear, removed, reconditioning
461-043 2.50 Hub, replacing seal
463-002 1.00 Axle, removing
463-003 1.50 Axle, installing
463-005 2.00 Drive shaft, replacing one side
463-014 2.00 Pinion rear, fitting new gasket
463-040 2.00 Hub reduction gear, replacing

7/11/2012 Volvo Construction Equipment 311


L70E
Op.no. time (h) Notes

463-041 4.50 Hub reduction gear removed, reconditioning


463-043 3.00 Hub, replacing seal

49 MISCELLANEOUS
491-006 2.00 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-005 3.00 Brake disc, replacing 60001 - 69999
21001 - 23999
516-050 3.50 Brake piston, replacing seals 21001 - 23999
60001 - 69999
517-001 0.50 Brake linings, checking wear

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-008 1.75 Foot brake valve, replacing
525-009 0.50 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure

55 PARKING BRAKE
550-014 1.25 Parking brake, replacing brake pads

6 STEERING
64 STEERING
645-006 6.00 Steering cylinder, replacing
645-015 0.50 Steering system, checking and adjusting standby
pressure
645-028 0.75 Steering system, checking and adjusting working
pressure
645-077 1.50 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
645-082 1.50 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

312 Volvo Construction Equipment 7/11/2012


L70E
Op.no. time (h) Notes

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
716-001 1.75 Counterweight, removing
716-002 1.75 Counterweight, fitting

74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 12.00 Frame joint, replacing bearings

75 AXLE SUSPENSION
755-001 1.00 Axle suspension, measuring axial and radial
clearanse
755-002 1.00 Axle suspension, adjusting axial clearance

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.75 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing
818-015 1.00 Cab suspension, rubber element replacing

87 AIR CONDITIONING UNIT


873-004 2.00 Heater core, replacing
873-006 1.25 Fan motor, replacing
873-008 1.00 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 1.00 Cooling unit, performance test
874-005 1.75 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 1.00 Belt, changing
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling

7/11/2012 Volvo Construction Equipment 313


L70E
Op.no. time (h) Notes

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-005 3.00 Pump suction hose and pipe, replacing
911-011 1.00 Oil cooler, replacing
911-038 5.00 Hydraulic oil tank, replacing
911-040 0.25 Hydraulic oil tank, vacuum-pumping, connecting
and disconnecting pump
912-001 8.00 Control valve, replacing
912-018 0.20 Back-up valve, checking and adjusting
912-021 0.30 Shock valve, tilt function, checking
912-023 0.60 Shock valve lift function, checking
912-030 4.50 Central valve, replacing
913-003 1.00 Hydraulic pump, checking and adjusting standby
pressure
913-004 1.00 Hydraulic pump, checking and adjusting max
working pressure
914-054 0.50 Servo valve, adjusting control
914-055 0.10 Servo pressure, checking and adjusting
914-058 3.50 Servo valve, replacing
914-063 1.00 Servo pressure, checking at the spool in control
valve
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 0.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-070 0.10 Boom suspension system, hydraulic oil pressure
in accumulators, depressurizing
916-071 2.00 Boom suspension system, changing accumulator
916-074 0.30 Boom suspension system, test drive with load

314 Volvo Construction Equipment 7/11/2012


L90D
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
171-001 0.50 Arrival inspection, according to programme
171-002 1.50 Delivery inspection, according to programme
172-002 4.50 Warranty inspection 100 hours
172-004 12.00 Warranty inspection 1000 hours
173-007 1.75 Maintenance service, every 250 hours
173-010 3.50 Maintenance service, every 500 hours
173-012 7.50 Maintenance service, every 1000 hours
173-014 12.00 Maintenance service, every 2000 hours
173-059 1.00 Engine, changing oil and filter
173-061 1.50 Transmission, changing oil and filter
173-070 1.50 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter
173-075 2.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-002 1.75 Compression test
210-070 5.50 Engine, removing
210-071 40.00 Engine removed, general overhaul
210-072 7.00 Engine, installing
211-002 8.00 Cylinder head, replacing gasket
211-018 10.00 Cylinder heads all, replacing gaskets
211-068 4.00 Cylinder heads all removed, decarbonizing and
grinding in valves
211-071 0.75 Cylinder head removed, pressure testing each
211-080 4.50 Cylinder heads all, removing
211-082 7.00 Cylinder heads all, fitting
212-007 4.00 Cylinder block, liners removed, milling of all liner
locations
212-011 0.50 Cylinder, cylinder heads removed, measuring
wear in all cylinders
213-010 14.00 Cylinder liner and piston, replacing one
213-018 24.00 Cylinder liners and pistons, replacing all
214-012 2.00 Valves, adjusting
214-021 0.25 Valve cover, fitting new gasket each
214-027 0.75 Inspection cover, fitting new gasket
214-030 14.00 Valves, decarbonizing and grinding
214-036 1.50 Valve covers, fitting new gasket
214-093 4.00 Rocker arm mechanism removed, reconditioning

7/11/2012 Volvo Construction Equipment 315


L90D
Op.no. time (h) Notes

215-002 6.00 Timing gear cover, fitting new gasket in machine


215-030 7.00 Timing gear, replacing in machine
215-032 8.00 Timing gear case, fitting new gasket in machine
216-014 2.50 Crankshaft, replacing front oil seal
216-018 12.00 Crankshaft, replacing rear oil seal
216-040 14.00 Flywheel housing and sump gasket, replacing
217-002 5.00 Sump gasket, replacing incl cleaning oil strainer
218-001 3.00 Rubber cushion, replacing

22 LUBRICATING SYSTEM
221-006 0.25 Oil pressure relief valve, replacing
221-014 6.00 Oil pump, replacing
223-006 1.50 Oil cooler, replacing

23 FUEL SYSTEM
233-001 0.50 Fuel system, bleeding
233-002 0.75 Feed pump, replacing
233-004 0.50 Feed pump, checking feed pressure
233-007 0.25 Feed pump, cleaning glass bowl and strainer
233-014 0.50 Fuel filters, replacing
233-015 0.25 Fuel filter extra, replacing
233-097 0.25 Feed pump removed, reconditioning
234-010 3.00 Fuel tank, replacing
236-001 0.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
236-030 1.50 Injection timing, checking and adjusting
236-044 1.50 Injection timing, checking
236-073 3.00 Injection pump, replacing incl setting injection
timing
237-002 2.00 Injectors, replacing all
237-004 0.75 Injector, replacing one
237-007 0.25 Overflow valve, replacing
237-016 1.50 Injectors, replacing copper sleeve in machine
237-018 0.50 Delivery pipe, replacing one
237-020 0.50 Pressure equalizer, replacing
237-080 2.00 Injectors removed, reconditioning all

25 INLET SYSTEM; EXHAUST SYSTEM


251-002 1.00 Induction manifold, replacing gasket
251-004 2.00 Exhaust manifold, replacing gasket
252-020 1.50 Silencer, replacing
252-021 0.50 Exhaust pipe, flexible tube, replacing
255-071 1.00 Turbocharger, replacing
255-073 2.00 Turbocharger removed, reconditioning
256-001 0.50 Air cleaner, cleaning filter element

316 Volvo Construction Equipment 7/11/2012


L90D
Op.no. time (h) Notes

256-002 0.25 Air cleaner, checking prssure drop indicator


256-003 0.25 Air cleaner, primary filter replacing
256-004 0.25 Air cleaner, secondary filter replacing
256-006 0.75 Preheating coil, replacing

26 COOLING SYSTEM
261-004 1.00 Coolant, changing
261-008 3.00 Radiator, replacing
261-012 1.00 Radiator hose upper, replacing
261-014 1.00 Radiator hoses lower, replacing
261-018 1.00 Expansion tank, replacing
262-002 2.00 Coolant pump, replacing
262-071 2.00 Coolant pump removed, reconditioning
262-098 1.00 Thermostat, replacing
263-012 0.75 Fan belt and/or alternator belt, replacing
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts

27 ENGINE CONTROL
273-021 0.75 Stop magnet, replacing
273-023 0.50 Electrical engine shut down, check and adjusting

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing
311-006 0.50 Earth lead to battery, replacing
311-008 1.00 Starter motor lead to battery, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.00 Alternator, replacing incl function check
321-025 0.50 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing

33 STARTING SYSTEM
331-018 0.75 Starter motor, replacing
333-001 0.75 Electric air pre-heater, replacing relay
334-001 0.50 Starter lock, replacing

35 LIGHTING
352-024 0.50 Headlight, complete, changing (high beam 1 pc.)
incl. setting
353-016 0.50 Rear lamp, replacing one

7/11/2012 Volvo Construction Equipment 317


L90D
Op.no. time (h) Notes

353-018 0.25 Rear lamp, replacing glass or bulb


356-056 0.50 Work lighting, replacing one head lamp assy

36 OTHER ELECTRICAL EQUIPMENT


361-002 0.25 Flasher unit, replacing relay
361-010 0.75 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
362-002 0.25 Horn, replacing
362-003 0.50 Reverse alarm, replacing
362-041 0.50 Rotating beacon, replacing
363-001 0.50 Windscreen wiper rear, replacing motor
363-002 0.75 Windscreen wiper front, replacing motor
363-004 0.25 Windscreen flusher pump, replacing
364-004 0.25 Switch, replacing
364-008 0.25 Brake light switch, replacing
367-052 1.25 V-ECU, replacing

37 CABLE; FUSE; RELAY


372-031 0.75 Relay CU201, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-003 0.50 Transmission oil pressure sensor, replacing
386-004 0.50 Transmission temperature sensor, replacing
386-005 0.50 Transmission, revolution sensor, replacing
386-006 0.50 Engine temperature sensor, replacing
386-007 0.75 Engine oil pressure sensor, replacing
386-011 1.25 Fuel level sender, replacing
387-004 0.50 Transmission temperature gauge, replacing
387-005 0.50 Information display, replacing

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
393-001 0.50 Voltage converter, replacing

4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 0.75 Transmission, check oil pressure
421-004 2.00 Oil pump, replacing
421-008 3.00 Gear selector valve, replacing
421-009 1.00 Gear selector valve removed, reconditioning
421-018 16.00 Converter, replacing
421-023 1.00 Lubrication and converter pressure valve,
replacing

318 Volvo Construction Equipment 7/11/2012


L90D
Op.no. time (h) Notes

421-041 1.00 Oil distributor and seals, replacing f and r or 1:st


and f or 3:rd and f
421-042 2.00 Oil distributor and seals, replacing 1st and 2nd or
2nd and reverse
421-043 3.00 Oil distributor and seals, replacing 3rd and 4th or
4th and reverse
421-047 0.75 Gear selector, replacing
421-048 0.75 Gear selector valve, replacing one solenoid
421-054 1.00 Seal for rear output shaft, replacing
421-071 40.00 Transmission removed, reconditioning
421-073 9.00 Transmission, removing (together with engine)
421-074 10.00 Transmission, installing (together with engine)

43 GEARBOX,
434-002 2.00 Dropbox, replacing seal for front otput shaft
434-004 1.00 Dropbox, replacing seal for rear output shaft
434-029 4.00 Dropbox removed, reconditioning
434-073 4.00 Dropbox, installing
434-074 4.00 Dropbox, removing

45 PROPELLER SHAFT
451-001 0.25 Propeller shaft and intermediate bearing, checking
radial clearance
451-002 2.00 Support or intermediate bearing, replacing
451-004 1.50 Propeller shaft, rear, replacing
451-007 1.50 Propeller shaft, in frame joint, replacing
451-010 2.00 Propeller shaft, front, replacing

46 FRONT AXLE; REAR AXLE


461-001 4.00 Axle, replacing
461-011 5.00 Centre gear , removing and fitting
461-012 6.00 Centre gear removed, reconditioning
461-014 2.00 Pinion front, fitting new gasket
461-042 6.00 Hub reduction gear, reconditioning one side
461-043 4.00 Hub, replacing seal
461-051 6.00 Differential lock, replacing selector fork and clutch
sleeves and adjusting
461-052 0.25 Differential lock front, repacking excl adjusting
461-053 1.00 Differential lock, adjusting engagement
463-001 8.00 Axle, replacing
463-011 8.00 Centre gear, removing and fitting
463-012 6.00 Centre gear removed, reconditioning
463-014 2.00 Pinion rear, fitting new gasket
463-042 6.00 Hub reduction gear, reconditioning one side
463-043 4.50 Hub, replacing seal

7/11/2012 Volvo Construction Equipment 319


L90D
Op.no. time (h) Notes

49 MISCELLANEOUS
491-006 1.50 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-004 4.00 Brake discs, replacing on both sides
516-050 3.00 Brake piston, replacing seals
517-001 0.50 Brake linings, checking wear
517-004 4.00 Brake disc, replacing both sides
517-050 3.00 Brake piston, replacing seals

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-002 0.50 Brake system, checking function, retardation
520-004 0.50 Brake system, adjusting unloading pressure
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-008 2.00 Foot brake valve, replacing
525-009 1.25 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure
527-002 0.50 Accumulator, replacing
527-004 2.00 Hydraulic pump, replacing

55 PARKING BRAKE
550-002 0.50 Parking brake, adjusting
550-004 1.50 Parking brake mechanical, replacing brake caliper
550-005 3.00 Parking brake, replacing brake disc
550-014 1.50 Parking brake, replacing brake pads

6 STEERING
64 STEERING
641-021 1.50 Adjustable steering column, replacing
645-003 0.25 Steering system working pressure, checking
645-006 1.75 Steering cylinder, replacing
645-010 2.00 Hydraulic pump, replacing
645-015 0.50 Steering system, checking and adjusting standby
pressure

320 Volvo Construction Equipment 7/11/2012


L90D
Op.no. time (h) Notes

645-020 3.00 Steering system, checking and adjusting shock


and anti-cavitation-valve
645-021 1.50 Valve block, replacing
645-028 0.75 Steering system, checking and adjusting working
pressure
645-054 2.00 Steering cylinder, replacing bearings
645-060 3.00 Steering cylinder, repacking in machine
645-073 2.00 Hydraulic pump removed, reconditioning
645-077 1.75 Steering cylinder removed, reconditioning incl
replacing bearings
645-081 1.50 Steering valve removed, reconditioning
645-082 2.00 Steering valve, replacing
647-093 1.00 Auxiliary steering, replacing hydraulic pump

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 12.00 Frame joint, replacing bearings

75 AXLE SUSPENSION
755-001 0.75 Axle suspension, measuring axial and radial
clearanse
755-002 1.00 Axle suspension, adjusting axial clearance

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.75 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing
818-015 1.75 Cab suspension, rubber element replacing

83 DOORS; HATCH; COVER PLATE, (all)


831-004 1.50 Door, replacing
831-006 0.75 Door lock, replacing
831-014 0.50 Door, replacing sealing strip

84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING


843-002 5.00 Windscreen, replacing
843-012 5.00 Rear window, replacing

7/11/2012 Volvo Construction Equipment 321


L90D
Op.no. time (h) Notes

843-013 5.00 Side window, replacing


843-048 5.00 Door window, replacing

85 CAB INTERIOR/UPHOLSTERY
852-006 1.25 Operators seat, air suspensioned, control,
replacing
852-007 1.25 Operators seat (air suspensioned), backrest
replacing

87 AIR CONDITIONING UNIT


872-001 0.25 Cab filter, replacing
873-004 1.00 Heater core, replacing
873-006 1.00 Fan motor, replacing
873-008 0.75 Heat control valve, replacing
873-009 0.75 Heat control, replacing
874-002 1.00 Refrigerant, draining
874-003 1.00 Cooling unit, performance test
874-005 1.75 Refrigerant, filling excl vacuum pumping
874-006 4.00 Compressor, replacing incl draining and filling
874-007 1.00 Belt, changing
874-011 3.00 Receiver, replacing incl draining and filling
874-012 4.00 Evaporator, replacing incl draining and filling
874-013 3.50 Expansion valve, replacing incl draining and filling
874-014 1.00 Thermostat, replacing
874-015 1.00 Compressor, replacing shaft seal (compressor
removed)
874-016 1.00 Compressor, replacing magnetic clutch
(compressor removed)
874-017 1.75 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
91 WORKING HYDRAULICS; SERVO HYDRAULICS
911-005 2.00 Pump suction hose and pipe, replacing
911-011 2.00 Oil cooler, replacing
911-038 5.00 Hydraulic oil tank, replacing
912-001 5.00 Control valve, replacing
912-002 4.00 Control valve removed, reconditioning
912-004 0.75 Control valve, low pressure valve, replacing
912-009 0.50 Shock valve, tilt function, checking and adjusting
912-011 0.75 Shock valve lift function, adjusting

322 Volvo Construction Equipment 7/11/2012


L90D
Op.no. time (h) Notes

913-002 1.00 Hydraulic pump, checking and adjusting unloading


pressure
913-004 1.00 Hydraulic pump, checking and adjusting max
working pressure
913-010 3.00 Hydraulic pump, replacing
913-011 2.00 Hydraulic pump removed, reconditioning
914-054 0.50 Servo valve, adjusting control
914-055 0.50 Servo pressure, checking and adjusting
914-057 0.50 Servo pressure, check
914-058 3.00 Servo valve, replacing
914-060 2.00 Servo pump, replacing
914-062 0.50 Pressure limiting valve, replacing
914-063 0.75 Servo pressure, checking at the spool in control
valve
914-075 2.00 Servo valve removed, reconditioning
915-001 1.00 Servo valve, solenoid replacing
916-001 0.50 Boom suspension system, functional check
916-002 0.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-004 1.50 Boom suspension system, checking closing
pressure
916-005 1.00 Boom suspension system, checking opening
pressure
916-073 2.50 Boom suspension system, changing valve

94 UNIT, LOAD HANDLING


945-002 2.00 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 4.00 Lift cylinder, repacking in machine
945-006 3.00 Lift cylinder removed, repacking
945-008 2.00 Tilt cylinder, replacing
945-009 4.00 Tilt cylinder, repacking in machine
945-010 3.00 Tilt cylinder removed, repacking
945-011 2.00 Implemental attachment, replacing hydraulic
cylinder
945-016 4.00 Lift frame, replacing bearing in upper mounting "O"
945-024 3.00 Tilting cylinder, changing bearing 'E-F' in machine
945-045 2.50 Implemental attachment/bucket attachment,
replacing bushes "A"
945-054 1.00 Implement attachment, replacing
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"

7/11/2012 Volvo Construction Equipment 323


L90D
Op.no. time (h) Notes

945-064 1.00 T-link, lower, replacing "IB"


945-066 2.50 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.00 Tilt arm, replacing bearing "GDF"
945-069 2.00 Tilt arm, replacing "GDF"

324 Volvo Construction Equipment 7/11/2012


L90E
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
170-005 0.25 Start of VCADS Pro computer and reading
machine data
172-002 3.50 Warranty inspection 100 hours
172-004 8.50 Warranty inspection 1000 hours
173-002 0.40 Maintenance service, daily
173-004 1.00 Maintenance service, every 50 hours
173-007 1.50 Maintenance service, every 250 hours
173-010 4.50 Maintenance service, every 500 hours
173-012 8.50 Maintenance service, every 1000 hours
173-014 10.00 Maintenance service, every 2000 hours
173-016 9.00 Maintenance service, every 3000 hours
173-018 10.00 Maintenance service, every 4000 hours
173-022 0.50 Maintenance service, every 6000 hours
173-061 1.50 Transmission, changing oil and filter
173-070 1.25 Axles, changing oil
173-074 1.75 Hydraulic oil tank, changing oil and filter
173-075 2.50 Hydraulic oil tank, changing oil and filter
incl.cleaning tank

2 ENGINE WITH MOUNTING AND EQUIPMENT


21 ENGINE
210-070 6.00 Engine, removing
210-072 8.50 Engine, installing
210-090 0.30 Camshaft and flywheel signals, checking with
VCADS Pro and oscilloscope
214-012 4.50 Valves, adjusting 22241 - 24999
67491 - 69999
71139 - 79999
214-093 4.00 Rocker arm mechanism removed, reconditioning
216-014 2.50 Crankshaft, replacing front oil seal
218-001 3.00 Rubber cushion, replacing

22 LUBRICATING SYSTEM
221-021 1.00 Lubrication oil pressure, check
223-006 1.00 Oil cooler, replacing

23 FUEL SYSTEM
233-001 0.40 Fuel system, bleeding
233-002 0.50 Feed pump, replacing
233-004 0.50 Feed pump, checking feed pressure
233-014 0.50 Fuel filters, replacing

7/11/2012 Volvo Construction Equipment 325


L90E
Op.no. time (h) Notes

234-010 4.00 Fuel tank, replacing


236-001 0.50 Idling speed, checking and adjusting
236-002 0.50 Stall speed, checking
237-007 0.25 Overflow valve, replacing

25 INLET SYSTEM; EXHAUST SYSTEM


252-021 0.50 Exhaust pipe, flexible tube, replacing
255-002 0.80 Turbocharger, inspection
256-002 0.50 Air cleaner, checking prssure drop indicator

26 COOLING SYSTEM
261-004 0.50 Coolant, changing
261-012 1.00 Radiator hose upper, replacing
261-014 1.00 Radiator hoses lower, replacing
261-018 0.75 Expansion tank, replacing
262-098 1.00 Thermostat, replacing
263-001 1.25 Fan motor, removing
263-003 1.25 Fan motor, installing
263-004 0.75 Fan motor, checking working pressure
263-010 0.40 Pump 3 (P3) standby pressure, checking
263-011 1.25 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)
263-012 0.75 Fan belt and/or alternator belt, replacing
263-015 1.50 Fan hydraulically driven, adjusting standby
pressure and maxpressure
263-018 0.25 Hydraulic cooling fan, revolution sensor replacing
263-022 1.00 Fan belt and/or alternator-, compressor belt,
replacing all belts
263-051 1.50 Cooling fan hydraulics, funktion check
263-080 2.50 Fan hydraulically driven, replacing pump

3 ELEC. SYSTEM; WARNING SYSTEM;


INFORMATION SYSTEM; INSTRUMENTS
31 BATTERY
311-002 1.00 Batteries, replacing
311-003 0.50 Main switch, replacing
311-006 1.00 Earth lead to battery, replacing
311-008 1.50 Starter motor lead to battery, replacing

32 ALTERNATOR; CHARGE REGULATOR


321-002 1.50 Alternator, replacing incl function check

33 STARTING SYSTEM
331-018 1.00 Starter motor, replacing

326 Volvo Construction Equipment 7/11/2012


L90E
Op.no. time (h) Notes

35 LIGHTING
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb

36 OTHER ELECTRICAL EQUIPMENT


367-052 0.50 V-ECU, replacing

37 CABLE; FUSE; RELAY


372-031 0.75 Relay CU201, replacing

38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM


386-007 0.75 Engine oil pressure sensor, replacing
386-011 3.00 Fuel level sender, replacing
386-031 0.75 Sensor unit (differential lock) adjusting

39 MISCELLANEOUS
390-901 1.00 CareTrack Early Basic, installation
390-902 2.00 CareTrack, installing new

4 POWER TRANSMISSION
41 CLUTCH; TORQUE CONVERTER
414-003 2.00 Converter, replacing (engine removed)

42 TRANSMISSION, HYDRAULIC CONTROL


421-002 0.70 Transmission, check oil pressure 21097 - 24999
66636 - 69999
70928 - 79999
421-002 0.70 Transmission, check oil pressure 20001 - 21096
66001 - 66635
70801 - 70927
421-004 2.00 Oil pump, replacing
421-008 3.00 Gear selector valve, replacing
421-047 1.00 Gear selector, replacing
421-048 0.75 Gear selector valve, replacing one solenoid
421-051 0.75 Transmission, resistance measuring of solenoides
421-068 12.00 Transmission, removing (upwards)
421-069 14.00 Transmission, installing (from above)

45 PROPELLER SHAFT
451-002 1.50 Support or intermediate bearing, replacing
451-004 1.00 Propeller shaft, rear, replacing
451-007 1.00 Propeller shaft, in frame joint, replacing
451-010 2.00 Propeller shaft, front, replacing

7/11/2012 Volvo Construction Equipment 327


L90E
Op.no. time (h) Notes

46 FRONT AXLE; REAR AXLE


461-002 2.50 Axle, removing
461-003 3.50 Axle, installing
461-005 2.00 Drive shaft, replacing one side
461-014 2.50 Pinion front, fitting new gasket
461-037 0.80 Hub reduction, removing 20001 - 24999
66001 - 69999
70801 - 79999
461-038 1.75 Hub reduction, installing 20001 - 24999
66001 - 69999
70801 - 79999
461-053 1.00 Differential lock, adjusting engagement
463-002 1.00 Axle, removing
463-003 1.50 Axle, installing
463-014 1.50 Pinion rear, fitting new gasket

49 MISCELLANEOUS
491-006 1.50 Oil cooler, replacing

5 BRAKE
51 WHEEL BRAKE
516-001 0.50 Brake linings, checking wear
516-005 3.00 Brake disc, replacing 70801 - 79999
66001 - 69999
20001 - 24999
516-050 3.50 Brake piston, replacing seals 20001 - 24999
66001 - 69999
70801 - 79999
517-001 0.50 Brake linings, checking wear

52 HYDRAULIC BRAKE SYSTEM


520-001 0.50 Brake system, checking function, hydraulic
520-005 0.50 Brake system, check and adjusting pressure in
circuit
520-037 1.00 Brake system, bleeding
525-008 1.75 Foot brake valve, replacing
525-009 0.50 Foot brake valve removed, reconditioning
527-001 0.50 Accumulator removed, checking charging
pressure

328 Volvo Construction Equipment 7/11/2012


L90E
Op.no. time (h) Notes

6 STEERING
64 STEERING
645-006 1.75 Steering cylinder, replacing
645-028 0.75 Steering system, checking and adjusting working
pressure
645-081 1.50 Steering valve removed, reconditioning
645-082 1.50 Steering valve, replacing

66 LEVER STEERING
660-003 0.50 Lever steering (CDC) adjusting steering speed
660-005 1.25 CDC, checking lever signals

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
71 FRAME
716-001 1.75 Counterweight, removing
716-002 1.75 Counterweight, fitting

74 FRAME LINK
741-005 0.50 Frame joint, checking clearance
741-036 12.00 Frame joint, replacing bearings

75 AXLE SUSPENSION
755-001 0.75 Axle suspension, measuring axial and radial
clearanse
755-002 1.00 Axle suspension, adjusting axial clearance

77 WHEELS; TRACKS; TYRE; HUB; DRUM


771-001 0.75 Wheel, removing and fitting one

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing

82 ENGINE HOOD; MUDGUARD; FOOT STEP


821-001 2.00 Engine hood, removing
821-002 2.50 Engine hood, installing

87 AIR CONDITIONING UNIT


873-004 2.00 Heater core, replacing

7/11/2012 Volvo Construction Equipment 329


L90E
Op.no. time (h) Notes

873-006 1.25 Fan motor, replacing


873-008 1.00 Heat control valve, replacing
874-007 1.00 Belt, changing
874-059 1.25 Evaporator, cleaning

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 3.00 Hydraulic system, bleeding

91 WORKING HYDRAULICS; SERVO HYDRAULICS


911-038 5.00 Hydraulic oil tank, replacing
912-001 8.00 Control valve, replacing
912-018 0.20 Back-up valve, checking and adjusting
912-021 0.30 Shock valve, tilt function, checking
912-023 0.60 Shock valve lift function, checking
912-030 4.50 Central valve, replacing
913-003 0.40 Hydraulic pump, checking and adjusting standby
pressure
913-004 0.40 Hydraulic pump, checking and adjusting max
working pressure
914-052 1.25 Accumulator, checking (pressure back-up for
servo circuit)
914-054 0.50 Servo valve, adjusting control
914-055 0.10 Servo pressure, checking and adjusting
914-058 3.50 Servo valve, replacing
916-002 0.75 Boom suspension accumulator, check and
adjusting
916-003 1.00 Boom suspension accumulator, reconditioning
916-006 0.50 Boom suspension system, pressure reduction,
safety valve, checking and adjusting
916-019 1.00 3rd/4th hydraulic function, pressure check
916-070 0.10 Boom suspension system, hydraulic oil pressure
in accumulators, depressurizing
916-071 2.00 Boom suspension system, changing accumulator
916-074 0.30 Boom suspension system, test drive with load

94 UNIT, LOAD HANDLING


945-002 3.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-003 0.25 Implement attachment, measuring clearence of
lower bearing
945-004 4.00 Lift cylinder, replacing
945-005 4.00 Lift cylinder, repacking in machine

330 Volvo Construction Equipment 7/11/2012


L90E
Op.no. time (h) Notes

945-006 3.00 Lift cylinder removed, repacking


945-008 3.00 Tilt cylinder, replacing
945-009 5.00 Tilt cylinder, repacking in machine
945-010 3.00 Tilt cylinder removed, repacking
945-011 2.00 Implemental attachment, replacing hydraulic
cylinder
945-016 5.00 Lift frame, replacing bearing in upper mounting "O"
945-054 1.75 Implement attachment, replacing
945-056 1.00 Implement attachment, repacking removed
hydraulic cylinder
945-062 2.00 T-link upper, replacing "HIJ"
945-063 0.75 T-link upper removed, replacing bearings "HIJ"
945-064 2.00 T-link, lower, replacing "IB"
945-066 2.00 Tilt link, replacing "GH"
945-067 0.75 Tilt link removed, replacing bearings "GH"
945-068 3.00 Tilt arm, replacing bearing "GDF"
945-069 3.00 Tilt arm, replacing "GDF"

7/11/2012 Volvo Construction Equipment 331


332 Volvo Construction Equipment 7/11/2012
VB-T 78 ETC
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
173-002 0.70 Maintenance service, daily
173-004 0.50 Maintenance service, every 50 hours
173-010 0.30 Maintenance service, every 500 hours
173-012 0.40 Maintenance service, every 1000 hours
173-014 4.00 Maintenance service, every 2000 hours
173-050 0.30 Greasing, daily
173-051 0.20 Greasing, 50 hrs

19 GENERAL
191-021 0.20 Service position 1
191-022 0.30 Service position 2

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
77 WHEELS; TRACKS; TYRE; HUB; DRUM
777-005 0.80 Vibration motor, removing
777-006 0.60 Vibration motor, installing

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
82 ENGINE HOOD; MUDGUARD; FOOT STEP
827-005 0.50 Walkway, removing
827-006 0.40 Walkway, installing
827-007 0.60 Deck platform, removing
827-008 0.50 Deck platform, installing

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
98 FUNCTION FOR ROAD CONSTRUCTION
982-003 2.50 Screed, removing
982-004 4.00 Screed, installing
982-015 2.00 Extension cylinder, removing
982-015 0.90 Extension cylinder, removing
982-016 3.00 Extension cylinder, installing
982-016 0.80 Extension cylinder, installing
982-026 0.40 End plate, replacing

7/11/2012 Volvo Construction Equipment 333


VB-T 78 ETC
Op.no. time (h) Notes

982-026 0.30 End plate, replacing


982-030 3.00 Sliding bearing, replacing
982-030 1.75 Sliding bearing, replacing
982-040 2.50 Brake cylinder, replacing
982-050 1.00 Crown control cylinder, replacing
982-050 2.50 Crown control cylinder, replacing
983-130 0.90 Vibration shaft, removing
983-131 0.80 Vibration shaft, installing
983-132 1.50 Vibration bearing, removing
983-133 1.25 Vibration bearing, installing
983-150 1.50 Tamper, adjusting
983-151 0.70 Tamper bar, removing
983-151 0.70 Tamper bar, removing
983-152 0.90 Tamper bar, installing
983-152 1.50 Tamper bar, installing
983-153 1.75 Tamper shaft, removing
983-153 1.50 Tamper shaft, removing
983-154 1.75 Tamper shaft, installing
983-154 2.00 Tamper shaft, installing
983-155 3.00 Tamper bearing, removing
983-156 2.00 Tamper bearing, installing
983-157 0.70 Tamper motor, removing
983-158 0.50 Tamper motor, installing
986-005 1.25 Heater bar, removing
986-005 1.00 Heater bar, removing
986-005 0.70 Heater bar, removing
986-005 1.25 Heater bar, removing
986-006 1.75 Heater bar, installing
986-006 1.75 Heater bar, installing
986-006 1.25 Heater bar, installing
986-006 0.50 Heater bar, installing
987-024 15.00 Screed plate, replacing
987-050 0.90 Deflector, removing
987-050 0.50 Deflector, removing
987-051 0.60 Deflector, installing
987-051 0.60 Deflector, installing

334 Volvo Construction Equipment 7/11/2012


VB-T 78 GTC
Op.no. time (h) Notes

1 STANDARD PARTS, SERVICE


17 SERVICE
173-002 0.70 Maintenance service, daily
173-004 0.50 Maintenance service, every 50 hours
173-010 0.30 Maintenance service, every 500 hours
173-012 0.40 Maintenance service, every 1000 hours
173-014 4.00 Maintenance service, every 2000 hours
173-050 0.30 Greasing, daily
173-051 0.20 Greasing, 50 hrs

19 GENERAL
191-021 0.20 Service position 1
191-022 0.30 Service position 2

7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;


WHEEL/TRACK UNIT
77 WHEELS; TRACKS; TYRE; HUB; DRUM
777-005 0.80 Vibration motor, removing
777-006 0.60 Vibration motor, installing

8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS


ANYWHERE
82 ENGINE HOOD; MUDGUARD; FOOT STEP
827-005 0.50 Walkway, removing
827-006 0.40 Walkway, installing
827-007 0.60 Deck platform, removing
827-008 0.50 Deck platform, installing

9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/


GRADING EQUIPM.; MISC. EQUIP.
98 FUNCTION FOR ROAD CONSTRUCTION
982-003 2.50 Screed, removing
982-004 4.00 Screed, installing
982-015 2.00 Extension cylinder, removing
982-015 0.90 Extension cylinder, removing
982-016 0.80 Extension cylinder, installing
982-016 3.00 Extension cylinder, installing
982-026 0.40 End plate, replacing

7/11/2012 Volvo Construction Equipment 335


VB-T 78 GTC
Op.no. time (h) Notes

982-026 0.30 End plate, replacing


982-030 3.00 Sliding bearing, replacing
982-030 1.75 Sliding bearing, replacing
982-040 2.50 Brake cylinder, replacing
982-050 1.00 Crown control cylinder, replacing
982-050 2.50 Crown control cylinder, replacing
983-130 0.90 Vibration shaft, removing
983-131 0.80 Vibration shaft, installing
983-132 1.50 Vibration bearing, removing
983-133 1.25 Vibration bearing, installing
983-150 1.50 Tamper, adjusting
983-151 0.70 Tamper bar, removing
983-151 0.70 Tamper bar, removing
983-152 1.50 Tamper bar, installing
983-152 0.90 Tamper bar, installing
983-153 1.75 Tamper shaft, removing
983-153 1.50 Tamper shaft, removing
983-154 1.75 Tamper shaft, installing
983-154 2.00 Tamper shaft, installing
983-155 3.00 Tamper bearing, removing
983-156 2.00 Tamper bearing, installing
983-157 0.70 Tamper motor, removing
983-158 0.50 Tamper motor, installing
987-024 15.00 Screed plate, replacing
987-050 0.90 Deflector, removing
987-050 0.50 Deflector, removing
987-051 0.60 Deflector, installing
987-051 0.60 Deflector, installing

336 Volvo Construction Equipment 7/11/2012