Download Volvo Wheel Loader L90G Service and Repair Manual PDF (English)

Access the comprehensive Volvo Wheel Loader L90G Service and Repair Manual PDF, your ultimate resource for maintaining and troubleshooting heavy equipment. This digital guide provides step-by-step instructions, detailed schematics, hydraulic and electrical diagrams, and engine specifications tailored specifically for the L90G model. Whether you are a professional mechanic or a fleet owner, this manual ensures peak performance and reduces costly downtime. Download instantly to execute precise diagnostics, routine maintenance, and major repairs safely and efficiently. www.themanualsgroup.com
 
MODEL COVERED :
Volvo L90G Wheel Loader

CONTENTS INCLUDED : 
Descriptions
3rd 4th hydraulic function, valve, description
3rd, alternatively 3rd 4th hydraulic function, description
3rd, or 3rd 4th hydraulic function, component location
5 V Power supply E-ECU, description and measuring
ACM, IO list
Air conditioning, tightening torques
Alarm, description
Alternator, description
Automatic differential brake, Limited Slip, description
Auxiliary brake (engine braking), description
Battery disconnector switch, description
Battery, charging
Battery, description
Boom Suspension System, component description
Boom suspension system, component location
Boom Suspension System, description
Booting sequence
Brake accumulator, description
Brake system, component location
Branching in cables
Bus communication supervision
Cab and air conditioning
Cab, description
Cable and component designations
Cable and component marking explanations
CareTrack W-ECU, description
CDC valve, lever steering, description
Central lubrication system, description
Central valve, description
Central warning
Change of lubrication interval
Chassis connection
Climate control system, description
Collection of basic data
Comfort Drive Control (CDC), component location
Comfort Drive Control (CDC), description
Communication with data Bus
Component locations
Components list
Conditions when checking
Connectors, overview
Connectors, position
Control valve, description
Cooling fan motor, description
Cooling fan, component location
Cooling fan, description
Cooling system, component location
Cooling system, description
Crankcase ventilation, description
Diagnostic tools, description
Differential lock, description
Dosage valves, description
Drive axles, description
Drivetrain, component location
ECC, IO list
ECO – accelerator pedal
E-ECU, IO list
Electric door opener, description
Electric welding
Electrical symbols and designations
Electrical system, description
Electrical system, work instructions
Electronic control system, description
Engine control unit E-ECU, description
Engine, description
Error codes, showing
Exhaust Aftertreatment System, component location
Exhaust Aftertreatment System, description
Exhaust gas recirculation (EGR), component location
Exhaust Gas Recirculation (EGR), description
Filling lubricant
Fire suppression system, component description
Foot brake valve, description
Frame joint, description
Frame, description
Front axle, component description
Fuel system, component location
Fuel system, description
General fault diagnosis information
Hood opening
Hydraulic attachment bracket, description 1
Hydraulic attachment bracket, description
Hydraulic components, cleanliness when handling
Hydraulic oil tank, description
Hydraulic pump flow regulation, description
Hydraulic pumps, description
Hydraulic transmission, description
I-ECU, IO list
Information display, axles brakes
Information display, check
Information display, electrical system
Information display, engine
Information display, general
Information display, hydraulics
Information display, operating display
Information display, service mode
Information display, service
Information display, settings
Information display, start lockout
Information display, transmission
Information display, vehicle info
Information display, vehicle messages
Infrared Thermometer
Inlet and exhaust system, component location
Inlet and exhaust system, description
Instrument panels
Intermittent wiper and washer
Key feed
Lead and connector checks
Leak detector 951 1207, new model
Lighting, description
Lubricating system, description
Lubrication system, component locations
Middle instrument panel with warning lights
Oil cooler, component description
Parameter settings
Parking brake, component location
Parking brake, function description
Pause heater, description
Power supply ECC, description and measuring
Power supply E-ECU, description and measuring
Power supply I-ECU, description and measuring
Power supply V2-ECU, description and measuring
Power supply V-ECU, description and measuring
Power supply W-ECU, description and measuring
Power supply, ACM (Aftertreatment Control Module), description and measuring
Preheating, description
Pressure monitor, description
Propeller shaft, component description
Pump unit, description
Rear axle mounting, component description
Rear axle, component description
Regeneration process, description
Reversible cooling fan, description
SAE error codes, translation to error messages, general
SAE J1708-1587 Information link, description and measuring
Secondary steering, component location
Secondary steering, description
Service
Servo system, description
Servo valve, description
Shift valve, description
Software parameters, description
Software, description
Software, parameter settings and read-outs
Special tools for troubleshooting
Steering cylinder, description
Steering system, component location
Steering system, description
Steering valve, description
System voltage
TP-Linkage’s bearing points
Transmission, component position
Troubleshooting strategy
Troubleshooting tools
Troubleshooting, air conditioning unit (AC)
Turbocharger, description
V2-ECU, IO list
VCADS Pro service tool
VCADS Pro socket, measuring
V-ECU, IO list
Vehicle control unit V2-ECU, description
Vehicle control unit V-ECU, description
Viscous cab suspension, description
W-ECU, IO list
Windows, general, gluing
Windows, general
Working hydraulic system, component location 1
Working hydraulic system, component location
Working hydraulic system, description
Diagrams
Explanations to hydraulic diagram
Hydraulic diagram transmission
Hydraulic diagram, complete full page
Hydraulic diagram, complete
Table of contents, wiring diagrams
Wiring diagram – Aftertreatment
Wiring diagram – Brake
Wiring diagram – BSS
Wiring diagram – Electrically controlled battery disconnector
Wiring diagram – Gear
Wiring diagram – Start
Wiring diagram WD201
Wiring diagram WD202
Wiring diagram WD260
Wiring diagram WD261
Wiring diagram WD262
Wiring diagram WD263
Wiring diagram WD265
Wiring diagram WD266
Wiring diagram WD267
Wiring diagram WD301 Update G
Wiring diagram WD301
Wiring diagram WD302
Wiring diagram WD303 Update G
Wiring diagram WD303
Wiring diagram WD304
Wiring diagram WD306
Wiring diagram WD308 Update G
Wiring diagram WD320
Wiring diagram WD321
Wiring diagram WD322
Wiring diagram WD323
Wiring diagram WD324
Wiring diagram WD325
Wiring diagram WD326
Wiring diagram WD330
Wiring diagram WD331
Wiring diagram WD333
Wiring diagram WD334
Wiring diagram WD335
Wiring diagram WD337 Update G
Wiring diagram WD350
Wiring diagram WD351
Wiring diagram WD352
Wiring diagram WD360 Update G
Wiring diagram WD360
Wiring diagram WD361
Wiring diagram WD362
Wiring diagram WD363 Update G
Wiring diagram WD363
Wiring diagram WD364 Update G
Wiring diagram WD371 Update G
Wiring diagram WD372 Update G
Wiring diagram WD373
Wiring diagram WD374
Wiring diagram WD375 Update G
Wiring diagram WD375
Wiring diagram WD376
Wiring diagram WD401
Wiring diagram WD402 Update G
Wiring diagram WD402
Wiring diagram WD403
Wiring diagram WD404
Wiring diagram WD405
Wiring diagram WD407 Update G
Wiring diagram WD501 Update G
Wiring diagram WD501
Wiring diagram WD601
Wiring diagram WD602
Wiring diagram WD604
Wiring diagram WD801
Wiring diagram WD802
Wiring diagram WD804 Update G
Wiring diagram WD804
Wiring diagram WD805
Wiring diagram WD806
Wiring diagram WD807
Wiring diagram WD808
Wiring diagram WD831 Update G
Wiring diagram WD901
Wiring diagram WD902
Wiring diagram WD903
Wiring diagram WD904
Wiring diagram WD905
Wiring diagram WD906
Wiring diagram WD908
Wiring diagram WD911
Wiring diagram WD913
Wiring diagram WD915 Update G
Installation Instructions
3rd hydraulic function, installing new
After market engine, transfer of components
Anti theft device, installing new
Attachment locking, installing new
Back up alarm, installing new
Battery disconnector switch, installing new
Boom suspension system, installing new
Cab front work light LED, installing new
Cab illuminated entrance LED, installing new
Cab rear work light LED, installing new
Cab side work light LED, installing new
Cab, air pre cleaner, installing new
CareTrack, installing new
Engine heater 120V, installing new
Engine heater 240V, installing new
Forward view camera, installing new
Front work light LED, installing new
Fuel filter extra, installing new
Grill work light LED, installing new
Hand throttle, instaling new
Lever steering (CDC), electric, installing new
Pre-cleaner cyclone type, installing new
Pre-cleaner oil bath type, installing new
Pre-cleaner turbo type, installing new
Protection for lighting, front, installing new
Radiator grill guard, installaing new
Radio, installing new
Rear view camera, installing new
Rear view mirror, installing new
Reversible fan, installing new
Rotating beacon, installing new
Single lever control, 2nd hydraulic function, installing new
Wind shield guard, installing new
Work light front, installing new
Work light rear, installing new
Repair
3rd 4th hydraulic function, checking and adjusting pressure
3rd 4th hydraulic function, shock valve, checking
3rd 4th hydraulic, functional check
Accelerator pedal, replace
Accumulator removed, checking charging pressure
Accumulator removed, checking
Accumulator, boom suspension system, discarding
Accumulator, discarding
Accumulator, installation
Accumulator, removal
Accumulators, checking in machine
ACM (After treatment control module), replacing, non-programmed
ACM (After treatment control module), replacing, pre-programmed
Actuator, replacing
Air conditioning, checking performance
Air mix door actuator, replacing
Air pump safety valve, replacing
Air pump, replacing
Attachment locking, functional check 1
Attachment locking, functional check
Automatic central lubrication, filter, cleaning replacing
Automatic lubrication pump unit, reconditioning
Axle suspension, replacing bushes and seals
Axle, installing
Axle, removing
Back-up valve, checking and adjusting
Back-up valve, replacing
Batteries, replacing
Battery condition, check
Battery, cables and connections, check
Bleeding air
Boom suspension accumulator, check and adjusting 1
Boom suspension accumulator, check and adjusting
Boom suspension accumulator, reconditioning
Boom suspension system, functional check
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom suspension system, left accumulator, installation
Boom suspension system, left accumulator, removal
Boom suspension system, pressure reduction, safety valve, checking and adjusting
Brake disc, replacing
Brake discs, measuring wear
Brake piston, replacing seals 1
Brake piston, replacing seals
Brake system charging, checking
Brake system, bleeding
Brake system, check and adjusting pressure in circuit
Brake system, checking function, retardation
Burner, replacing
Cab, extra prefilter, replacing
Cab, installing
Cab, main filter, replacing
Cab, prefilter, replace when required
Cab, removing
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, check
CareTrack battery, replacing
Charge air cooler, installing
Charge air cooler, removing
Climate unit, installing
Climate unit, removing
Comfort drive control (CDC), angle sensor, changing
Comfort drive control (CDC), solenoid valve, changing
Comfort Drive Control, servo pressure, checking
Compression test
Compressor, replacing
Condenser, replacing
Coolant level, checking
Coolant pump, replacing
Coolant, change
Coolant’s freezing point, check
Cooling system, pressure control
Counterweight, fitting
Counterweight, removing
Crankcase ventilation separator, replacing
Crankshaft, replacing front oil seal
Diesel particulate filter, checking and cleaning
Differential lock, adjusting
Differential lock, function check
Door lock cylinder, replacing
Drive axles, oil, draining
Drive axles, oil, filling
Drive belts, check 1
Drive belts, check
Drying filter, replacing
ECC, MID 146, changing non-programmed ECU
ECC, MID 146, changing pre-programmed ECU
E-ECU, MID 128, changing non-programmed ECU
E-ECU, MID 128, changing pre-programmed ECU
EGR Actuator, replacing
EGR cooler, cleaning
EGR cooler, replacing
EGR pressure sensor, replacing
EGR reed valve, checking
EGR reed valve, replacing
EGR temperature sensor, replacing
EGR valve, replacing
EGR Venturi tube, replacing
Electric door opener, control unit, replacing
Electric door opener, locking motor, replacing
Electric door opener, opening support motor, replacing
Electric door opener, rotor switch, replacing
Engine air cleaner, replacing
Engine belts, replacing
Engine hood, installing
Engine hood, manually operating
Engine hood, removing
Engine oil filter, replacing
Engine oil level, checking
Engine oil, draining
Engine oil, filling
Engine radiator, oil cooler and condensor (if installed), clean
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor (crank shaft), replacing
Engine, installing
Engine, removing
Error codes when calibrating
Evaporator, replacing incl draining and filling
Evaporator, replacing
Exhaust pipe, flexible tube, replacing
Expansion valve, replacing
Fan motor, replacing
Feed pump, checking feed pressure
Fire suppression system, actions after activation
Fire suppression system, actions after manual activation
Fire suppression system, component location
Frame joint, replacing bearings
Front axle, breather filter, replacing
Front wheel, installation
Front wheel, removal
Fuel control valve (FCV), replacing
Fuel filters, primary and secondary filter, replace
Fuel metering unit A, replacing
Fuel metering unit B, replacing
Fuel pump, replacing
Fuel rail pressure sensor, replacing
Fuel system, bleeding
Fuel tank breather filter, replacing
Gear selector valve, replacing one solenoid
Glow plug control unit, replacing
Glow plug, replacing
Grease Locations
Heat control valve, replacing
Heater core, replacing
High pressure fuel pump, replacing
High pressure fuel system, pressure relief
Hinge, lubricating
Hub reduction, installing 1
Hub reduction, installing
Hub reduction, removing 1
Hub reduction, removing
Hub, replacing seal 1
Hub, replacing seal
Hydraulic couplings
Hydraulic cylinder, installing piston’s lock brace 1
Hydraulic cylinder, installing piston’s lock brace
Hydraulic oil level, checking
Hydraulic oil tank, draining
Hydraulic oil tank, return oil filter, replace, and magnetic rod, clean
Hydraulic oil tank, sediment drain
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic oil, filling
Hydraulic power control valve, replacing
Hydraulic pump P2, installation
Hydraulic pump P2, removal
Hydraulic pump P3, checking function
Hydraulic pump P3, installation
Hydraulic pump P3, removal
Hydraulic pump, checking and adjusting standby pressure and working pressure 1
Hydraulic pump, checking and adjusting standby pressure and working pressure
Hydraulic system, bleeding
Hydraulic system, warming up
Hydraulic tank and hydraulic transmission, ventilation filter, replacing
I-ECU, MID 140, changing non-programmed ECU
I-ECU, MID 140, changing pre-programmed ECU
Injector sleeves, replacing
Injectors, replacing all
Left steering cylinder, installing
Left steering cylinder, removing
Lever steering (CDC), functional check
Lift cylinder, repacking in machine 1
Lift cylinder, repacking in machine 2
Lift cylinder, repacking in machine
Lift lower function, checking
Lifting time, checking
Lubrication oil pressure, checking with pressure gauge
Lubrication, 50 hours maintenance interval
Lubrication, 250 hours maintenance interval
Lubrication, 500 hours maintenance interval
Lubrication, 1000 hours maintenance interval
Lubrication, 2000 hours maintenance interval
Lubrication, 4000 hours maintenance interval
Maintenance service, every 50 hours
Maintenance service, every 250 hours
Maintenance service, every 500 hours
Maintenance service, every 1000 hours
Maintenance service, every 2000 hours
Maintenance service, every 4000 hours
Maintenance service, every 4500 hours
Maintenance service, every 6000 hours
Maintenance service, fire suppression system
Maintenance service, first 1000 hours
Mechanical release of parking brake
NOx sensor, replacing
Oil bath air cleaner oil, changing
Oil plugs, installing
Oil-bath air cleaner’s reservoir (optional equipment), clean, and oil, change
Oil-bath air cleaner’s reservoir (optional equipment), oil, check
Operator’s seat, securing
Oxidation catalyst, replacing
Parking Brake – Assembly
Parking Brake – Disassembly
Parking Brake – Installation
Parking brake assembly, removing
Parking brake, adjusting
Parking brake, function checking
Parking brake, replacing brake pads
Pause heater, replacing
Plastic hood, repairing
Pressure relief valve (PRV), replacing
Radiator, installing
Radiator, removing
Rear axle, breather filter, replace
Rear wheel, installing
Rear wheel, removing
Refrigerant, draining
Refrigerant, filling incl vacuum pumping
Restore operating condition after all test and adjustment work
Restore the machine to original condition
Right steering cylinder, installing
Right steering cylinder, removing
Seal for front output shaft, replacing
Seal for rear output shaft, replacing
Secondary steering pump, checking and adjusting working pressure
Servo accumulator, installation 1
Servo accumulator, installation
Servo accumulator, removal 1
Servo accumulator, removal
Servo pressure, checking and adjusting
Servo pressure, checking at the spool in control valve
Shock valve lift function, checking
Shock valve, tilt function, checking
Spark plug cable, replacing
Spark plug control unit, replacing
Spark plug, checking
Spark plug, replacing
Stall speed, checking
Steering cylinder removed, reconditioning excl replacing bearings
Steering system, checking and adjusting working pressure
Steering system, checking and adjusting working pressureb 1
Steering system, function check
System test
Take the hose away from the draining point of engine oil and replace the cap
Tilt cylinder, repacking in machine
Tilt, functional check
Towing
Transmission oil filter, replacing
Transmission oil pressure, checking
Transmission oil, checking level
Transmission oil, draining
Transmission oil, filling
Transmission suction strainer, cleaning
Transmission, calibration
Transmission, function check
Transmission, installing
Transmission, removing
Turbocharger, installing
Turbocharger, removing
Tyres, wear and air pressure, checking
V2-ECU, MID 249, changing non-programmed ECU
V2-ECU, MID 249, changing pre-programmed ECU
Valves, adjusting 1
Valves, adjusting
VCADS Pro, connecting problems
VCADS Pro, Operations
V-ECU, MID 187, changing non-programmed ECU
V-ECU, MID 187, changing pre-programmed ECU
Warming up machine
Waste gate, testing
Wheel brakes, functional check
Window pane, installation
Windscreen, replacing
Service Bulletins
AC compressor, fill with oil
Air bleeding of the central lubrication system
Air cleaner
Air pump filter cleaning – PSID133 FMI 12, PPID340 FMI 12
Air pump
Alternative lubricants for axles with wet brakes
Attachment brackets 86453 and 86454 1
Attachment brackets 86453 and 86454
Automatic greasing systems of foreign manufacture
Automatic transmission lubricants
Battery and alternator test procedure
Battery cable chafing against the rear frame
Battery maintenance guideline for long term stock machines
Burner ignition device improvement
Cables cut under operator seat
CDC function, disengaging
CDC-system, product improvements
Central lubrication 1
Central lubrication, oxide on pins
Central lubrication
Chafing battery cable
Check method on engine oil consumption
Cleaning of the machine
Clogged T-fitting
Cranking problems
D- arm cracks
D4H – D8H EATS air pump improvement
DEF AdBlue AUS32 sampling, method
Diagnostic improvements D4H-D8H
Discontinued recommendation for usage of anti-corrosion agent in cooling system
EATS burner improvement
EATS sensor failure
ECU improvements
ECU, functional check
EGR cooler leaking coolant internally
EGR temperature sensor
Engine coolant expansion tank
Engine hood actuator
Engine oil cooler improvement
Fork arms, information warranty matters, altered procedures
Fuel pressure read-out
Fuel sampling, method
Fuse box decal with wrong information
Greasing of hydraulic pump drive shaft
Heat shield clamp, breaking
Heater unit, external leakage
Improved climate control system
Improved EATS air pump
Improved hour recorder
Improved wiper motor 1
Improved wiper motor
Injector fuel return flow measurement
Installation of ferrites on the cable harness to the air pump for the regeneration system
Instructions for crack in lifting frame
Instructions for drilling in ROPS structure
Instructions for shielded metal arc welding
Lamp bracket with rubber suspension
Limitation, TP-linkage
Loose seat base
Maintenance service, every 2000 hours
Missing decal information in the Operator’s manual
New air breather filter to the hydraulic oil tank
New bracket for the mudguard
New brake pressure sensor
New BSS valve
New cab heater element
New CareTrack W-ECU2
New condenser
New gear lever combi-switch
New I-ECU introduction
New NOx sensor for Tier 4i Stage IV engines D6H D8H
New rear frame
New software for full-automatic regeneration (option)
New software release V2013.2.1
New software release V2013.4.0
New software release V2013.6.0
New software release V2015.3.0
New software release V2015.3.1
New software V2014.3.0
New software version V2013.6.1
New sound absorbers
New switch for attachment lock
New TechTool VCADS Pro interface
New tightening torque process for the D4H, D6H cylinder head bolts
New transmission
New V-ECU and V2-ECU
New wheel loaders L60G, L70G and L90G
Oil analyses
Oil sampling, method
Operator adaptation of electric servo lever functions with VCADS Pro
Power control valve, removal
Protection cover
Protection of the cab’s main wire harness
Quality of illustrations in technical reports
Radio band setting
Recommendations for Oil Sampling Intervals
Reinforced attachment bracket
Repair instructions for attachments
Repair report for central lubrication pumps
Repair Report for Volvo transmissions
Reporting of product misuse & near-miss report
Reports
Rusting lifting eye
Seals
Semi-automatic regeneration
Serial number location on machine components
Software release summary WLO G-models
Turbo charger waste gate hose comes loose – MID128 PID131 FMI0, MID128 PPID326 FMI14
Tyres, various types
Volvo Product incident accident report & Interview Form
Water intrusion in cab
Windshield guard interferes with nipple
Special tool catalog
General
Index
Hooks
1. Enviroment and Safety equipment
2. Measuring equipment
3. Tightening and Loosening tools
4. Lifting equipment
5. Pullers and Pressing equipment
6. Drifts
7. Guide pins and Guide sleeves
8. Pliers
9. Fixtures
10. Tech Tool
11. Spare parts
Specifications
3rd 4th hydraulic function, specifications
3rd 4th hydraulic function, tightening torques
Air conditioning, specifications
Alternator 80 A, specification
Alternator, specification
Automatic lubrication system, specifications
Battery, specifications
Battery, weight
Boom Suspension System, specifications
Boom Suspension System, tightening torques
Brake accumulator, specifications
Brake system, specifications
Cabin, tightening torques
Control valve, lever steering (CDC), specifications
Control valve, specifications
Control valve, torque value
Conversion tables
Coolant
Cooling fan rpm, specifications
Cooling fan, tightening torques
Cooling system, tightening torques
Counterweight, tightening torques
Counterweight, weight
EGR system, tightening torques
Electrical system, specifications
Engine oil pressure, specification
Engine, fill quantities
Engine, software specifications
Engine, specification 1
Engine, specification
Engine, tightening torques 1
Engine, tightening torques
Exhaust aftertreatment system, specifications
Fire suppression system, specification
Frame joint, tightening torques
Front and rear axles, specifications
Front and rear axles, tightening torque
Front and rear axles, volume
Fuel system, specifications
Function times, specifications
Hydraulic connections, tightening torques
Hydraulic pump (P2), specifications
Hydraulic pump (P3), specifications
Hydraulic pumps, tightening torques
Hydraulic system, volume
Hydraulic transmission, capacity
Inlet and exhaust system, tightening torques
Lever steering (CDC), specifications
Lift cylinder, tightening torques
Lighting, specifications
Lubrication system, specifications 1
Lubrication system, specifications
Lubrication system, tightening torques
Parking brake, specifications
Preheating, specifications
Propeller shaft, tightening torque
Recommended lubricants
Secondary steering pump, specifications
Servo system, specifications
Standard tightening torques
Starter motor, specifications
Steering cylinder, tightening torque
Steering, specifications
Temperature limits for cooling fan speed, specifications
Thermostat, specifications
Tightening torque, fuel system
Tilt cylinder, tightening torques
Transmission, specifications
Transmission, tightening torques
Wheel brake, specification
Wheel, tightening torque
Time Guide Currrent generation
Time Guide Previous generation

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