VOLVO CONSTRUCTION EQUIPMENT

Recycling Manual

L150F, L180F, L220F

MORE CARE. BUILT IN.

 Foreword
1

Foreword
Foreword
Caring for the environment is one of Volvo’s core values, along with quality
and safety.
This brochure is for all those who work with dismantling and scrapping of a
complete machine, both service workshops as well as dismantling compa-
nies and recycling companies. It can also be used for service work during
the machine’s lifetime, as a guide for handling used products that are
replaced during repairs and service.
The purpose is to facilitate correct handling of hazardous waste or other
equipment and components that may cause personal injury and environ-
mental damage. It also serves as a material map to see which materials are
included in the product.
The brochure does not include any instructions for recycling technicians
since these will change with time, and an instruction from today may prove
to be completely different in the future. There is also national legislation and
a variety of local regulations that differ significantly.
The information in the brochure is developed for Volvo L150F, L180F, and
L220F, and shall not be used in any way for other products.
Information and data included in the brochure are valid at the time of publi-
cation. We reserve the right to change specifications and equipment with-
out prior notice.
This recycling manual is for a so-called ’basic machine’. When the machine
is purchased, a variety of optional equipment may be selected and all of
these are not included or described in this manual.

Overall perspective
Volvo Construction Equipment’s overall perspective on how environmental
aspects shall be fulfilled means that the company’s products are regarded
in a much greater context:
• Society works for common environmental legislation and facilitates good
work planning and provides systems for recycling.
• Volvo and its sub-suppliers replace materials that have negative impact
on man and the environment, and improve use of products and manufac-
turing methods.
• Dealers make sure that the customers get the right machines that are ex-
actly adapted to their applications.
• Operators and owners handle the machines correctly with regards to
use, service, and maintenance.
• Recycling is performed in a manner that is safe to both man and the en-
vironment. Scrapping and dismantling take place in a way that enables
maximized reuse or recycling of the machine.
 Safety
2

Safety
Safety
Volvo Construction Equipment AB assumes that work with our machines
follows the safety and work instructions included in the Service manual and
Operator’s manual for the model in question.
Dismantling and recycling of machines shall be performed by personnel
with sufficient knowledge, and in a professional manner in order to avoid
personal injury and environmental damage.
If in effect, national legislation governing dismantling of machines is the pri-
mary legislation to be followed. This Recycling manual is only a supplement
to the valid Service manual and Operator’s manual for Volvo L150F, L180F,
and L220F.
 Recycling Work
3

Recycling Work
Work and recycling
A Volvo wheel loader consists of metals to approx. 80%. In general, metals
are suitable for recycling. However, in certain cases the components’
design and installation may make recycling impossible, both practically and
economically, despite the included materials themselves being recyclable.
The recycling process has 5 readily identifiable steps, where one should
strive to get the biggest fractions of the machine’s material as high up as
possible on the recycling steps.

Recycling steps
Strive to get as much material as possible, as high as possible, on the steps.
Source: Thomas Magnusson IVF

Main work process when dismantling Volvo wheel loaders

This work process should be followed for dismantling work to proceed in
an optimal way:
1 Identify the machine by reading signs and plates as well as the instruc-
tions in the manual.
2 Check governing regulations/legislation for recycling and producer re-
sponsibility. Also check if there are special safety aspects for disman-
tling.
3 Decontaminate the machine from fluids and specially marked compo-
nents that have to be removed and sorted out for special handling.
4 Dismantle the machine in a safe and environmentally correct manner.
5 Sort the dismantled parts and components in fractions for recycling.
 Sorting
4

Sorting
Sorting
There is a number of thought fractions in which to sort the material, exam-
ples of these are found below. Handling of these fractions is governed by
national legislation and local regulations, which shall be followed.
• Materials and components that can be reused as components in old
and/or new machines. These may be in need of repairs or upgrades in
order to meet quality requirements. For example, this may be engine, ax-
les, transmission, and hydraulic cylinders.
• Materials that can be material-recycled with or without loss of quality. Ex-
amples of material recycling without loss of quality are metals and certain
plastics. Loss of quality refers to, e.g., plastics that only can be given a
dark colour when material-recycled.
• Materials for energy extraction are, among others, unsorted plastics and
oils.
• Materials that have to be deposited mainly come from fragmentation and
unsorted materials.

Producer responsibility
A number of the machine’s components are governed by the principle of
producer responsibility, which means that they shall be taken care of
according to special instructions. These instructions may vary from one
country to another. If you do not know what this includes or are unsure
about applicable governing regulations, contact your Volvo dealer or Volvo
directly.
 Identifying
5

Identifying
Identifying the machines
This manual is only valid for the stated models; Volvo L150F, L180F, and
L220F, see illustration below for identification marking. The machines have
been manufactured in Sweden by Volvo Construction Equipment AB from
the year 2007. The primary colour is yellow.

1 Machine PIN, Product Identification Number (stamped on right side).

2 Product plate including, among other things, machine type and PIN. Ad-
ditional plate with, among other things, CE-marking (only for country of
origin within the EU), as well as an emission plate. A total of three plates.
3 Plate identifying that ROPS-test has been performed and approved.
4 CIN-plate (Component Identification Number) for engine.
5 CIN-plate for transmission
6 CIN-plate for boom
7 CIN-plate for front axle
8 CIN-plate for rear axle
 Materials - Identifying
6

Materials - Identifying
A marking system is used where all plastic parts are marked with a material
code, making the materials easy to identify. Many materials can be granu-
lated and reused, while other plastics are used for energy extraction by
incineration. Certain plastics must be taken care of in a special way or
destroyed, through some form of pre-treatment.
Volvo standards applicable to these machines are:
• Std 103-0002 Material identification and marking of components made
of plastic or elastic material
• Std 5052,41 Material identification and marking of plastic parts
• Std 5052,411 Symbols and abbreviations
• Std 5052,412 Symbols for plastic containers

The following few examples show what the marking may look like:

>ABS< Part consisting of one material, in this case ABS-plastic.

>ABS+PC< Part consisting of a mix of two materials.

>PVC,PUR,ABS< Part consisting of 3 materials where PVD is the visible (coating) and PUR with inclusion of ABS. ABS is biggest by weight (under-
lined).

>PP – MD30< Part containing reinforcing or filler material with 30 percent by weight.

For more complicated mixtures, see Std 103-0002.

Contact your Volvo dealer or Volvo directly to obtain these standards.
 Decontamination
Draining fluids 7

Decontamination
Draining fluids
It is important that fluids are handled in a safe and correct manner, with
regards to national legislation as well as local regulations.
Follow instructions in the Service manual and Operator’s manual for drain-
ing fluids in axles, tanks, and other containers and/or reservoirs.
The following table is intended to serve as a checklist.

Total volume in litres

Machine type

Position L150F L180F L220F

Engine, including filters 49 49 49

Transmission and torque converter, including filters 50 50 48

Front axle, including hub reduction 49 49 82

Rear axle, including hub reduction 59 59 76

Rear axle cradle - - 3

Hydraulic system 261 265 330

Hydraulic oil tank 156 156 226

Fuel tank 335 335 335

Cooling system 60 60 60

Oil bath pre-cleaner 9,1 9,1 9,1

Refrigerant (R134a) 2,1 kg 2,1 kg 2,1 kg

Washer fluid reservoir 5 5 5

Filter
There is a wide range of filters on the machine that, when dismantled, con-
tain impurities and the medium which they filter. Note that there are special
regulations for handling of filters.
Filter table. This table is intended to serve as a checklist.

Number Position Medium Quanti- Comments

ty

1 Transmission Transmission oil 1

2 Engine Oil 3

3 Engine Coolant 1

4 Hydraulic tank Hydraulic fluid 1

5 Rear axle Oil 1 In comb. with axle oil cooling

6 Front axle Oil 1 In comb. with axle oil cooling

7 Air cleaner Air 2 Paper + filter

8 Cab Air 2 Paper filter

9 Engine compart- Diesel 2

ment

- Breathing Air / oil mist 5 Axles, transmission, hydraulic tank, and fuel tank
 Decontamination
8 Components with special safety and environmental aspects

5 9
8

1
2
6

Components with special safety and environmental aspects

The following components shall be handled with the extreme care and high-
est safety. For handling, see Service manual and Operator’s manual.

Number Component Aspect

1 Battery Sulphuric acid

2 Accumulators for Boom Suspension System Pressurized container

3 Accumulators for lowering load Pressurized container

4 Accumulators for steering Pressurized container

5 Accumulators for service brake Pressurized container

6 Accumulators for P-brake Pressurized container

7 Air conditioning unit Refrigerant*

- Gaskets of fluor rubber/fluor silicone Generate hydrogen fluoride and hydrofluoric acid
(used to withstand high temperatures in, e.g., engines, transmissions, axles, hydraulic when exposed to intense heat (fire). **)
motors, and pumps)

* Note that special regulations apply when working with refrigerant.

** Be extremely careful where you suspect presence of fluor rubber.
See Service manual and Operator’s manual for more information.
 Decontamination
Components with special safety and environmental aspects 9

6 7
4
3 5

2
 Dismantling
10 Material weights, complete machine

Dismantling
Material weights, complete machine
The following weights are approximate. They do not apply to machines with
optional equipment.
Volvo’s wheel loaders consist of metals to approx. 80%. In general, metals
are suitable for material recycling.

Weight in kg
Machine type

Material L150F L180F L220F

Steel/iron 18290 21610 25630

Copper 43 43 43

Aluminium 140 140 140

Bronze bushings 35 35 35

Lead batteries 81 81 81

Glass 74 74 74

Polymer materials & rubber 120 120 130

Tires 2400 2400 2720

Fluids, oils, and chemicals 740 740 850

Other 1000 1110 1400

Total* 22920 26350 31110

* Varies depending on equipment, e.g., tires and bucket.

 Components
11

Components
Number Component Weight in kg

L150F L180F L220F

1 Transmission 830 830 830

2 Counterweight 1450 3360 4250

3 Engine 1200 1200 1200

4 Boom 1625 1749 2028

5 Front axle, complete 1460 1460 2183

6 Rear axle, complete 1630 1650 2050

7 Front frame 1980 2545 2590

8 Rear frame 1840 1840 1940

9 Radiator for engine 126 126 126

10 Cab, complete 831 831 831

• Steel 610 610 610

• Plastics 81 81 81

• Glass 74 74 74

• Seat 36 36 36

3
10
9

7
8
4

1 6

5
 Electronics
12

Electronics
The machines have 4-6 so-called ECUs (Electronic Control Unit), and the
number of ECUs depends on what equipment is installed on the machine.
One is on the engine, one or two on the back wall in the cab, one in the
instrument panel, and one or two on the right side in the cab. In the cab
there are also two circuit boards, containing a number of relays and fuses.
One circuit board is located on the back wall and the other one is on the
right front pillar.

6
1

2
4

Number Part Material Note

1 V-ECU Circuit board + metal

2 Circuit board Circuit board

3 I-ECU Circuit board + plastic Instrument panel

4 ECC Circuit board + plastic Climate control unit (AC)

5 W-ECU Circuit board + plastic CareTrack

6 V2-ECU Circuit board + metal CDC + electric servo

7 Circuit board Circuit board Control panel

 Plastics
Plastics 13

Plastics
Plastics

1 3 4

Number Part Material Note

1 Air ducts PP+elastic+mineral

2 Instrument panel PP+elastic+mineral

3 Air duct ABS

4 Cover PP

5 Side panel PP

6 Air duct PP+elastic+mineral

7 Bottom part PP+elastic+mineral

 Plastics
14 Plastics

Plastics

Number Part Material Note

1 Casing ABS

2 Casing PC+ABS

3 Wrist support PUR

 Plastics
Plastics 15

Plastics

3 1

Volvo Construction
Equipment

1032102

Number Part Material Note

1 Floor mat PUR

2 Floor mat PUR

3 Exterior roof ABS + PMMA foil

 Plastics
16 Plastics

Plastics

C C B

D 3

D B

A
4

Number Part Material Note

1 Exterior panel right PP+elastic+mineral

2 Cover right PP+elastic+mineral

3 Exterior panel left PP+elastic+mineral

4 Cover left PP+elastic+mineral 2 parts

 Plastics
Plastics 17

Plastics

Number Part Material Note

1 Panel inside door ABS

2 Panel inside rear ABS

3 Climate cover PP+elastic+mineral

4 Climate cover PP+elastic+mineral

 Plastics
18 Plastics

Plastics

Number Part Material Note

1 Ceiling (headlining) Polyester

2 Rearview mirror inside ABS 2 pcs.

3 Sun visor VELBEX Contains PVC

 Plastics
Plastics 19

Plastics

Number Part Material Note

1 Expansion tank PP
 Plastics
20 Plastics

Plastics

Number Part Material Note

1 Washer fluid reservoir PP Motors (2) can easily be removed.

 Plastics
Plastics 21

Plastics

Number Part Material Note

1 Cover for air cleaner PP

2 Hose for air cleaner EPDM

 Plastics
22 Plastics

Plastics

Number Part Material Note

1 Grill PDCPD Embedded steel bushings

2 Top part PDCPD

 Plastics
Plastics 23

Plastics

1
2

Number Part Material Note

1 Fender widener, front Styrene rubber

2 Fender widener, rear Styrene rubber

3 Splash guard, front Reinforced rubber cloth

4 Splash guard, rear Reinforced rubber cloth 2 pcs.

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