VOLVO L120E WHEEL LOADER SERVICE REPAIR MANUAL PDF – 1755 PAGES

Detailed Workshop Documentation for Engine, Transmission, Steering and Hydraulic Repairs

The Volvo L120E Wheel Loader Service Repair Manual is a comprehensive 1,755-page technical publication covering the maintenance, troubleshooting, inspection, adjustment, and repair of the Volvo L120E wheel loader.

With technical information updated in 2020, this PDF manual brings together detailed descriptions of the machine's major systems, electrical and hydraulic diagrams, equipment installation instructions, workshop repair procedures, safety information, and technical specifications.

The publication provides particularly useful coverage of the Volvo D7 engine, electronic fuel injection system, APS II transmission controls, Comfort Drive Control (CDC), Boom Suspension System (BSS), and automatic Return-to-Dig functions.

It also contains practical repair procedures for high-pressure fuel system components, transmission pressure checks, steering system adjustments, hydraulic pump testing, brake servicing, and air conditioning repairs.

The combination of system explanations, circuit diagrams, and component-specific service instructions makes this manual a technical reference for professional workshops and experienced Volvo equipment owners.

MANUAL INFORMATION

• Manufacturer: Volvo Construction Equipment
• Machine Model: Volvo L120E Wheel Loader
• Manual Type: Service Repair / Workshop Manual
• Format: PDF
• Total Pages: 1,755
• Technical Information Updated: 2020
• Delivery: Digital Download

WHAT DOES THIS VOLVO L120E MANUAL COVER?

The publication is organized into descriptions, electrical and hydraulic diagrams, installation instructions, repair procedures, safety information, and technical specifications.

1. GENERAL MAINTENANCE AND SERVICE INFORMATION

The opening sections contain essential information for carrying out workshop maintenance and repair operations.

Included topics:

• General machine descriptions
• Recommended lubricants and oils
• Battery charging
• Brake and hydraulic system cleanliness
• Electric welding precautions
• Hydraulic system repair practices
• Electrical system safety
• Manual parking brake release
• Machine towing procedures

2. VOLVO D7 ENGINE – MECHANICAL COMPONENTS

The engine section contains detailed descriptions of the D7 engine and its principal mechanical components.

ENGINE STRUCTURE AND COMPONENTS

• D7 cylinder block
• Crankshaft
• Camshaft
• Connecting rods
• Pistons
• Cylinder liners
• Cylinder head
• Cylinder head gasket
• Engine timing gears
• Engine mounting
• Vibration damper
• Valve mechanism
• Crankcase ventilation

ENGINE SERVICE PROCEDURES

• Engine removal
• Engine installation
• Cylinder compression testing
• Front crankshaft oil seal replacement
• Front engine mounting replacement
• Oil pan resealing
• Valve adjustment
• Engine stall speed checking
• Engine oil pressure testing

3. ELECTRONIC FUEL INJECTION AND HIGH-PRESSURE FUEL SYSTEM

The manual provides descriptions and repair procedures for the engine's electronically controlled fuel system.

FUEL SYSTEM COMPONENTS

• Fuel feed pump
• Fuel filters
• Fuel rail
• High-pressure fuel pump
• Fuel Control Valve (FCV)
• Fuel rail pressure sensor
• Pressure Relief Valve (PRV)
• Injectors
• Unit pumps
• Engine electronic control unit

FUEL SYSTEM REPAIR PROCEDURES

• Fuel system bleeding
• Fuel feed pressure testing
• Fuel filter inspection
• High-pressure fuel pump checking
• High-pressure fuel pump replacement
• FCV checking and replacement
• Fuel rail pressure sensor replacement
• Injector replacement
• PRV inspection and replacement

The documentation also includes instructions for working with electronic fuel injection equipment.

4. ENGINE COOLING AND REVERSIBLE FAN SYSTEM

The manual includes information about the engine cooling system and the hydraulically controlled cooling fan.

COOLING SYSTEM

• Cooling system description
• Coolant pump replacement
• Thermostat replacement
• Radiator removal
• Radiator installation
• Cooling fan motor replacement
• Cooling fan hydraulic function checks

REVERSIBLE COOLING FAN

• Reversible fan description
• Electrical control information
• Hydraulic circuit description
• Fan fault indication and troubleshooting
• Cooling fan maximum speed checks
• Fan maximum pressure checks
• Pump P3 standby pressure testing

5. TURBOCHARGER, LUBRICATION AND AIR INTAKE

The engine documentation also includes:

• Turbocharger descriptions
• Turbocharger inspection
• Air cleaner descriptions
• Lubrication system information
• Engine oil pump
• Preheating coil
• Internal Exhaust Gas Recirculation (IEGR)
• Engine intake and exhaust-related functions

6. ELECTRICAL SYSTEM AND ELECTRONIC CONTROL UNITS

The electrical section explains the machine's electronic control architecture and monitored functions.

ELECTRONIC CONTROL SYSTEM

• Engine Control Unit (E-ECU)
• Instrument Control Unit (I-ECU)
• Vehicle Control Unit (V-ECU)
• Control unit communication
• Data bus communication
• Software functions
• Software parameter settings
• Control unit voltage supply
• Sensor voltage supply

CONTROL UNIT SERVICE

• E-ECU replacement
• I-ECU replacement
• V-ECU replacement
• ECU error symptoms
• Electrical troubleshooting strategies
• Connector and cable checks

7. VCADS PRO AND ELECTRONIC TROUBLESHOOTING

The manual includes diagnostic information for investigating electrical and electronic system faults.

Included topics:

• VCADS Pro service tool
• General fault diagnosis
• SAE error code interpretation
• Troubleshooting tools
• Special electrical test equipment
• Control unit communication interruptions
• Reduced computer communication
• Electrical input signal monitoring
• Electrical output signal monitoring
• Software parameter settings
• Relay checks
• Sensor and connector testing

8. INSTRUMENT PANEL AND MACHINE MONITORING

The manual explains the information display, warning indicators, and service monitoring functions.

ENGINE MONITORING

• Engine oil pressure
• Engine oil level
• Coolant level
• Coolant temperature
• Fuel level
• Fuel temperature
• Fuel consumption
• Boost pressure
• Charge-air temperature
• Engine speed
• Engine protection
• Engine shutdown
• High fuel temperature protection

TRANSMISSION MONITORING

• Transmission oil pressure
• Transmission oil temperature
• Transmission oil level
• Transmission oil filter
• Transmission slipping
• Transmission overspeed
• Transmission protection
• Gear selector functions

HYDRAULIC AND BRAKE MONITORING

• Hydraulic oil level
• Hydraulic oil temperature
• Brake pressure
• Brake pressure charging
• Brake testing
• Axle oil temperature
• Boom Suspension System
• Central lubrication
• Secondary steering

DISPLAY FUNCTIONS

• Initial display
• Operating display
• Information display
• Service display
• Service interval information
• Software settings
• Warning messages

9. APS II TRANSMISSION AND POWER TRAIN

The power transmission section includes technical descriptions and workshop procedures for the drivetrain.

TRANSMISSION SYSTEM

• APS II transmission control
• Gear selection
• Gearshifting
• Gear selector valve
• Gearshifting solenoids
• Hydraulic transmission
• Planetary gear
• Final drive
• Differential lock
• Torque converter

TRANSMISSION SERVICE PROCEDURES

• Transmission removal
• Transmission installation
• Transmission oil pressure testing
• Gear selector valve removal and installation
• Gear selector solenoid resistance measurement
• Torque converter removal and installation
• Differential lock sensor adjustment

10. DRIVE AXLES, HUBS AND DIFFERENTIALS

The manual contains procedures for servicing the front and rear axles.

Included operations:

• Front axle removal
• Front axle installation
• Rear axle removal
• Rear axle installation
• Drive shaft replacement
• Hub seal replacement
• Rear axle mounting play measurement
• Differential lock sensor adjustment

11. BRAKING SYSTEM

The braking section includes descriptions and procedures for the service brakes and parking brake.

BRAKE COMPONENTS

• Foot brake valve
• Parking brake
• Brake accumulators
• Brake wear indicators
• Brake hydraulic circuits

BRAKE REPAIR PROCEDURES

• Brake accumulator checking
• Brake disc wear inspection
• Brake disc replacement
• Brake system bleeding
• Brake hydraulic function checks
• Brake retardation testing
• Foot brake pedal angle adjustment
• Foot brake pedal clearance adjustment
• Foot brake valve reconditioning
• Parking brake mechanical release
• Brake circuit pressure testing and adjustment

12. STEERING SYSTEM AND COMFORT DRIVE CONTROL

The steering section provides information about the conventional hydraulic steering system and CDC lever steering.

STEERING SYSTEM DESCRIPTION

• Steering valve
• Steering hydraulic pump
• Steering cylinders
• Steering control valve
• Shift valve
• Secondary steering
• Comfort Drive Control (CDC)

STEERING REPAIR PROCEDURES

• Steering pressure testing
• Steering pressure adjustment
• Steering valve replacement
• Steering valve reconditioning
• Left steering cylinder replacement
• Secondary steering functional checks
• CDC steering signal checks
• Lever steering speed adjustment
• Lever steering control valve adjustment

13. HYDRAULIC PUMPS P1, P2 AND P3

The manual includes service procedures and technical references for the machine's hydraulic pumps.

PUMP P1 AND P2

• Load-sensing pressure checks
• Flow control checks
• Standby pressure testing
• Standby pressure adjustment
• Working pressure testing
• Working pressure adjustment

PUMP P3

• Cooling fan and brake pump functions
• Cooling fan maximum speed checks
• Cooling fan maximum pressure checks
• P3 standby pressure testing

14. WORKING HYDRAULIC SYSTEM

The hydraulic system section explains the equipment used for loader operation.

HYDRAULIC COMPONENTS

• Hydraulic oil tank
• Hydraulic pumps
• Central block
• Hydraulic control valve
• Servo system
• Lifting cylinder
• Tilting cylinder
• Hydraulic couplings
• Hydraulic pressure monitoring

HYDRAULIC SERVICE

• Hydraulic system bleeding
• Hydraulic standby pressure testing
• Hydraulic working pressure testing
• Servo pressure testing and adjustment
• Servo valve adjustment
• Servo valve replacement
• Hydraulic system troubleshooting

15. BOOM SUSPENSION SYSTEM (BSS)

The manual contains detailed information about the Boom Suspension System.

Included procedures:

• BSS system description
• Boom suspension accumulator replacement
• Hydraulic accumulator depressurization
• Accumulator reconditioning
• Accumulator precharge pressure checking
• Accumulator precharge adjustment
• Pressure-reducing valve adjustment
• Boom Suspension System troubleshooting
• BSS test drive with load

16. RETURN-TO-DIG AND AUTOMATIC LIFT ARM LOWERING

The manual includes descriptions of the automatic lift arm lowering function.

Included information:

• Return-to-Dig operating description
• Automatic lift arm lowering
• Return-to-Dig valve block
• Boom position sensors
• Bucket position sensors
• Return-to-Dig installation instructions

17. THIRD AND FOURTH HYDRAULIC FUNCTIONS

The documentation covers auxiliary hydraulic functions and attachment equipment.

Included topics:

• Third hydraulic function
• Fourth hydraulic function
• Auxiliary hydraulic pressure checks
• Auxiliary hydraulic pressure adjustment
• Hydraulic attachment locking
• Attachment bracket cylinder reconditioning
• Hydraulic attachment lock cylinder replacement

18. CENTRAL LUBRICATION SYSTEM

The manual includes information about automatic lubrication.

Included topics:

• Central lubrication system description
• Lubrication cycle
• Lubrication system status indication
• Lubrication cycle selection
• Lubrication system specifications

19. OPERATOR CAB AND AIR CONDITIONING

The cab section provides technical information for the operator environment and climate control equipment.

CAB AND CLIMATE SYSTEMS

• Cab description
• Cab suspension
• Air conditioning
• Automatic Temperature Control (ATC)
• Climate control system
• Relay-controlled air conditioning
• Software-controlled air conditioning

CAB REPAIR PROCEDURES

• Cab removal
• Cab installation
• Engine hood removal
• Engine hood installation
• Air conditioning performance checks
• ATC troubleshooting
• Air conditioning evaporator cleaning
• Fan motor replacement
• Heater core replacement
• Heat control valve replacement
• Viscous cab suspension replacement

20. ELECTRICAL WIRING DIAGRAMS

The manual contains electrical wiring diagrams and component references.

Included diagram groups:

• Wiring diagrams 1–13
• Wiring diagram 15B
• Wiring diagrams 16–35
• Wiring diagrams 101–103
• Wiring diagram 107
• Additional diagram versions 9B, 19C, 21B and 21C
• Updated CDC wiring diagram 17
• Heavy-duty 120-amp alternator diagram
• Electrical circuit list

21. HYDRAULIC CIRCUIT DIAGRAMS

The hydraulic diagram section includes circuit references for several machine systems and configurations.

Included diagrams:

• Complete hydraulic diagrams
• Hydraulic fan and brake system diagrams
• Reversible fan and brake hydraulic diagram
• Steering hydraulic diagrams
• CDC and secondary steering hydraulic diagrams
• Working hydraulic diagrams
• Differential lock hydraulic diagrams
• BSS hydraulic diagrams
• Hydraulic attachment lock diagrams
• Third and fourth hydraulic function diagrams

Several hydraulic diagrams are included in multiple versions.

22. OPTIONAL EQUIPMENT INSTALLATION

The manual contains installation instructions for selected optional equipment.

HYDRAULIC AND CONTROL EQUIPMENT

• Third hydraulic function
• Fourth hydraulic function
• Hydraulic attachment locking
• Boom Suspension System
• Return-to-Dig
• Lever steering
• Single-lever control

ELECTRICAL AND MACHINE ACCESSORIES

• CareTrack
• Engine heater
• Reversible fan
• Hand throttle
• Radio installation kit
• Additional working lights
• Rotating warning beacon
• Electrically heated accessories
• Instructor seat
• Sun blind
• Protective grille
• Tail lamp guard

CAB AND ENGINE EQUIPMENT

• Air conditioning
• Electric AC fan
• Oil-bath air cleaner
• Heat insulation kit

23. WORKSHOP SAFETY INFORMATION

The safety section includes precautions for servicing heavy construction machinery.

Included topics:

• General workshop safety
• Hydraulic system safety
• Hydraulic accumulator handling
• Battery safety
• Fuel and oil handling
• Air conditioning refrigerant safety
• Safe lifting and supporting
• Working under a raised boom
• Tyre handling
• Fire prevention
• Decontamination
• Environmentally hazardous fluids
• Waste handling
• Machine towing and booster battery starting

24. TECHNICAL SPECIFICATIONS

The manual provides reference specifications for the major machine systems.

ENGINE AND FUEL SYSTEM

• Engine specifications
• Engine capacities and weights
• Fuel feed pump specifications
• Injection pump specifications
• Injector specifications
• Cooling system specifications
• Cooling fan motor specifications
• Cooling fan speed specifications
• Lubrication system specifications
• Intercooler specifications

ELECTRICAL SYSTEM

• Alternator specifications
• Battery specifications
• Starter motor specifications
• Lighting specifications
• Electrical system specifications

TRANSMISSION AND DRIVELINE

• Hydraulic transmission specifications
• Transmission oil volume
• Transmission weight
• Torque converter specifications
• Front axle specifications
• Rear axle specifications
• Axle capacities
• Propeller shaft tightening torques

BRAKES AND STEERING

• Brake accumulator specifications
• Brake valve specifications
• Parking brake specifications
• Front and rear wheel brake specifications
• Steering system specifications

HYDRAULIC SYSTEM

• Hydraulic pump P1 specifications
• Hydraulic pump P2 specifications
• Hydraulic pump P3 specifications
• Hydraulic system volume
• Servo system specifications
• Boom Suspension System specifications
• Hydraulic control valve specifications
• Hydraulic cylinder specifications
• Hydraulic function times

ADDITIONAL REFERENCES

• Tightening torques
• Conversion tables
• Component weights
• Recommended lubricants
• Alternative fuels
• Air conditioning specifications
• Refrigerant quantities

PRACTICAL WORKSHOP APPLICATIONS

This manual can assist with operations such as:

• Testing D7 engine compression
• Checking electronic fuel injection components
• Replacing injectors and high-pressure fuel pumps
• Diagnosing E-ECU, I-ECU and V-ECU faults
• Consulting VCADS Pro troubleshooting information
• Testing APS II transmission pressure
• Servicing front and rear axle components
• Checking brake accumulator pressure
• Adjusting CDC lever steering
• Testing hydraulic pump P1 and P2 pressures
• Checking pump P3 cooling fan functions
• Troubleshooting Boom Suspension System faults
• Servicing hydraulic attachment locking
• Reviewing Return-to-Dig system information
• Consulting wiring and hydraulic diagrams

WHO IS THIS MANUAL FOR?

This publication is suitable for:

• Professional Volvo wheel loader technicians
• Heavy equipment repair workshops
• Construction machinery maintenance teams
• Independent diesel and hydraulic equipment mechanics
• Fleet maintenance departments
• Experienced Volvo L120E owners carrying out service and repair work

IMPORTANT COMPATIBILITY INFORMATION

This manual is identified for the Volvo L120E Wheel Loader.

Some electrical and hydraulic diagrams, repair procedures, and installation instructions relate to specific machine configurations or optional equipment.

Before purchasing, verify your machine model, serial number, and installed options to determine whether the relevant documentation applies to your equipment.

The 2020 information update refers to the manual's technical documentation and does not necessarily represent the machine's manufacturing year.

DIGITAL PDF DELIVERY

This product is supplied as a digital PDF workshop manual.

The publication includes:

• 1,755 pages of technical documentation
• Volvo D7 engine descriptions and repair procedures
• Electronic fuel injection system information
• Engine cooling and reversible fan documentation
• E-ECU, I-ECU and V-ECU troubleshooting
• VCADS Pro diagnostic references
• APS II transmission information
• Brake and axle repair procedures
• CDC steering system documentation
• Hydraulic pump P1, P2 and P3 checks
• Boom Suspension System procedures
• Return-to-Dig system information
• Electrical wiring diagrams
• Hydraulic circuit diagrams
• Optional equipment installation instructions
• Workshop safety information
• Technical specifications and tightening torques

Digital product only. No printed manual will be shipped.

A compatible PDF reader is required to view the document.

IMPORTANT DOWNLOAD INFORMATION

Due to the large file size, this manual is delivered via a Dropbox download link to ensure a smooth downloading experience without overloading our website. No software installation, Dropbox account, or login is required to access and download your manual. Simply open the provided link and download the file directly to your device. If you experience any issues accessing or downloading your manual, please don't hesitate to contact us. We're always happy to help and will assist you as quickly as possible!

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Detailed contens:

COVER
DESCRIPTION
(0) GENERAL
Description
(1) STANDARD PARTS, SERVICE
Charging batteries
Cleanliness, brake and hydraulic systems
Electric welding
Parking brake, manually releasing
Recommended lubricants, oils
Repairing hydraulic system
Working on the electrical system of the machine
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Air cleaner, description
Camshaft, description (2)
Camshaft, description
Connecting rod, description
Control unit, description (2)
Control unit, description
Cooling system, description (2)
Cooling system, description
Crankshaft, description
Cylinder head gasket, description
Cylinder head, description
Cylinder liner, description
D7 cylinder block with crankcase ventilation, description and operation
Engine mounting, description
Engine timing gear, description
Engine, description (2)’
Engine, description
Fan speed control, description
Fuel feed pump, description
Fuel filter, description
Fuel rail, description
Fuel system, description (2)
Fuel system, description
High pressure fuel pump, description
Injectors, description (2)
Injectors, description
Instructions for working with electronic fuel injection
Internal Exhaust Gas Recirculation (IEGR), description
Lubrication system, description
Oil pump, description
Pistons, description
Preheating coil, description
Reversible cooling fan (2)
Reversible cooling fan, electric description
Reversible cooling fan, hydraulic diagram description
Reversible cooling fan, trouble-shooting fault indication
Reversible cooling fan
Turbocharger, description
Unit pump, description
Valves, description
Vibration damper, description (2)
Vibration damper, description
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Abbreviations, wiring diagrams
Accelerator Pedal
Adapter cable 999 0020
Air filter pressure
Alternator, description
APS II
APS
Attachment locking
Automatic engine shut-off
Automatic lift arm lowering (Return to dig) (2)
Automatic lift arm lowering (Return to dig)
Axle oil temperature
Back-up alarm
Barometric pressure
Battery, changing
Battery, charging
Battery, description
Boom Suspension System (BSS) (2)
Boom Suspension System (BSS)
Boost pressure
Brake pressure charging
Brake pressure
Brake test
Cable and component designations
Cable and component marking explanations (2)
Cable and component marking explanations
Camshaft speed
Central lubrication, status indication
Central lubrication
Charge-air temperature (2)
Charge-air temperature
Collection of basic data
Communication cable explanation
Communication with data buses (2)
Communication with data buses
Component list 1 alternator, batteries, capacitors, electronic units
Component list 2 diodes
Component list 3 fuses
Component list 4 heating coils, instruments, service connections
Component list 5 lights
Component list 6 control-, warning lights
Component list 7 solenoid valves
Component list 9 relays
Component list 11 sensors
Component list 12 switches
Component list Motors, resistors, monitoring system
Conditions when checking
Connecting special tools
Connectors, overview
Coolant Level
Coolant temperature, engine (2)
Coolant temperature, engine
Coolant temperature, outlet radiator
Cooling fan adjustment
Description of table for software functions
Differential lock
Display panel and keypad, general
Display panel, information displays
Display panel, initial display
Display panel, operating display
Downshifting signal
Electrical distribution box, description
Electrical symbols and designations
Electrical system, description
Electrical system, work instructions
Electronic control system, description
Engine control unit E-ECU, changing (2)
Engine control unit E-ECU, changing
Engine control unit E-ECU, description
Engine control unit E-ECU, error symptom
Engine Oil Level
Engine oil pressure (2)
Engine oil pressure
Engine On Off
Engine Protection
Engine Shutdown
Engine speed for E-ECU
Engine speed for V-ECU
Exhaust Gas Recirculation (EGR)
Extension cable 999 0062
Frame ground connections and signal ground.
Fuel consumption
Fuel Level (2)
Fuel Level
Fuel temperature
Fully automatic
Gear Selector
Gearshifting solenoids
General fault diagnosis information
Hand Throttle
Hydraulic Oil Level
Hydraulic oil temperature
Hydraulic power limitation
Increased engine rpm
Increased fan speed for AC
Indication of serious engine fault
Information display unit, setting (2)
Information display unit, setting
Information display, general
Injectors
Instrument control unit I-ECU, changing
Instrument control unit I-ECU, error symptom
Instrument control unit I-ECU, functional description
Instruments
Interruption in computer communication
Interval Wiper
Key feed
Lead and connector checks
Lighting, description
Middle instrument panel with warning lights
Multi-pin breaker box 999 8699
Outdoor temperature
Output brake pressure
Overspeed, transmission
Parking brake
Preheating coil, description (2)
Preheating coil, description
Preheating of inlet air
Preheating, description
Protection for high fuel temperature, common rail
RE Relay, general check
Reduced computer communication
SAE error codes, translation to error messages, general
SE504 Monitor brake pressure charging
SE901 SE902 Sensor, automatic boom kick-out and bucket positioner
Secondary steering (2)
Secondary steering (3)
Secondary steering
Service display unit, axles and brakes
Service display unit, electrical control input signals 1
Service display unit, electrical control input signals 2
Service display unit, electrical control input signals 3
Service display unit, electrical control output signals 1
Service display unit, electrical control output signals 2
Service display unit, electrical system battery voltage
Service display unit, engine
Service display unit, general
Service display unit, hydraulics
Service display unit, settings
Service display unit, transmission
Service interval
Service panel, electrical feed sensor
Setting software parameters
Soft start and safety for AC
Software functions per function group
Software, description
Special tools for troubleshooting
Speed limitation for lever steering (CDC)
Speed limitation
Starter motor engagement
Starting system, description
System voltage
Temperature induction air
Theft protection
Time-controlled high idle
Tire radius
Transmission disengagement
Transmission oil filter
Transmission oil level
Transmission oil pressure
Transmission oil temperature (2)
Transmission oil temperature
Transmission protection
Transmission slipping (2)
Transmission slipping
Travelling speed
Troubleshooting strategy
Troubleshooting tools
Turbine speed
Unit pumps
VCADS Pro service tool
Vehicle control unit V-ECU, changing
Vehicle control unit V-ECU, description
Vehicle control unit V-ECU, error symptom
Voltage feed E-ECU, I-ECU, V-ECU
Voltage feed for sensors
Warming of hydraulic oil
Washer fluid level
Water in fuel
Wiping during and after washing
(4) POWER TRANSMISSION
Description (2)
Description
Differential lock
Drive shaft, changing (2)
Drive shaft, changing
Final drive
Gear selector valve, measuring resistance of solenoids
Gearshifting, description
General description
Hydraulic transmission, description
Planetary gear
Transmission, installing
Transmission, removing
(5) BRAKE
Foot brake valve, description
General description
Parking brake, description
Wear indicator, description
(6) STEERING
Comfort Drive Control, description
Control valve, description
Electrical system, description
Hydraulic pump, description
Hydraulic system, description
Secondary steering, description
Shift valve, description
Shift valve, function description
Steering cylinder, sectional view
Steering valve, description
Steering, description
Steering, function description
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Counterweight, replacing
Frame, description
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
AC relay-controlled, description
AC safety, relay-controlled, description
AC software-controlled, description
Air conditioning, description
ATC, description
Cab suspension, description
Cab, description
Climate control system, description
Components
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
3rd, alternatively 3rd 4th hydraulic function, description
Automatic lift arm lowering (Return-To-Dig), description
Boom Suspension System, description of function
Boom Suspension System, description
Boom, description
Central block, description
Central lubrication system, description
Control valve, description
Hydraulic attachment lock (software-controlled), description
Hydraulic attachment lock with raised servo pressure, description
Hydraulic couplings, description
Hydraulic oil tank, description
Hydraulic pump, description
Hydraulic pumps, description
Hydraulic system, description
Lifting cylinder
Lubrication cycle, description
Pressure monitor, description
Servo system, description
Tilting cylinder
Valve block for Return To Dig, description
Working hydraulic system, description
Diagrams
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator, 120 amp HD
Circuit list
Wiring diagram 1
Wiring diagram 2
Wiring diagram 3
Wiring diagram 4
Wiring diagram 5
Wiring diagram 6
Wiring diagram 7
Wiring diagram 8
Wiring diagram 9
Wiring diagram 9B
Wiring diagram 10
Wiring diagram 11
Wiring diagram 12
Wiring diagram 13
Wiring diagram 15B
Wiring diagram 16
Wiring diagram 17 Updateted CDC
Wiring diagram 17
Wiring diagram 18
Wiring diagram 19
Wiring diagram 19C
Wiring diagram 20
Wiring diagram 21
Wiring diagram 21B
Wiring diagram 21C
Wiring diagram 22
Wiring diagram 23
Wiring diagram 24
Wiring diagram 25
Wiring diagram 26
Wiring diagram 27
Wiring diagram 28
Wiring diagram 29
Wiring diagram 30
Wiring diagram 31
Wiring diagram 32
Wiring diagram 33
Wiring diagram 34
Wiring diagram 35
Wiring diagram 101
Wiring diagram 102
Wiring diagram 103
Wiring diagram 107
(6) STEERING
Hydraulic diagram, steering with CDC and secondary steering 2
Hydraulic diagram, steering with CDC and secondary steering
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
Explanations to hydraulic diagram
Hydraulic diagram, complete 2
Hydraulic diagram, complete 3
Hydraulic diagram, complete
Hydraulic diagram, fan, brake system 2
Hydraulic diagram, fan, brake system
Hydraulic diagram, reversible fan, brake system
Hydraulic diagram, steering 2
Hydraulic diagram, steering 3
Hydraulic diagram, steering with CDC and secondary steering 2
Hydraulic diagram, steering with CDC and secondary steering
Hydraulic diagram, steering
Hydraulic diagram, working hydraulics, differential lock 2.
Hydraulic diagram, working hydraulics, differential lock, BSS, attachment lock, 3rd 4th function
Hydraulic diagram, working hydraulics, differential lock, BSS
Hydraulic diagram, working hydraulics, differential lock
Installation Instruction
3 d hydralicfunktion
3rd hydraulic function 2
3rd hydraulic function
4th hydraulic function
AC Electrical fan
Air conditioning
Attachment lock 2
Attachment lock
Boom suspension system
CARE TRACK 2
CARE TRACK 3
CARE TRACK
Electrically heated
Engine heater 2
Engine heater
Extra working light
Hand throttle control
Heat insulation kit
Lever steering
Mounting kit
Oil-bath air cleaner 2
Oil-bath air cleaner
Protecting grating
Protective grille, headlamp
Radio installation kit
Radio kit
Return to dig
Reversible fan
Rotating warning beacon
Seat for the instructor
Single lever control
Sun blind
Tail lamp guard
Working light 2
Working light
REPAIR
(0) GENERAL
E 1234, Nipple
E 1281 Nipple
E 1708, Checking point
E-2017
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
Fuel system, bleeding (2)
Fuel system, bleeding
Hydraulic pump, max working pressure, checking and adjusting
Towing
Transmission oil pressure, checking (2)
Transmission oil pressure, checking (3)
Transmission oil pressure, checking (4)
Transmission oil pressure, checking (5)
Transmission oil pressure, checking (6)
Transmission oil pressure, checking
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Coolant pump, replacing
Cooling fan hydraulics, funktion check
Cooling fan motor, replacing
Crankshaft front oil seal, replacing (2)
Crankshaft front oil seal, replacing
Cylinder compression, testing
Engine ECU, removing
Engine mounting, front, replacing.
Engine, installing (2)
Engine, installing
Engine, removing (2)
Engine, removing
Feed pump pressure, checking (2)
Flexible hose, replacing
Fuel control valve (FCV), checking
Fuel control valve (FCV), replacing
Fuel feed pressure, checking
Fuel filter, checking
Fuel rail pressure sensor, replacing
Fuel system, bleeding (2)
Fuel system, bleeding
High pressure fuel pump, checking
High pressure fuel pump, replacing
Injector, replacing
Injectors, replacing
Oil pan, resealing
Oil pressure, checking
Pressure relief valve (PRV), inspecting
Pressure relief valve (PRV), replacing
Pump 3 (P3) Cooling fan pump Brake pump. Cooling fan, checking max. rpm
Pump 3 (P3) Fan pump Brake pump Fan, check max pressure
Pump 3 (P3) standby pressure, checking (2)
Pump 3 (P3) standby pressure, checking
Pump unit, replacing
Radiator, installing (2)
Radiator, installing
Radiator, removing (2)
Radiator, removing
Stall speed, checking
Thermostat, replacing (2)
Thermostat, replacing
Turbocharger, inspecting
Valves, adjusting (2)
Valves, adjusting
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator, replacing incl function checking
(4) POWER TRANSMISSION
Front axle, installing
Front axle, removing
Gear selector valve, removing and installing (2)
Gear selector valve, removing and installing
Hub seal, replacing
Hub, changing seal (2)
Hub, changing seal (3)
Hub, changing seal
Measuring axial and radial play, rear axle mounting
Rear axle, installing
Rear axle, removing
Sensor for differential lock, adjusting
Torque converter, removing, installing
Transmission oil pressure, checking (2)
Transmission oil pressure, checking
(5) BRAKE
Accumulator, checking (removed)
Brake discs, changing
Brake discs, checking wear
Brake system hydraulic function, checking
Brake system, bleeding
Brake system, retardation, checking function
Foot brake pedal, adjusting angle and pedal clearance
Foot brake valve removed, reconditioning
Parking brake, mechanical release
Pressure in circuit, checking and adjusting
(6) STEERING
Checking LS-pressure for pump 1 (P1) and pump 2 (P2)
Flow control Pump 1 (P1) and Pump 2 (P2)
Function test, secondary steering (2)
Function test, secondary steering
Hydraulic pump, standby pressure, checking and adjusting
Lever steering CDC, checking steering signals
Lever steering, adjusting steering speed
Lever steering, checking and adjusting control valve
Stand-by pressure Pump 1 (P1) and Pump 2 (P2), checking and adjusting
Steer cylinder, left, changing
Steering pressure, checking and adjusting
Steering valve, reconditioning (removed)
Steering valve, replacing
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Wheel, removing and installing
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, checking performance
Air conditioning, troubleshooting, software-controlled ATC
Cab, installing
Cab, removing
Engine hood, installing (2)
Engine hood, installing
Engine hood, removing (2)
Engine hood, removing
Evaporator in air conditioning system, cleaning
Fan motor, changing
Heat control valve, changing
Heater core, changing
Viscous cab suspension, changing one unit
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
3rd, alternatively 3rd 4th hydraulic function, max. pressure, checking and adjusting
Attachment bracket cylinder, reconditioning
Attachment locking hydraulic cylinder (vision-optimised bracket), replacing
Boom suspension system, accumulator, changing
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom Suspension System, pressure-reducing valve, adjusting
Boom suspension system, reconditioning accumulator
Boom suspension system, test drive with load
Boom Suspension System, troubleshooting (2)
Boom Suspension System, troubleshooting
Checking LS-pressure for pump 1 (P1) and pump 2 (P2)
Discarded accumulators
ervo pressure, checking and adjusting
Flow control Pump 1 (P1) and Pump 2 (P2)
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic pump, max working pressure, checking and adjusting
Hydraulic pump, standby pressure, checking and adjusting
Hydraulic system, bleeding
Implemental attachment hydraulic cylinder, replacing
Precharge pressure in accumulators, checking and adjusting
Servo valve, operating controls, adjusting
Servo valve, replacing
Shock valve lift function, checking
Shock valve, tilt function, checking
Stand-by pressure Pump 1 (P1) and Pump 2 (P2), checking and adjusting
Working hydraulics, troubleshooting
Working pressure Pump 1 (P1) and Pump 2 (P2), checking and adjustment
Safety
(1) STANDARD PARTS, SERVICE
CE-marking, EMC-directive
Checklist after a fire or heat exposure
Decontamination
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Fire prevention measures
Health hazards with paint, plastics and rubber
Safety concerns everybody! 2
Safety concerns everybody!
Safety rules when servicing
Safety when handling accumulators
Safety when handling oils and fuel
Safety when handling the machine
Safety when lifting and supporting complete machine
Safety when using lifting equipment
Safety when working on hydraulic systems
Safety when working with air conditioning refrigerant
Safety when working with batteries
Some simple rules regarding tyre handling 2
Some simple rules regarding tyre handling
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
Working under raised boom
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
Safety when working on hydraulic systems
Specification
(0) GENERAL
Air conditioning unit, specifications
Air conditioning, tightening torques
Air distribution, specifications
Alternator, specifications
Battery, specification
Battery, weight
Boom and cylinders, specifications
Boom Suspension System, specifications
Boom Suspension System, tightening torques
Brake accumulator, capacity
Brake accumulator, specifications
Brake valve, specifications
Cab, tightening torques
Cab, weight
Central block, specifications
Central lubrication system, specifications
Control valve, specifications
Conversion tables
Cooling fan motor, specifications
Cooling fan rpm, specifications 2
Cooling fan rpm, specifications
Cooling system, specifications 2
Cooling system, specifications
Cooling system, volume
Counterweight, weight
Electrical system, specifications
Engine, specifications 2.
Engine, specifications 3
Engine, specifications 4
Engine, specifications 5
Engine, specifications 6
Engine, specifications 7
Engine, specifications
Engine, volume
Engine, weight 2
Engine, weight
Frame, specifications
Frame, tightening torque
Front axle, capacity
Front axle, specification
Front axle, tightening torque
Front axle, weight
Front wheel brakes, specification
Front wheel brakes, tightening torques
Front wheel brakes, weight
Fuel feed pump, specifications 2
Fuel feed pump, specifications 3
Fuel feed pump, specifications 4
Fuel feed pump, specifications
Fuel system, tightening torques 2
Fuel system, tightening torques
Fuel tank, volume 2
Fuel tank, volume 3
Fuel tank, volume 4
Fuel tank, volume
Function times, specifications
Hydraulic connections, tightening torques
Hydraulic pump (P1), specifications
Hydraulic pump (P2), specifications
Hydraulic pump (P3), specifications
Hydraulic system, volume
Hydraulic transmission, specifications
Hydraulic transmission, volume
Hydraulic transmission, weight
Injection pump, specifications
Injectors, specifications 2
Injectors, specifications
Intercooler, specifications
Lighting, specifications
Lubrication system, specifications
Oil-bath air cleaner, volume
Operator’s seat, weight
Parking brake, specifications 2
Parking brake, specifications
Preheating, specifications
Propeller shaft, tightening torque
Rear axle, capacity
Rear axle, specification
Rear axle, tightening torques
Rear axle, weight
Rear wheel brakes, specifications
Rear wheel brakes, tightening torques
Rear wheel brakes, weight
Servo system, specifications
Speed sensor, tightening torque
Starter motor, specifications
Steering, hydraulic equipment, specifications
Steering, hydraulic equipment, tightening torques
Steering, specification
Thermostat, specifications
Tightening torques
Torque converter, specifications
Torque converter, tightening torque
Torque converter, weight
Valve system specifications 2
Valve system specifications
Wheel, tightening torque
Wheel, weight
Wheels, specifications 2
Wheels, specifications
(1) STANDARD PARTS, SERVICE
Alternative fuels
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Air cleaner, preheater, specifications
Cooling fan motor, specifications
Cooling fan rpm, specifications
Cooling system, specifications 2
Cooling system, specifications
Cooling system, volume
Engine, specifications 2
Engine, specifications 3
Engine, specifications 4
Engine, specifications 5
Engine, specifications
Engine, volume
Engine, weight 2
Engine, weight
Fuel feed pump, specifications 2
Fuel feed pump, specifications
Fuel system, tightening torques
Fuel tank, volume 2
Fuel tank, volume
Hydraulic pump (P3), specifications
Injection pump, specifications
Injectors, specifications
Intercooler, specifications
Lubrication system, specifications
Oil-bath air cleaner, volume
Preheating, specifications
Thermostat, specifications
Valve system specifications 2
Valve system specifications
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator, specifications
Battery, specification
Battery, weight
Electrical system, specifications
Lighting, specifications
Preheating, specifications
Starter motor, specifications
(4) POWRER TRANSMISSION
Front axle, capacity
Front axle, specification
Front axle, tightening torque
Front axle, weight
Hydraulic transmission, specifications
Hydraulic transmission, volume
Hydraulic transmission, weight
Propeller shaft, tightening torque
Rear axle, capacity
Rear axle, specification
Rear axle, tightening torques
Rear axle, weight
Torque converter, specifications
Torque converter, tightening torque
Torque converter, weight
(5) BRAKE
Brake accumulator, capacity
Brake accumulator, specifications
Brake valve, specifications
Front wheel brakes, specification
Front wheel brakes, tightening torques
Front wheel brakes, weight
Hydraulic pump (P3), specifications
Parking brake, specifications
Rear wheel brakes, specifications
Rear wheel brakes, tightening torques
Rear wheel brakes, weight
(6) STEERING
Steering, hydraulic equipment, specifications
Steering, hydraulic equipment, tightening torques
Steering, specification
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Counterweight, weight
Frame, specifications
Frame, tightening torque
Wheel, tightening torque
Wheel, weight
Wheels, specifications
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Air conditioning unit, specifications
Air conditioning, refrigerant, weight
Air conditioning, specifications
Air conditioning, tightening torques
Air distribution, specifications
Cab, weight
Operator’s seat, weight
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
Boom and cylinders, specifications
Boom Suspension System, specifications
Boom Suspension System, tightening torques
Central block, specifications
Central lubrication system, specifications
Control valve, specifications
Function times, specifications
Hydraulic connections, tightening torques
Hydraulic pump (P1), specifications
Hydraulic pump (P2), specifications
Hydraulic pump (P3), specifications
Hydraulic system, volume
Selecting lubrication cycle
Servo system, specifications