VOLVO L120G WHEEL LOADER SERVICE REPAIR MANUAL PDF – 2310 PAGES

Detailed Engine, Aftertreatment, Electrical and Hydraulic Repair Documentation

The Volvo L120G Wheel Loader Service Repair Manual provides 2,310 pages of technical workshop information for servicing, diagnosing, inspecting, and repairing the Volvo L120G wheel loader.

Featuring technical information updated in 2020, this digital PDF publication covers the machine's major mechanical and electronic systems, including the engine, exhaust aftertreatment equipment, electrical control units, hydraulic transmission, drive axles, brakes, steering, operator cab, and working hydraulics.

A particularly important part of this manual is its detailed coverage of the Exhaust Aftertreatment System, including Diesel Particulate Filter (DPF) servicing, Diesel Oxidation Catalyst (DOC) replacement, Exhaust Gas Recirculation (EGR) components, regeneration procedures, burner system checks, and related sensors.

The documentation also includes VCADS Pro diagnostic references, extensive electrical wiring diagrams with selected Update G versions, hydraulic transmission diagrams, and detailed service procedures for hydraulic pumps P1, P2, and P3.

For workshop technicians, the manual provides more than general system descriptions. It includes specific procedures for checking pressures, replacing components, inspecting hydraulic functions, servicing electronic control modules, and consulting technical specifications.

MANUAL DETAILS

• Manufacturer: Volvo Construction Equipment
• Equipment Model: Volvo L120G Wheel Loader
• Manual Type: Service Repair / Workshop Manual
• Format: PDF
• Total Pages: 2,310
• Information Updated: 2020
• Delivery: Digital Download

WHAT IS INCLUDED IN THIS VOLVO L120G MANUAL?

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

1. GENERAL SERVICE AND WORKSHOP INFORMATION

The manual includes general maintenance and workshop references used when inspecting and servicing the machine.

Covered topics:

• General service information
• Electric welding precautions
• Technical checking points
• Special diagnostic and workshop tools
• Hydraulic component cleanliness
• Hydraulic couplings
• Service-related inspection procedures
• Machine towing
• Standard service references

2. ENGINE SYSTEM DESCRIPTION

The engine section explains the principal systems responsible for engine operation and performance.

ENGINE AND AIR SYSTEMS

• Engine general description
• ECO accelerator pedal
• Auxiliary engine braking
• Crankcase ventilation
• Cooling system
• Cooling fan motor
• Reversible cooling fan
• Inlet and exhaust system
• Turbocharger
• Engine lubrication system

FUEL AND EMISSIONS SYSTEMS

• Fuel system description
• Exhaust Gas Recirculation (EGR)
• Exhaust Aftertreatment System
• Regeneration process

3. EXHAUST AFTERTREATMENT, DPF AND DOC

The manual contains extensive service information for the exhaust aftertreatment system.

DIESEL PARTICULATE FILTER (DPF)

• DPF checking and cleaning
• DPF bracket replacement
• Regeneration system description
• Related aftertreatment components

DIESEL OXIDATION CATALYST (DOC)

• DOC replacement
• Exhaust aftertreatment system T-junction replacement
• Exhaust flexible pipe replacement

BURNER AND AIR SYSTEM

• Burner function checks
• Burner replacement
• Air pump replacement
• Air pump safety valve replacement
• Spark plug inspection
• Spark plug replacement
• Spark plug cable replacement
• Spark plug control unit replacement

AFTERTREATMENT ELECTRONICS

• Aftertreatment Control Module (ACM) replacement
• Programmed and non-programmed ACM replacement procedures
• NOx sensor replacement
• Fuel metering unit A replacement
• Fuel metering unit B replacement

This section is especially relevant when working on aftertreatment-related components and regeneration equipment.

4. EXHAUST GAS RECIRCULATION (EGR) SYSTEM

The manual includes specific inspection and replacement procedures for the EGR system.

Included operations:

• EGR system functional checks
• EGR actuator replacement
• EGR cooler replacement
• EGR pressure sensor replacement
• EGR temperature sensor replacement
• EGR reed valve inspection
• EGR reed valve replacement
• EGR valve replacement
• EGR venturi tube replacement

5. ENGINE FUEL INJECTION AND HIGH-PRESSURE SYSTEM

The fuel system repair section provides information for checking and replacing fuel delivery components.

FUEL SYSTEM SERVICE

• Fuel system bleeding
• Feed pump pressure testing
• Fuel pump replacement
• High-pressure fuel pump replacement
• High-pressure fuel system pressure relief
• Fuel Control Valve (FCV) replacement
• Fuel rail pressure sensor replacement
• Pressure Relief Valve (PRV) replacement
• Injector replacement
• Injector sleeve replacement

6. ENGINE MECHANICAL REPAIR PROCEDURES

The manual includes procedures for removing, installing, testing, and servicing major engine components.

ENGINE SERVICE OPERATIONS

• Engine removal
• Engine installation
• Cylinder compression testing
• Valve adjustment
• Stall speed testing
• Engine belt replacement
• Rear engine mounting replacement
• Front crankshaft oil seal replacement
• Crankcase ventilation separator replacement
• Camshaft rotation speed sensor replacement
• Crankshaft rotation speed sensor replacement

COOLING AND LUBRICATION

• Cooling system pressure checks
• Coolant pump replacement
• Thermostat replacement
• Radiator removal and installation
• Charge air cooler replacement
• Lubrication oil pressure testing
• Carbon dioxide checks in the coolant system
• Carbon dioxide checks in the fuel system

ADDITIONAL ENGINE COMPONENTS

• Turbocharger removal and installation
• Wastegate checking
• Fan control valve seal replacement
• Glow plug replacement
• Glow plug control unit replacement
• Preheating coil replacement
• Throttle replacement

7. ELECTRICAL SYSTEM AND ELECTRONIC CONTROL UNITS

The manual provides detailed descriptions of the electronic control systems and their communication functions.

ELECTRICAL SYSTEM INFORMATION

• Electrical system descriptions
• Battery and charging system
• Alternator
• Battery disconnector switch
• Chassis connections
• Cable and component identification
• Electrical connectors
• Electrical symbols
• Instrument panels
• Lighting systems
• Warning systems
• Preheating system

ELECTRONIC CONTROL UNITS

• Engine Control Unit (E-ECU)
• Vehicle Control Unit (V-ECU)
• Vehicle Control Unit (V2-ECU)
• Instrument Control Unit (I-ECU)
• Aftertreatment Control Module (ACM)
• Electronic Climate Control (ECC)
• CareTrack W-ECU

The manual includes input/output lists for several control units.

8. ELECTRONIC COMMUNICATION AND DIAGNOSTICS

The electrical documentation covers control unit communication, error reporting, and troubleshooting methods.

Included topics:

• Electronic control system operation
• ECU booting sequence
• Communication with data buses
• Bus communication supervision
• Interrupted communication
• Software descriptions
• Software parameter settings
• Error code display
• SAE error code interpretation
• Electrical connector checks
• General fault diagnosis
• Troubleshooting strategies
• Special troubleshooting tools

9. VCADS PRO AND TECH TOOL

The manual includes diagnostic references for electronic and mechanical systems.

Included information:

• VCADS Pro service tool
• VCADS Pro error codes
• VCADS Pro operations
• VCADS Pro connection troubleshooting
• Electronic control unit service procedures
• Tech Tool operations for braking systems
• Diagnostic operations for transmission, steering, and hydraulics

10. INSTRUMENTATION AND INFORMATION DISPLAY

The publication contains descriptions of the information display and machine monitoring functions.

MONITORED SYSTEMS

• Engine information
• Transmission information
• Electrical system information
• Hydraulic system information
• Axle and brake information
• Vehicle information

DISPLAY FUNCTIONS

• Operating display
• Service display
• Service mode
• Display settings
• Error code presentation
• Vehicle messages
• Start lockout
• Central warning
• Alarm functions

11. ELECTRICAL WIRING DIAGRAMS

The manual contains an extensive collection of electrical wiring diagrams.

DEDICATED SYSTEM DIAGRAMS

• Aftertreatment wiring diagram
• Brake wiring diagram
• BSS wiring diagram
• Electrically controlled battery disconnector wiring diagram
• Gear wiring diagram
• Start wiring diagram

NUMBERED WIRING DIAGRAM GROUPS

• WD201–WD202
• WD260–WD268 and WD270
• WD301–WD304, WD306 and WD308
• WD320–WD326
• WD330–WD335 and WD337
• WD350–WD352
• WD360–WD364
• WD371–WD376
• WD401–WD406
• WD501
• WD601–WD602 and WD604
• WD801–WD802
• WD804–WD808 and WD831
• WD903–WD905
• WD909–WD911
• WD913–WD915

UPDATE G DIAGRAM VERSIONS

Selected diagrams include Update G versions, such as:

• WD270
• WD301
• WD303
• WD306
• WD333
• WD335
• WD337
• WD350
• WD352
• WD362–WD364
• WD374–WD375
• WD501
• WD804
• WD831
• WD911
• WD914–WD915

These diagrams provide references for electrical circuit identification and troubleshooting.

12. HYDRAULIC TRANSMISSION

The power transmission section contains system descriptions, diagnostic references, and repair procedures.

TRANSMISSION COMPONENTS

• Hydraulic transmission
• Transmission oil cooler
• Propeller shaft
• Drive axles
• Differential lock
• Automatic differential brake
• Limited-slip differential

TRANSMISSION REPAIR

• Transmission removal
• Transmission installation
• Transmission functional checks
• Transmission oil pressure testing
• Transmission calibration error codes
• Gear selector solenoid replacement
• Lock-up valve replacement
• Heat exchanger replacement
• Front output shaft seal replacement
• Rear output shaft seal replacement

13. AXLES, DIFFERENTIALS AND HUB REDUCTIONS

The manual includes repair procedures for the drivetrain.

Included operations:

• Axle removal and installation
• Differential lock adjustment
• Differential lock functional checks
• Hub reduction removal
• Hub reduction installation
• Hub seal replacement
• Axle suspension bushing and seal replacement
• Front and rear axle breather filter replacement

14. BRAKING SYSTEM

The braking section provides procedures for inspecting and servicing the hydraulic and mechanical braking equipment.

BRAKE COMPONENTS

• Brake accumulators
• Automatic brake valve
• Foot brake valve
• Parking brake
• Wheel brakes
• Axle oil cooler

BRAKE REPAIR PROCEDURES

• Brake accumulator pressure checks
• Brake accumulator removal and installation
• Brake disc wear measurement
• Brake disc replacement
• Brake piston seal replacement
• Brake system charging checks
• Brake circuit pressure testing and adjustment
• Brake system bleeding
• Brake retardation testing
• Automatic brake function testing
• Parking brake function checks
• Parking brake disc and seal replacement
• Wheel brake function testing

15. STEERING AND COMFORT DRIVE CONTROL

The steering section includes conventional hydraulic steering, secondary steering, and CDC lever steering information.

STEERING SYSTEM

• Steering valve
• Steering cylinders
• Steering pressure monitoring
• Steering shift valve
• Secondary steering pump
• Secondary steering system

COMFORT DRIVE CONTROL (CDC)

• CDC lever steering
• CDC joystick replacement
• CDC angle sensor replacement
• CDC solenoid valve replacement
• CDC servo pressure testing
• CDC functional checks

STEERING REPAIR

• Left steering cylinder removal and installation
• Right steering cylinder removal and installation
• Steering cylinder bearing replacement
• Steering cylinder reconditioning
• Steering cylinder seal replacement
• Steering system pressure checks
• Secondary steering pump pressure testing and adjustment

16. FRAME, WHEELS AND AXLE SUSPENSION

The manual includes procedures for selected structural components.

Included operations:

• Frame joint bearing replacement
• Counterweight removal and installation
• Front wheel removal and installation
• Rear wheel removal and installation
• Axle suspension servicing

17. OPERATOR CAB AND CLIMATE CONTROL

The cab section includes descriptions and repair procedures for operator comfort equipment.

CAB COMPONENTS

• Cab removal and installation
• Engine hood removal and installation
• Engine hood manual operation
• Door lock cylinder replacement
• Electric door opener repairs
• Windscreen replacement
• Side window replacement
• Window installation
• Viscous cab suspension

CLIMATE CONTROL SYSTEM

• Air conditioning troubleshooting
• Climate control unit removal and installation
• Air conditioning compressor replacement
• Condenser replacement
• Evaporator replacement
• Expansion valve replacement
• Drying filter replacement
• Heater core replacement
• Heat control valve replacement
• Fan motor replacement
• Air mix door actuator replacement
• Refrigerant draining and filling

18. WORKING HYDRAULIC SYSTEM

The hydraulic section provides information about the machine's working hydraulic components and control functions.

HYDRAULIC COMPONENTS

• Hydraulic oil tank
• Hydraulic pumps
• Hydraulic pump flow regulation
• Central valve
• Main control valve
• Hydraulic pressure monitoring
• Hydraulic attachment bracket
• Hydraulic pump unit

HYDRAULIC SERVICE

• Hydraulic system bleeding
• Hydraulic system warm-up
• Hydraulic standby pressure testing
• Hydraulic working pressure testing
• Load-sensing pressure checks
• Servo pressure testing and adjustment
• Hydraulic pump removal and installation
• Hydraulic system testing

19. HYDRAULIC PUMPS P1, P2 AND P3

The manual includes specific procedures for the machine's hydraulic pumps.

PUMP SERVICE OPERATIONS

• Hydraulic pump P1 removal
• Hydraulic pump P1 installation
• Hydraulic pump P2 removal
• Hydraulic pump P2 installation
• Hydraulic pump P3 checking
• Hydraulic pump P3 removal
• Hydraulic pump P3 installation
• Standby pressure checking and adjustment
• Working pressure checking and adjustment
• Load-sensing pressure testing

20. LIFT AND TILT HYDRAULIC FUNCTIONS

The manual contains repair procedures for the lifting and tilting equipment.

LIFT SYSTEM

• Lift cylinder seal replacement in the machine
• Lift and lower function testing
• Lift/lower angle sensor replacement
• Lift solenoid valve replacement
• Lower solenoid valve replacement
• Lifting time measurement
• Lift shock valve checking

TILT SYSTEM

• Tilt cylinder seal replacement in the machine
• Tilt function checks
• Tilt angle sensor replacement
• Tilt-in solenoid valve replacement
• Tilt-out solenoid valve replacement
• Tilt shock valve checking

21. BOOM SUSPENSION SYSTEM (BSS)

The Boom Suspension System section includes component descriptions and detailed service procedures.

Included operations:

• BSS system descriptions
• Boom suspension accumulator checks
• Accumulator pressure adjustment
• Accumulator reconditioning
• Accumulator removal and installation
• Hydraulic accumulator depressurization
• Pressure-reduction safety valve testing and adjustment
• Boom Suspension System functional checks

22. THIRD AND FOURTH HYDRAULIC FUNCTIONS

The manual includes information about auxiliary hydraulic circuits.

Included operations:

• Third hydraulic function
• Fourth hydraulic function
• Third and fourth hydraulic pressure checks
• Auxiliary hydraulic pressure adjustment
• Shock valve checking
• Solenoid valve replacement
• Auxiliary hydraulic functional checks
• Hydraulic attachment locking checks

23. AUTOMATIC LUBRICATION SYSTEM

The manual contains descriptions and service information for the automatic lubrication system.

Included topics:

• Central lubrication system
• Lubrication interval adjustment
• Lubricant filling
• Lubrication dosage valves
• Automatic lubrication pump reconditioning
• Automatic lubrication system updates

24. FIRE SUPPRESSION SYSTEM

The manual includes information about fire suppression equipment.

Included topics:

• Fire suppression system components
• Fire suppression system operation
• Procedures following automatic activation
• Procedures following manual activation

25. HYDRAULIC CIRCUIT DIAGRAMS

The documentation contains hydraulic diagrams for the transmission and working hydraulic systems.

Included diagrams:

• Hydraulic transmission diagram
• Additional hydraulic transmission diagram version
• Basic machine hydraulic diagram
• Complete hydraulic diagram
• Additional complete hydraulic diagram version
• Hydraulic diagram explanations

26. OPTIONAL EQUIPMENT INSTALLATION

The manual contains installation instructions for a range of machine accessories and optional systems.

HYDRAULIC AND STEERING EQUIPMENT

• Third hydraulic function
• Third and fourth hydraulic functions
• Hydraulic attachment locking
• Boom Suspension System
• Electric CDC lever steering
• Single-lever hydraulic controls

ELECTRICAL AND MONITORING EQUIPMENT

• CareTrack
• Anti-theft device
• Forward-view camera
• LED work lights
• Rotating beacon
• Flashing strobe warning beacon
• Backup alarm
• 24V connector

ENGINE AND PROTECTION EQUIPMENT

• Engine heater
• Hand throttle
• High-sulphur fuel conversion kit
• Reversible cooling fan
• Oil-bath air pre-cleaner
• Turbo-type air pre-cleaner
• Radiator grille guard
• Windscreen guard
• Front lighting protection

CAB AND ADDITIONAL ACCESSORIES

• Radio
• Rear-view mirror
• Additional work lights
• Cab air pre-cleaner

27. WORKSHOP SAFETY INFORMATION

The safety section contains precautions for servicing and repairing heavy machinery.

Included topics:

• General workshop safety
• Machine handling precautions
• Safe lifting and supporting
• Hydraulic system safety
• Hydraulic accumulator handling
• Battery handling
• Fuel and oil handling
• Air conditioning refrigerant safety
• Tyre handling
• Fire prevention
• Inspection following fire or heat exposure
• Working under a raised boom
• Environmental protection
• Hazardous fluid handling
• Waste handling
• Service positions

28. TECHNICAL SPECIFICATIONS

The specifications section provides reference data for the major machine systems.

ENGINE SPECIFICATIONS

• Engine technical specifications
• Engine software specifications
• Engine capacities
• Cooling system specifications
• Fuel system specifications
• EGR system tightening torques
• Exhaust aftertreatment specifications
• Exhaust aftertreatment tightening torques
• Lubrication system specifications
• Turbocharger tightening torques
• Valve mechanism specifications

ELECTRICAL SPECIFICATIONS

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

TRANSMISSION AND DRIVELINE

• Hydraulic transmission capacity
• Transmission specifications
• Transmission tightening torques
• Front and rear axle specifications
• Axle oil volumes
• Axle tightening torques
• Propeller shaft tightening torques

BRAKE AND STEERING

• Brake accumulator specifications
• Brake system specifications
• Parking brake specifications
• Wheel brake specifications
• Steering specifications
• CDC lever steering specifications
• Secondary steering pump specifications

HYDRAULIC SYSTEM

• Hydraulic pump P1 specifications
• Hydraulic pump P2 specifications
• Hydraulic pump P3 specifications
• Hydraulic system volume
• Hydraulic control valve specifications
• Servo system specifications
• Boom Suspension System specifications
• Third and fourth hydraulic function specifications
• Automatic lubrication system specifications
• Fire suppression system specifications
• Hydraulic function times

ADDITIONAL TECHNICAL REFERENCES

• Recommended lubricants
• Alternative fuels
• Coolant information
• Air conditioning refrigerant quantities
• Counterweight weight
• General tightening torques
• Conversion tables

PRACTICAL WORKSHOP APPLICATIONS

The Volvo L120G Service Repair Manual can support tasks such as:

• Inspecting and cleaning the DPF
• Checking aftertreatment burner operation
• Replacing EGR system components
• Servicing fuel injection components
• Checking engine compression
• Replacing electronic control units
• Consulting VCADS Pro diagnostic procedures
• Tracing electrical circuits using Update G diagrams
• Testing hydraulic transmission pressure
• Servicing differential locks and hub reductions
• Checking brake accumulator pressure
• Replacing brake discs and seals
• Testing CDC steering functions
• Adjusting hydraulic pump working pressure
• Servicing lift and tilt cylinders
• Checking Boom Suspension System accumulators
• Maintaining automatic lubrication equipment
• Consulting hydraulic circuit diagrams

WHO IS THIS MANUAL FOR?

This publication is suitable for:

• Volvo construction equipment service technicians
• Professional wheel loader mechanics
• Independent heavy equipment repair workshops
• Fleet maintenance departments
• Construction equipment maintenance contractors
• Experienced Volvo L120G owners performing maintenance and repair work

IMPORTANT COMPATIBILITY NOTICE

This manual is identified for the Volvo L120G Wheel Loader.

The documentation contains multiple electrical diagram versions, optional equipment procedures, and system configurations.

Before purchasing, verify your machine model, serial number, and installed equipment to determine whether the relevant procedures apply to your wheel loader.

The 2020 information update refers to the technical documentation and should not be interpreted as the machine's manufacturing year.

DIGITAL PDF DELIVERY

This product is supplied as a digital PDF service repair manual.

The publication includes:

• 2,310 pages of workshop documentation
• Engine descriptions and repair procedures
• DPF, DOC, EGR and regeneration system information
• Electronic fuel system repairs
• VCADS Pro and Tech Tool references
• Electrical control unit documentation
• Extensive wiring diagrams with Update G versions
• Transmission and driveline repair procedures
• Brake and steering service instructions
• Hydraulic pump P1, P2 and P3 information
• Lift and tilt hydraulic cylinder repairs
• Boom Suspension System procedures
• Automatic lubrication and fire suppression information
• 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 documentation.

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 contents:

COVER
DESCRIPTIONS
(0) GENERAL
Leak detector 951 1207, description
(1) STANDARD PARTS, SERVICE
Electric welding
Service
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Auxiliary brake (engine braking), description
Cooling fan motor, description
Cooling system, description (2)
Cooling system, description
Crankcase ventilation, description
ECO – accelerator pedal
Engine, description
Exhaust Aftertreatment System, description
Exhaust Gas Recirculation (EGR), description
Fuel system, description
Inlet and exhaust system, description
Lubricating system, description
Regeneration process, description
Reversible cooling fan, description
Turbocharger, description
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
ACM, I O list
Alarm, description
Alternator, description (2)
Alternator, description
Battery disconnector switch, description
Battery, charging
Battery, description
Booting sequence
Branching in cables
Bus communication supervision
Cable and component designations
Cable and component marking explanations
CareTrack W-ECU, description
Central warning
Chassis connection
Collection of basic data
Communication with data buses
Components list
Conditions when checking
Connectors, overview
ECC, I O list
E-ECU, I O list
Electrical symbols and designations
Electrical system, description
Electrical system, work instructions
Electronic control system, description
Engine control unit E-ECU, description
Error codes, showing
General fault diagnosis information
Hood opening
I-ECU, I O list
Information display, axles brakes
Information display, check (2)
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
Instrument panels
Intermittent wiper and washer
Key feed
Lead and connector checks
Lighting, description
Middle instrument panel with warning lights
Preheating, description
SAE error codes, translation to error messages, general
Software parameters, description
Software, description
Special tools for troubleshooting
System voltage
Troubleshooting strategy
Troubleshooting tools
V2-ECU, I O list
VCADS Pro service tool
VCADS Pro, Error codes
V-ECU, I O list
Vehicle control unit V2-ECU, description
Vehicle control unit V-ECU, description
W-ECU, I O list
(4) POWER TRANSMISSION
Automatic differential brake, Limited Slip, description
Differential lock, description
Drive axles, description
Front axle, component description
Hydraulic transmission, description
Oil cooler, component description
Propeller shaft, component description
Rear axle mounting, component description
Rear axle, component description
VCADS Pro, Operations (2)
VCADS Pro, Operations
(5) BRAKE
Automatic brake valve, description
Axle oil cooler, description
Brake accumulator, description
Braking system, description
Foot brake valve, description
Parking brake, component description
Parking brake, function description
Tech Tool, operations
VCADS Pro, Operations
(6) STEERING
CDC valve, lever steering, description
Comfort Drive Control (CDC), description
Pressure monitor, description
Secondary steering pump, description
Secondary steering, description
Shift valve, description
Steering cylinder, description
Steering system, description
Steering valve, description
VCADS Pro, Operations
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Frame joint, description
Frame, description
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, tightening torques
Cab, description
Climate control system, description
Electric door opener, description
Pause heater, description
Troubleshooting, air conditioning unit (AC)
Viscous cab suspension, description
Windows, general, gluing
Windows, general
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
3rd, or 3rd 4th hydraulic function, description
Boom Suspension System, component description
Boom Suspension System, description
Central lubrication system, description
Central valve, description
Change of lubrication interval
Control valve, description
Diagnostic tools, description
Dosage valves, description
Filling lubricant
Fire suppression system, component description
Fire suppression system, functional description
Hydraulic attachment bracket, description
Hydraulic components, cleanliness when handling
Hydraulic oil tank, description
Hydraulic pump flow regulation, description
Hydraulic pumps, description
Parameter settings
Pressure monitor, description
Pump unit, description
Shift valve, description
Software, parameter settings and read-outs
TP-Linkage’s bearing points
VCADS Pro, Operations
Working hydraulic system, description
Diagrams
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
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 WD264
Wiring diagram WD265
Wiring diagram WD266
Wiring diagram WD267
Wiring diagram WD268
Wiring diagram WD270 Update G
Wiring diagram WD270
Wiring diagram WD301 Update G (2)
Wiring diagram WD301 Update G
Wiring diagram WD301
Wiring diagram WD302
Wiring diagram WD303 Update G
Wiring diagram WD303
Wiring diagram WD304 (2)
Wiring diagram WD304
Wiring diagram WD306 Update G
Wiring diagram WD306
Wiring diagram WD308
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 Update G
Wiring diagram WD333
Wiring diagram WD334
Wiring diagram WD335 Update G
Wiring diagram WD335
Wiring diagram WD337 Update G
Wiring diagram WD350 Update G
Wiring diagram WD350
Wiring diagram WD351
Wiring diagram WD352 Update G
Wiring diagram WD352
Wiring diagram WD360
Wiring diagram WD361
Wiring diagram WD362 Update G
Wiring diagram WD362
Wiring diagram WD363 Update G
Wiring diagram WD363
Wiring diagram WD364 Update G
Wiring diagram WD371
Wiring diagram WD372
Wiring diagram WD373
Wiring diagram WD374 Update G
Wiring diagram WD374
Wiring diagram WD375 Update G
Wiring diagram WD375
Wiring diagram WD376
Wiring diagram WD401
Wiring diagram WD402
Wiring diagram WD403
Wiring diagram WD404
Wiring diagram WD405
Wiring diagram WD406
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 WD903
Wiring diagram WD904
Wiring diagram WD905
Wiring diagram WD909
Wiring diagram WD910
Wiring diagram WD911 Update G
Wiring diagram WD911
Wiring diagram WD913
Wiring diagram WD914 Update G
Wiring diagram WD915 Update G
(4) POWRER TRANSMISSION
Hydraulic diagram transmission (2)
Hydraulic diagram transmission
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
Explanations to hydraulic diagram
Hydraulic diagram, basic machine
Hydraulic diagram, complete (2)
Hydraulic diagram, complete
INSTALLATION INSTRUCTIONS
3rd 4th hydraulic function, installing new
3rd hydraulic function, installing new
24V connector, installing new
After market engine, transfer of components
Anti theft device, installing new
Attachment locking, installing new
Back up alarm, installing new
Boom suspension system, installing new
Cab front work light 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
CARETRACK
Engine heater, installing new (2)
Engine heater, installing new
Forward view camera, installing new
Front work light LED, installing new
Grill work light LED, installing new
Hand throttle, installing new
High Sulphur Fuel Conversion kit, installing new
Lever steering (CDC), electric, installing new
Pre-cleaner oil bath type, installing new
Pre-cleaner turbo type, installing new
Protection for lighting, front, installing new
Radiator grille guard, installing new
Radio, installing new (2)
Radio, installing new (3)
Radio, installing new
Rear view mirror, installing new
Reversible fan, installing new
Rotating beacon, installing new
Single lever control, 2nd hydraulic function, installing new
Single lever control, 3rd hydraulic function, installing new
Warning beacon flashing strobe light, installing new
Wind shield guard, installing new
Work light extra front, installing new
Work light front, installing new
Work light rear, installing new (2)
Work light rear, installing new
Repair
(0) GENERAL
88830557 User Instruction
E 1708, Checking point
E1711
E-2000
E-2001
E-2010
E-2015
E-2017
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
Boom suspension accumulator, checking and adjusting 2
Boom suspension accumulator, checking and adjusting
Brake discs, measuring wear
Brake system charging, checking
Diesel particulate filter, checking and cleaning
Front axle, breather filter, replacing
Hydraulic pump, standby pressure and working pressure, checking and adjusting
Oil plugs, installing
Parking brake, manually releasing
Rear axle, breather filter, replace
Spark plug, replacing
Steering system working pressure, checking and adjusting
Towing
Valves, adjusting 2
Valves, adjusting
Wheel brakes function, checking
(2) ENGINE WITH MOUNTING AND EQUIPMENT
ACM (Aftertreatment control module) non-programmed, replacing
ACM (Aftertreatment control module) pre-programmed, replacing
Air pump safety valve, replacing
Air pump, replacing
Burner function, checking
Burner, replacing
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, checking
Charge air cooler, replacing
Coolant pump, replacing
Cooling system pressure, checking
Crankcase ventilation separator, replacing
Crankshaft front oil seal, replacing
Cylinder compression, testing
Diesel particulate filter, checking and cleaning
DOC (Diesel oxidation catalyst), replacing
DPF (Diesel particulate filter) bracket, replacing
E-ECU MID 128 non-programmed, replacing
E-ECU MID 128 pre-programmed, replacing
EGR actuator, replacing
EGR cooler, replacing
EGR pressure sensor, replacing
EGR reed valve, inspecting
EGR reed valve, replacing
EGR system function, checking
EGR temperature sensor, replacing
EGR valve, replacing
EGR venturi tube, replacing
Engine belts, replacing
Engine mounting rear, changing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor (crank shaft), replacing
Engine, installing
Engine, removing
Exhaust aftertreatment system T-junction, replacing
Exhaust pipe flexible tube, replacing
Fan control valve, seal replacing
Feed pump pressure, checking 2
Feed pump pressure, checking
Fuel control valve (FCV), replacing
Fuel metering unit A, replacing
Fuel metering unit B, replacing
Fuel pump, replacing
Fuel rail pressure sensor, replacing
Fuel system, bleeding
Glow plug control unit, replacing
Glow plug, replacing
High pressure fuel pump, replacing
High pressure fuel system pressure, relieving
Injector sleeves, replacing
Injectors, replacing
Lubrication oil pressure, checking with pressure gauge
NOx sensor, replacing
Preheating coil, replacing
Pressure relief valve (PRV), replacing
Radiator, installing
Radiator, removing
Spark plug cable, replacing
Spark plug control unit, replacing
Spark plug, inspecting
Spark plug, replacing
Stall speed, checking
Thermostat, replacing
Throttle, replacing
Turbocharger, installing
Turbocharger, removing
Valves, adjusting
VCADS Pro, Operations
Wastegate, checking
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator, installing
Alternator, removing
Batteries, replacing
Battery condition, checking
CareTrack battery, replacing
I-ECU MID 140 non-programmed, replacing
I-ECU MID 140 pre-programmed, replacing
Starter lock, replacing
VCADS Pro, connecting problems
VCADS Pro, Operations
V-ECU MID 187 non-programmed, replacing
V-ECU MID 187 pre-programmed, replacing
(4) POWRER TRANSMISSION
Axle suspension bushes and seals, replacing
Axle, installing
Axle, removing
Differential lock, adjusting
Differential lock, function check
Error codes when calibrating
Gear selector valve, replacing one solenoid
Heat exchanger, replacing
Hub reduction, installing 2
Hub reduction, installing
Hub reduction, removing 2
Hub reduction, removing
Hub seal, replacing 2
Hub seal, replacing
Lock up valve, replacing
Seal for front output shaft, replacing
Seal for rear output shaft, replacing
Transmission oil pressure, checking
Transmission, function check 2
Transmission, function check
Transmission, installing
Transmission, removing
(5) BRAKE
Accumulator (removed) charging pressure, checking
Accumulator, discarding
Accumulator, installing
Accumulator, removing
Accumulators, checking in machine
Automatic brake function, checking
Brake disc, replacing
Brake discs, measuring wear
Brake discs, replacing
Brake piston seals, replacing 2
Brake piston seals, replacing
Brake system charging, checking
Brake system circuit pressure, checking and adjusting
Brake system retardation function, checking
Brake system, bleeding 2
Brake system, bleeding
Parking brake discs and seals, replacing
Parking brake function, checking
Wheel brakes function, checking
(6) STEERING
Accumulator, discarding
Comfort drive control (CDC) angle sensor, changing
Comfort Drive Control (CDC) joystick, changing
Comfort drive control (CDC) solenoid valve, changing
Comfort Drive Control, servo pressure, checking
Error codes when calibrating
Left steering cylinder bearings, replacing
Left steering cylinder, installing
Left steering cylinder, removing
Lever steering (CDC) function, checking
Right steering cylinder, installing
Right steering cylinder, removing
Right steering cylinder, replacing bearings
Secondary steering pump working pressure, checking and adjusting
Steering cylinder removed, reconditioning excl replacing bearings
Steering cylinder removed, reconditioning incl replacing bearings
Steering cylinder, repacking
Steering system function, checking
Steering system working pressure, checking and adjusting
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Counterweight, installing
Counterweight, removing
Frame joint, replacing bearings
Front wheel, installing
Front wheel, removing
Rear wheel, installing
Rear wheel, removing
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Accelerator pedal, replace
Actuator, replacing
Air conditioning, checking performance
Air mix door actuator, replacing
Cab, installing
Cab, removing
Climate unit, installing
Climate unit, removing
Compressor, replacing
Condenser, replacing
Door lock cylinder, replacing 2
Door lock cylinder, replacing
Drying filter, replacing
ECC MID 146 non-programmed ECU, replacing
ECC MID 146 pre-programmed ECU, 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 hood, installing
Engine hood, manually operating
Engine hood, raising and securing
Engine hood, removing
Evaporator, replacing
Expansion valve, replacing
Fan motor, replacing
Heat control valve, replacing
Heater core, replacing
Operator’s seat, securing
Plastic hood, repairing
Refrigerant, draining
Refrigerant, filling incl vacuum pumping
Side window, replacing
Window pane, installing
Windscreen, replacing
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
3rd 4th hydraulic function, pressure, checking and adjusting
3rd 4th hydraulic function, shock valve, checking
3rd 4th hydraulic function, solenoid valve, replacing
3rd 4th hydraulic, functional check
Accumulator removed, checking
Accumulator, boom suspension system, discarding
Accumulator, discarding 2
Accumulator, discarding
Attachment locking, checking
Automatic lubrication pump unit, reconditioning
Back-up valve, checking and adjusting
Back-up valve, replacing
Bleeding air
Boom suspension accumulator, checking and adjusting
Boom suspension accumulator, reconditioning
Boom suspension system, checking
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom suspension system, left accumulator, installing 2
Boom suspension system, left accumulator, installing
Boom suspension system, left accumulator, removing 2
Boom suspension system, left accumulator, removing
Boom suspension system, pressure reduction, safety valve, checking and adjusting
Boom suspension system, right accumulator, installing 2
Boom suspension system, right accumulator, installing
Boom suspension system, right accumulator, removing 2
Boom suspension system, right accumulator, removing
Error codes when calibrating
Fire suppression system, actions after activation
Fire suppression system, actions after manual activation
Hydraulic couplings
Hydraulic cylinder, piston’s lock brace, installing
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic pump P1, installing
Hydraulic pump P1, removing
Hydraulic pump P2, installing
Hydraulic pump P2, removing
Hydraulic pump P3, checking
Hydraulic pump P3, installing
Hydraulic pump P3, removing
Hydraulic pump, standby pressure and working pressure, checking and adjusting
Hydraulic system, bleeding
Hydraulic system, warming up
Lift cylinder, repacking in machine
Lift lower function, checking
Lift lower, angle sensor, changing
Lift, solenoid valve, changing
Lifting time, checking
Lower, solenoid valve, changing
LS (load sense) pressure, checking
Servo accumulator, installing 2
Servo accumulator, installing
Servo accumulator, removing 2
Servo accumulator, removing
Servo pressure, at the spool in control valve, checking
Servo pressure, checking and adjusting
Shock valve lift function, checking
Shock valve, tilt function, checking
Single lever control electric servo, replacing
System test
Tilt cylinder, repacking in machine
Tilt in out, angle sensor, changing
Tilt in, solenoid valve, changing
Tilt out, solenoid valve, changing
Tilt, checking
Update of automatic lubrication system
V2-ECU, MID 249, changing non-programmed ECU
V2-ECU, MID 249, changing pre-programmed ECU
Safety
(1) STANDARD PARTS, SERVICE
CE-marking, EMC-directive
Checking function
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!
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 working on hydraulic systems
Safety when working with air conditioning refrigerant
Safety when working with batteries
Service position 1 (2)
Service position 1
Service position 2 (2)
Service position 2
Some simple rules regarding tyre handling
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
Working on the electrical system of the machine
Working under raised boom
Specification
(0) GENERAL
Conversion tables
Engine, software specifications
Engine, specifications
Engine, tightening torques
Exhaust aftertreatment system, specifications
Flywheel, tightening torques
Fuel system, specifications
Lubrication system, specifications
Lubrication system, tightening torques
Oil sump, tightening torque
Tightening torques
Valve mechanism, specifications
(1) STANDARD PARTS, SERVICE
Alternative fuels
Coolant
Recommended lubricants
Wheel brake, specification
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Cooling fan rpm, specifications
Cooling fan, tightening torques
Cooling system, specifications
EGR system, tightening torques
Engine oil pressure, specification
Engine, capacities
Engine, software specifications
Engine, specifications
Engine, tightening torques
Exhaust aftertreatment system, specifications
Exhaust aftertreatment system, tightening torques
Flywheel, tightening torques
Fuel system, specifications
Fuel system, tightening torques
Inlet and exhaust system, tightening torques
Lubrication system, specifications
Lubrication system, tightening torques
Oil sump, tightening torque
Preheating, specifications
Temperature limits for cooling fan speed, specifications
Thermostat, specifications
Turbocharger, tightening torques
Valve mechanism, specifications
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator 80 A, specification
Alternator, specification
Battery, specifications
Battery, weight
Electrical system, specifications
Lighting, specifications
Preheating, specifications
Starter motor, specifications
(4) POWRER TRANSMISSION
Axle suspension, tightening torque
Front and rear axles, specifications
Front and rear axles, tightening torque
Front and rear axles, volume
Hydraulic transmission, capacity
Propeller shaft, tightening torque
Rear axle mounting, volume
Transmission, specifications (2)
Transmission, specifications
Transmission, tightening torques (2)
Transmission, tightening torques
(5) BRAKE
Brake accumulator, specifications
Brake system, specifications
Parking brake, specifications
Wheel brake, specification
(6) STEERING
Lever steering (CDC), specifications
Lever steering CDC, tightening torques
Secondary steering pump, specifications
Steering cylinder, tightening torque
Steering, specifications
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Counterweight, tightening torques
Counterweight, weight
Frame joint, tightening torques
Wheel, tightening torque
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, refrigerant, weight (2)
Air conditioning, refrigerant, weight
Air conditioning, specifications
Cabin, tightening torques
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
3rd 4th hydraulic function, specifications
3rd 4th hydraulic function, tightening torques
Automatic lubrication system, specifications
Boom Suspension System, specifications
Boom Suspension System, tightening torques
Control valve, specifications
Control valve, tightening torques
Fire suppression system, specification
Function times, specifications
Hydraulic connections, tightening torques
Hydraulic pump (P1), specifications
Hydraulic pump (P2), specifications
Hydraulic pump (P3), specifications
Hydraulic pumps, tightening torques
Hydraulic system, volume
Lift cylinder, tightening torques
Recommended lubricants
Servo system, specifications
Tilt cylinder, tightening torques