VOLVO L150E WHEEL LOADER SERVICE REPAIR MANUAL PDF – 1990 PAGES

Complete Workshop Documentation for Engine, Transmission, Electrical and Hydraulic Repairs

The Volvo L150E Wheel Loader Service Repair Manual is an extensive 1,990-page technical publication designed to support the maintenance, inspection, troubleshooting, adjustment, and repair of Volvo L150E wheel loaders.

With technical information updated in 2022, this digital PDF manual combines system descriptions, workshop repair procedures, electrical wiring diagrams, hydraulic schematics, optional equipment installation instructions, safety information, and detailed technical specifications.

A distinctive feature of this publication is its coverage of D9 and D10/D10B engine-related documentation, including fuel injection systems, unit injectors, engine timing components, lubrication circuits, turbochargers, and cooling systems.

The manual also provides service information for the AWB40B transmission, APS II electronic transmission controls, Comfort Drive Control (CDC), Boom Suspension System (BSS), Return-to-Dig, and hydraulic pumps P1, P2, and P3.

Its repair section includes practical operations such as injection pump installation and injection angle setting, transmission fault diagnosis, brake pressure adjustment, hydraulic cylinder repairs, steering valve reconditioning, and replacement of major machine components.

This makes the publication a useful technical resource for professional construction equipment workshops, fleet maintenance teams, and experienced Volvo wheel loader owners.

MANUAL INFORMATION

• Manufacturer: Volvo Construction Equipment
• Equipment Model: Volvo L150E Wheel Loader
• Manual Type: Service Repair / Workshop Manual
• Format: PDF
• Total Pages: 1,990
• Technical Information Updated: 2022
• Delivery: Digital Download

WHAT IS INCLUDED IN THIS VOLVO L150E SERVICE REPAIR MANUAL?

The documentation is organized into six principal categories:

1. Descriptions
2. Diagrams
3. Installation Instructions
4. Repair
5. Safety
6. Specifications

These categories cover the engine, electronic controls, power transmission, brakes, steering, frame, operator cab, working hydraulics, and optional equipment.

1. GENERAL SERVICE AND WORKSHOP INFORMATION

The manual contains general instructions and technical references for servicing heavy construction equipment.

Included topics:

• General machine descriptions
• Battery charging
• Electric welding precautions
• Brake and hydraulic system cleanliness
• Recommended lubricants and oils
• Electrical system service precautions
• Manual parking brake release
• Machine transport and lifting considerations
• Towing procedures

2. D9 AND D10/D10B ENGINE DOCUMENTATION

The engine section includes technical information identified for D9 and D10/D10B engine systems.

D9 ENGINE COMPONENTS

• D9 engine identification
• D9 engine descriptions
• D9 cylinder block
• D9 cylinder head
• D9 cylinder head gasket
• D9 cylinder liners and pistons
• D9 crankshaft and vibration damper
• D9 camshaft
• D9 engine timing gears
• D9 valve mechanism
• D9 cooling system
• D9 turbocharger
• D9 fuel system
• D9 lubrication system
• D9 piston cooling system

D10 AND D10B REFERENCES

• D10 engine identification
• D10 valve mechanism
• D10 lubrication system
• D10B fuel feed pump
• D10B cylinder compression testing
• D10B fuel system bleeding
• D10B valve adjustment

The presence of multiple engine-related references makes it important to verify which procedures correspond to the engine installed in your machine.

3. ENGINE MECHANICAL COMPONENTS

The manual provides descriptions and repair information for the main engine assemblies.

ENGINE STRUCTURE

• Cylinder block
• Cylinder head
• Cylinder head gasket
• Cylinder liners
• Pistons and piston rings
• Connecting rods
• Main and big-end bearings
• Crankshaft
• Camshaft
• Timing gears
• Valve mechanism
• Engine mounting
• Vibration damper

ENGINE REPAIR PROCEDURES

• Engine removal
• Engine installation
• Cylinder compression testing
• Crankshaft front oil seal replacement
• Engine mounting rubber cushion replacement
• Camshaft speed sensor replacement
• Engine rotation speed sensor replacement
• Valve adjustment
• Valve cover gasket replacement

4. FUEL INJECTION AND UNIT INJECTOR SYSTEM

The manual includes technical descriptions of fuel injection components and procedures for their inspection and repair.

FUEL SYSTEM COMPONENTS

• Fuel feed pump
• Fuel filters
• Injection pump
• Fuel injection regulator
• Unit injectors
• Delphi unit injector
• Injection advance curve
• Fuel flow
• Electronic fuel injection controls

FUEL SYSTEM SERVICE PROCEDURES

• Fuel system bleeding
• Fuel feed pressure testing
• Fuel feed pump replacement
• Fuel filter inspection
• Fuel pump inspection
• Fuel pump valve inspection
• Unit injector replacement
• Injector replacement
• Injection pump installation
• Injection angle setting

The injection pump installation and injection angle setting procedures are particularly relevant for engine timing and fuel system servicing.

5. ENGINE LUBRICATION AND OIL COOLING

The lubrication section covers the engine's oil circulation and related components.

Included topics:

• Engine lubrication system
• Oil pump
• Oil cooler
• Oil filters
• Piston cooling system
• Lubrication oil pressure testing
• Oil pump replacement
• Oil cooler replacement
• Engine oil pressure checks

6. COOLING SYSTEM AND REVERSIBLE FAN

The manual provides technical information for the engine cooling system and hydraulically operated cooling fan.

COOLING SYSTEM COMPONENTS

• Coolant pump
• Thermostat
• Thermostat housing
• Radiator
• Intercooler
• Cooling fan motor
• Hydraulic cooling fan
• Reversible cooling fan

COOLING SYSTEM REPAIR

• Coolant pump replacement
• Thermostat replacement
• Radiator replacement
• Charge air cooler replacement
• Cooling fan motor replacement
• Cooling fan motor non-return valve replacement
• Cooling fan hydraulic function checks
• Reversible cooling fan function checks

7. TURBOCHARGER AND AIR INTAKE SYSTEM

The manual includes descriptions and repair procedures for the engine air intake and turbocharger equipment.

Included topics:

• Turbocharger descriptions
• D9 turbocharger information
• Turbocharger inspection
• Turbocharger replacement
• Charge air system inspection
• Charge air cooler replacement
• Air cleaner descriptions
• Intake and exhaust system information
• Internal Exhaust Gas Recirculation (IEGR)

8. ELECTRICAL SYSTEM AND ELECTRONIC CONTROL UNITS

The electrical section describes the machine's control units, sensors, electrical circuits, and monitored functions.

ELECTRONIC CONTROL UNITS

• Engine Control Unit (E-ECU)
• Instrument Control Unit (I-ECU)
• Vehicle Control Unit (V-ECU)
• Electronic control system descriptions
• Control unit voltage supply
• Data bus communication

ELECTRICAL SYSTEM COMPONENTS

• Alternator
• Batteries
• Electrical distribution box
• Fuses
• Relays
• Sensors
• Solenoid valves
• Switches
• Electrical connectors
• Lighting equipment
• Warning indicators

9. VCADS PRO AND ELECTRONIC DIAGNOSTICS

The manual includes information related to electronic troubleshooting and VCADS Pro operations.

Included topics:

• VCADS Pro service tool
• General fault diagnosis
• SAE error code interpretation
• Electronic troubleshooting strategies
• Special diagnostic tools
• Communication interruptions
• Software functions
• Software parameter settings
• Electrical input signal monitoring
• Electrical output signal monitoring
• Engine speed signal checking
• Camshaft and flywheel signal testing using VCADS Pro and an oscilloscope
• Cylinder compression testing with VCADS Pro
• Idle and stall speed checks using VCADS Pro

10. INSTRUMENT PANEL AND MACHINE MONITORING

The documentation includes descriptions of machine monitoring functions and service displays.

ENGINE MONITORING

• Engine oil pressure
• Engine oil temperature
• Engine oil level
• Engine crankcase pressure
• Coolant temperature
• Coolant level
• Fuel feed pressure
• Fuel consumption
• Engine speed
• Engine protection
• Engine shutdown

TRANSMISSION MONITORING

• Transmission oil pressure
• Transmission oil temperature
• Transmission oil level
• Transmission oil filter
• Transmission slipping
• Transmission overspeed
• Gear selection
• Transmission protection

HYDRAULIC AND BRAKE MONITORING

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

DISPLAY FUNCTIONS

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

11. APS II AND AWB40B POWER TRANSMISSION

The power transmission section includes descriptions and repair procedures for the hydraulic transmission and drivetrain.

TRANSMISSION SYSTEMS

• AWB40B transmission descriptions
• APS II transmission control
• Hydraulic transmission
• Gear selector valve
• Gearshifting functions
• Differential brake
• Differential lock
• Rear axle mounting
• Torque converter

TRANSMISSION REPAIR PROCEDURES

• Transmission fault diagnosis
• Transmission oil pressure testing
• Transmission removal
• Transmission installation
• Gear selector valve removal and installation
• Gear selector solenoid resistance measurement
• Torque converter removal and installation
• Transmission oil cooler replacement
• Rear output shaft seal replacement

12. AXLES, DIFFERENTIALS AND DRIVE SHAFTS

The manual includes repair procedures for selected drivetrain components.

Included operations:

• Differential lock adjustment
• Differential lock sensor adjustment
• Rear axle mounting play measurement
• Axle mounting bushing replacement
• Propeller shaft support bearing replacement
• Rear output shaft seal replacement

13. BRAKING SYSTEM

The braking section provides descriptions and workshop repair information.

BRAKE SYSTEM COMPONENTS

• Hydraulic service brakes
• Foot brake valve
• Parking brake
• Brake wear indicators

BRAKE REPAIR PROCEDURES

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

14. STEERING AND COMFORT DRIVE CONTROL

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

STEERING COMPONENTS

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

STEERING REPAIR PROCEDURES

• Steering system working pressure checks
• Steering pressure adjustment
• Secondary steering function tests
• CDC steering signal checks
• Lever steering speed adjustment
• Lever steering control valve adjustment
• Steering valve replacement
• Steering valve reconditioning
• Steering cylinder replacement
• Steering cylinder reconditioning
• Steering cylinder link bearing replacement
• Shift valve reconditioning

15. HYDRAULIC PUMPS P1, P2 AND P3

The manual includes technical specifications and repair procedures for the machine's hydraulic pump systems.

PUMP P1

• Working hydraulics
• Brake system
• Servo system
• Hydraulic pump replacement
• Working pressure testing
• Standby pressure testing

PUMP P2

• Steering and associated hydraulics
• Hydraulic pump replacement
• Hydraulic flow and pressure references

PUMP P3

• Cooling fan pump
• Brake pump
• Cooling fan maximum speed checking
• Standby pressure checking and adjustment
• Hydraulic pump replacement

16. WORKING HYDRAULIC SYSTEM

The working hydraulic section covers the loader's hydraulic control and actuation equipment.

HYDRAULIC COMPONENTS

• Hydraulic pumps
• Hydraulic oil tank
• Central valve
• Control valve
• Compensator block
• Servo system
• Lift cylinders
• Tilt cylinders
• Hydraulic attachment locking

HYDRAULIC REPAIR PROCEDURES

• Hydraulic pump replacement
• Hydraulic standby pressure checking
• Hydraulic working pressure adjustment
• Hydraulic system bleeding
• Hydraulic oil tank removal and installation
• Central valve reconditioning
• Central valve replacement
• Control valve replacement
• Servo valve replacement
• Servo valve reconditioning
• Servo pressure adjustment
• Hydraulic system troubleshooting

17. LIFT AND TILT CYLINDER REPAIRS

The manual includes specific procedures for servicing the lifting and tilting equipment.

LIFT CYLINDER SERVICE

• Lift cylinder replacement
• Lift cylinder seal replacement in the machine
• Lift cylinder bearing replacement
• Lift frame bearing replacement
• Lifting time checking
• Lift shock valve checking

TILT CYLINDER SERVICE

• Tilt cylinder replacement
• Tilt cylinder seal replacement in the machine
• Tilt cylinder bearing replacement
• Tilt shock valve checking

18. BOOM SUSPENSION SYSTEM (BSS)

The Boom Suspension System section contains descriptions and detailed service procedures.

Included operations:

• BSS system descriptions
• Boom suspension accumulator replacement
• Accumulator pressure release
• Accumulator reconditioning
• Accumulator precharge pressure checking
• Accumulator precharge adjustment
• Pressure-limiting valve setting
• BSS troubleshooting
• BSS test drive with load
• Valve block V1 removal and installation
• Valve block V2 removal and installation

19. RETURN-TO-DIG AND AUXILIARY HYDRAULIC FUNCTIONS

The manual includes information about automatic lift arm lowering and auxiliary hydraulic equipment.

RETURN-TO-DIG

• Automatic lift arm lowering
• Return-to-Dig valve block
• Return-to-Dig system description
• Return-to-Dig installation instructions

AUXILIARY HYDRAULICS

• Third hydraulic function
• Fourth hydraulic function
• Auxiliary hydraulic pressure checking and adjustment
• Hydraulic attachment locking
• Servo valve installation

20. CENTRAL LUBRICATION SYSTEM

The manual contains descriptions and specifications for the central lubrication system.

Included topics:

• Central lubrication system
• Lubrication cycle
• Lubrication status monitoring
• Lubrication cycle selection
• Lubrication system specifications

21. FRAME, JOINTS AND WHEEL EQUIPMENT

The frame section includes descriptions and repair information for the machine's structural components.

Included operations:

• Frame joint clearance checking
• Frame joint bearing replacement
• Frame joint pin replacement
• Wheel removal and installation
• Protective plate removal

22. OPERATOR CAB AND CLIMATE CONTROL

The manual includes descriptions and repair procedures for the operator cab and air conditioning equipment.

CAB COMPONENTS

• Cab suspension
• Viscous cab suspension
• Cab removal and installation
• Engine hood removal and installation
• Cab-related electrical equipment

AIR CONDITIONING AND ATC

• Air conditioning descriptions
• Automatic Temperature Control (ATC)
• Relay-controlled ATC troubleshooting
• Software-controlled ATC troubleshooting
• Air conditioning performance testing
• Evaporator cleaning
• Fan motor replacement
• Heater core replacement
• Heat control valve replacement

23. ELECTRICAL WIRING DIAGRAMS

The manual includes a collection of electrical wiring diagrams and component references.

Included diagram groups:

• Wiring diagrams 1–13
• Wiring diagram 15B
• Wiring diagrams 16–21
• Wiring diagrams 21B and 21C
• Wiring diagrams 23–31
• Wiring diagrams 33–35
• Wiring diagrams 100–103
• Wiring diagram 107
• Updated CDC wiring diagram 17
• Heavy-duty 120-amp alternator diagram
• Electrical circuit list

24. HYDRAULIC CIRCUIT DIAGRAMS

The hydraulic diagram section provides circuit references for the machine's main hydraulic systems.

Included diagrams:

• Complete hydraulic system diagrams
• Cooling fan and axle oil cooling diagrams
• Cooling fan and brake system diagram
• Reversible fan and brake system diagram
• Steering hydraulic diagrams
• Working hydraulics and differential lock diagram
• Hydraulic diagram explanations

25. OPTIONAL EQUIPMENT INSTALLATION INSTRUCTIONS

The manual contains installation instructions for various optional equipment and accessories.

HYDRAULIC EQUIPMENT

• Third hydraulic function
• Fourth hydraulic function
• Hydraulic attachment locking
• Boom Suspension System
• Axle oil cooler
• Extra hydraulic oil cooler
• Servo valve installation

ENGINE AND COOLING ACCESSORIES

• Engine heater
• Reversible cooling fan
• Cyclone pre-cleaner
• Oil-bath air cleaner
• Hand throttle control

ELECTRICAL AND CAB ACCESSORIES

• CareTrack
• Additional work lights
• Rotating warning beacon
• Electrically heated rear-view mirrors
• Radio installation kit
• Instructor seat
• Sun blind
• Air conditioning equipment

MACHINE PROTECTION ACCESSORIES

• Protective headlamp grille
• Tail lamp guard
• Protective grating
• Fender widener
• Swing-out rear mudguards

26. WORKSHOP SAFETY INFORMATION

The manual includes safety guidance for workshop operations.

Included topics:

• General servicing safety
• Hydraulic accumulator handling
• Hydraulic system safety
• Battery safety
• Oil and fuel handling
• Air conditioning refrigerant safety
• Safe lifting and supporting
• Tyre handling
• Fire prevention
• Decontamination
• Hazardous fluid handling
• Environmental protection
• Waste handling
• Service position information

27. TECHNICAL SPECIFICATIONS

The specifications section contains reference data for major machine components.

ENGINE AND FUEL SYSTEM

• Engine specifications
• Engine capacities
• Engine weights
• Fuel feed pump specifications
• Injection pump specifications
• Unit injector specifications
• Cooling system specifications
• Cooling fan specifications
• Lubrication system specifications
• Emission system specifications

TRANSMISSION AND DRIVELINE

• Hydraulic transmission specifications
• Transmission oil pressure specifications
• Transmission capacities
• Torque converter specifications
• Front axle specifications
• Rear axle specifications
• Drive shaft specifications

BRAKES AND STEERING

• Service brake specifications
• Parking brake specifications
• Foot brake valve specifications
• Steering cylinder specifications
• Steering hydraulic specifications

HYDRAULIC SYSTEM

• Pump P1 specifications
• Pump P2 specifications
• Pump P3 specifications
• Hydraulic system volume
• Hydraulic cylinder specifications
• Hydraulic valve specifications
• Boom Suspension System specifications
• Servo system specifications

ADDITIONAL TECHNICAL DATA

• Electrical system specifications
• Alternator specifications
• Battery specifications
• Air conditioning specifications
• Refrigerant quantities
• Frame specifications
• Component weights
• Tightening torques
• Conversion tables
• Recommended lubricants

PRACTICAL WORKSHOP APPLICATIONS

This manual can assist with operations such as:

• Identifying D9 and D10/D10B engine components
• Checking fuel injection system operation
• Setting injection pump timing
• Replacing unit injectors
• Testing engine compression
• Diagnosing engine control signals with VCADS Pro
• Checking AWB40B transmission oil pressure
• Servicing differential lock components
• Inspecting brake discs
• Adjusting hydraulic brake pressure
• Checking CDC steering signals
• Reconditioning steering valves
• Testing hydraulic pump P3 standby pressure
• Replacing hydraulic pumps
• Servicing lift and tilt cylinders
• Troubleshooting Boom Suspension System faults
• Consulting wiring and hydraulic circuit diagrams

WHO IS THIS MANUAL FOR?

This technical publication is suitable for:

• Professional Volvo construction equipment technicians
• Wheel loader repair workshops
• Heavy equipment diesel mechanics
• Construction machinery fleet maintenance departments
• Hydraulic system repair specialists
• Experienced Volvo L150E owners carrying out service and repair work

IMPORTANT COMPATIBILITY INFORMATION

This manual is identified for the Volvo L150E Wheel Loader.

The table of contents includes technical references to multiple engine types, including D9 and D10/D10B, as well as different optional equipment configurations.

Not every engine procedure, electrical circuit, or hydraulic arrangement necessarily applies to every machine.

Before purchasing, verify your machine model, serial number, engine configuration, and installed equipment.

The 2022 information update refers to the technical documentation and does not necessarily indicate the machine's manufacturing year.

DIGITAL PDF DELIVERY

This product is supplied as a digital PDF workshop manual.

The publication includes:

• 1,990 pages of technical documentation
• D9 and D10/D10B engine-related information
• Fuel injection and unit injector service procedures
• Injection pump timing instructions
• Engine cooling and reversible fan documentation
• VCADS Pro diagnostic references
• APS II and AWB40B transmission information
• Brake and steering repair procedures
• CDC lever steering documentation
• Hydraulic pump P1, P2 and P3 specifications
• Lift and tilt cylinder repair procedures
• Boom Suspension System information
• Return-to-Dig and auxiliary hydraulic functions
• 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 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:

Descriptions
(0) GENERAL
Description
(1) STANDARD PARTS, SERVICE
Cleanliness, brake and hydraulic systems 2
Charging batteries
In a lift or other confined space
Lift
On another vehicle’s platform
Working on the electrical system of the machine
Over ramp
Electric welding 2
Parking brake, manually releasing
Electric welding
Cleanliness, brake and hydraulic systems
Recommended lubricants, oils
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Pump 3 (P3) Cooling fan pump Brake pumpFlow and pressure control, description
Engine control unit (E-ECU), description
Reversible cooling fan, electric description
Reversible cooling fan, hydraulic diagram description
Cooling fan motor, description
Reversible cooling fan 2
Reversible cooling fan
Hydraulic cooling fan, description
Thermostat, description
Thermostat housing, description
Coolant pump, description
Cooling system, description D9
Coolant circulation in engine, description
Cooling system, description 2
Cooling system, description
Intercooler, description
Preheating coil, description 2
Preheating coil, description
Air cleaner, description 2
Air cleaner, description
Turbocharger, description D9 2
Turbocharger, description D9
Turbocharger, description 2
Turbocharger, description
Intake and exhaust system, description
Control unit, description
Unit injectors, description D9
Unit injector, Delphi, description
Injectors, description
Regulator, description
Injection pump, description
Injection advance curve, description
Fuel filters, description D9
Fuel filter, description 2
Fuel feed pump, description D10B
Fuel feed pump, description D9
Fuel filter, description
Instructions for working with electronic fuel injection
Fuel system, description 2
Fuel flow, description D9
Fuel system, description D9
Fuel system, description
Oil cooler, description
Description, oil pump 2
Description, oil pump
Lubrication system, principle
Lubrication oil pump and oil cooler, description
Lubrication system, description D10
Lubrication system, description D9
Piston cooling system, description D9
Lubrication system, description 2
Lubrication system, description
Engine mounting, description
Oil sump, description D9
Main and big-end bearing, description
Vibration damper, description
Connecting rods, description
Crankshaft and vibration damper, description D9
Crankshaft, description
Timing gear casing, description
Timing gear, description
Engine timing gear, description D9
Camshaft, description D9
Camshaft, description
Engine timing gears, description
Internal Exhaust Gas Recirculation (IEGR), description
Valve mechanism, description D9
Valve mechanism, description D10
Valves and valve seats, description
Valve mechanism, description
Piston rings, description
Pistons, description
Cylinder liners and pistons, description D9
Cylinder liner, description 2
Cylinder liner, description
Crankcase ventilation, D9
Cylinder block, description D9
Cylinder block, description 3
Cylinder block, description 2
Cylinder block, description
Cylinder head, description D9
Cylinder head, description 2
Cylinder head gasket, description D9
Cylinder head, description
Engine identification, D10
Engine identification, D9
Engine, description D9
Engine, description
General description
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
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)
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
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 10 Signals, shift solenoids
Component list 11 sensors
Component list 12 switches
Conditions when checking
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, description
Engine crankcase pressure
Engine Oil Level
Engine oil pressure 2
Engine oil pressure
Engine oil temperature 2
Engine oil temperature
Engine On Off
Engine Protection
Engine Shutdown
Engine speed for E-ECU 2
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 feed pressure
Fuel shut-off (D10)
Fuel temperature (D10)
Fully automatic
Gear Selector
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
Information display, general
Injectors
Instrument control unit I-ECU, functional description
Instruments
Interruption in computer communication
Interval Wiper
Key feed
Lead and connector checks
Lighting, description
Limitation of engine speed on first gear
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
PWM2302 Actuator injection angle (MID 128 SID 20)
Reduced computer communication
SAE error codes, translation to error messages, general
SE504 Monitor brake pressure charging
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 (rpm) injection pump
Speed limitation for lever steering (CDC)
Speed limitation
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
VCADS Pro service tool
Vehicle control unit V-ECU, description
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 AWB40B 2
Description AWB40B 3
Description AWB40B
Description
Differential brake, description
Differential lock
Gear selector valve, measuring resistance of solenoids
Gearshifting, description
General description
Hydraulic transmission, description
Rear axle mounting
(5) BRAKE
Foot brake valve, description
Hydraulic brake system, description
Parking brake, description
Wear indicator, description
(6) STEERING
Control valve, description
Hydraulic system, description
Electrical system, description
Comfort Drive Control, description
Secondary steering, description
Shift valve, function description
Shift valve, description
Steering valve, description
Steering cylinder, cross section
Hydraulic pumps, description
Steering, function description
Steering, description
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Frame joint, description
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
Electrical system, description
Viscous cab suspension, description
(9) HYDRAULIC SYSTEM;DIGGING HANDLING GRADING EQUIPM.; MISC. EQUIP
Central lubrication system, description
Pressure monitor, description
Lubrication cycle, description
TP linkage bearing points
Tilting cylinder
Lifting cylinder
Hydraulic attachment lock (software-controlled), description
Hydraulic attachment lock with raised servo pressure, description
3rd, or 3rd 4th hydraulic function, description
Boom Suspension System, description of function
Boom Suspension System, description
Valve block for Return To Dig, description
Automatic lift arm lowering (Return-To-Dig), description
Servo system, description
Pump 1 (P1) and Pump 2 (P2), principle diagram
Symbol diagram, pump control
Compensator block, description
Hydraulic pumps, description
Central valve, description
Control valve, description
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 20
Wiring diagram 21
Wiring diagram 21B
Wiring diagram 21C
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 33
Wiring diagram 34
Wiring diagram 35
Wiring diagram 100
Wiring diagram 101
Wiring diagram 102
Wiring diagram 103
Wiring diagram 107
(9) HYDRAULIC SYSTEM;DIGGING HANDLING GRADING EQUIPM.; MISC. EQUIP
Explanations to hydraulic diagram
Hydraulic diagram, complete (2)
Hydraulic diagram, complete
Hydraulic diagram, fan, axle oil cooling (2)
Hydraulic diagram, fan, axle oil cooling
Hydraulic diagram, fan, brake system
Hydraulic diagram, reversible fan, brake system
Hydraulic diagram, steering (2)
Hydraulic diagram, steering
Hydraulic diagram, working hydraulics, differential lock
Installation Instructions
Extra workelihgts
Working light
Extra working light
Swing out mudguards, rear
Sun blind
Rotating warning beacon
Reversible fan
Return-to-dig
Electrically heated rear-view mirrors
Radio installation kit
Radio kit, right left
Protective grille, headlamp
Protecting grating
Tail lamp guard
Single lever control
Servo valve, 3rd hydraulic function
Oil-bath air cleaner
Mounting kit, wide seat
Seat for the instructor
Hand throttle control
Fender Widener
Extra hydraulic oil cooler
Engine heater, (230 V)
Engine heater, (220 V)
Engine heater 2
Engine heater,
Cyclon precleaner,
Lever steering
CareTrack 2
CareTrack
Care Track
Cab rubber pad
Boom suspension system
Axle oil cooler 2
Axle oil cooler
Attachment lock 2
Attachment lock
Air conditioning 2
Air conditioning
4th hydralic function
3rd hydraulic function
Repair
(0) GENERAL
E1711
E-2017
Infrared Thermometer
Operation numbers for additional work
Section 4.5 Power transmission, Brakes
(1) STANDARD PARTS, SERVICE
Towing
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope
Charge air cooler, replacing
Charge air cooler, replacing2
Charge air system, inspection
Checking stalling speed
Compression test, D10B
Coolant pump, changing
Coolant pump, replacing
Cooling fan hydraulics, funktion check
Cooling fan motor, changing non-return valve
Cooling fan motor, replacing
Cooling fan motor, replacing2
Crankshaft front oil seal, replacing
Crankshaft front seal, replacement
Cylinder compression, testing
Cylinder compression, VCADS Pro
Engine mount rubber cushion, replacing
Engine mount rubber cushion, replacing2
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor, replacing
Engine rotation speed sensor, replacing2
Engine, installing
Engine, installing2
Engine, installing3
Engine, removing
Engine, removing2
Engine, removing3
Fan motor, checking working pressure
Feed pump pressure, checking
Feed pump pressure, checking2
Feed pump, replacing
Feed pump, replacing2
Fuel filter, checking
Fuel pump (valves), inspecting
Fuel pump, inspecting
Fuel system, air bleeding, D10B
Fuel system, bleeding
Fuel system, bleeding2
Fuel system, bleeding3
Fuel tank, removal
Idle, VCADS Pro
Injection pump, installing, and setting injection angle
Injectors, replacing
Lubrication oil pressure, checking with pressure gauge
Lubrication oil pressure, checking with pressure gauge2
Lubrication oil pressure, checking with pressure gauge3
Lubrication oil pressure, checking
Oil cooler, replacing
Oil cooler, replacing2
Oil cooler, replacing3
Oil pressure, check
Oil pump, replacement
Pump 3 (P3) Radiator fanBrake pump Max. fan speed, checking the setting
Pump 3 (P3) standby pressure, checking and adjusting (LS-line removed)
Pump 3 (P3) standby pressure, checking and adjusting (LS-line removed)2
Pump 3 (P3) standby pressure, checking and adjusting (LS-line removed)3
Radiator, replacing
Radiator, replacing2
Reversible cooling fan, funktion check
Stall speed, VCADS Pro
Thermostat, replacing
Thermostat, replacing2
Turbocharger, changing
Turbocharger, inspecting
Turbocharger, replacing
Turbocharger, replacing2
Unit injector, replacing
Valve cover, changing gasket
Valves, adjusting, D10B
Valves, adjusting
Valves, adjusting2
Valves, adjusting3
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator, replacing incl function checking
(4) POWER TRANSMISSION
Differential lock, adjusting
Gear selector valve, removing and installing
Gear selector valve, removing and installing2
Measuring axial and radial play, rear axle mounting
Propeller shaft, changing support bearing
Replacing the bushing in the axle mounting
Seal for rear output shaft, replacing
Sensor for differential lock, adjusting
Torque converter, removing, installing
Transmission oil cooler, changing
Transmission oil pressure, checking
Transmission oil pressure, checking2
Transmission, fault diagnosis
Transmission, installing (from above)
Transmission, removing (upwards)
(5) BRAKE
Brake discs, checking wear
Brake discs, replacing
Brake system circuit pressure, checking and adjusting
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
(6) STEERING
Function test, secondary steering
Function test, secondary steering2
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
Shift valve, reconditioning (removed)
Steering cylinder, link bearing, changing
Steering cylinder, reconditioning
Steering cylinder, replacement
Steering system working pressure, checking and adjusting
Steering valve, reconditioning (removed)
Steering valve, reconditioning (removed)2
Steering valve, replacing
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Frame joint clearance, checking
Frame joint, changing bearings and pins
Protective plate, removing
Wheel, removing and installing
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, checking performance
Air conditioning, troubleshooting, relay-controlled ATC
Air conditioning, troubleshooting, software-controlled ATC
Cab, installing
Cab, removing
Engine hood, installing
Engine hood, installing2
Engine hood, installing3
Engine hood, installing4
Engine hood, removing
Engine hood, removing2
Engine hood, removing3
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
3rd4th hydraulic function, pressure, checking and adjusting
Back-up valve, checking and adjusting
Boom suspension system, changing accumulator
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom Suspension System, pressure limiting valve, setting
Boom suspension system, reconditioning accumulator
Boom suspension system, test drive with load
Boom Suspension System, troubleshooting
Boom Suspension System, troubleshooting2
Boom Suspension System, valve block V1, installing
Boom Suspension System, valve block V1, removing
Boom Suspension System, valve block V2, installing
Boom Suspension System, valve block V2, removing
Central valve, reconditioning (removed)
Central valve, replacing
Central valve, replacing2
Control valve, replacing
Discarded accumulators
Hydraulic couplings, installation instructions
Hydraulic cylinder, piston’s lock brace, installing
Hydraulic oil tank, installing
Hydraulic oil tank, removing
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic pump P1, replacing
Hydraulic pump P1, replacing2
Hydraulic pump P3, replacing
Hydraulic pump P3, replacing2
Hydraulic pump, max working pressure, checking and adjusting
Hydraulic pump, stand-by pressure (LS-line removed), checking and adjusting
Hydraulic pump, standby pressure, checking and adjusting
Hydraulic pumps P2 and P3, replacing
Hydraulic system, bleeding
Implemental attachment hydraulic cylinder, replacing
Lift cylinder removed, bearings C-P, replacing
Lift cylinder, repacking in machine
Lift cylinder, replacing
Lift frame, replacing bearing in lower bucket- or implement attachment
Lifting time, checking
Precharge pressure in accumulators, checking and adjusting
Servo pressure, checking and adjusting
Servo pressure, checking and adjusting2
Servo valve, operating controls, adjusting
Servo valve, reconditioning (removed)
Servo valve, replacing
Shock valve lift function, checking
Shock valve, tilt function, checking
Tilt cylinder removed, replacing bearings E-F
Tilt cylinder, repacking in machine
Tilt cylinder, replacing
Tilting cylinder, replacing bearing ‘E’ in machine
Working hydraulics and servo system, trouble-shooting
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
Service position 1
Some simple rules regarding tyre handling 2
Some simple rules regarding tyre handling
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP.
Specifications
(0) GENERAL
3rd 4th hydraulic function, specifications
Air conditioning, refrigerant, weight 2
Air conditioning, refrigerant, weight 3
Air conditioning, refrigerant, weight
Air conditioning, specifications
Air conditioning, tightening torques
Air distribution, specifications
Alternator, specifications
Axle suspension, tightening torques
Battery, specification
Battery, weight
Boom Suspension System, specifications
Cab, tightening torques
Cab, weight
Central lubrication system, specifications
Control cylinders, weight
Conversion tables
Cooling fan max. speed, specifications
Cooling fan motor, specifications
Cooling system specifications
Cooling system volume
Counterweight, weight
Drive shafts, specifications
Electrical system, specifications
Emission system specifications
Engine mounting, tightening torque
Engine, specifications 2
Engine, specifications 3
Engine, specifications 4
Engine, specifications
Engine, volume 2
Engine, volume
Engine, weight 2
Engine, weight
Foot brake valve, specifications
Frame joint, tightening torques
Frame, specifications
Frame, tightening torque
Frame, weight
Front axle, tightening torque
Front axle, weight 2
Front axle, weight
Fuel feed pump, specifications 2
Fuel feed pump, specifications 3
Fuel feed pump, specifications
Fuel tank, volume 2
Fuel tank, volume
Gas valve, tightening torque
Hydraulic connections, tightening torques
Hydraulic cylinders, specifications
Hydraulic cylinders, tightening torques
Hydraulic system, volume
Hydraulic transmission, specifications
Hydraulic transmission, tightening torques
Hydraulic transmission, volume
Hydraulic transmission, weight
Injection pump, specifications
Injectors, specifications 2
Injectors, specifications
Intercooler specifications
Lighting, specifications
Lubrication system, specification 2
Lubrication system, specification
Noise reduction plates, weight
Oil cooler, specifications
Oil filter specifications 2
Oil filter specifications
Oil-bath air cleaner, volume
Operator’s seat, weight
Parking brake, specifications 2
Parking brake, specifications
Preheating, specifications
Propeller shaft, tightening torque
Propeller shaft, weight
Protective plate, tightening torque
Protective plate, weight
Pump 1, (P1) Working hydraulics, brake system, servo system, specifications 2
Pump 1, (P1) Working hydraulics, brake system, servo system, specifications
Pump 2 (P2) Steering and other hydraulics, specifications 2
Pump 2 (P2) Steering and other hydraulics, specifications
Pump 3 (P3) Cooling fan pump Brake pump, specifications 2
Pump 3 (P3) Cooling fan pump Brake pump, specifications 3
Pump 3 (P3) Cooling fan pump Brake pump, specifications
Rear axle, capacity
Rear axle, tightening torques
Rear axle, weight
Rocker arm shaft, tightening torques
Service brakes, specifications
Servo system, specifications
Starter motor, specifications
Steering cylinder, specifications
Steering cylinder, tightening torque
Steering, specification 2
Steering, specification
Thermostat, specifications
Tightening torques 2
Tightening torques
Torque converter, specifications 2
Torque converter, specifications
Torque converter, tightening torque
Torque converter, weight
Transmission oil pressure, specifications
Unit injectors, specifications
Valve cover, tightening torque
Valve mechanism, double rocker arm
Valve system specifications 2
Valve system specifications
Valves, working hydraulics, specifications
Wheel, weight
Wheels, tightening torques
Working and servo system, specifications
(1) STANDARD PARTS, SERVICE
Service brakes, specifications
Alternative fuels
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Pump 3 (P3) Cooling fan pump Brake pump, specifications
Cooling fan motor, specifications
Cooling fan max. speed, specifications
Thermostat, specifications
Cooling system specifications
Cooling system volume
Intercooler specifications
Preheating, specifications
Oil-bath air cleaner, volume
Air cleaner, preheater, specifications
Emission system specifications
Injectors, checking
Injectors, specifications
Unit injectors, specifications 2
Unit injectors, specifications
Injection pump, specifications
Fuel tank, volume
Fuel feed pump, specifications 3
Fuel feed pump, specifications 2
Fuel feed pump, specifications
Oil cooler, specifications
Oil filter specifications 2
Oil filter specifications
Lubrication system, specification 3
Lubrication system, specification 2
Lubrication system, specification
Valve system specifications 4
Valve system specifications 3
Valve mechanism, double rocker arm
Rocker arm shaft, tightening torques
Valve system specifications 2
Valve system specifications
Valve cover, tightening torque
Engine mounting, tightening torque
Engine suspension, tightening torques
Engine, volume 2
Engine, volume
Engine, weight
Engine, specifications 3
Engine, specifications 2
Engine, 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) POWER TRANSMISSION
Rear axle, tightening torques
Rear axle, capacity
Rear axle, weight
Front axle, capacity
Front axle, tightening torque
Front axle, weight
Drive shafts, specifications
Propeller shaft, tightening torque
Propeller shaft, weight
Transmission oil pressure, specifications
Hydraulic transmission, specifications
Hydraulic transmission, tightening torques
Hydraulic transmission, weight
Hydraulic transmission, volume
Torque converter, tightening torque
Torque converter, weight
Torque converter, specifications 2
Torque converter, specifications
(5) BRAKE
Foot brake valve, specifications
Parking brake, specifications
Pump 3 (P3) Cooling fan pump Brake pump, specifications
Service brakes, specifications
(6) STEERING
Pump 2 (P2) Steering and other hydraulics, specifications
Steering cylinder, specifications
Steering cylinder, tightening torque
Steering, specification 2
Steering, specification
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Wheels, tightening torques
Wheel, weight
Frame joint, tightening torques
Counterweight, weight
Protective plate, tightening torque
Protective plate, weight
Frame, tightening torque
Frame, weight
Frame, specifications
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, refrigerant, weight 2
Air conditioning, refrigerant, weight 3
Air conditioning, refrigerant, weight
Air conditioning, specifications
Air conditioning, tightening torques
Air distribution, specifications
Cab, weight
Noise reduction plates, weight
Operator’s seat, weight
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
3rd 4th hydraulic function, specifications
Boom Suspension System, specifications
Central lubrication system, specifications
Control cylinders, weight
Flow compensator, basic setting, specifications
Gas valve, tightening torque
Hydraulic connections, tightening torques
Hydraulic cylinders, specifications
Hydraulic cylinders, tightening torques
Hydraulic system, volume
Pump 1, (P1) Working hydraulics, brake system, servo system, specifications 2
Pump 1, (P1) Working hydraulics, brake system, servo system, specifications
Pump 2 (P2) Steering and other hydraulics, specifications
Pump 3 (P3) Cooling fan pump Brake pump, specifications
Selecting lubrication cycle
Servo system, specifications
Valves, working hydraulics, specifications
Working and servo system, specifications