VOLVO L150F WHEEL LOADER SERVICE REPAIR MANUAL PDF – 1951 PAGES

Workshop Documentation for Engine, Transmission, Electrical Systems, Brakes and Hydraulics

The Volvo L150F Wheel Loader Service Repair Manual is a comprehensive 1,951-page technical publication covering maintenance, troubleshooting, inspection, adjustment, component replacement, and workshop repair procedures for the Volvo L150F wheel loader.

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

Particular attention is given to the machine's electronic control architecture, including the E-ECU, V-ECU, V2-ECU, I-ECU, and Electronic Climate Control (ECC) systems.

The publication also covers hydraulic transmission Lock-Up functions, RBB braking system information, Comfort Drive Control (CDC), Boom Suspension System (BSS), automatic lubrication, hydraulic pumps P1–P3, and fire suppression equipment.

Extensive VCADS Pro diagnostic references and electrical diagrams make this manual especially useful when investigating electronic faults, control unit problems, transmission malfunctions, and hydraulic performance issues.

MANUAL INFORMATION

• Manufacturer: Volvo Construction Equipment
• Equipment Model: Volvo L150F Wheel Loader
• Manual Type: Service Repair / Workshop Manual
• Format: PDF
• Total Pages: 1,951
• Technical Information Updated: 2022
• Delivery: Digital Download

WHAT DOES THIS VOLVO L150F MANUAL INCLUDE?

The documentation is organized into six principal sections:

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

Together, these sections provide technical coverage of the engine, electronic control systems, power transmission, axles, brakes, steering, frame, cab, hydraulic equipment, and selected optional accessories.

1. GENERAL SERVICE AND MAINTENANCE INFORMATION

The opening sections contain workshop practices and general service instructions.

Included topics:

• Battery charging
• Brake and hydraulic system cleanliness
• Electrical welding precautions
• Hydraulic system repair practices
• Electrical system servicing
• Fire suppression system maintenance
• Machine towing
• Manual parking brake release

2. ENGINE SYSTEM AND MAJOR COMPONENTS

The engine section describes the main engine systems and supporting components.

ENGINE SYSTEM DESCRIPTIONS

• Engine general description
• Electronic fuel injection
• Fuel supply system
• Engine lubrication system
• Engine cooling system
• Air intake and exhaust system
• Intercooler
• Turbocharger
• Internal Exhaust Gas Recirculation (IEGR)
• Engine preheating
• Accelerator pedal
• Hand throttle
• Auxiliary engine braking

ENGINE REPAIR PROCEDURES

• Engine removal
• Engine installation
• Cylinder compression testing
• Camshaft wear inspection
• Engine rotation speed sensor replacement
• Rocker arm mechanism reconditioning
• Valve adjustment
• Engine lubrication pressure checking

3. ELECTRONIC FUEL INJECTION AND UNIT INJECTORS

The manual contains information for the electronically controlled fuel system.

Included topics:

• Fuel system description
• Fuel filter
• Fuel feed pump
• Delphi unit injector
• Electronic fuel injection precautions
• Fuel pump inspection
• Fuel pump valve inspection
• Fuel feed pressure testing
• Fuel system bleeding
• Injector replacement

The publication also includes checks involving carbon dioxide in the fuel system and diagnostic operations using VCADS Pro.

4. ENGINE COOLING AND REVERSIBLE FAN

The manual covers the engine cooling circuit and hydraulically controlled fan equipment.

COOLING SYSTEM COMPONENTS

• Cooling system
• Cooling fan
• Cooling fan motor
• Reversible cooling fan
• Radiator
• Intercooler
• Fan control valve

COOLING SYSTEM REPAIR PROCEDURES

• Cooling fan hydraulic function checking
• Cooling fan motor replacement
• Fan control valve removal and installation
• Fan control valve seal replacement
• Radiator replacement
• Pump P3 maximum pressure checking
• Cooling fan speed checking and adjustment
• Pump P3 standby pressure checking and adjustment

5. ELECTRONIC CONTROL UNITS AND COMMUNICATION SYSTEMS

The electrical section contains detailed information about the machine's control units and electronic communication.

CONTROL UNITS COVERED

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

CONTROL SYSTEM INFORMATION

• Electronic control system description
• Control unit input/output lists
• Data bus communication
• Bus communication supervision
• Software functions
• Software parameter descriptions
• Electrical supply and chassis connections
• Reduced computer communication
• Interrupted computer communication
• Limp Home function

CONTROL UNIT REPLACEMENT AND PROGRAMMING

• E-ECU MID 128 replacement
• I-ECU MID 140 replacement
• V-ECU MID 187 replacement
• V2-ECU MID 249 replacement
• ECC MID 146 replacement
• Pre-programmed and non-programmed ECU replacement procedures
• VCADS Pro programming operations

6. VCADS PRO DIAGNOSTICS AND TROUBLESHOOTING

The manual includes diagnostic information for identifying faults and checking machine systems.

Included topics:

• VCADS Pro service tool
• VCADS Pro error codes
• SAE error code interpretation
• General fault diagnosis
• Troubleshooting strategies
• Special troubleshooting tools
• Lead and connector checking
• Electrical signal monitoring
• Software parameter descriptions
• Electronic control unit programming
• Camshaft and flywheel signal testing with VCADS Pro and an oscilloscope
• Cylinder compression testing with VCADS Pro
• Engine idle testing
• Engine stall speed testing
• Transmission diagnostic operations

7. INSTRUMENT PANEL AND INFORMATION DISPLAY

The manual includes detailed descriptions of the operator information system.

DISPLAY FUNCTIONS

• Operating display
• Vehicle information
• Vehicle messages
• Engine information
• Transmission information
• Hydraulic system information
• Axle and brake information
• Electrical system information
• Service mode
• Display settings
• Start lockout
• Machine hours
• Travelling speed
• Fuel consumption
• Warning messages

8. ELECTRICAL COMPONENTS AND POWER SUPPLY

The electrical system documentation includes component lists and circuit references.

Included components:

• 80 A alternator
• Batteries
• Battery disconnector switch
• Fuses
• Relays
• Diodes
• Sensors
• Solenoid valves
• PWM valves
• Motors
• Switches
• Lights
• Electrical connectors
• Control units
• Service sockets

ELECTRICAL SERVICE PROCEDURES

• Battery condition checking
• Battery replacement
• Starter lock replacement
• Electrical troubleshooting
• Control unit replacement

9. HYDRAULIC TRANSMISSION AND LOCK-UP SYSTEM

The power transmission section describes the hydraulic transmission and associated control functions.

TRANSMISSION COMPONENTS AND FUNCTIONS

• Hydraulic transmission
• Transmission Lock-Up
• Lock-Up valve
• Lock-Up solenoid
• RBB system
• Differential lock
• Automatic differential brake
• Limited Slip function
• Drive axles

TRANSMISSION REPAIR PROCEDURES

• Transmission removal
• Transmission installation
• Transmission oil pressure testing
• Transmission functional checks
• Transmission solenoid replacement
• Transmission pressure sensor replacement
• Main pressure valve replacement
• Lock-Up function checking
• Lock-Up valve replacement
• Lock-Up solenoid replacement
• Front output shaft seal replacement
• Rear output shaft seal replacement
• Heat exchanger replacement

10. AXLES, HUB REDUCTIONS AND DIFFERENTIALS

The manual contains repair procedures for drivetrain and axle components.

Included operations:

• Axle removal
• Axle installation
• Differential lock adjustment
• Differential lock function checking
• Hub reduction removal
• Hub reduction installation
• Hub seal replacement
• Drive axle inspection references
• Transmission calibration error codes

11. BRAKING SYSTEM AND RBB

The braking section includes technical descriptions and repair procedures.

BRAKE SYSTEM COMPONENTS

• Service brakes
• Parking brake
• Foot brake valve
• Automatic brake valve
• Brake accumulators
• RBB braking system

BRAKE REPAIR PROCEDURES

• Brake accumulator checking
• Brake accumulator charging pressure checking
• Brake disc wear measurement
• Brake disc replacement
• Brake piston seal replacement
• Brake circuit pressure checking and adjustment
• Brake system hydraulic function testing
• Brake retardation testing
• Brake system bleeding
• Automatic brake function checking
• Foot brake valve reconditioning
• Parking brake disc and seal replacement
• Parking brake function checking

12. STEERING AND COMFORT DRIVE CONTROL (CDC)

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

STEERING COMPONENTS

• Steering valve
• Shift valve
• Secondary steering
• CDC control valve
• CDC angle sensor
• CDC solenoid valve
• Steering pressure monitor

STEERING REPAIR PROCEDURES

• Steering system functional checks
• Steering working pressure checking and adjustment
• Secondary steering pump pressure checking and adjustment
• CDC angle sensor replacement
• CDC control valve installation
• CDC solenoid valve replacement
• CDC servo pressure testing
• CDC lever steering function checking
• Steering valve replacement
• Shift valve removal and installation

13. HYDRAULIC PUMPS P1, P2 AND P3

The manual includes specifications and repair procedures for the machine's hydraulic pumps.

HYDRAULIC PUMP SERVICE

• Hydraulic pump P1 removal and installation
• Hydraulic pump P2 removal and installation
• Hydraulic pump P3 installation
• Maximum working pressure checking
• Maximum working pressure adjustment
• Standby pressure checking
• Standby pressure adjustment
• Load-sensing pressure checking
• Pump-related tightening torques

14. WORKING HYDRAULIC SYSTEM

The working hydraulic section describes the hydraulic equipment used for lifting, tilting, and attachment functions.

SYSTEM COMPONENTS

• Hydraulic oil tank
• Hydraulic pumps
• Central valve
• Control valves
• Servo system
• Hydraulic attachment bracket
• Hydraulic pressure monitors
• Lift function
• Tilt function
• Floating position

HYDRAULIC REPAIR PROCEDURES

• Hydraulic system bleeding
• Hydraulic oil tank vacuum pumping
• Central valve removal and installation
• Servo valve removal and installation
• Servo pressure testing
• Servo valve control adjustment
• Hydraulic system functional testing
• Hydraulic pressure adjustment

15. LIFT AND TILT ELECTRONIC CONTROLS

The manual includes service procedures for electronically controlled lift and tilt functions.

LIFT CONTROL

• Lift angle sensor replacement
• Lift solenoid valve replacement
• Lowering solenoid valve replacement
• Lift function testing
• Lifting time checking
• Lift shock valve checking

TILT CONTROL

• Tilt angle sensor replacement
• Tilt-in solenoid valve replacement
• Tilt-out solenoid valve replacement
• Tilt function checking

16. BOOM SUSPENSION SYSTEM (BSS)

The manual includes component descriptions, system explanations, and repair procedures for the Boom Suspension System.

Included topics:

• Boom Suspension System description
• BSS component descriptions
• Accumulator pressure checking
• Accumulator pressure adjustment
• Accumulator reconditioning
• Accumulator depressurization
• Left accumulator removal and installation
• Right accumulator removal and installation
• Pressure reduction and safety valve checking
• Pressure reduction and safety valve adjustment

17. AUXILIARY HYDRAULIC FUNCTIONS AND ATTACHMENT LOCKING

The manual contains service information for auxiliary hydraulic equipment.

Included topics:

• Third hydraulic function
• Fourth hydraulic function
• Auxiliary hydraulic pressure checking
• Auxiliary hydraulic pressure adjustment
• Auxiliary hydraulic shock valve checking
• Auxiliary hydraulic solenoid replacement
• Hydraulic attachment locking
• Attachment locking checks

18. AUTOMATIC LUBRICATION SYSTEM

The manual covers the automatic lubrication system and its associated components.

Included topics:

• Central lubrication system description
• Lubrication pump unit
• Dosage valves
• Lubrication interval adjustment
• Lubricant filling
• Automatic lubrication pump reconditioning
• Automatic lubrication system updates
• Lubrication system specifications

19. FIRE SUPPRESSION SYSTEM

An important feature of this manual is its documentation for the machine's fire suppression equipment.

Included topics:

• Fire suppression system component descriptions
• Fire suppression system functional descriptions
• Fire suppression system maintenance
• Actions after automatic activation
• Actions after manual activation
• Fire suppression system specifications

20. FRAME, AXLE SUSPENSION AND WHEELS

The frame section contains repair procedures for structural and suspension components.

Included operations:

• Frame joint clearance checking
• Frame joint bearing replacement
• Frame joint pin replacement
• Axle suspension bushing replacement
• Axle suspension seal replacement
• Front wheel removal and installation
• Rear wheel removal and installation

21. OPERATOR CAB AND ELECTRONIC CLIMATE CONTROL

The manual contains technical information for the operator cab, climate control system, and cab-mounted equipment.

CAB AND CLIMATE SYSTEMS

• Air conditioning
• Electronic Climate Control (ECC)
• Cab viscous suspension
• Pause heater
• Windows
• Cab electrical components

CAB REPAIR PROCEDURES

• Cab removal and installation
• Climate unit removal and installation
• Air conditioning compressor replacement
• Condenser replacement
• Evaporator replacement
• Expansion valve replacement
• Receiver replacement
• Air mix door actuator replacement
• Heater core replacement
• Heat control valve replacement
• Fan motor replacement
• ECC control unit replacement
• Windscreen replacement
• Side window replacement
• Door lock replacement
• Door lock cylinder replacement
• Viscous cab suspension replacement

22. ELECTRICAL WIRING DIAGRAMS

The manual includes an extensive collection of electrical wiring diagrams covering different systems and configurations.

Included diagram groups:

• Wiring diagrams 201–207
• Wiring diagrams 301–319
• Wiring diagrams 401–409
• Wiring diagram 501
• Wiring diagrams 601–604
• Wiring diagrams 801–807
• Wiring diagrams 901–915

Several wiring diagrams are included in multiple versions.

The electrical documentation also includes component lists, connector references, electrical symbols, and cable identification information.

23. COMPLETE HYDRAULIC DIAGRAMS

The hydraulic diagram section contains multiple versions of the complete machine hydraulic schematic.

Included documentation:

• Complete hydraulic diagram
• Complete hydraulic diagram versions 2–6
• Hydraulic diagram explanations

These diagrams support understanding of hydraulic circuit arrangements and system connections.

24. OPTIONAL EQUIPMENT INSTALLATION INSTRUCTIONS

The manual contains installation instructions for selected optional equipment.

HYDRAULIC AND CONTROL EQUIPMENT

• Third hydraulic function
• Hydraulic attachment locking
• Boom Suspension System
• CDC electric lever steering
• CDC hydraulic lever steering
• Single-lever control

COOLING AND ENGINE EQUIPMENT

• Axle oil cooler
• Reversible cooling fan
• Engine heater
• Additional fuel filter
• Oil-bath pre-cleaner
• Hand throttle
• Filtered alternator

CAMERAS AND VISIBILITY EQUIPMENT

• Forward-view camera
• Rear-view camera
• Front-view mirror
• Attachment work light
• Additional front work lights
• Rear work lights
• Rotating beacon

PROTECTION AND OTHER ACCESSORIES

• Front lighting protection
• Rear lighting protection
• Radiator grille guard
• Swing-out fender
• CareTrack

25. WORKSHOP SAFETY INFORMATION

The manual includes workshop safety guidance for servicing construction machinery.

Included topics:

• General service safety
• Hydraulic system safety
• Accumulator handling
• Battery safety
• Fuel and oil handling
• Air conditioning refrigerant safety
• Safe lifting and supporting
• Tyre handling
• Fire prevention
• Fire and heat exposure checks
• Working under a raised boom
• Environmental protection
• Waste handling
• Decontamination
• Booster battery starting

26. TECHNICAL SPECIFICATIONS

The manual contains specifications for major machine systems.

ENGINE

• Engine specifications
• Engine capacities
• Fuel feed pump specifications
• Injector checking
• Cooling system volume
• Cooling fan speed specifications
• Lubrication system specifications
• Valve mechanism specifications

ELECTRICAL SYSTEM

• Electrical system specifications
• 80 A alternator specifications
• Battery specifications
• Control unit information

TRANSMISSION AND AXLES

• Hydraulic transmission specifications
• Transmission capacity
• Transmission tightening torques
• Front axle specifications
• Rear axle specifications
• Axle oil capacities
• Propeller shaft tightening torques

BRAKES AND STEERING

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

HYDRAULICS

• Hydraulic pump P1 specifications
• Hydraulic pump P2 specifications
• Hydraulic pump P3 specifications
• Hydraulic system volume
• Servo system specifications
• Boom Suspension System specifications
• Control valve specifications
• Hydraulic connection tightening torques

ADDITIONAL REFERENCES

• Automatic lubrication system specifications
• Fire suppression system specifications
• Air conditioning specifications
• Refrigerant quantities
• Frame tightening torques
• Wheel tightening torques
• Recommended lubricants
• Conversion tables

PRACTICAL WORKSHOP APPLICATIONS

This manual can assist with operations such as:

• Diagnosing electronic control unit faults
• Programming replacement ECUs using VCADS Pro
• Checking engine compression
• Testing fuel system pressure
• Replacing fuel injectors
• Checking cooling fan hydraulic pressure
• Diagnosing transmission Lock-Up problems
• Testing differential lock operation
• Replacing hub seals
• Measuring brake disc wear
• Checking brake accumulator pressure
• Servicing CDC steering components
• Testing hydraulic pump standby pressure
• Checking lift and tilt angle sensors
• Servicing Boom Suspension System accumulators
• Maintaining the automatic lubrication system
• Reviewing fire suppression system service procedures
• Consulting electrical and hydraulic diagrams

WHO IS THIS MANUAL FOR?

This publication is suitable for:

• Volvo wheel loader service technicians
• Heavy equipment repair workshops
• Construction machinery fleet maintenance teams
• Diesel equipment mechanics
• Hydraulic and electrical system technicians
• Experienced Volvo L150F owners carrying out service and repair work

IMPORTANT COMPATIBILITY INFORMATION

This manual is identified for the Volvo L150F Wheel Loader.

Certain repair procedures, wiring diagrams, hydraulic arrangements, and optional equipment installation instructions may apply only to specific machine configurations.

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

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

DIGITAL PDF DELIVERY

This product is supplied as a digital PDF workshop manual.

The publication includes:

• 1,951 pages of technical documentation
• Engine and electronic fuel injection information
• E-ECU, V-ECU, V2-ECU, I-ECU and ECC documentation
• VCADS Pro diagnostics and programming references
• Hydraulic transmission and Lock-Up system information
• RBB braking system descriptions
• CDC steering service procedures
• Hydraulic pump P1, P2 and P3 specifications
• Lift and tilt electronic control procedures
• Boom Suspension System documentation
• Automatic lubrication system information
• Fire suppression system service references
• Extensive electrical wiring diagrams
• Complete hydraulic diagrams
• Optional equipment installation instructions
• Workshop safety information
• Technical specifications and tightening torques

Digital product only. No printed manual will be shipped.

A compatible PDF reader is required to view the document.

IMPORTANT DOWNLOAD INFORMATION

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

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Detailed contents:

Descriptions
(1) STANDARD PARTS, SERVICE
Charging of batteries
Cleanliness, brake and hydraulic systems
Electric welding 2
Electric welding
Maintenance service, fire suppression system
Repairing hydraulic system
Working on the electrical system of the machine
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Accelerator Pedal
Air cleaner, description
Auxiliary brake (engine braking), description
Cooling fan motor, description
Cooling fan, description
Cooling system, description
Engine, description
Fuel filter, description
Fuel system, description
Hand Throttle
Instructions for working with electronic fuel injection
Intake and exhaust system, description
Intercooler, description
Internal Exhaust Gas Recirculation (IEGR), description
Lubrication system, description
Preheating, description
Reversible cooling fan, description
Turbocharger, description 2
Turbocharger, description
Unit injector, Delphi, description
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
CareTrack W-ECU, description
Central warning
Alarm, description
Information display, check 02
Information display, settings
Information display, service mode 2
Information display, service mode
Information display, service 2
Information display, service
Information display, vehicle messages
Information display, vehicle info
Information display, electrical system 2
Information display, electrical system
Information display, axles brakes 2
Information display, axles .brakes
Information display, hydraulics 2
Information display, hydraulics
Information display, transmission
Information display, engine
Information display, operating display
Information display, start lockout
Information display, general
Machine hours
Travelling speed
Fuel consumption
Washer fluid level
Middle instrument panel with warning lights
Instrument panels
Chassis connection
Battery disconnector switch, description
V2-ECU, I O list
V-ECU, I O list
I-ECU, I O list
E-ECU, I O list
ECC, I O list
Component list Switches
Component list Solenoid valves
Component list Signals, shift solenoids
Component list Sensors
Component list Relays
Component list PWM valves
Component list Motors, resistors, monitoring system
Component list Lights
Component list Heating coils, instruments, service socket
Component list Fuses
Component list, diodes
Component list Alternator, batteries, capacitors, electronic units, voltage outlet
Cable and component marking explanations 2
Cable and component marking explanations
Cable and component designations
Electrical symbols and designations
Engine control unit E-ECU, description
Vehicle control unit V2-ECU, description
Vehicle control unit V-ECU, description
Instrument control unit I-ECU, functional description
Electronic climate control unit ECC, description
Connectors, overview
Theft protection
Intermittent wiper and washer
Limp Home
Interruption in computer communication
Reduced computer communication
Lighting, description
Preheating, description
Booting sequence
Alternator 80 A, description
Battery, charging
Battery, description
Key feed
System voltage
VCADS Pro service tool
VCADS Pro, Error codes
Special tools for troubleshooting
Troubleshooting tools
Lead and connector checks
Conditions when checking
Bus communication supervision
Communication with data buses 2
SAE error codes, translation to error messages, general
Information display, check
Collection of basic data
Troubleshooting strategy
General fault diagnosis information
Software parameters, description
Communication with data buses
Electronic control system, description
Software, description
Electrical system, description
Electrical system, work instructions
(4) POWER TRANSMISSION
Automatic differential brake, Limited Slip, description
Differential lock, description 2
Differential lock, description
Drive axles, description 2
Drive axles, description
Hydraulic transmission, description
Lock up, description
RBB, description
(5) BRAKE
Automatic brake valve, description
Brake accumulator, description
Braking system with RBB, description
Braking system, description 2
Braking system, description
Foot brake valve, description
Parking brake, description 2
Parking brake, description
(6) STEERING
CDC valve, lever steering, description
Comfort Drive Control (CDC), description
Pressure monitor, description
Secondary steering, description
Shift valve, description
Steering valve, description
Steering system, description
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Frame joint, description
Frame, description
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, description
Pause heater, description 2
Pause heater, description
Troubleshooting, air conditioning unit (AC)
Viscous cab suspension, description
Windows, general
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
Boom Suspension System, component description
Boom Suspension System, description 2
Boom Suspension System, description
Central lubrication system, description
Central valve, description
Change of lubrication interval
Control valve, description 2
Control valve, description 3
Control valve, description
Diagnostic tools, description
Dosage valves, description
Filling lubricant
Fire suppression system, component description
Fire suppression system, functional description
Floating position, description
Hydraulic attachment bracket, description
Hydraulic oil tank, description
Hydraulic pump flow regulation, description
Hydraulic pumps, description
Hydraulic system, description
Lift function, description 2
Lift function, description
Pressure monitor, description
Pump unit, description
Shift valve, description
Software, parameter settings and read-outs
Tilt function, description
TP-Linkage’s bearing points
Diagrams
(4) POWER TRANSMISSION
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Table of contents, wiring diagrams
Wiring diagram 201
Wiring diagram 202
Wiring diagram 203
Wiring diagram 204
Wiring diagram 205
Wiring diagram 206
Wiring diagram 207
Wiring diagram 301 2
Wiring diagram 301 3
Wiring diagram 301
Wiring diagram 302 2
Wiring diagram 302 3
Wiring diagram 302
Wiring diagram 303
Wiring diagram 304
Wiring diagram 305
Wiring diagram 306
Wiring diagram 308
Wiring diagram 309
Wiring diagram 310
Wiring diagram 311 2
Wiring diagram 311 3
Wiring diagram 311
Wiring diagram 312
Wiring diagram 313
Wiring diagram 314 2
Wiring diagram 314
Wiring diagram 315 2
Wiring diagram 315 3
Wiring diagram 315
Wiring diagram 316
Wiring diagram 317
Wiring diagram 319
Wiring diagram 401 2
Wiring diagram 401
Wiring diagram 402
Wiring diagram 403 2
Wiring diagram 403
Wiring diagram 404
Wiring diagram 405
Wiring diagram 407
Wiring diagram 408 2
Wiring diagram 408
Wiring diagram 409
Wiring diagram 501 2
Wiring diagram 501 3
Wiring diagram 501
Wiring diagram 601 2
Wiring diagram 601
Wiring diagram 602 2
Wiring diagram 602
Wiring diagram 604 2
Wiring diagram 604
Wiring diagram 801
Wiring diagram 802
Wiring diagram 804 2
Wiring diagram 804
Wiring diagram 805 2
Wiring diagram 805
Wiring diagram 806 2
Wiring diagram 806
Wiring diagram 807
Wiring diagram 901 2
Wiring diagram 901
Wiring diagram 902 2
Wiring diagram 902
Wiring diagram 903
Wiring diagram 904
Wiring diagram 909
Wiring diagram 910
Wiring diagram 911 2
Wiring diagram 911
Wiring diagram 912 2
Wiring diagram 912
Wiring diagram 913
Wiring diagram 915
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
Explanations to hydraulic diagram
Hydraulic diagram, complete 2
Hydraulic diagram, complete 3
Hydraulic diagram, complete 4
Hydraulic diagram, complete 5
Hydraulic diagram, complete 6
Hydraulic diagram, complete
Installation Instruction
3rd hydraulic function, installing new
Attachment locking, installing new
Attachment work light, installing new
Axle oil cooler and reversilble fan, installing new 2
Axle oil cooler and reversilble fan, installing new
Boom suspension system, installing new
caretrack 2
caretrack
Engine heater, (230 V)
Filtered alternator, installing new
Forward view camera, installing new
Front view mirror, installing new
Fuel filter extra, installing new
Hand throttle, installing new
heated and adjustible
Lever steering (CDC), electric, installing new
Lever steering (CDC), hydraulic, installing new 2
Lever steering (CDC), hydraulic, installing new
Pre-cleaner oil-bath type
Protection for lighting, front, installing new
Protection for lighting, rear, installing new
Radiator grille guard, installing new
Rear view camera, installing new
Rotating beacon, installing new
Single lever control, installing new 2
Single lever control, installing new
Swing out fender, 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
E 1708, Checking point
E1680, Holder
E1711
E-2000
E-2001
E2003
E-2005
E-2017
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
Boom suspension accumulator, checking and adjusting
Brake discs, measuring wear 2
Brake discs, measuring wear
Hydraulic pump, max working pressure, checking and adjusting 2
Hydraulic pump, max working pressure, checking and adjusting
Parking brake, manually releasing
Steering system working pressure, checking and adjusting 2
Steering system working pressure, checking and adjusting 3
Steering system working pressure, checking and adjusting
Towing
Transmission oil pressure, checking 2
Transmission oil pressure, checking 3
Transmission oil pressure, checking 4
Transmission oil pressure, checking 5
Transmission oil pressure, checking
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope
Camshaft, checking wear
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, checking
Charge air system, inspection
Cooling fan hydraulics, funktion check
Cooling fan motor, replacing
Cylinder compression, testing 2
Cylinder compression, testing
Cylinder compression, VCADS Pro
Cylinder compression, VCADS Pro2
E-ECU MID 128 non-programmed, replacing
E-ECU MID 128 pre-programmed, replacing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor, replacing
Engine, installing 2
Engine, installing
Engine, removing 2
Engine, removing
Fan control valve, installing
Fan control valve, removing
Fan control valve, seal replacing
Feed pump pressure, checking
Fuel pump (valves), inspecting
Fuel pump, inspecting
Fuel system, bleeding
Idle, VCADS Pro
Injectors, replacing
Lubrication oil pressure, checking with pressure gauge
Pump 3 (P3) standby pressure, checking and adjusting (LS-line removed)
Pump 3 (P3), max pressure and fan speed, checking and adjusting
Radiator, replacing
Rocker arm mechanism removed, reconditioning
Stall speed, VCADS Pro 2
Stall speed, VCADS Pro
Valves, adjusting 2
Valves, adjusting
VCADS Pro, central systems updating, replace component
VCADS Pro, MID 128, programming E-ECU
VCADS Pro, Operations
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Batteries, replacing
Battery condition, checking
I-ECU MID 140 non-programmed, replacing
I-ECU MID 140 pre-programmed, replacing
Starter lock, replacing
VCADS Pro, Operations
V-ECU MID 187 non-programmed, replacing
V-ECU MID 187 pre-programmed, replacing
(4) POWER TRANSMISSION
Axle, installing
Axle, removing
Differential lock, adjusting
Differential lock, function check
Error codes when calibrating
Heat exchanger, replacing
Hub reduction, installing 2
Hub reduction, installing 3
Hub reduction, installing
Hub reduction, removing 2
Hub reduction, removing
Hub seal, replacing 2
Hub seal, replacing
Lock up valve, replacing
Lock up, function check
Lock up, solenoid valve, replacing
Main pressure valve, replacing
Seal for front output shaft, replacing
Seal for rear output shaft, replacing
Transmission oil pressure, checking
Transmission pressure sensor, replacing
Transmission solenoid, replacing
Transmission, functional check
Transmission, installing
Transmission, removing
VCADS Pro, Operations
(5) BRAKE
Accumulator (removed) charging pressure, checking
Accumulator, checking
Accumulator, discarding
Automatic brake function, checking
Brake disc, replacing
Brake discs, measuring wear 2
Brake discs, measuring wear
Brake discs, replacing
Brake pedal, adjusting angle
Brake piston seals, replacing 2
Brake piston seals, replacing
Brake system circuit pressure, checking and adjusting
Brake system hydraulic function, checking
Brake system retardation function, checking
Brake system, bleeding
Foot brake valve removed, reconditioning
Foot brake valve, installing
Foot brake valve, removing
Parking brake discs and seals, replacing
Parking brake function, checking
VCADS Pro, Operations
(6) STEERING
Accumulator, discarding
Comfort drive control (CDC) angle sensor, changing
Comfort drive control (CDC) control valve, installing
Comfort drive control (CDC) solenoid valve, changing 2
Comfort drive control (CDC) solenoid valve, changing
Comfort Drive Control, servo pressure, checking
Error codes when calibrating
Lever steering (CDC) function, checking
Secondary steering pump working pressure, checking and adjusting
Shift valve, installing
Shift valve, removing
Steering system function, checking
Steering system working pressure, checking and adjusting
Steering valve, replacing
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Axle suspension, replacing bushes and seals
Frame joint clearance, checking
Frame joint, changing bearings and pins
Front wheel, installing
Front wheel, removing
Rear wheel, installing
Rear wheel, removing
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Air mix door actuator, replacing
Cab, installing 2
Cab, installing
Cab, removing 2
Cab, removing
Climate unit, installing
Climate unit, removing
Compressor, replacing incl draining and filling
Condenser, replacing incl draining and filling
Door lock cylinder, replacing 2
Door lock cylinder, replacing
Door lock, replacing
ECC (Electronic Climate Control), replacing 2
ECC (Electronic Climate Control), replacing
ECC MID 146 non-programmed ECU, replacing
ECC MID 146 pre-programmed ECU, replacing
Engine hood, installing
Engine hood, removing
Evaporator, replacing incl draining and filling
Expansion valve, replacing incl draining and filling
Fan motor, replacing
Heat control valve, replacing
Heater core, replacing 2
Heater core, replacing
Operator’s seat, securing
Receiver, replacing incl draining and filling 2
Receiver, replacing incl draining and filling
Side window, replacing 2
Temperature sensor cooling system, replacing
Viscous cab suspension, changing one unit
Windscreen, replacing
(9) HYDRAULIC SYSTEM;DIGGING HANDLING GRADING 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
Accumulator removed, checking
Accumulator, boom suspension system, discarding
Accumulator, checking (pressure back-up for servo circuit)
Accumulator, discarding 2
Accumulator, discarding
Attachment locking, checking
Automatic lubrication pump unit, reconditioning
Back-up valve, checking and adjusting
Bleeding air
Boom suspension accumulator, checking and adjusting
Boom suspension accumulator, reconditioning
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom suspension system, left accumulator, installing
Boom suspension system, left accumulator, removing
Boom suspension system, pressure reduction, safety valve, checking and adjusting
Boom suspension system, right accumulator, installing
Boom suspension system, right accumulator, removing
Central valve, installing
Central valve, removing
Error codes when calibrating
Fire suppression system, actions after activation
Fire suppression system, actions after manual activation
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic pump P1, installing
Hydraulic pump P1, removing
Hydraulic pump P2, installing 2
Hydraulic pump P2, installing
Hydraulic pump P2, removing
Hydraulic pump P3, installing
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 system, bleeding
Lift lower, angle sensor, changing 2
Lift lower, angle sensor, changing
Lift, functional check
Lift, solenoid valve, changing
Lifting time, checking
Lower, solenoid valve, changing
LS (load sense) pressure, checking
Servo accumulator, installing
Servo accumulator, removing
Servo pressure, at the spool in control valve, checking 2
Servo pressure, at the spool in control valve, checking
Servo pressure, checking and adjusting
Servo valve, control, adjusting
Servo valve, installing
Servo valve, removing
Shock valve lift function, checking
System test
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! (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 (2)
Service position 1
Service position 2 (2)
Service position 2
Some simple rules regarding tyre handling (2)
Some simple rules regarding tyre handling
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
Working under raised boom
(9) HYDRAULIC SYSTEM;DIGGING HANDLING GRADING EQUIPM.; MISC. EQUIP.
Specifications
(0) GENERAL
3rd 4th hydraulic function, specifications
Air conditioning, refrigerant, weight
Air conditioning, tightening torques
Alternator 80 A, specification
Axle suspension, tightening torques
Battery, specifications
Battery, weight
Boom Suspension System, specifications
Boom Suspension System, tightening torques
Brake accumulator, specifications
Brake system, specifications
Brake valve, tightening torques
Cab, tightening torque
Control valve, lever steering (CDC), specifications
Control valve, specifications
Conversion tables (2)
Conversion tables
Cooling fan rpm, specifications (2)
Cooling fan rpm, specifications
Cooling system, volume
Electrical system, specifications
Engine management system
Engine, capacities
Engine, specifications (2)
Engine, specifications (3)
Engine, specifications
Frame joint, tightening torques
Frame, tightening torque
Front and rear axles, specifications
Front and rear axles, tightening torque
Front and rear axles, volume
Fuel feed pump, specifications
Fuel system, tightening torques
Hydraulic connections, tightening torques
Hydraulic pump (P1), specifications
Hydraulic pump (P2), specifications
Hydraulic pump (P3), specifications
Hydraulic pumps, tightening torques
Hydraulic system, volume
Hydraulic transmission, capacity
Hydraulic transmission, specifications (2)
Hydraulic transmission, specifications (3)
Hydraulic transmission, specifications
Hydraulic transmission, tightening torques
Lever steering (CDC), specifications
Lubrication system, specifications
Parking brake, specifications
Preheating, specifications
Propeller shaft, tightening torque
Rear axle mounting, volume
Rocker arm shaft, tightening torques
Secondary steering pump, specifications
Service brakes, specifications (2)
Service brakes, specifications
Servo system, specifications
Starter motor, specifications
Steering cylinder, tightening torque
Steering, specifications
Temperature limits for cooling fan speed, specifications.
Thermostat, specifications
Tightening torques, cooling fan
Tightening torques
Valve cover, tightening torque
Valve mechanism, double rocker arm
Valve mechanism, tightening torques
Valve system, specification
Wheel brake, tightening torques
Wheels, tightening torques
(1) STANDARD PARTS, SERVICE
Alternative fuels
Recommended lubricants, oils
Service brakes, specifications
Wheel brake, specification
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Cooling fan rpm, specifications
Cooling system, volume
Engine, capacities
Engine, specifications (2)
Engine, specifications
Fuel feed pump, specifications
Fuel system, tightening torques
Hydraulic pump (P3), specifications
Injectors, checking
Lubrication system, specifications
Temperature limits for cooling fan speed, specifications.
Thermostat, specifications
Tightening torques, cooling fan
Valve cover, tightening torque
Valve mechanism, tightening torques
Valve system, specification (2)
Valve system, specification
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator 80 A, specification
Battery, specifications
Battery, weight
Electrical system, specifications
(4) POWER TRANSMISSION
Front and rear axles, specifications
Front and rear axles, tightening torque
Front and rear axles, volume (2)
Front and rear axles, volume
Hydraulic transmission, capacity
Hydraulic transmission, specifications (2)
Hydraulic transmission, specifications (3)
Hydraulic transmission, specifications
Hydraulic transmission, tightening torques (2)
Hydraulic transmission, tightening torques (3)
Hydraulic transmission, tightening torques (4)
Hydraulic transmission, tightening torques
Propeller shaft, tightening torque
(5) BRAKE
Brake accumulator, specifications
Brake system, specifications
Brake valve, tightening torques
Parking brake, specifications
Service brakes, specifications
Wheel brake, specification
Wheel brake, tightening torques
(6) STEERING
Control valve, lever steering (CDC), specifications
Lever steering (CDC), specifications
Secondary steering pump, specifications
Steering cylinder, tightening torque
Steering, specifications
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Axle suspension, tightening torque
Frame joint, tightening torques
Frame, tightening torque
Wheels, tightening torques
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, refrigerant, weight
Air conditioning, specifications
Air conditioning, tightening torques
Cab, tightening torque
(9) HYDRAULIC SYSTEM;DIGGING HANDLING GRADING EQUIPM.; MISC. EQUIP.
3rd 4th hydraulic function, specifications
Automatic lubrication system, specifications
Boom Suspension System, tightening torques
Control valve, specifications
Fire suppression system, specification
Function times, specifications
Hydraulic connections, tightening torques
Hydraulic pump (P1), specifications
Hydraulic pump (P2), specifications
Hydraulic pumps, tightening torques
Hydraulic system, volume
Recommended lubricants
Servo system, specifications