VOLVO L350H WHEEL LOADER SERVICE REPAIR MANUAL PDF – 2020

The Volvo L350H Wheel Loader Service Repair Manual provides extensive technical documentation for servicing, diagnosing, maintaining, adjusting, and repairing the Volvo L350H wheel loader.

This PDF technical manual, with information dated 2020, covers the engine, fuel system, exhaust aftertreatment equipment, electrical and electronic controls, hydraulic transmission, drive axles, brakes, steering, operator cab, and working hydraulic systems.

The documentation includes detailed system descriptions, mechanical repair procedures, component removal and installation instructions, diagnostic references, electrical wiring diagrams, hydraulic circuit diagrams, technical specifications, safety procedures, and installation instructions for selected optional equipment.

Special attention is given to the AdBlue/DEF system, Diesel Particulate Filter (DPF), Exhaust Gas Recirculation (EGR), Selective Catalytic Reduction (SCR), Comfort Drive Control (CDC), Boom Suspension System (BSS), CareTrack, and electronically controlled hydraulic equipment.

This manual is a practical technical resource for professional mechanics, heavy equipment repair workshops, construction machinery maintenance technicians, fleet maintenance departments, and Volvo L350H wheel loader owners.

MANUAL DETAILS

• Manufacturer: Volvo Construction Equipment
• Equipment Model: L350H Wheel Loader
• Manual Type: Service Repair Manual
• File Format: PDF
• Documentation Year: 2020
• Delivery: Digital Download

WHAT IS INCLUDED IN THIS SERVICE REPAIR MANUAL?

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

1. ENGINE SYSTEM DESCRIPTION

The engine section explains the operation of major engine systems and associated components.

ENGINE OPERATION AND CONTROL

• Engine descriptions and reference values
• Engine fuel system
• Engine lubrication system
• Engine cooling system
• Cooling fan operation
• Reversible cooling fan
• Cooling fan motor
• Crankcase ventilation
• ECO accelerator pedal
• Auxiliary engine braking
• Air intake and exhaust system

EXHAUST AFTERTREATMENT

• Exhaust Aftertreatment System descriptions
• AdBlue/DEF pump diagnostics
• Exhaust aftertreatment fuel system diagnostics
• Exhaust Gas Recirculation (EGR)
• Internal Exhaust Gas Recirculation (IEGR)
• Regeneration process
• Fuel injector inspection

ENGINE DIAGNOSTICS

• Engine reference values
• Volvo Tech Tool operations
• Diagnostic procedures and system descriptions

2. ENGINE SERVICE AND MECHANICAL REPAIR

The repair section contains procedures for inspecting, adjusting, removing, installing, and replacing major engine components.

ENGINE MECHANICAL COMPONENTS

• Engine removal and installation
• Engine mounting replacement
• Camshaft timing checks
• Camshaft replacement
• Crankshaft front oil seal replacement
• Crankshaft rear oil seal replacement
• Cylinder compression testing
• Rocker arm replacement
• Valve adjustment
• Engine belt replacement
• Engine rotation speed sensor replacement
• Damper bearing and rubber bellows replacement

FUEL SYSTEM SERVICE

• Fuel system air checks
• Fuel system bleeding
• Feed pump pressure testing
• Feed pump replacement
• Fuel injector replacement
• Injector sleeve replacement
• Fuel system component inspections

ENGINE COOLING AND LUBRICATION

• Cooling system pressure testing
• Cooling fan motor replacement
• Fan control valve seal replacement
• Radiator replacement
• Engine oil pressure testing
• Engine oil consumption checks
• Oil cooler leakage checks
• Oil cooler replacement
• Oil level sensor replacement

TURBOCHARGER AND EXHAUST

• Turbocharger inspection
• Turbocharger replacement
• Variable turbocharger actuator replacement
• Wastegate actuator replacement
• Inlet throttle replacement
• Exhaust flexible pipe replacement
• Muffler replacement
• Silencer removal and installation

3. ADBLUE/DEF AND EXHAUST AFTERTREATMENT REPAIR

The manual contains dedicated service procedures for the engine emissions control equipment.

ADBLUE/DEF SYSTEM

• AdBlue/DEF pump unit replacement
• AdBlue/DEF pump component replacement
• AdBlue/DEF hose replacement
• AdBlue/DEF nozzle replacement
• AdBlue/DEF tank cleaning
• AdBlue/DEF tank armature replacement
• AdBlue/DEF quality testing
• AdBlue/DEF draining

DPF, EGR AND SCR SYSTEMS

• Diesel Particulate Filter (DPF) inspection and cleaning
• EGR cooler pressure testing
• EGR cooler replacement
• EGR valve replacement
• Internal EGR valve replacement
• EGR venturi tube cleaning
• EGR venturi tube replacement
• SCR dosing system inspection
• Aftertreatment fuel dosing unit replacement
• Aftertreatment fuel nozzle cleaning and replacement
• Exhaust aftertreatment fuel flow testing
• NOx sensor replacement

ELECTRONIC ENGINE CONTROLS

• Engine Control Module (ECM) replacement
• Aftertreatment Control Module (ACM) replacement
• Pre-programmed and non-programmed control module replacement procedures

4. ELECTRICAL AND ELECTRONIC CONTROL SYSTEMS

The electrical section provides information about the machine's electrical architecture, control modules, sensors, connectors, and diagnostic functions.

ELECTRICAL EQUIPMENT

• Electrical system descriptions
• Electrical distribution box
• Batteries and charging system
• Alternator
• Starter motor
• Battery disconnector switch
• Electrical component identification
• Cable and connector markings
• Chassis connections
• Electrical symbols and designations

ELECTRONIC CONTROL MODULES

• Engine Control Module (ECM)
• Aftertreatment Control Module (ACM)
• Climate Control Module (CCM)
• Transmission Electronic Control Unit (T-ECU)
• GPMECU1
• GPMECU2
• GPMECU3
• HMICU
• W-ECU

The documentation includes input and output lists for several electronic control modules.

ELECTRONIC DIAGNOSTICS

• Electronic control system operation
• General fault diagnosis information
• Troubleshooting strategy
• Troubleshooting tools
• Electrical lead and connector checks
• Software parameter information
• Information display service mode
• Limp-home operation
• Volvo Tech Tool operations

5. ELECTRICAL WIRING DIAGRAMS

A major feature of this publication is its extensive collection of numbered electrical wiring diagrams.

INCLUDED DIAGRAM SERIES

• WD201–WD224 series
• WD301–WD337 series
• WD350–WD375 series
• WD401–WD405 series
• WD501
• WD601–WD604 series
• WD801–WD831 series
• WD903–WD913 series

The documentation also includes a wiring diagram table of contents.

These diagrams support electrical circuit identification, component connection checks, and troubleshooting of the machine's electrical and electronic systems.

6. POWER TRANSMISSION AND DRIVE AXLES

The power transmission section covers the hydraulic transmission, driveline, axles, and associated components.

TRANSMISSION SYSTEM

• Hydraulic transmission operation
• Hydraulic transmission calibration
• Transmission hydraulic diagram
• Transmission removal and installation
• Transmission function testing
• Transmission oil pressure testing
• Transmission warm-up procedures
• Gear selector solenoid replacement
• Lock-up valve replacement
• Transmission heat exchanger replacement
• Transmission output shaft speed sensor replacement
• Transmission calibration error codes

DRIVE AXLES AND DRIVELINE

• Drive axle descriptions
• Front axle components
• Rear axle components
• Propeller shaft components
• Limited-slip differential operation
• Axle removal and installation
• Axle suspension bush, bearing, and seal replacement
• Hub reduction removal and installation

7. BRAKE SYSTEM SERVICE AND REPAIR

The braking system section provides technical descriptions and service procedures for the machine's braking equipment.

BRAKE SYSTEM COMPONENTS

• Service brake system
• Brake accumulators
• Foot brake valve
• Parking brake
• Axle oil cooler

BRAKE SERVICE PROCEDURES

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

8. STEERING SYSTEM AND COMFORT DRIVE CONTROL

The steering section contains technical descriptions, calibration information, and repair procedures.

STEERING COMPONENTS

• Steering system
• Steering control valve
• Steering cylinders
• Secondary steering
• External priority valve
• Steering pressure monitor
• Steering shift valve
• Steering accumulator

COMFORT DRIVE CONTROL (CDC)

• CDC system operation
• CDC calibration
• CDC lever steering valve
• CDC joystick replacement
• CDC angle sensor replacement
• CDC solenoid valve replacement
• CDC servo pressure testing
• CDC function checks

STEERING REPAIR PROCEDURES

• Left steering cylinder removal and installation
• Right steering cylinder removal and installation
• Steering accumulator inspection
• Steering accumulator removal and installation
• Steering system function checks
• Steering working pressure testing and adjustment
• Secondary steering pump pressure testing and adjustment

9. FRAME, WHEELS AND STRUCTURAL COMPONENTS

This section provides information for selected structural components.

Included topics:

• Frame joint descriptions
• Frame joint bearing replacement
• Counterweight removal and installation
• Front wheel removal and installation
• Rear wheel removal and installation

10. OPERATOR CAB AND AIR CONDITIONING

The cab section covers climate control equipment, operator comfort components, and selected exterior assemblies.

CAB EQUIPMENT

• Electric door opener
• Viscous cab suspension
• Engine hood removal and installation
• Door lock cylinder replacement
• Windscreen replacement
• Window installation
• Operator seat securing

AIR CONDITIONING AND HEATING

• Air conditioning system operation
• Climate control system description
• Air conditioning performance checks
• Air conditioning troubleshooting
• Climate Control Module (CCM) replacement
• Climate unit removal and installation
• Air conditioning compressor replacement
• Condenser replacement
• Evaporator replacement
• Expansion valve replacement
• Heater core replacement
• Heat control valve replacement
• Fan motor replacement
• Refrigerant filling and vacuum pumping
• Cooling unit leak detection

11. WORKING HYDRAULIC SYSTEM

The hydraulic section contains detailed information about hydraulic pumps, control valves, servo systems, lift and tilt cylinders, and pressure regulation.

HYDRAULIC SYSTEM COMPONENTS

• Hydraulic oil tank
• Hydraulic pumps
• Hydraulic pump flow regulation
• Central hydraulic valve
• Main hydraulic control valve
• Servo hydraulic system
• Hydraulic pressure monitoring
• Hydraulic lift cylinders
• Hydraulic tilt cylinders

HYDRAULIC PUMP SERVICE

• Hydraulic pump P1 removal and installation
• Hydraulic pump P2 removal and installation
• Hydraulic pump P3 inspection
• Hydraulic pump P3 removal and installation
• Hydraulic standby pressure testing
• Hydraulic working pressure testing and adjustment
• Load-sensing pressure checks
• Servo pressure testing and adjustment

HYDRAULIC CYLINDERS AND CONTROL VALVES

• Lift cylinder seal replacement in the machine
• Tilt cylinder seal replacement in the machine
• Tilt cylinder replacement
• Lift and lower function testing
• Tilt function testing
• Lift and tilt angle sensor replacement
• Lift and lower solenoid valve replacement
• Tilt solenoid valve replacement
• Hydraulic shock valve testing
• Load-sensing disconnecting solenoid valve replacement

HYDRAULIC ATTACHMENT EQUIPMENT

• Hydraulic attachment locking
• Attachment locking checks
• Bucket removal and installation
• Lift frame bearing replacement
• Z-Linkage bearing points

12. BOOM SUSPENSION SYSTEM (BSS)

The manual contains dedicated information for the Boom Suspension System.

Included topics:

• Boom Suspension System description
• Boom suspension components
• Boom suspension accumulator inspection
• Accumulator pressure adjustment
• Accumulator reconditioning
• Left accumulator removal and installation
• Right accumulator removal and installation
• Hydraulic accumulator depressurization
• Boom suspension safety valve testing and adjustment
• Boom Suspension System function checks

13. THIRD AND FOURTH HYDRAULIC FUNCTIONS

The documentation includes information for additional hydraulic functions.

Included topics:

• Third hydraulic function
• Fourth hydraulic function
• Hydraulic function calibration
• Hydraulic shock valve testing
• Hydraulic solenoid valve replacement
• Hydraulic function checks
• Hydraulic attachment locking
• Electric servo lever control

14. CENTRAL LUBRICATION SYSTEM

The manual includes technical information for the automatic lubrication equipment.

Included topics:

• Central lubrication system operation
• Lubrication points
• Lubricant filling
• Lubrication interval adjustment
• Automatic lubrication pump unit reconditioning
• Automatic lubrication system updates

15. ELECTRICAL AND HYDRAULIC CIRCUIT DIAGRAMS

The documentation contains technical diagrams for major machine systems.

ELECTRICAL DIAGRAMS

• Numbered wiring diagrams
• Electrical component identification
• Electrical circuit references

HYDRAULIC DIAGRAMS

• Hydraulic transmission diagram
• Complete working hydraulic system diagram
• Hydraulic diagram explanations

These diagrams help technicians understand system operation and identify electrical and hydraulic connections.

16. EQUIPMENT INSTALLATION INSTRUCTIONS

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

Included topics:

• Third hydraulic function installation
• 24V electrical connector installation
• Front LED working lights
• Rear LED working lights
• CareTrack equipment
• Emergency stop installation
• 120V engine heater installation
• 240V engine heater installation
• Forward-view camera installation
• Hand throttle installation
• Multi-lever hydraulic control installation
• Single-lever hydraulic control installation
• Cyclone-type air pre-cleaner installation
• Oil-bath air pre-cleaner installation
• Radio installation
• Rear-view mirror installation
• Rotating warning beacon installation
• Flashing strobe warning beacon installation

17. SAFETY AND WORKSHOP PROCEDURES

The manual includes a dedicated safety section.

Included topics:

• General service safety rules
• Machine handling precautions
• Safe lifting and supporting
• Working under a raised boom
• Hydraulic system safety
• Battery safety
• Electrical system safety
• Air conditioning refrigerant precautions
• Fuel and oil handling
• Tyre handling
• Fire prevention
• Fire and heat exposure inspections
• Environmental protection
• Hazardous fluid handling
• Waste disposal
• Machine towing
• Booster battery starting
• Service positions

18. TECHNICAL SPECIFICATIONS AND SERVICE DATA

The specifications section provides technical reference information for major machine systems.

ENGINE SPECIFICATIONS

• Engine specifications
• Engine capacities
• Fuel system specifications
• Cooling system specifications
• Lubrication system specifications
• Cooling fan speed references
• Engine tightening torques

ELECTRICAL SPECIFICATIONS

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

TRANSMISSION AND BRAKES

• Transmission specifications
• Transmission capacity
• Front and rear axle specifications
• Axle oil volumes
• Brake system specifications
• Brake accumulator specifications
• Parking brake specifications

STEERING AND HYDRAULICS

• Steering system specifications
• CDC calibration specifications
• Hydraulic pump P1 specifications
• Hydraulic pump P2 specifications
• Hydraulic pump P3 specifications
• Hydraulic system volume
• Control valve specifications
• Servo system specifications
• Boom Suspension System specifications
• Working hydraulic calibration specifications

GENERAL REFERENCE INFORMATION

• Recommended lubricants
• Coolant recommendations
• Alternative fuels
• AdBlue/DEF specifications
• Standard tightening torques
• Component tightening torques

DIAGNOSTICS AND TROUBLESHOOTING

The Volvo L350H manual contains diagnostic and troubleshooting references for:

• Engine operation
• Fuel injection
• Exhaust aftertreatment
• AdBlue/DEF equipment
• DPF and EGR systems
• Electronic control modules
• Electrical wiring and connections
• Transmission operation and calibration
• Brake system pressure and function
• Steering and CDC
• Hydraulic pumps and control valves
• Lift and tilt equipment
• Air conditioning
• Automatic lubrication

The documentation also includes Volvo Tech Tool operations for selected machine systems.

BENEFITS OF THIS SERVICE REPAIR MANUAL

This publication can help users:

• Access Volvo L350H technical service documentation
• Perform engine inspection and repair procedures
• Maintain AdBlue/DEF, DPF, EGR, and SCR equipment
• Diagnose electronic control systems
• Consult electrical wiring diagrams
• Service the transmission and drive axles
• Inspect and repair brake and steering components
• Maintain Comfort Drive Control equipment
• Test hydraulic pressures and service hydraulic components
• Maintain the Boom Suspension System
• Repair lift and tilt hydraulic equipment
• Install selected optional equipment
• Follow workshop safety procedures
• Consult technical specifications and tightening torques

WHO IS THIS MANUAL FOR?

This publication is suitable for:

• Professional Volvo construction equipment mechanics
• Heavy equipment service technicians
• Construction machinery repair workshops
• Fleet maintenance departments
• Equipment maintenance companies
• Volvo L350H wheel loader owners responsible for servicing and repairs

IMPORTANT COMPATIBILITY INFORMATION

This manual is identified for the Volvo L350H Wheel Loader.

The documentation may include procedures and diagrams for different equipment configurations and optional systems.

Before purchasing, verify the machine model, serial number, installed equipment, and relevant configuration.

Some procedures may apply only to particular machine versions or optional equipment.

The documentation year 2020 does not necessarily indicate the machine's manufacturing year.

DIGITAL PDF DOWNLOAD

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

What you receive:

• Volvo L350H technical service documentation
• Engine descriptions and repair procedures
• AdBlue/DEF, DPF, EGR, and SCR service information
• Electrical and electronic control system documentation
• Electrical wiring diagrams
• Transmission and axle repair procedures
• Brake and steering system servicing
• Comfort Drive Control documentation
• Operator cab and air conditioning repair information
• Working hydraulic system repair procedures
• Hydraulic circuit diagrams
• Boom Suspension System documentation
• CareTrack-related technical information
• Equipment installation instructions
• Safety and workshop procedures
• Technical specifications and tightening torque references
• Digital delivery – no printed book will be shipped

A compatible PDF reader is required to access the document.

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Detailed content:

DESCRIPTIONS
(1) STANDARD PARTS, SERVICE
Service
(2) ENGINE WITH MOUNTING AND EQUIPMENT
AdBlue® DEF pump unit diagnostics, description
Auxiliary brake (engine braking), description (2)
Auxiliary brake (engine braking), description
Coolant with anti-freeze and corrosion protection, recommendation
Cooling fan motor, description
Cooling fan, description
Cooling system, description (2)
Cooling system, description
Crankcase ventilation, description (2)
Crankcase ventilation, description
ECO – accelerator pedal
Engine, description (2)
Engine, description (3)
Engine, description
Engine, reference values
Exhaust aftertreatment fuel system diagnostics, description
Exhaust Aftertreatment System, description
Exhaust Gas Recirculation (EGR), description
Fuel system, description (2)
Fuel system, description
Injectors, checking
Inlet and exhaust system, description (2)
Inlet and exhaust system, description
Internal Exhaust Gas Recirculation (IEGR), description
Lubrication system, description (2)
Lubrication system, description
Regeneration process, description
Reversible cooling fan, description
Tech Tool, operations (2)
Tech Tool, operations (3)
Tech Tool, operations
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
ACM, I O list
Alternator, description
Battery disconnector switch, description
Battery, charging
Battery, description
Cable and component designations
Cable and component marking explanations
CareTrack W-ECU, description
CCM, I O list
Chassis connection
Collection of basic data
Components list
Conditions when checking
Connectors, overview
ECM (Engine Control Module), I O list
Electrical distribution box, description
Electrical symbols and designations
Electrical system, description
Electrical system, work instructions
Electronic control system, description
General fault diagnosis information
GPMECU1, I O list
GPMECU2, I O list
GPMECU3, I O list
HMICU, I O list
Information display, general
Information display, service mode
Intermittent wiper and washer
Lead and connector checks
Limp home function, description
Rear vision system
Reverse warning system, description
Software parameters, description (2)
Software parameters, description
Starter motor, description
Tech Tool, operations
T-ECU, I O list
Troubleshooting strategy
Troubleshooting tools
W-ECU, I O list
(4) POWER TRANSMISSION
Automatic differential brake, Limited Slip, description
Drive axles, description
Front axle, component description
Hydraulic transmission calibration, description
Hydraulic transmission, description
Propeller shaft, component description
Rear axle, component description
(5) BRAKE
Axle oil cooler, description
Brake accumulator, description
Braking system, description
Foot brake valve, description
Parking brake, component description
Parking brake, function description
Tech Tool, operations
(6) STEERING
Calibration of Comfort Drive Control (CDC), function description
CDC valve, lever steering, description
Comfort Drive Control (CDC), description
Pressure monitor, description
Priority valve, external, description
Secondary steering, description
Shift valve, description
Steering cylinder, description
Steering system, description
Steering valve, description
Tech Tool, operations
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Frame joint, description
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, function description
Air conditioning, tightening torques
Climate control system, description
Electric door opener, description
Pause heater, description
Tech Tool, operations
Viscous cab suspension, description (2)
Viscous cab suspension, description
Windows, general, gluing
Windows, general
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
3rd, or 3rd 4th hydraulic function, description
Boom Suspension System, component description
Boom Suspension System, description
Calibration of 3rd 4th hydraulic function, description
Calibration of lift lower function, description
Calibration of tilt in out function, description
Central lubrication system, description
Central valve, description
Change of lubrication interval
Control valve, description
Diagnostic tools, description
Dosage valves, description
Filling lubricant
Hydraulic attachment locking, description
Hydraulic components, cleanliness when handling
Hydraulic oil tank, description
Hydraulic pump flow regulation, description
Hydraulic pumps, description
Lever control, electric servo, description
Lifting cylinder, description
Lubrication points, central lubrication
Parameter settings
Pressure monitor, description
Pump unit, description
Servo system, description (2)
Servo system, description
Shift valve, description
Software, parameter settings and read-outs
Tech Tool, operations
Tilt cylinder, description
Working hydraulic system, description (2)
Working hydraulic system, description
Z-Linkage bearing points
Diagrams
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Table of contents, wiring diagrams
Wiring diagram WD201
Wiring diagram WD208
Wiring diagram WD210
Wiring diagram WD211
Wiring diagram WD212
Wiring diagram WD214
Wiring diagram WD220
Wiring diagram WD221
Wiring diagram WD223
Wiring diagram WD224
Wiring diagram WD301
Wiring diagram WD302
Wiring diagram WD303
Wiring diagram WD304
Wiring diagram WD305
Wiring diagram WD306
Wiring diagram WD320
Wiring diagram WD321
Wiring diagram WD322
Wiring diagram WD324
Wiring diagram WD325
Wiring diagram WD326
Wiring diagram WD330
Wiring diagram WD331
Wiring diagram WD333
Wiring diagram WD334
Wiring diagram WD335
Wiring diagram WD337
Wiring diagram WD350
Wiring diagram WD351
Wiring diagram WD352
Wiring diagram WD360
Wiring diagram WD361
Wiring diagram WD362
Wiring diagram WD363
Wiring diagram WD371
Wiring diagram WD372
Wiring diagram WD373
Wiring diagram WD374
Wiring diagram WD375
Wiring diagram WD401
Wiring diagram WD403
Wiring diagram WD404
Wiring diagram WD405
Wiring diagram WD501
Wiring diagram WD601
Wiring diagram WD602
Wiring diagram WD604
Wiring diagram WD801
Wiring diagram WD802
Wiring diagram WD804
Wiring diagram WD805
Wiring diagram WD806
Wiring diagram WD807
Wiring diagram WD808
Wiring diagram WD831
Wiring diagram WD903
Wiring diagram WD904
Wiring diagram WD909
Wiring diagram WD910
Wiring diagram WD911
Wiring diagram WD912 2
Wiring diagram WD912
Wiring diagram WD913
(4) POWRER TRANSMISSION
Hydraulic diagram transmission
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
Explanations to hydraulic diagram
Hydraulic diagram, complete
INSTALLATION INSTRUCTIONS
3rd hydraulic function, installing new
24V connector, installing new
Cab front work light LED, installing new
Cab rear work light LED, installing new
CARE TRACK
Emergency stop, installing new
Engine heater 120V, installing new
Engine heater 240V, installing new
Forward view camera, installing new
Hand throttle, installing new
Multi lever control, 3rd hydraulic function, installing new
Pre-cleaner cyclone type, installing new
Pre-cleaner oil bath type, installing new
Radio, installing new
Rear view mirror, installing new
Rotating beacon, installing new
Single lever control, 2nd hydraulic function, installing new
Single lever control, 3rd hydraulic function, installing new
Warning beacon flashing strobe light, installing new
Repair
(0) GENERAL
88830557 User Instruction
E 1708, Checking point
E1711
E-2001
E-2004
E-2007
E-2014
E-2015
E-2016
E-2017
E-2018
E-2026
E-2027
E-2029
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
Parking brake, manually releasing
(2) ENGINE WITH MOUNTING AND EQUIPMENT
ACM (Aftertreatment control module) non-programmed, replacing
ACM (Aftertreatment control module) pre-programmed, replacing
AdBlue® DEF hoses, replacing
AdBlue® DEF nozzle, replacing
AdBlue® DEF pump unit, components, replacing
AdBlue® DEF pump unit, replacing
AdBlue® DEF quality, checking
AdBlue® DEF tank armature, replacing
AdBlue® DEF tank, cleaning
AdBlue® DEF, draining
Aftertreatment fuel dosing unit, replacing
Aftertreatment fuel nozzle, cleaning
Aftertreatment fuel nozzle, replacing
Air in fuel system, checking
Camshaft setting, checking
Camshaft, replacing 2
Camshaft, replacing
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, checking
Compressor, replacing
Cooling fan motor, replacing
Cooling system pressure, checking
Crankcase ventilation separator, replacing
Crankshaft front oil seal, replacing
Crankshaft rear oil seal, replacing
Cylinder compression, testing 2
Cylinder compression, testing
Damper bearings and rubber bellows, replacing
DPF (Diesel particulate filter), checking and cleaning
EGR cooler pressure, testing 2
EGR cooler pressure, testing
EGR cooler, replacing
EGR valve (internal), replacing
EGR valve, replacing
EGR venturi tube, cleaning
EGR venturi tube, replacing
Engine belts, replacing
Engine control module (ECM), replacing non-programmed 2
Engine control module (ECM), replacing non-programmed
Engine control module (ECM), replacing pre-programmed 2
Engine control module (ECM), replacing pre-programmed
Engine mount rubber cushion, replacing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor (crank shaft), replacing
Engine, installing 2
Engine, installing
Engine, removing 2
Engine, removing
Exhaust aftertreatment system fuel flow, checking
Exhaust pipe flexible tube, replacing 2
Exhaust pipe flexible tube, replacing
Fan control valve, seal replacing
Feed pump pressure, checking
Feed pump, replacing
Fuel system, bleeding
High pressure air system pressure, checking
Injector sleeves, replacing
Injectors, replacing 2
Injectors, replacing
Inlet throttle, replacing
Lubrication oil consumption, checking
Lubrication oil pressure, checking with pressure gauge
Muffler, replacing
NOx sensor, replacing
Oil cooler, leakage check 2
Oil cooler, leakage check
Oil cooler, replacing 2
Oil cooler, replacing
Oil level sensor, replacing
Radiator, replacing
Rocker arms, replacing
SCR (Selective catalytic reduction) dosing system, checking
Silencer, installing
Silencer, removing
Stall speed, checking
Turbocharger, inspecting 2
Turbocharger, inspecting
Turbocharger, replacing 2
Turbocharger, replacing
Valves, adjusting (2)
Valves, adjusting
Variable turbocharger actuator, replacing
Wastegate actuator, replacing
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Batteries, replacing
Battery condition, checking
GPMECU1 non-programmed, replacing
GPMECU1 pre-programmed, replacing
GPMECU2 non-programmed, replacing
GPMECU2 pre-programmed, replacing
GPMECU3 non-programmed, replacing
GPMECU3 pre-programmed, replacing
HMICU non-programmed, replacing
HMICU pre-programmed, replacing
Starter lock, replacing
Starter motor, replacing 2
Starter motor, replacing
Tech Tool, operations
T-ECU, replacing
W-ECU, replacing, non-programmed
W-ECU, replacing, pre-programmed
(4) POWRER TRANSMISSION
Axle suspension, replacing bushes bearings and seals
Axle, installing
Axle, removing
Error codes when calibrating
Gear selector valve, replacing one solenoid
Heat exchanger, replacing
Hub reduction, installing 2
Hub reduction, installing
Hub reduction, removing 2
Hub reduction, removing
Hydraulic transmission, warming up
Induction sensor for output shaft, replacing
Lock up valve, replacing
Tech Tool, operations
T-ECU, replacing
Transmission oil pressure, checking
Transmission, function check
Transmission, installing
Transmission, removing
(5) BRAKE
Accumulator (removed) charging pressure, checking
Accumulator, discarding
Accumulator, installing
Accumulator, removing
Accumulators, checking in machine
Brake disc, replacing
Brake discs, measuring wear
Brake discs, replacing
Brake piston seals, replacing 2
Brake piston seals, replacing
Brake system charging, checking
Brake system circuit pressure, checking and adjusting
Brake system retardation function, checking
Brake system, bleeding
Parking brake discs and seals, replacing
Parking brake function, checking
Parking brake, checking wear
(6) STEERING
Accumulator, discarding
Comfort drive control (CDC) angle sensor, changing
Comfort Drive Control (CDC) joystick, changing
Comfort drive control (CDC) solenoid valve, changing
Comfort Drive Control, servo pressure, checking
Left steering cylinder, installing
Left steering cylinder, removing
Lever steering (CDC) function, checking
Right steering cylinder, installing
Right steering cylinder, removing
Secondary steering pump working pressure, checking and adjusting
Steering accumulator removed, checking
Steering accumulator, installing
Steering accumulator, removing
Steering system function, checking
Steering system working pressure, checking and adjusting
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Counterweight, installing
Counterweight, removing
Frame joint, replacing bearings
Front wheel, installing
Front wheel, removing
Rear wheel, installing
Rear wheel, removing
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, checking performance
Air mix door actuator, replacing
CCM, replacing
Climate unit, installing
Climate unit, removing
Compressor, replacing
Condenser, replacing
Cooling unit, leak detection
Door lock cylinder, replacing
Drying filter, replacing
Electric door opener, control unit, replacing
Electric door opener, locking motor, replacing
Electric door opener, opening support motor, replacing
Electric door opener, rotor switch, replacing
Engine hood, installing 2
Engine hood, installing
Engine hood, removing 2
Engine hood, removing
Evaporator, replacing
Expansion valve, replacing 2
Expansion valve, replacing
Fan motor, replacing
Heat control valve, replacing
Heater core, replacing
Operator’s seat, securing
Refrigerant, filling incl vacuum pumping
Troubleshooting, air conditioning unit (AC)
Viscous cab suspension, changing all units
Window pane, installing
Windscreen, replacing 2
Windscreen, replacing
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
3rd 4th hydraulic function, shock valve, checking
3rd 4th hydraulic function, solenoid valve, replacing
3rd 4th hydraulic, functional check
Accumulator removed, checking
Accumulator, boom suspension system, discarding
Accumulator, discarding 2
Accumulator, discarding
Attachment locking, checking
Automatic lubrication pump unit, reconditioning
Back-up valve, checking and adjusting
Bleeding air
Boom suspension accumulator, checking and adjusting
Boom suspension accumulator, reconditioning
Boom suspension system, checking
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom suspension system, left accumulator, installing
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
Bucket, installing
Bucket, removing
Error codes when calibrating
Hydraulic couplings
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, installing
Hydraulic pump P1, removing
Hydraulic pump P2, installing
Hydraulic pump P2, removing
Hydraulic pump P3, checking
Hydraulic pump P3, installing
Hydraulic pump P3, removing
Hydraulic pump, standby pressure and working pressure, checking and adjusting
Hydraulic system, bleeding
Hydraulic system, warming up
Lift cylinder, repacking in machine
Lift frame, replacing bearing in lower bucket- or implement attachment
Lift lower function, checking
Lift lower, angle sensor, changing
Lift lower, LS-disconnecting, solenoid valve, replacing 2
Lift lower, LS-disconnecting, solenoid valve, replacing
Lift, solenoid valve, changing 2
Lift, solenoid valve, changing
Lower, solenoid valve, changing 2
Lower, solenoid valve, changing
LS (load sense) pressure, checking
Pressure back-up valve, replacing
Servo accumulator, installing
Servo accumulator, removing
Servo pressure, at the spool in control valve, checking
Servo pressure, checking and adjusting
Shock valve lift function, checking 2
Shock valve lift function, checking
Shock valve, tilt function, checking 2
Shock valve, tilt function, checking
System test
Tilt cylinder, repacking in machine
Tilt cylinder, replacing
Tilt in out, angle sensor, changing
Tilt in, solenoid valve, changing 2
Tilt in, solenoid valve, changing
Tilt out, solenoid valve, changing 2
Tilt out, solenoid valve, changing
Tilt, checking
Tilt, LS-disconnecting, solenoid valve, replacing 2
Tilt, LS-disconnecting, solenoid valve, replacing
Update of automatic lubrication system
SAFETY
(1) STANDARD PARTS, SERVICE
CE-marking, EMC-directive
Checking function
Checklist after a fire or heat exposure
Decontamination
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Fire prevention measures
Health hazards with paint, plastics and rubber
Safety concerns everybody!
Safety rules when servicing
Safety when handling oils and fuel
Safety when handling the machine
Safety when lifting and supporting complete machine
Safety when working on hydraulic systems
Safety when working with air conditioning refrigerant
Safety when working with batteries
Service position 1
Service position 2
Some simple rules regarding tyre handling
Starting with booster batteries
Towing
Waste handling
Working in environmentally contaminated areas
Working on the electrical system of the machine
Working under raised boom
SPECIFICATIONS
(0) GENERAL
Tightening torques
(1) STANDARD PARTS, SERVICE
AdBlue® DEF
Alternative fuels
Coolant
Recommended lubricants (2)
Recommended lubricants
(2) ENGINE WITH MOUNTING AND EQUIPMENT
AdBlue®DEF
Cooling fan rpm, specifications
Cooling fan, tightening torques
Cooling system, specifications
Cooling system, tightening torques
EGR system, tightening torques
Engine, capacities (2)
Engine, capacities
Engine, specifications
Engine, tightening torques
Fuel fast fill system, specification
Fuel system, specifications
Fuel system, tightening torques
Inlet and exhaust system, specification (2)
Inlet and exhaust system, specification
Inlet and exhaust system, tightening torques
Lubrication system, specifications
Lubrication system, tightening torques
Reversible cooling fan, tightening torques
Temperature limits for cooling fan speed, specifications (2)
Temperature limits for cooling fan speed, specifications
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator 80 A, specification
Battery, specifications
Electrical system, specifications
Electrical system, tightening torques
Lighting, specifications
Starter motor, specifications
Starter motor, tightening torques
(4) POWER TRANSMISSION
Axle suspension, tightening torque
Front and rear axles, specifications
Front and rear axles, tightening torque
Front and rear axles, volume
Hydraulic transmission, capacity
Propeller shaft, tightening torque
Rear axle mounting, volume
Transmission, specifications
Transmission, tightening torques
(5) BRAKE
Brake accumulator, specifications
Brake system, specifications
Parking brake, specifications
Wheel brake, specification
(6) STEERING
Calibration of Comfort Drive Control (CDC), specification
Lever steering (CDC), specifications
Lever steering CDC, tightening torques
Secondary steering pump, specifications
Steering cylinder, tightening torque
Steering, specifications
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Counterweight, tightening torques
Counterweight, weight
Frame joint, tightening torques
Wheels, tightening torques
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, refrigerant, weight
Air conditioning, specifications
Cabin, tightening torques
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
3rd 4th hydraulic function, specifications
3rd 4th hydraulic function, tightening torques
Automatic lubrication system, specifications
Boom Suspension System, specifications
Boom Suspension System, tightening torques
Calibration of working hydraulics, specifications
Control valve, specifications
Control valve, tightening torques
Function times, specifications
Hydraulic connections, tightening torques
Hydraulic pump (P1), specifications
Hydraulic pump (P2), specifications
Hydraulic pump (P3), specifications
Hydraulic pumps, tightening torques
Hydraulic system, volume
Lift cylinder, tightening torques
Recommended lubricants
Servo system, specifications
Tilt cylinder, tightening torques