VOLVO L60G WHEEL LOADER SERVICE REPAIR MANUAL PDF – 2083 PAGES

Keep your Volvo L60G wheel loader service work organized with this extensive 2,083-page Service Repair Manual, featuring technical information updated in 2020.

From investigating electronic warning messages to checking transmission pressures or servicing the exhaust aftertreatment system, this PDF workshop publication brings together the technical information needed for a wide range of maintenance, diagnostic, and repair operations.

The manual covers the engine and fuel system, electrical equipment, electronic control units, hydraulic transmission, drive axles, braking and steering systems, operator cab, and working hydraulics.

It includes component descriptions, repair and replacement procedures, electrical wiring diagrams, hydraulic circuit diagrams, service specifications, adjustment instructions, and workshop safety guidance.

Particularly useful sections address VCADS Pro diagnostics, ECU communication and error codes, DPF regeneration components, EGR equipment, Comfort Drive Control (CDC), and Boom Suspension System (BSS).

The documentation is suitable for experienced heavy equipment technicians, independent repair workshops, fleet maintenance teams, and Volvo L60G owners who perform technical maintenance and repairs.

MANUAL INFORMATION

• Equipment Manufacturer: Volvo Construction Equipment
• Machine: Volvo L60G Wheel Loader
• Publication: Service Repair / Workshop Manual
• Document Format: PDF
• Total Length: 2,083 Pages
• Information Updated: 2020
• Product Type: Digital Download

EXPLORE THE TECHNICAL CONTENT

The manual is organized into six principal documentation groups: descriptions, diagrams, installation instructions, repair procedures, safety information, and technical specifications.

The following overview highlights the major systems and service operations included in the publication.

1. GENERAL SERVICE INFORMATION

The introductory material provides essential references for workshop operations.

Topics include:

• General service information
• Electric welding precautions
• Leak detector 951 1207
• Service tools and checking points
• Infrared thermometer
• Additional work operation numbers
• General workshop procedures

2. ENGINE SYSTEMS AND OPERATING PRINCIPLES

Understand the main engine systems and the components responsible for engine operation, cooling, lubrication, and exhaust management.

ENGINE DESCRIPTION

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

EMISSIONS AND REGENERATION

• Exhaust Aftertreatment System
• Exhaust Gas Recirculation (EGR)
• Regeneration process
• Diesel Particulate Filter (DPF) related systems

3. ENGINE MAINTENANCE AND MECHANICAL REPAIRS

This section contains practical procedures for engine inspection, removal, installation, adjustment, and component replacement.

ENGINE MECHANICAL SERVICE

• Engine removal and installation
• Rear engine mounting replacement
• Crankshaft front oil seal replacement
• Cylinder compression testing
• Engine belt replacement
• Valve adjustment
• Engine stall speed testing
• Camshaft rotation speed sensor replacement
• Crankshaft rotation speed sensor replacement

COOLING AND AIR INTAKE

• Cooling system pressure testing
• Coolant pump replacement
• Radiator removal and installation
• Charge-air cooler removal and installation
• Crankcase ventilation separator replacement
• Turbocharger removal and installation
• Wastegate inspection

LUBRICATION AND FUEL DELIVERY

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

4. DPF REGENERATION AND EXHAUST AFTERTREATMENT REPAIRS

One of the notable areas of this L60G manual is its coverage of exhaust aftertreatment components, including burner-related service operations.

DIESEL PARTICULATE FILTER AND BURNER

• DPF inspection and cleaning
• Diesel Oxidation Catalyst (DOC) replacement
• Burner function testing
• Burner replacement
• Air pump replacement
• Air pump safety valve replacement
• Fuel metering unit A replacement
• Fuel metering unit B replacement
• Spark plug inspection and replacement
• Spark plug cable replacement
• Spark plug control unit replacement

EXHAUST GAS RECIRCULATION

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

ADDITIONAL AFTERTREATMENT COMPONENTS

• Exhaust aftertreatment T-junction replacement
• NOx sensor replacement
• Aftertreatment Control Module (ACM) replacement
• Exhaust flexible pipe replacement

5. ELECTRICAL ARCHITECTURE AND ECU COMMUNICATION

The electrical section explains how the Volvo L60G electronic systems communicate and how faults can be investigated.

ELECTRICAL SYSTEM DESCRIPTION

• Electrical system operation
• Electrical system work instructions
• Battery and charging system
• Alternator
• Battery disconnector switch
• System voltage
• Chassis connections
• Electrical symbols
• Cable and component designations
• Connector identification

CONTROL MODULES

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

DATA COMMUNICATION AND MONITORING

• Communication with data buses
• Bus communication supervision
• ECU input and output lists
• Electronic control system descriptions
• Software parameters
• Booting sequence
• Alarm functions
• Central warning system

6. INFORMATION DISPLAY AND FAULT DIAGNOSIS

The L60G documentation includes extensive information about the machine's electronic information display and diagnostic functions.

INFORMATION DISPLAY

• General display functions
• Operating display
• Service mode
• Engine information
• Transmission information
• Hydraulic information
• Electrical system information
• Axle and brake information
• Vehicle information
• Vehicle messages
• Display settings
• Start lockout information

FAULT DIAGNOSIS

• Error code display
• SAE error code interpretation
• Troubleshooting strategy
• Troubleshooting tools
• Electrical lead and connector checks
• Special diagnostic tools

7. VCADS PRO DIAGNOSTIC INFORMATION

The manual includes references to VCADS Pro, an important diagnostic system covered in the L60G documentation.

VCADS PRO TOPICS

• VCADS Pro service tool
• VCADS Pro operations
• VCADS Pro error codes
• VCADS Pro socket measurements
• VCADS Pro connection problems
• Diagnostic procedures for selected machine systems

These references can help technicians understand diagnostic operations and locate relevant service information when investigating machine faults.

8. ELECTRICAL WIRING DIAGRAMS

The publication contains an extensive collection of numbered electrical wiring diagrams, including several entries identified as Update G.

SYSTEM DIAGRAMS

• Exhaust aftertreatment
• Brake system
• Boom Suspension System
• Electrically controlled battery disconnector
• Gear control
• Starting system

NUMBERED WIRING DIAGRAM GROUPS

• WD201–WD202
• WD260–WD267
• WD301–WD337 (selected diagrams)
• WD350–WD376 (selected diagrams)
• WD401–WD407 (selected diagrams)
• WD501
• WD601, WD602 and WD604
• WD801–WD831 (selected diagrams)
• WD901–WD915 (selected diagrams)

The collection includes selected revised diagram entries marked Update G.

These diagrams provide references for tracing electrical connections, locating circuit components, and troubleshooting electronic equipment.

9. HYDRAULIC TRANSMISSION AND DRIVE SYSTEM

The power transmission section covers transmission operation and service procedures.

TRANSMISSION SYSTEM

• Hydraulic transmission description
• Transmission hydraulic diagram
• Transmission oil pressure testing
• Transmission functional checks
• Transmission removal and installation
• Gear selector valve solenoid replacement
• Transmission heat exchanger replacement
• Transmission calibration error codes

DRIVE AXLES AND DIFFERENTIALS

• Front axle descriptions
• Rear axle descriptions
• Rear axle mounting
• Differential lock
• Limited-slip differential
• Automatic differential brake
• Propeller shaft
• Hub reduction assemblies

DRIVELINE REPAIRS

• Axle removal and installation
• Axle suspension bushing and seal replacement
• Differential lock adjustment
• Differential lock function testing
• Hub reduction removal and installation
• Hub seal replacement
• Front output shaft seal replacement
• Rear output shaft seal replacement

10. BRAKE SYSTEM INSPECTION AND REPAIR

The brake section includes descriptions, pressure testing, and repair procedures.

BRAKING EQUIPMENT

• Service braking system
• Brake accumulators
• Foot brake valve
• Parking brake

BRAKE SERVICE PROCEDURES

• Brake accumulator pressure checks
• Brake accumulator removal and installation
• Brake disc wear measurement
• Brake disc replacement
• Brake piston seal replacement
• Brake system charging checks
• Brake circuit pressure testing and adjustment
• Brake system bleeding
• Brake retardation function testing
• Wheel brake functional checks
• Parking brake pad replacement
• Parking brake disassembly and assembly
• Manual parking brake release

11. STEERING AND COMFORT DRIVE CONTROL

The steering section provides information about steering components, secondary steering, and CDC lever steering.

STEERING SYSTEM

• Steering system description
• Steering control valve
• Steering cylinders
• Steering pressure monitoring
• Secondary steering
• Steering hydraulic pressure testing

COMFORT DRIVE CONTROL (CDC)

• CDC system description
• CDC lever steering valve
• CDC angle sensor replacement
• CDC solenoid valve replacement
• CDC servo pressure testing
• CDC functional testing

STEERING REPAIR

• Left steering cylinder removal and installation
• Right steering cylinder removal and installation
• Steering cylinder reconditioning
• Secondary steering pump pressure testing and adjustment
• Steering working pressure testing and adjustment

12. FRAME, WHEELS AND COUNTERWEIGHT

The frame section includes procedures for structural components and wheel assemblies.

Included topics:

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

13. OPERATOR CAB AND CLIMATE CONTROL

The manual contains information for servicing the operator cab, climate equipment, and related components.

CAB COMPONENTS

• Cab descriptions
• Electric door opener
• Viscous cab suspension
• Engine hood
• Accelerator pedal
• Cab removal and installation
• Door lock cylinder replacement
• Windscreen replacement
• Side window replacement
• Window installation
• Plastic hood repair

HEATING AND AIR CONDITIONING

• Climate control system
• Air conditioning troubleshooting
• Air conditioning performance testing
• 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 draining
• Refrigerant filling and vacuum pumping
• Electronic Climate Control ECU replacement

14. WORKING HYDRAULIC SYSTEM

The hydraulic section provides technical information for hydraulic pumps, valves, servo controls, and working equipment.

HYDRAULIC COMPONENTS

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

HYDRAULIC SERVICE

• 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
• Servo pressure checks at the control valve spool
• Hydraulic system bleeding
• Hydraulic system warm-up
• Hydraulic back-up valve testing and replacement

15. LIFTING AND TILTING EQUIPMENT

The documentation includes service procedures for the machine's lifting and tilting functions.

LIFTING SYSTEM

• Lift cylinder seal replacement in the machine
• Lift and lower function testing
• Lifting time measurement
• Lift shock valve inspection

TILTING SYSTEM

• Tilt cylinder seal replacement in the machine
• Tilt function testing
• Tilt shock valve inspection

HYDRAULIC CONTROL

• Hydraulic servo accumulator removal and installation
• Hydraulic system functional testing
• Hydraulic attachment locking checks

16. BOOM SUSPENSION SYSTEM (BSS)

The manual includes dedicated technical information for the Boom Suspension System.

Included topics:

• Boom Suspension System descriptions
• BSS component descriptions
• Boom suspension accumulator inspection
• Accumulator pressure adjustment
• Accumulator reconditioning
• Left accumulator removal and installation
• Hydraulic accumulator depressurization
• Boom suspension safety valve testing and adjustment
• Boom Suspension System functional checks

17. THIRD AND FOURTH HYDRAULIC FUNCTIONS

The documentation contains information about auxiliary hydraulic functions.

Included topics:

• Third hydraulic function
• Fourth hydraulic function
• Auxiliary hydraulic valve descriptions
• Hydraulic pressure testing and adjustment
• Shock valve inspection
• Auxiliary hydraulic function testing
• Hydraulic attachment bracket
• Attachment locking checks

18. CENTRAL LUBRICATION AND FIRE SUPPRESSION

The manual includes information for selected auxiliary equipment.

AUTOMATIC LUBRICATION

• Central lubrication system description
• Lubrication interval adjustment
• Lubricant filling
• Lubrication pump unit
• Lubrication pump reconditioning

FIRE SUPPRESSION

• Fire suppression system component descriptions
• Procedures following fire suppression system activation
• Procedures following manual activation

19. HYDRAULIC CIRCUIT DIAGRAMS

The manual includes hydraulic circuit diagrams for major machine systems.

Included diagrams:

• Hydraulic transmission diagram
• Complete working hydraulic system diagram
• Explanations of hydraulic diagram references

These diagrams help technicians identify hydraulic components and understand circuit connections.

20. EQUIPMENT INSTALLATION INSTRUCTIONS

The publication contains installation instructions for selected optional equipment.

HYDRAULIC AND MACHINE EQUIPMENT

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

ELECTRICAL EQUIPMENT

• CareTrack installation
• Anti-theft device installation
• Battery main switch installation
• Backup alarm installation
• Forward-view camera installation
• Rear-view camera installation
• LED working lights
• Rotating warning beacon
• Radio installation

ENGINE AND PROTECTION EQUIPMENT

• 120V engine heater installation
• 240V engine heater installation
• Additional fuel filter installation
• Hand throttle installation
• High-sulphur fuel conversion kit
• Reversible fan installation
• Cyclone-type air pre-cleaner
• Oil-bath air pre-cleaner
• Turbo-type air pre-cleaner
• Radiator grille guard
• Windscreen guard
• Front lighting protection

21. SAFETY AND WORKSHOP PRECAUTIONS

The safety section covers precautions for servicing and handling heavy equipment.

Included topics:

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

22. TECHNICAL SPECIFICATIONS AND SERVICE DATA

The specifications section contains reference values for major machine systems.

ENGINE SPECIFICATIONS

• Engine technical specifications
• Engine software specifications
• Engine fill quantities
• Fuel system specifications
• Cooling system specifications
• Lubrication system specifications
• Engine oil pressure
• Cooling fan speed
• Exhaust aftertreatment specifications
• Engine tightening torques

ELECTRICAL SPECIFICATIONS

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

TRANSMISSION AND AXLES

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

BRAKE AND STEERING

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

WORKING HYDRAULICS

• Hydraulic pump P2 specifications
• Hydraulic pump P3 specifications
• Hydraulic system volume
• Hydraulic control valve specifications
• Servo system specifications
• Boom Suspension System specifications
• Third and fourth hydraulic function specifications

GENERAL REFERENCES

• Recommended lubricants
• Coolant recommendations
• Alternative fuels
• Conversion tables
• Standard tightening torques

KEY AREAS FOR TROUBLESHOOTING

The Volvo L60G manual provides technical references for investigating issues involving:

• Electronic error codes and warning messages
• ECU communication
• VCADS Pro diagnostic operations
• Engine fuel delivery
• DPF regeneration and burner operation
• EGR components
• Transmission pressure and operation
• Differential lock
• Brake circuit pressure
• Steering and CDC equipment
• Hydraulic pump pressure
• Hydraulic control valves
• Boom Suspension System
• Cab climate control
• Automatic lubrication

WHY CHOOSE THIS VOLVO L60G MANUAL?

A wheel loader combines mechanical, hydraulic, and electronic systems that often need to be evaluated together during service work.

This manual brings the relevant technical information into one publication, helping users:

• Locate model-specific repair procedures
• Identify electronic control modules and related circuits
• Interpret diagnostic references and error messages
• Consult extensive electrical wiring diagrams
• Inspect DPF regeneration equipment
• Perform engine component replacement procedures
• Check transmission and brake pressures
• Service steering and CDC equipment
• Inspect hydraulic pumps and control valves
• Repair lifting and tilting components
• Maintain the Boom Suspension System
• Consult technical specifications and tightening torques

INTENDED USERS

This manual is suitable for:

• Volvo construction equipment service technicians
• Independent heavy machinery mechanics
• Wheel loader repair workshops
• Construction equipment fleet maintenance teams
• Equipment maintenance contractors
• Volvo L60G owners carrying out technical maintenance and repair work

IMPORTANT MODEL COMPATIBILITY INFORMATION

This publication is identified for the Volvo L60G Wheel Loader.

The documentation includes different electrical diagram versions and information relating to optional equipment.

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

Some repair procedures, diagrams, and installation instructions may apply only to specific machine configurations.

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

DIGITAL PDF DELIVERY

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

The download includes documentation covering:

• 2,083 pages of technical information
• Engine service and repair
• DPF regeneration and burner equipment
• EGR system repair procedures
• VCADS Pro diagnostics
• Electronic control modules
• Electrical wiring diagrams, including Update G references
• Hydraulic transmission and drive axles
• Brake and steering systems
• Comfort Drive Control
• Operator cab and climate control
• Hydraulic pump and valve servicing
• Boom Suspension System
• Hydraulic circuit diagrams
• Optional equipment installation instructions
• Workshop safety procedures
• Technical specifications and tightening torques

Digital product only. No physical manual will be shipped.

A compatible PDF reader is required to open the document.

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Detailed contentns:

Descriptions
(0) GENERAL
Leak detector 951 1207, description
(1) STANDARD PARTS, SERVICE
Electric welding (2)
Electric welding
Service
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Auxiliary brake (engine braking), description
Cooling fan motor, description
Cooling fan, description
Cooling system, description
Crankcase ventilation, description
ECO – accelerator pedal
Engine, description
Exhaust Aftertreatment System, description
Exhaust Gas Recirculation (EGR), description
Fuel system, description
Inlet and exhaust system, description
Lubricating system, description
Regeneration process, description
Reversible cooling fan, description
Turbocharger, description
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
ACM, I O list
Alarm, description (2)
Alarm, description
Alternator, description (2)
Alternator, description
Battery disconnector switch, description
Battery, charging
Battery, description
Booting sequence
Branching in cables
Bus communication supervision
Cable and component designations
Cable and component marking explanations
CareTrack W-ECU, description
Central warning
Chassis connection
Collection of basic data
Communication with data buses
Components list
Conditions when checking
Connectors, overview
ECC, I O list
E-ECU, I O list
Electrical symbols and designations
Electrical system, description
Electrical system, work instructions
Electronic control system, description
Engine control unit E-ECU, description
Error codes, showing
General fault diagnosis information
Hood opening
I-ECU, I O list
Information display, axles brakes
Information display, check (2)
Information display, check
Information display, electrical system
Information display, engine
Information display, general
Information display, hydraulics
Information display, operating display
Information display, service mode
Information display, service
Information display, settings
Information display, start lockout
Information display, transmission
Information display, vehicle info
Information display, vehicle messages
Instrument panels
Intermittent wiper and washer
Key feed
Lead and connector checks
Lighting, description
Middle instrument panel with warning lights
Preheating, description
SAE error codes, translation to error messages, general
Software parameters, description
Software, description
Special tools for troubleshooting
System voltage
Troubleshooting strategy
Troubleshooting tools
V2-ECU, I O list
VCADS Pro service tool
VCADS Pro socket, measuring
VCADS Pro, Error codes
V-ECU, I O list
Vehicle control unit V2-ECU, description
Vehicle control unit V-ECU, description
W-ECU, I O list
(4) POWER TRANSMISSION
Automatic differential brake, Limited Slip, description
Differential lock, description
Drive axles, description
Front axle, component description
Hydraulic transmission, description
Oil cooler, component description
Propeller shaft, component description
Rear axle mounting, component description
Rear axle, component description
VCADS Pro, Operations
(5) BRAKE
Brake accumulator, description
Braking system, description
Foot brake valve, description
Parking brake, function description
Tightening torque
VCADS Pro, Operations
(6) STEERING
CDC valve, lever steering, description
Comfort Drive Control (CDC), description
Pressure monitor, description
Secondary steering, description
Steering cylinder, description
Steering system, description
Steering valve, description
VCADS Pro, Operations
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Frame joint, description
Frame, description
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, tightening torques
Cab, description
Climate control system, description
Electric door opener, description
Pause heater, description
Troubleshooting, air conditioning unit (AC)
Viscous cab suspension, description
Windows, general, gluing
Windows, general
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
3rd 4th hydraulic function, valve, description
3rd, or 3rd 4th hydraulic function, description
Boom Suspension System, component description
Boom Suspension System, description
Central lubrication system, description
Central valve, description
Change of lubrication interval
Control valve, description
Diagnostic tools, description
Dosage valves, description
Filling lubricant
Fire suppression system, component description
Hydraulic attachment bracket, description
Hydraulic components, cleanliness when handling
Hydraulic oil tank, description
Hydraulic pump flow regulation, description
Hydraulic pumps, description
Parameter settings
Pressure monitor, description
Pump unit, description
Servo system, description
Servo valve, description
Shift valve, description
Software, parameter settings and read-outs
TP-Linkage’s bearing points
VCADS Pro, Operations
Working hydraulic system, description
Diagrams
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Table of contents, wiring diagrams
Wiring diagram – Aftertreatment
Wiring diagram – Brake 2
Wiring diagram – Brake
Wiring diagram – BSS
Wiring diagram – Electrically controlled battery disconnector
Wiring diagram – Gear
Wiring diagram – Start
Wiring diagram WD201
Wiring diagram WD202
Wiring diagram WD260
Wiring diagram WD261
Wiring diagram WD262
Wiring diagram WD263
Wiring diagram WD264
Wiring diagram WD265
Wiring diagram WD266
Wiring diagram WD267
Wiring diagram WD301 Update G 2
Wiring diagram WD301 Update G
Wiring diagram WD301
Wiring diagram WD302
Wiring diagram WD303 Update G
Wiring diagram WD303
Wiring diagram WD304 2
Wiring diagram WD304
Wiring diagram WD306
Wiring diagram WD308 Update G
Wiring diagram WD320
Wiring diagram WD321
Wiring diagram WD322
Wiring diagram WD323
Wiring diagram WD324
Wiring diagram WD325
Wiring diagram WD326
Wiring diagram WD330
Wiring diagram WD331
Wiring diagram WD333 Update G
Wiring diagram WD333
Wiring diagram WD334
Wiring diagram WD335
Wiring diagram WD337 Update G
Wiring diagram WD350
Wiring diagram WD351
Wiring diagram WD352
Wiring diagram WD360 Update G
Wiring diagram WD360
Wiring diagram WD361
Wiring diagram WD362
Wiring diagram WD363 Update G
Wiring diagram WD363
Wiring diagram WD364 Update G
Wiring diagram WD371 Update G
Wiring diagram WD372 Update G
Wiring diagram WD373
Wiring diagram WD374
Wiring diagram WD375 Update G
Wiring diagram WD375
Wiring diagram WD376
Wiring diagram WD401
Wiring diagram WD402 Update G
Wiring diagram WD402
Wiring diagram WD403
Wiring diagram WD404
Wiring diagram WD405
Wiring diagram WD407 Update G
Wiring diagram WD501 Update G
Wiring diagram WD501
Wiring diagram WD601
Wiring diagram WD602
Wiring diagram WD604
Wiring diagram WD801
Wiring diagram WD802
Wiring diagram WD804 Update G
Wiring diagram WD804
Wiring diagram WD805
Wiring diagram WD806
Wiring diagram WD807
Wiring diagram WD808
Wiring diagram WD831 Update G
Wiring diagram WD901
Wiring diagram WD902
Wiring diagram WD903
Wiring diagram WD904
Wiring diagram WD905
Wiring diagram WD906
Wiring diagram WD908
Wiring diagram WD911
Wiring diagram WD913
Wiring diagram WD915 Update G
(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 4th hydraulic function, installing new
3rd hydraulic function, installing new
After market engine, transfer of components
Anti theft device, installing new
Attachment locking, installing new
Back up alarm, installing new
Battery main switch, installing new
Boom suspension system, installing new
Cab front work light LED, installing new
Cab rear work light LED, installing new
Cab side work light LED, installing new
Cab, air pre cleaner, installing new
care track
CareTrack, installing new
Engine heater 120V, installing new
Engine heater 240V, installing new
Forward view camera, installing new
Front work light LED, installing new
Fuel filter extra, installing new
Grill work light LED, installing new
Hand throttle, installing new
High Sulphur Fuel Conversion kit, installing new
Lever steering (CDC), electric, installing new
Pre-cleaner cyclone type, installing new
Pre-cleaner oil bath type, installing new
Pre-cleaner turbo type, installing new
Protection for lighting, front, installing new
Radiator grille guard, installing new
Radio, installing new (2)
Radio, installing new (3)
Radio, installing new
Rear view camera, installing new (2)
Rear view camera, installing new
Reversible fan, installing new
Rotating beacon, installing new
Single lever control, 2nd hydraulic function, installing new
Wind shield guard, installing new
Work light front, installing new
Work light rear, installing new (2)
Work light rear, installing new
Repair
(0) GENERAL
88830557 User Instruction
E 1708, Checking point
E1706
E1711
E-2000
E-2001
E-2017
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
Boom suspension accumulator, checking and adjusting
Brake discs, measuring wear
Brake system charging, checking
Diesel particulate filter, checking and cleaning
Front axle, breather filter, replacing
Hydraulic pump, standby pressure and working pressure, checking and adjusting
Oil plugs, installing
Parking brake, manually releasing
Rear axle, breather filter, replace
Spark plug, replacing
Steering system working pressure, checking and adjusting
Towing
Valves, adjusting
Wheel brakes function, checking
(2) ENGINE WITH MOUNTING AND EQUIPMENT
ACM (Aftertreatment control module) non-programmed, replacing
ACM (Aftertreatment control module) pre-programmed, replacing
Air pump safety valve, replacing
Air pump, replacing
Burner function, checking
Burner, replacing
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, checking
Charge air cooler, installing
Charge air cooler, removing
Coolant pump, replacing
Cooling system pressure, checking
Crankcase ventilation separator, replacing
Crankshaft front oil seal, replacing
Cylinder compression, testing
Diesel particulate filter, checking and cleaning
DOC (Diesel oxidation catalyst), replacing
E-ECU MID 128 non-programmed, replacing
E-ECU MID 128 pre-programmed, replacing
EGR actuator, replacing
EGR cooler, replacing
EGR pressure sensor, replacing
EGR reed valve, inspecting
EGR reed valve, replacing
EGR system function, checking
EGR temperature sensor, replacing
EGR valve, replacing
EGR venturi tube, replacing
Engine belts, replacing
Engine mounting rear, changing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor (crank shaft), replacing
Engine, installing
Engine, removing
Exhaust aftertreatment system T-junction, replacing
Exhaust pipe flexible tube, replacing
Feed pump pressure, checking
Fuel control valve (FCV), replacing
Fuel metering unit A, replacing
Fuel metering unit B, replacing
Fuel pump, replacing
Fuel rail pressure sensor, replacing
Fuel system, bleeding
Glow plug control unit, replacing
Glow plug, replacing
High pressure fuel pump, replacing
High pressure fuel system pressure, relieving
Injector sleeves, replacing
Injectors, replacing
Lubrication oil pressure, checking with pressure gauge
NOx sensor, replacing
Pressure relief valve (PRV), replacing
Radiator, installing
Radiator, removing
Spark plug cable, replacing
Spark plug control unit, replacing
Spark plug, inspecting
Spark plug, replacing
Stall speed, checking
Turbocharger, installing
Turbocharger, removing
Valves, adjusting
VCADS Pro, Operations
Wastegate, checking
(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, connecting problems
VCADS Pro, Operations
V-ECU MID 187 non-programmed, replacing
V-ECU MID 187 pre-programmed, replacing
(4) POWRER TRANSMISSION
Axle suspension bushes and seals, replacing
Axle, installing
Axle, removing
Differential lock, adjusting
Differential lock, function check
Error codes when calibrating
Gear selector valve, replacing one solenoid
Heat exchanger, replacing
Hub reduction, installing 2
Hub reduction, installing
Hub reduction, removing 2
Hub reduction, removing
Hub seal, replacing 2
Hub seal, replacing
Seal for front output shaft, replacing
Seal for rear output shaft, 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 assembly, removing 2
Parking brake assembly, removing
Parking brake brake pads, replacing
Parking brake function, checking
Parking brake, assembling
Parking brake, disassembling
Parking brake, installing
Wheel brakes function, checking
(6) STEERING
Accumulator, discarding
Comfort drive control (CDC) angle sensor, changing
Comfort drive control (CDC) solenoid valve, changing
Comfort Drive Control, servo pressure, checking
Error codes when calibrating
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 cylinder removed, reconditioning excl replacing bearings
Steering system function, checking
Steering system working pressure, checking and adjusting
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEEL TRACK UNIT
Counterweight, installing
Counterweight, removing
Frame joint, replacing bearings
Front wheel, installing
Front wheel, removing
Rear wheel, installing
Rear wheel, removing
(8) MACHINERY HOUSE;CAB;EXTERIOR TRIM PARTS ANYWHERE
Accelerator pedal, replace
Actuator, replacing
Air conditioning, checking performance
Air mix door actuator, replacing
Cab, installing
Cab, removing
Climate unit, installing
Climate unit, removing
Compressor, replacing
Condenser, replacing
Door lock cylinder, replacing 2
Door lock cylinder, replacing
Drying filter, replacing
ECC MID 146 non-programmed ECU, replacing
ECC MID 146 pre-programmed ECU, replacing
Electric door opener, control unit, replacing
Electric door opener, locking motor, replacing
Electric door opener, opening support motor, replacing
Electric door opener, rotor switch, replacing
Engine hood, installing
Engine hood, manually operating
Engine hood, raising and securing
Engine hood, removing
Evaporator, replacing
Expansion valve, replacing
Fan motor, replacing
Heat control valve, replacing
Heater core, replacing
Operator’s seat, securing
Plastic hood, repairing
Refrigerant, draining
Refrigerant, filling incl vacuum pumping
Side window, replacing
Window pane, installing
Windscreen, replacing
(9) HYDRAULIC SYSTEM;DIGGING HANDING GRANDING EQUIPM.; MISC. EQUIP
3rd 4th hydraulic function, pressure, checking and adjusting
3rd 4th hydraulic function, shock valve, checking
3rd 4th hydraulic, functional check
Accumulator removed, checking
Accumulator, boom suspension system, discarding
Accumulator, discarding 2
Accumulator, discarding
Attachment locking, checking
Automatic lubrication pump unit, reconditioning
Back-up valve, checking and adjusting
Back-up valve, replacing
Bleeding air
Boom suspension accumulator, checking and adjusting
Boom suspension accumulator, reconditioning
Boom suspension system, checking
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom suspension system, left accumulator, installing
Boom suspension system, left accumulator, removing
Boom suspension system, pressure reduction, safety valve, checking and adjusting
Fire suppression system, actions after activation
Fire suppression system, actions after manual activation
Hydraulic couplings
Hydraulic cylinder, piston’s lock brace, installing
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic pump 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 2
Lift cylinder, repacking in machine
Lift lower function, checking
Lifting time, checking
LS (load sense) pressure, checking
Servo accumulator, installing 2
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
Shock valve, tilt function, checking
System test
Tilt cylinder, repacking in machine
Tilt, checking
V2-ECU, MID 249, changing non-programmed ECU
V2-ECU, MID 249, changing pre-programmed ECU
Safety
(1) STANDARD PARTS, SERVICE
CE-marking, EMC-directive
Checking function
Checklist after a fire or heat exposure
Decontamination
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Fire prevention measures
Health hazards with paint, plastics and rubber
Safety concerns everybody!
Safety rules when servicing
Safety when handling accumulators
Safety when handling oils and fuel
Safety when handling the machine
Safety when lifting and supporting complete machine
Safety when working on hydraulic systems
Safety when working with air conditioning refrigerant
Safety when working with batteries
Service position 1 2
Service position 1
Service position 2 2
Service position 2
Some simple rules regarding tyre handling
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
Working on the electrical system of the machine
Working under raised boom
Specifications
(0) GENERAL
Conversion tables
EGR system, tightening torques
Engine, software specifications
Engine, specifications
Engine, tightening torques
Fuel system, specifications
Lubrication system, specifications (2)
Lubrication system, specifications
Thermostat, specifications
Tightening torques
(1) STANDARD PARTS, SERVICE
Alternative fuels
Coolant
Recommended lubricants
Wheel brake, specification
(2) ENGINE WITH MOUNTING AND EQUIPMENT
Cooling fan rpm, specifications
Cooling fan, tightening torques
Cooling system, specifications
Cooling system, tightening torques
EGR system, tightening torques
Engine oil pressure, specification
Engine, fill quantities
Engine, software specifications
Engine, specifications
Engine, tightening torques
Exhaust aftertreatment system, specifications
Fuel system, specifications
Fuel system, tightening torques
Inlet and exhaust system, tightening torques
Lubrication system, specifications
Lubrication system, tightening torques
Oil sump, tightening torque
Preheating, specifications
Temperature limits for cooling fan speed, specifications
Thermostat, specifications
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator 80 A, specification
Alternator, specification
Battery, specifications
Battery, weight
Electrical system, specifications
Lighting, specifications
Preheating, specifications
Starter motor, specifications
(4) POWER TRANSMISSION
Front and rear axles, tightening torque (2)
Front and rear axles, tightening torque
Front and rear axles, volume
Hydraulic transmission, capacity
Propeller shaft, tightening torque
Transmission, specifications (2)
Transmission, specifications (3)
Transmission, specifications (4)
Transmission, specifications
Transmission, tightening torques
(5) BRAKE
Brake accumulator, specifications
Brake system, specifications
Parking brake, specifications
Wheel brake, specification
(6) STEERING
Lever steering (CDC), specifications
Secondary steering pump, specifications
Steering cylinder, tightening torque
Steering, specifications
(7) FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL, TRACK UNIT
Counterweight, tightening torques
Counterweight, weight
Frame joint, tightening torques
Wheel, tightening torque
(8) MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
Air conditioning, refrigerant, weight (2)
Air conditioning, refrigerant, weight
Air conditioning, specifications
Cabin, tightening torques
(9) HYDRAULIC SYSTEM, DIGGING, 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
Control valve, specifications
Control valve, tightening torques
Fire suppression system, specification
Function times, specifications
Hydraulic connections, tightening torques
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