VOLVO L60H WHEEL LOADER SERVICE REPAIR MANUAL PDF – 2450 PAGES

Volvo L60H Technical Workshop Library – Engine Aftertreatment, Tech Tool Diagnostics, Powertrain Repairs, Electronic Controls and Hydraulic Calibration

A Volvo L60H wheel loader combines diesel engine technology, exhaust emissions control, electronic monitoring, hydraulic power transmission, and precisely regulated working hydraulics. Servicing these systems requires reliable technical information that goes beyond ordinary maintenance instructions.

The Volvo L60H Wheel Loader Service Repair Manual provides 2,450 pages of workshop documentation covering component operation, diagnostic procedures, mechanical repairs, electrical troubleshooting, hydraulic testing, equipment installation, and technical specifications.

This publication is particularly useful for workshops dealing with modern diesel emissions equipment. It includes dedicated procedures for AdBlue/DEF dosing components, Selective Catalytic Reduction (SCR), Diesel Particulate Filter (DPF), Diesel Oxidation Catalyst (DOC), Exhaust Gas Recirculation (EGR), and regeneration system checks.

Another important part of the documentation concerns the machine's electronic architecture. The manual identifies the Engine Control Module (ECM), Aftertreatment Control Module (ACM), GPMECU1–3, HMICU, CCM, and CareTrack W-ECU, together with input/output references, replacement procedures, and Volvo Tech Tool service operations.

Beyond engine and electronics, the publication addresses transmission calibration, Lock-Up valve servicing, drive axle repairs, braking systems, CDC steering, hydraulic pump adjustments, Boom Suspension System, and auxiliary hydraulic equipment.

The workshop procedures are supported by electrical wiring diagrams, hydraulic schematics, component specifications, tightening torques, and safety instructions.

Whether investigating a fuel pressure problem, replacing an aftertreatment component, testing steering pressure, or servicing a hydraulic cylinder, this manual provides a structured technical reference for the Volvo L60H.

MANUAL INFORMATION

• Manufacturer: Volvo Construction Equipment
• Equipment: Volvo L60H Wheel Loader
• Document Type: Service Repair / Workshop Manual
• Number of Pages: 2,450
• Digital Format: PDF
• Language: English
• Technical Information Updated: 2022
• Delivery: Digital Download

DISCOVER THE TECHNICAL SECTIONS

The documentation is organized into machine descriptions, electrical and hydraulic diagrams, installation instructions, workshop repairs, safety procedures, and technical specifications.

Below is a detailed guide to the subjects covered.

ENGINE AND DIESEL EMISSIONS TECHNOLOGY

Engine Construction and Operation

The engine section explains the principal mechanical systems and their associated controls.

Subjects include:

• Engine general description
• Engine reference values
• Fuel supply system
• Lubrication system
• Cooling system
• Crankcase ventilation
• Inlet and exhaust system
• Auxiliary engine braking
• ECO accelerator pedal
• Reversible cooling fan
• Engine control and monitoring

Engine Mechanical Repair

The manual includes procedures for:

• Engine removal
• Engine installation
• Engine replacement
• Rear engine mounting replacement
• Cylinder compression testing
• Engine belt replacement
• Valve clearance adjustment
• Valve cover removal and installation
• Engine stall speed checking
• Engine lubrication oil consumption checking
• Engine lubrication oil pressure measurement

ADBLUE/DEF AND SCR SYSTEM SERVICING

The Volvo L60H documentation contains a substantial section dedicated to the AdBlue/DEF supply and dosing system.

System descriptions and diagnostics:

• AdBlue/DEF pump unit diagnostics
• Exhaust Aftertreatment System
• SCR dosing system checking
• AdBlue/DEF quality checking
• AdBlue/DEF crystallization checking
• Regeneration process
• Aftertreatment Control Module

AdBlue/DEF Pump and Supply Repairs

Workshop operations include:

• AdBlue/DEF pump unit replacement
• Pump unit filter replacement
• Pump unit flushing
• Pump inlet nipple replacement
• AdBlue/DEF hose replacement
• AdBlue/DEF dosing injector replacement
• AdBlue/DEF mixing tube replacement

AdBlue/DEF Tank Servicing

The manual also provides instructions for:

• AdBlue/DEF tank removal and replacement
• AdBlue/DEF tank cleaning
• Tank armature replacement
• Tank armature cleaning
• Tank armature suction filter replacement
• AdBlue/DEF draining

SCR Exhaust Components

Additional procedures include:

• SCR dosing system checking
• SCR muffler replacement
• Aftertreatment control module replacement
• Regeneration log checking

These chapters are especially relevant when servicing the emissions control equipment fitted to applicable L60H configurations.

DPF, DOC AND EGR REPAIR PROCEDURES

The manual separately documents exhaust filtration, oxidation catalyst components, and exhaust gas recirculation.

Diesel Particulate Filter and Oxidation Catalyst

• DPF checking and cleaning
• DOC replacement
• Regeneration process descriptions
• Regeneration log inspection
• Exhaust aftertreatment system references

Exhaust Gas Recirculation

EGR service procedures:

• EGR cooler replacement
• EGR valve replacement
• EGR reed valve replacement
• EGR venturi tube cleaning
• EGR venturi tube replacement

The technical specifications also include EGR system tightening torques.

HIGH-PRESSURE FUEL SYSTEM

The fuel injection chapters cover the main components of the engine's high-pressure fuel delivery system.

Fuel system components:

• High-pressure fuel pump
• Fuel rail
• Fuel rail pressure sensor
• Fuel Control Valve (FCV)
• Pressure Relief Valve (PRV)
• Injectors
• Injector sleeves
• High-pressure fuel pipes
• Fuel feed pump

Service procedures include:

• High-pressure fuel pump replacement
• Fuel rail replacement
• Fuel rail pressure sensor replacement
• FCV replacement
• PRV replacement
• Injector replacement
• Injector sleeve replacement
• High-pressure fuel pipe replacement
• Fuel feed pump pressure checking
• Fuel system bleeding
• Carbon dioxide checking in the fuel system

TURBOCHARGER, AIR INTAKE AND COOLING

The engine support systems are covered through component descriptions and repair instructions.

Turbocharger and air intake:

• Turbocharger replacement
• Inlet throttle replacement
• Inlet and exhaust system descriptions
• Flexible exhaust pipe replacement

Cooling system:

• Cooling system pressure checking
• Coolant pump replacement
• Coolant valve replacement
• Thermostat replacement
• Radiator and charge-air cooler removal
• Radiator and charge-air cooler installation
• Reversible cooling fan operation
• Cooling fan motor descriptions
• Cooling fan speed specifications

The manual also includes checking for carbon dioxide in the coolant system.

ELECTRONIC CONTROL ARCHITECTURE

The Volvo L60H uses several electronic control modules for machine operation, monitoring, and communication.

The manual provides input/output information for the following units:

Electronic Unit	Documentation Included
ECM	Engine Control Module input/output list
ACM	Aftertreatment Control Module input/output list
GPMECU1	Input/output list and replacement procedures
GPMECU2	Input/output list and replacement procedures
GPMECU3	Input/output list and replacement procedures
HMICU	Input/output list and replacement procedures
CCM	Input/output list and replacement procedure
W-ECU	CareTrack input/output list and replacement procedures

Electronic Module Replacement

The repair section identifies pre-programmed and non-programmed replacement procedures for several electronic units.

Included operations:

• ECM replacement
• ACM replacement
• GPMECU1 replacement
• GPMECU2 replacement
• GPMECU3 replacement
• HMICU replacement
• W-ECU replacement
• CCM replacement

VOLVO TECH TOOL SERVICE OPERATIONS

A distinguishing feature of the L60H manual is its use of Volvo Tech Tool references.

The table of contents identifies Tech Tool operations across:

• Engine systems
• Electronic control systems
• Transmission
• Brakes
• Steering
• Cab systems
• Working hydraulics

The manual also contains descriptions of diagnostic tools, software parameter settings, service mode, and troubleshooting strategies.

Important: The product supplies technical documentation only. Volvo Tech Tool software, diagnostic licenses, interfaces, and physical diagnostic equipment are not included.

ELECTRICAL SYSTEM AND MACHINE MONITORING

The electrical chapters explain the components involved in power supply, starting, monitoring, and machine communication.

Electrical subjects:

• Electrical system operation
• Electronic control system
• Alternator
• Battery charging
• Battery disconnector switch
• Starter motor
• Preheating
• System voltage
• Electronic booting sequence
• Cable and component designations
• Chassis connections
• Connectors
• Software parameters
• Lead and connector checks
• Limp-home function

Machine Information Display

The documentation includes:

• Information display operation
• Service mode
• Software parameter references
• Fault diagnosis procedures
• General troubleshooting tools
• Rear vision system
• Reverse warning system
• Intermittent wiper and washer

ELECTRICAL WIRING DIAGRAM COLLECTION

The publication contains numerous numbered wiring diagrams, including diagrams dedicated to particular machine systems.

System-specific wiring diagrams:

• Aftertreatment
• Brakes
• Boom Suspension System
• Comfort Drive Control
• Electrically controlled battery disconnector
• Gear control
• Starting system

The battery disconnector diagrams include key-operated and manually operated arrangements, with or without emergency stop, as identified in the documentation.

Numbered Wiring Diagrams

Diagram references include:

• WD201–WD202
• WD260–WD266
• WD268–WD270
• WD301–WD306
• WD320–WD322
• WD324–WD327
• WD330–WD331
• WD333–WD335 and WD337
• WD350–WD352
• WD360–WD363
• WD371–WD376
• WD401–WD406
• WD501
• WD601–WD602 and WD604
• WD801–WD802
• WD804–WD808
• WD831
• WD901–WD905
• WD908–WD913
• WD915
• WD930
• WD953

Several diagram numbers appear in multiple versions.

These references are useful when identifying circuits, checking electrical connections, and tracing component signals.

TRANSMISSION AND DRIVETRAIN SERVICE

The powertrain section addresses hydraulic transmission operation, calibration, and mechanical repairs.

Transmission System

Included information:

• Hydraulic transmission descriptions
• Hydraulic transmission calibration
• Transmission hydraulic diagrams
• Transmission functional testing
• Transmission oil pressure checking
• Transmission warm-up
• Calibration error codes

Transmission Repairs

Repair procedures include:

• Transmission removal
• Transmission installation
• Lock-Up valve replacement
• Gear selector solenoid replacement
• Transmission heat exchanger replacement
• Front output shaft seal replacement
• Rear output shaft seal replacement

Drive Axles and Differentials

The drivetrain documentation also covers:

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

Axle repair procedures:

• Axle removal and installation
• Differential lock adjustment
• Differential lock functional checking
• Hub reduction removal and installation
• Hub seal replacement
• Axle suspension bush and seal replacement

SERVICE BRAKES AND PARKING BRAKE

The braking system chapters combine functional descriptions with inspection, testing, and component repair procedures.

Hydraulic Braking System

Brake components:

• Brake accumulators
• Foot brake valve
• Wheel brakes
• Brake discs
• Brake piston seals
• Brake hydraulic circuits

Testing and repairs:

• Brake accumulator pressure checking
• Brake accumulator removal and installation
• Brake system charging checking
• Brake circuit pressure checking and adjustment
• Brake retardation functional testing
• Brake system bleeding
• Brake disc wear measurement
• Brake disc replacement
• Brake piston seal replacement

Parking Brake

The manual contains instructions for:

• Parking brake manual release
• Parking brake function checking
• Parking brake adjustment
• Parking brake pad replacement
• Parking brake assembly removal
• Parking brake disassembly
• Parking brake reassembly
• Parking brake installation

STEERING SYSTEM AND CDC CALIBRATION

The steering section covers conventional hydraulic steering, secondary steering, and Comfort Drive Control.

Steering Components

• Steering valve
• Steering cylinders
• Pressure monitor
• Secondary steering
• Steering hydraulic system

Steering Repair Procedures

• Steering system functional checking
• Steering working pressure checking and adjustment
• Left steering cylinder removal and installation
• Right steering cylinder removal and installation
• Steering cylinder reconditioning
• Steering accumulator removal and installation
• Steering accumulator checking
• Secondary steering pump working pressure checking and adjustment

Comfort Drive Control (CDC)

The CDC section includes:

• CDC operation
• CDC calibration descriptions
• CDC angle sensor replacement
• CDC joystick replacement
• CDC solenoid valve replacement
• CDC servo pressure checking
• CDC lever steering functional checking

FRAME, COUNTERWEIGHT AND WHEELS

The manual provides procedures for structural and wheel-related repairs.

Included operations:

• Counterweight removal
• Counterweight installation
• Frame joint bearing replacement
• Front wheel removal and installation
• Rear wheel removal and installation
• Frame joint specifications
• Wheel tightening torques

CAB, AIR CONDITIONING AND OPERATOR EQUIPMENT

The cab documentation covers climate control, windows, seating, and mechanical cab components.

Cab and Bodywork

• Cab removal and installation
• Engine hood removal and installation
• Engine hood raising and securing
• Plastic hood repair
• Door lock cylinder replacement
• Side window replacement
• Windscreen replacement
• Window pane installation
• Viscous cab suspension replacement
• Operator seat securing

Electric Door Opener

The manual contains repair procedures for:

• Door opener control unit
• Locking motor
• Opening support motor
• Rotor switch

Climate Control and Air Conditioning

Included operations:

• Air conditioning performance checking
• Air conditioning troubleshooting
• Climate unit removal and installation
• Compressor replacement
• Condenser replacement
• Evaporator replacement
• Expansion valve replacement
• Drying filter replacement
• Heater core replacement
• Heat control valve replacement
• Fan motor replacement
• Air mix door actuator replacement
• Refrigerant draining
• Refrigerant filling and vacuum pumping
• Cooling unit leak detection

The cab descriptions also include the pause heater and climate control system.

WORKING HYDRAULIC SYSTEM

The hydraulic chapters explain the machine's lifting, tilting, attachment control, and servo-operated hydraulic functions.

System components:

• Hydraulic pumps
• Hydraulic oil tank
• Central valve
• Control valve
• Servo valve
• Hydraulic pressure monitor
• Hydraulic pump flow regulation
• Hydraulic attachment locking
• Lifting cylinders
• Tilt cylinders
• TP-Linkage bearing points

HYDRAULIC PUMPS P2 AND P3

The manual includes specific repair procedures for pumps P2 and P3.

Pump P2

• Pump removal
• Pump installation
• Technical specifications

Pump P3

• Pump functional checking
• Pump removal
• Pump installation
• Technical specifications

Hydraulic Pressure Adjustment

• Standby pressure checking
• Standby pressure adjustment
• Working pressure checking
• Working pressure adjustment
• Load-sensing pressure checking
• Hydraulic system warm-up
• Hydraulic system bleeding

HYDRAULIC SERVO AND ELECTRONIC CALIBRATION

The L60H documentation includes both hydraulic servo descriptions and electronically controlled function calibration references.

Servo system:

• Electric servo lever control
• Hydraulic servo lever control
• Servo valve operation
• Servo pressure checking
• Servo pressure adjustment
• Servo pressure measurement at the control valve spool
• Servo accumulator removal and installation

Hydraulic calibration:

• Lift/lower function calibration
• Tilt-in/tilt-out function calibration
• Third and fourth hydraulic function calibration
• Calibration error codes
• Software parameter settings and read-outs

LIFT AND TILT CYLINDER REPAIR

The manual includes procedures for servicing the loader's working cylinders.

Workshop operations:

• Lift cylinder repacking in the machine
• Tilt cylinder repacking in the machine
• Hydraulic cylinder piston lock brace installation
• Lift/lower functional checking
• Tilt function checking
• Lift angle sensor replacement
• Tilt angle sensor replacement
• Lift inductive sensor adjustment
• Tilt inductive sensor adjustment
• Lift shock valve checking
• Tilt shock valve checking

These procedures are particularly relevant to hydraulic cylinder seal servicing and working equipment diagnosis.

THIRD AND FOURTH HYDRAULIC FUNCTIONS

The auxiliary hydraulic section includes information about additional hydraulic equipment and attachment control.

Included subjects:

• Third hydraulic function
• Third and fourth hydraulic functions
• Auxiliary hydraulic valve descriptions
• Auxiliary hydraulic pressure checking and adjustment
• Auxiliary hydraulic shock valve checking
• Auxiliary hydraulic solenoid valve replacement
• Auxiliary hydraulic functional checking
• Hydraulic attachment locking checking

BOOM SUSPENSION SYSTEM (BSS)

The Boom Suspension System documentation includes operation, hydraulic pressure regulation, and component repairs.

BSS procedures:

• Boom suspension functional checking
• Accumulator pressure checking and adjustment
• Accumulator removal and installation
• Accumulator reconditioning
• Accumulator depressurization
• Pressure reduction valve checking
• Safety valve checking and adjustment
• BSS solenoid valve replacement

AUTOMATIC CENTRAL LUBRICATION

The publication includes descriptions and maintenance information for the automatic lubrication system.

Topics covered:

• Central lubrication system
• Lubrication pump unit
• Dosage valves
• Lubrication points
• Lubrication interval changes
• Lubricant filling
• Automatic lubrication pump reconditioning
• Automatic lubrication system update

FIRE SUPPRESSION SYSTEM

The manual includes technical information for the fire suppression equipment.

Documented subjects:

• Fire suppression system components
• Fire suppression system operation
• Actions following system activation
• Actions following manual activation
• Fire suppression system specifications
• Fire suppression tightening torques

HYDRAULIC AND TRANSMISSION DIAGRAMS

The diagram section includes:

• Hydraulic transmission diagrams
• Basic machine hydraulic diagrams
• Complete hydraulic system diagrams
• Explanations of hydraulic symbols and circuit functions

Several hydraulic diagram versions are included in the table of contents.

OPTIONAL EQUIPMENT INSTALLATION INSTRUCTIONS

The manual contains installation procedures for various machine accessories and optional systems.

Hydraulic and Control Equipment

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

Electrical and Safety Equipment

• CareTrack
• Emergency stop
• Back-up alarm
• Reverse warning system
• Forward-view camera
• Rotating beacon
• Flashing warning beacon
• LED seat belt beacon

Lighting

• LED front work lights
• LED cab front work lights
• LED cab rear work lights
• LED cab side work lights
• LED grille work lights
• LED illuminated cab entrance

Engine and Filtration Accessories

• Engine heater 120V
• Engine heater 240V
• High Sulphur Fuel Conversion Kit
• Reversible fan
• Cyclone pre-cleaner
• Oil-bath pre-cleaner
• Turbo-type pre-cleaner
• Cab air pre-cleaner

Cab and Protective Accessories

• Radio
• Rear-view mirrors
• Radiator grille guard
• Windscreen guard
• Hand throttle
• Decal set

The installation procedures apply to the equipment configurations identified in the manual. Not all optional equipment is fitted to every Volvo L60H.

WORKSHOP SAFETY AND ENVIRONMENTAL PROCEDURES

The safety section addresses precautions for servicing heavy equipment and working with pressurized systems.

Included subjects:

• Machine service positions
• Hydraulic system safety
• Battery handling
• Electrical system safety
• Air conditioning refrigerant safety
• Tyre handling
• Safe lifting and supporting
• Working under a raised boom
• Oil and fuel handling
• Fire prevention
• Checks after fire or heat exposure
• Decontamination
• Environmentally hazardous fluids
• Waste handling
• Towing procedures

TECHNICAL SPECIFICATIONS AND SERVICE DATA

The publication provides specifications and tightening torque information across the machine's principal systems.

Technical Area	Reference Data
Engine	Specifications, capacities, reference values, tightening torques
Fuel system	Fuel system specifications and tightening torques
AdBlue/DEF	Fluid specifications and related service information
Exhaust aftertreatment	SCR, EGR, inlet and exhaust system references
Cooling	Cooling system specifications, fan speed limits
Electrical	Alternator, battery, starter motor, lighting
Transmission	Transmission specifications, capacities, tightening torques
Axles	Front and rear axle specifications and fluid volumes
Brakes	Brake accumulators, wheel brakes, parking brake
Steering	CDC calibration, secondary steering pump, steering cylinders
Frame	Counterweight, frame joint, wheel tightening torques
Cab	Air conditioning, refrigerant weight, cabin tightening torques
Hydraulic pumps	P2 and P3 specifications
Working hydraulics	Control valves, pressure settings, function times
Boom suspension	BSS specifications and tightening torques
Auxiliary hydraulics	Third and fourth hydraulic function specifications
Automatic lubrication	Lubrication system specifications
Fire suppression	System specifications and tightening torques

PRACTICAL WORKSHOP APPLICATIONS

This Volvo L60H manual can be used as a technical reference when performing tasks such as:

• Diagnosing AdBlue/DEF dosing system problems
• Checking SCR dosing system operation
• Inspecting and cleaning the DPF
• Replacing the DOC
• Servicing EGR components
• Testing engine compression
• Replacing high-pressure fuel components
• Investigating electronic control module faults
• Consulting Volvo Tech Tool procedures
• Tracing electrical circuits
• Checking transmission pressure
• Servicing Lock-Up valve components
• Repairing drive axles and hub reductions
• Testing brake accumulators
• Adjusting parking brakes
• Calibrating CDC steering
• Servicing steering cylinders
• Adjusting hydraulic pressure
• Calibrating lift and tilt functions
• Repacking hydraulic cylinders
• Servicing Boom Suspension System components
• Maintaining automatic lubrication equipment

WHO IS THIS MANUAL FOR?

This publication is intended for:

• Heavy equipment service technicians
• Construction machinery repair workshops
• Diesel engine specialists
• Hydraulic system technicians
• Equipment fleet maintenance departments
• Electrical diagnostics technicians
• Experienced Volvo L60H owners

CHECK MACHINE COMPATIBILITY BEFORE ORDERING

This product is identified as the Volvo L60H Wheel Loader Service Repair Manual.

Before purchasing, confirm your equipment model, serial number, engine and emissions configuration, installed electronic modules, and optional hydraulic equipment.

Certain wiring diagrams, repair instructions, and installation procedures may apply only to particular machine configurations.

Technical Information Updated: 2022 identifies the documentation update year. It does not necessarily represent the year in which the machine was manufactured.

DIGITAL PDF FORMAT

This product contains 2,450 pages of technical service and repair documentation in PDF format.

The manual includes system descriptions, mechanical repair instructions, diagnostic references, electrical wiring diagrams, hydraulic diagrams, installation instructions, safety guidance, and technical specifications.

Digital product only. No physical book or printed manual will be shipped.

A PDF reader is required to open 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
(0) GENERAL
(1) STANDARD PARTS, SERVICE
(2) ENGINE WITH MOUNTING AND EQUIPMENT
AdBlue® DEF pump unit diagnostics, description
Auxiliary brake (engine braking), description
Coolant with anti-freeze and corrosion protection, recommendation
Cooling fan motor, description
Cooling fan, description
Cooling system, description
Crankcase ventilation, description
ECO – accelerator pedal
Engine, description 2
Engine, description
Engine, reference values
Exhaust Aftertreatment System, description
Exhaust Gas Recirculation (EGR), description
Fuel system, description
Inlet and exhaust system, description
Lubrication system, description
Regeneration process, description
Reversible cooling fan, description
Tech Tool, operations 2
Tech Tool, operations
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
ACM, I O list
Alternator 80 A, description
Alternator, description
Battery disconnector switch, description
Battery, charging
Battery, description
Booting sequence
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 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
Hood opening
Information display, general
Information display, service mode
Intermittent wiper and washer
Key feed
Lead and connector checks
Limp home function, description
Preheating, description
Rear vision system
Reverse warning system, description
Software parameters, description
Starter motor, description
System voltage
Tech Tool, operations
Troubleshooting strategy
Troubleshooting tools
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 calibration, description
Hydraulic transmission, description 2
Hydraulic transmission, description 3
Hydraulic transmission, description
Propeller shaft, component description
Rear axle mounting, component description
Rear axle, component description
Tech Tool, operations
(5) BRAKE
Brake accumulator, description
Braking system, description
Foot brake valve, description
Parking brake, component description
Parking brake, function description
Tech Tool, operations
Tightening torque
(6) STEERING
Calibration of Comfort Drive Control (CDC), function description
CDC valve, lever steering, description
Comfort Drive Control (CDC), description 2
Comfort Drive Control (CDC), description
Pressure monitor, description
Secondary steering, description 2
Secondary steering, description
Steering cylinder, description
Steering system, description 2
Steering system, description
Steering valve, description
Tech Tool, 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, function description
Air conditioning, tightening torques 2
Air conditioning, tightening torques
Cab, description
Climate control system, description
Driver seat, component description 2
Driver seat, component description 3
Driver seat, component description
Electric door opener, description
Pause heater, description
Tech Tool, operations
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 2
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 2
Control valve, description
Diagnostic tools, description
Dosage valves, description
Filling lubricant
Fire suppression system, component description
Fire suppression system, functional description
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
Lever control, hydraulic servo, description
Lifting cylinder, description
Lubrication points, central lubrication
Parameter settings
Pressure monitor, description
Pump unit, description
Servo system, description 2
Servo system, description
Servo valve, description
Shift valve, description
Software, parameter settings and read-outs
Tilt cylinder, description
TP-Linkage’s bearing points
Working hydraulic system, description 2
Working hydraulic system, description 3
Working hydraulic system, description
Diagrams
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Table of contents, wiring diagrams
Wiring diagram – Aftertreatment 2
Wiring diagram – Aftertreatment
Wiring diagram – Brake
Wiring diagram – BSS
Wiring diagram – CDC
Wiring diagram – Electrically controlled battery disconnector – Key operated, with emergency stop
Wiring diagram – Electrically controlled battery disconnector – Manual, with emergency stop
Wiring diagram – Electrically controlled battery disconnector – Manual, without emergency stop
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 2
Wiring diagram WD264
Wiring diagram WD265
Wiring diagram WD266
Wiring diagram WD268
Wiring diagram WD269
Wiring diagram WD270
Wiring diagram WD301 2
Wiring diagram WD301
Wiring diagram WD302
Wiring diagram WD303
Wiring diagram WD304 2
Wiring diagram WD304
Wiring diagram WD305
Wiring diagram WD306
Wiring diagram WD320 2
Wiring diagram WD320
Wiring diagram WD321 2
Wiring diagram WD321
Wiring diagram WD322 2
Wiring diagram WD322 3
Wiring diagram WD322
Wiring diagram WD324 2
Wiring diagram WD324 3
Wiring diagram WD324
Wiring diagram WD325
Wiring diagram WD326
Wiring diagram WD327
Wiring diagram WD330
Wiring diagram WD331
Wiring diagram WD333
Wiring diagram WD334
Wiring diagram WD335 2
Wiring diagram WD335
Wiring diagram WD337
Wiring diagram WD350 2
Wiring diagram WD350
Wiring diagram WD351 2
Wiring diagram WD351
Wiring diagram WD352 2
Wiring diagram WD352
Wiring diagram WD360 2
Wiring diagram WD360 3
Wiring diagram WD360
Wiring diagram WD361 2
Wiring diagram WD361
Wiring diagram WD362
Wiring diagram WD363
Wiring diagram WD371
Wiring diagram WD372
Wiring diagram WD373 2
Wiring diagram WD373
Wiring diagram WD374 2
Wiring diagram WD374
Wiring diagram WD375
Wiring diagram WD376
Wiring diagram WD401
Wiring diagram WD402 2
Wiring diagram WD402
Wiring diagram WD403
Wiring diagram WD404
Wiring diagram WD405
Wiring diagram WD406
Wiring diagram WD501 2
Wiring diagram WD501
Wiring diagram WD601 2
Wiring diagram WD601
Wiring diagram WD602 2
Wiring diagram WD602
Wiring diagram WD604
Wiring diagram WD801
Wiring diagram WD802 2
Wiring diagram WD802
Wiring diagram WD804
Wiring diagram WD805
Wiring diagram WD806
Wiring diagram WD807
Wiring diagram WD808
Wiring diagram WD831
Wiring diagram WD901
Wiring diagram WD902 2
Wiring diagram WD902
Wiring diagram WD903
Wiring diagram WD904 2
Wiring diagram WD904
Wiring diagram WD905
Wiring diagram WD908 2
Wiring diagram WD908
Wiring diagram WD909
Wiring diagram WD910
Wiring diagram WD911 2
Wiring diagram WD911
Wiring diagram WD912
Wiring diagram WD913 2
Wiring diagram WD913
Wiring diagram WD915 2
Wiring diagram WD915
Wiring diagram WD930
Wiring diagram WD953
(4) POWER TRANSMISSION
Hydraulic diagram transmission 2
Hydraulic diagram transmission
(9) HYDRAULIC SYSTEM, DIGGING, HANDLING, GRADING EQUIPM, MISC. EQUIP
Hydraulic diagram, basic machine 5
Hydraulic diagram, basic machine 4
Hydraulic diagram, basic machine 3
Hydraulic diagram, basic machine 2
Hydraulic diagram, basic machine
Hydraulic diagram, complete 6
Hydraulic diagram, complete 5
Hydraulic diagram, complete 4
Hydraulic diagram, complete 3
Hydraulic diagram, complete 2
Hydraulic diagram, complete
Explanations to hydraulic diagram
Installation Instruction
3rd 4th hydraulic function, installing new
3rd hydraulic function, installing new (2)
3rd hydraulic function, installing new
Attachment locking, installing new
Back up alarm, installing new
Boom suspension system, installing new
Cab front work light LED, installing new
Cab illuminated entrance 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
Decal set, installing new
Emergency stop, installing new
Engine heater 120V, installing new
Engine heater 240V, installing new
Forward view camera, installing new
Front work light LED, installing new (2)
Front work light LED, installing new
Grill work light LED, installing new
Hand throttle, installing new
High Sulphur Fuel Conversion kit, installing new
LED beacon for seat belt, installing new
Lever steering (CDC), electric, installing new
Multi lever control, 3rd hydraulic function, installing new
Pre-cleaner cyclone type, installing new
Pre-cleaner oil bath type, installing new
Pre-cleaner turbo type, installing new
Radiator grille guard, installing new
Radio, installing new
Rear view mirror, installing new
Reverse warning system, installing new
Reversible fan, installing new
Rotating beacon, installing new
Single lever control, 2nd hydraulic function, installing new (2)
Single lever control, 2nd hydraulic function, installing new
Single lever control, 3rd hydraulic function, installing new (2)
Single lever control, 3rd hydraulic function, installing new
Single lever control, 4th hydraulic function, installing new
ulti lever control, 4th hydraulic function, installing new
Warning beacon flashing strobe light, installing new
Wind shield guard, installing new
Repair
(0) GENERAL
88830557 User Instruction
E 1708, Checking point
E1706
E1711
E-2001
E-2005
E-2014
E-2015
E-2017
Infrared Thermometer
Operation numbers for additional work
(1) STANDARD PARTS, SERVICE
AdBlue®DEF pump unit filter, replacing
Hydraulic pressure, checking
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 dosing injector, replacing
AdBlue®DEF hoses, replacing
AdBlue®DEF mixing tube, replacing
AdBlue®DEF pump unit, filter, replacing
AdBlue®DEF pump unit, flushing
AdBlue®DEF pump unit, inlet nipple, replacing
AdBlue®DEF pump unit, replacing
AdBlue®DEF quality, checking
AdBlue®DEF tank armature suction filter, replacing
AdBlue®DEF tank armature, cleaning
AdBlue®DEF tank armature, replacing
AdBlue®DEF tank, cleaning
AdBlue®DEF tank, replacing
AdBlue®DEF, draining
Carbon dioxide in coolant system, checking
Carbon dioxide in fuel system, checking
Coolant pump, replacing
Coolant valve, replacing
Cooling system pressure, checking
Crystallization of AdBlue®DEF, checking
Cylinder compression, testing
DOC (Diesel oxidation catalyst), replacing
DPF (Diesel particulate filter), checking and cleaning
EGR cooler, replacing
EGR reed valve, replacing
EGR valve, replacing
EGR venturi tube, cleaning
EGR venturi tube, replacing
Engine belts, replacing
Engine control module (ECM), replacing non-programmed
Engine control module (ECM), replacing pre-programmed
Engine mounting rear, changing
Engine, installing
Engine, removing
Engine, replacing (2)
Engine, replacing
Exhaust pipe flexible tube, replacing
Feed pump pressure, checking
Fuel control valve (FCV), replacing
Fuel rail pressure sensor, replacing
Fuel rail, replacing
Fuel system, bleeding
High pressure fuel pipes, replacing
High pressure fuel pump, replacing
Injector sleeves, replacing
Injectors, replacing
Inlet throttle, replacing
Lubrication oil consumption, checking
Lubrication oil pressure, checking with pressure gauge
Pressure relief valve (PRV), replacing
Radiator and charge air cooler, installling
Radiator and charge air cooler, removing
Regeneration log, checking
SCR (Selective catalytic reduction) dosing system, checking
SCR (Selective catalytic reduction) muffler, replacing
Stall speed, checking
Thermostat, replacing
Turbocharger, replacing
Valve cover, installing
Valve cover, removing
Valves, adjusting
(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
Tech Tool, operations
W-ECU, replacing, non-programmed
W-ECU, replacing, pre-programmed
(4) POWER 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
Hydraulic transmission, warming up
Lock up valve, replacing
Seal for front output shaft, replacing
Seal for rear output shaft, replacing
Transmission oil pressure, checking (2)
Transmission oil pressure, checking
Transmission, function check (2)
Transmission, function check
Transmission, installing
Transmission, removing
(5) BRAKE
Accumulator (removed) charging pressure, checking
Accumulator, discarding
Accumulator, installing
Accumulator, removing
Accumulators, checking in machine
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
Parking brake brake pads, replacing
Parking brake function, checking
Parking brake, adjusting
Parking brake, assembling
Parking brake, disassembling
Parking brake, installing
(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 cylinder removed, reconditioning excl replacing bearings
Steering system function, checking
Steering system working pressure, checking and adjusting
(7) FRAME;SPRINGS;DAMPING;AXLE SUSPENSION; WHEELTRUCK 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
Actuator, replacing
Air conditioning, checking performance
Air mix door actuator, replacing
Cab, installing
Cab, removing
CCM, replacing
Climate unit, installing
Climate unit, removing
Compressor, replacing
Condenser, replacing
Cooling unit, leak detection
Door lock cylinder, replacing (2)
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
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
Troubleshooting, air conditioning unit (AC)
Viscous cab suspension, changing one unit
Window pane, installing
Windscreen, replacing
(9) HYDRAULIC SYSTEM;DIGGINGHANDLING GRADING EQUIPM.;MISC.EQUIP
3rd4th hydraulic function, pressure, checking and adjusting
3rd4th hydraulic function, shock valve, checking
3rd4th hydraulic function, solenoid valve, replacing
3rd4th 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, accumulator, installing
Boom suspension system, accumulator, removing
Boom suspension system, checking
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom suspension system, pressure reduction, safety valve, checking and adjusting
Boom suspension system, solenoid valve, replacing
Error codes when calibrating
Fire suppression system, actions after activation
Fire suppression system, actions after manual activation
Hydraulic couplings
Hydraulic cylinder, piston’s lock brace, installing
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic pump 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
Inductive sensor, lift, adjusting
Inductive sensor, tilt, adjusting
Lift cylinder, repacking in machine
Liftlower function, checking
Liftlower, angle sensor, changing
LS (load sense) pressure, checking
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
Tech Tool, operations
Tilt cylinder, repacking in machine
Tilt inout, angle sensor, changing
Tilt, checking
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
Conversion tables
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 (2)
Cooling system, specifications
Cooling system, tightening torques
EGR system, tightening torques
Engine, capacities
Engine, specifications
Engine, tightening torques
Fuel system, specifications
Fuel system, tightening torques
Inlet and exhaust system, specification
Inlet and exhaust system, tightening torques
Lubrication system, specifications
Lubrication system, tightening torques
Temperature limits for cooling fan speed, specifications
Valve mechanism, specifications
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Alternator 80 A, specification
Battery, specifications
Battery, weight
Electrical system, specifications
Electrical system, tightening torques
Lighting, specifications
Preheating, specifications
Starter motor, specifications
Starter motor, tightening torques
(4) POWER TRANSMISSION
Front and rear axles, specifications
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 (5)
Transmission, specifications (6)
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
Frame joint, tightening torques
Wheel, tightening torque
(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 (2)
Control valve, specifications
Control valve, tightening torques
Fire suppression system, specification
Fire Suppression System, tightening torques
Function times, specifications (2)
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