VOLVO L90G WHEEL LOADER SERVICE REPAIR MANUAL PDF – 2132 PAGES

Volvo L90G Workshop Service Documentation – Engine, DPF, EGR, Fuel Injection, Transmission, Electronics and Hydraulic Repairs

When a Volvo L90G wheel loader requires mechanical repairs, electronic troubleshooting, hydraulic pressure adjustments, or component replacement, access to the correct technical documentation can make workshop operations more organized and efficient.

The Volvo L90G Wheel Loader Service Repair Manual contains 2,132 pages of service information, including repair instructions, machine system descriptions, electrical wiring diagrams, hydraulic schematics, installation procedures, safety guidance, and technical specifications.

The publication addresses both conventional mechanical assemblies and electronically controlled systems. Its coverage extends from engine compression testing and high-pressure fuel system repairs to exhaust aftertreatment servicing, electronic control module replacement, transmission repairs, and hydraulic cylinder maintenance.

Particular attention is given to the Diesel Particulate Filter (DPF), Diesel Oxidation Catalyst (DOC), Exhaust Gas Recirculation (EGR), exhaust regeneration equipment, and electronically controlled fuel delivery components.

For electrical troubleshooting, the manual includes VCADS Pro service operations, electronic control unit input/output references, machine information display functions, and a large collection of wiring diagrams.

The hydraulic documentation covers pressure checking, pump servicing, servo control, Boom Suspension System (BSS), auxiliary hydraulic functions, and procedures for repacking lift and tilt cylinders while they remain installed on the machine.

This digital workshop publication is intended for qualified service technicians, construction equipment repair businesses, maintenance teams, and experienced owners working on Volvo L90G wheel loaders.

MANUAL INFORMATION

• Manufacturer: Volvo Construction Equipment
• Model: Volvo L90G Wheel Loader
• Manual Category: Service Repair / Workshop Manual
• Total Pages: 2,132
• File Type: PDF
• Language: English
• Technical Information Updated: 2022
• Delivery: Digital Download

WHAT IS INCLUDED IN THIS MANUAL?

The service documentation is divided into six main areas:

• Machine and component descriptions
• Electrical and hydraulic diagrams
• Installation instructions
• Repair and adjustment procedures
• Workshop safety information
• Technical specifications

The sections below provide a closer look at the systems and operations documented in the manual.

VOLVO L90G WHEEL LOADER SERVICE REPAIR MANUAL PDF

1. ENGINE MECHANICAL SYSTEMS

The engine chapters explain the operation of the power unit and its supporting systems.

Engine descriptions include:

• Engine general arrangement
• Crankcase ventilation
• Fuel system
• Lubrication system
• Cooling system
• Inlet and exhaust system
• Turbocharger
• ECO accelerator pedal
• Auxiliary engine braking
• Reversible cooling fan

Engine workshop procedures include:

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

The manual also supplies engine specifications, fluid quantities, software references, and tightening torques.

2. HIGH-PRESSURE FUEL INJECTION SYSTEM

The Volvo L90G documentation includes procedures for servicing high-pressure fuel delivery components.

Fuel system repair topics:

• High-pressure fuel pump replacement
• Fuel pump replacement
• Fuel feed pump pressure checking
• Fuel rail pressure sensor replacement
• Fuel Control Valve (FCV) replacement
• Fuel metering unit A replacement
• Fuel metering unit B replacement
• Pressure Relief Valve (PRV) replacement
• Fuel injector replacement
• Injector sleeve replacement
• High-pressure fuel system depressurization
• Fuel system bleeding

Additional testing procedures include checking for carbon dioxide in the fuel system.

These subjects are particularly relevant when investigating fuel pressure irregularities, injection system faults, or engine operating problems.

3. EXHAUST AFTERTREATMENT AND REGENERATION

One of the distinguishing features of this manual is its coverage of the engine's exhaust aftertreatment equipment.

Documented components and functions:

• Exhaust Aftertreatment System
• Aftertreatment Control Module (ACM)
• Diesel Particulate Filter (DPF)
• Diesel Oxidation Catalyst (DOC)
• Exhaust regeneration process
• Burner assembly
• Burner air pump
• NOx sensor
• Exhaust aftertreatment T-junction

Repair and testing operations:

• DPF checking and cleaning
• DOC replacement
• Burner functional checking
• Burner replacement
• Air pump replacement
• Air pump safety valve replacement
• Spark plug inspection
• Spark plug replacement
• Spark plug cable replacement
• Spark plug control unit replacement
• NOx sensor replacement
• Exhaust T-junction replacement
• Flexible exhaust pipe replacement

The manual also includes replacement procedures for pre-programmed and non-programmed ACM units.

4. EXHAUST GAS RECIRCULATION (EGR)

The EGR section provides descriptions and service instructions for the components responsible for exhaust gas recirculation.

Included operations:

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

Technical specifications and tightening torque references for EGR components are also included.

5. TURBOCHARGER AND CHARGE-AIR SYSTEM

The air intake and turbocharger documentation includes:

• Turbocharger operation
• Turbocharger removal
• Turbocharger installation
• Wastegate checking
• Charge-air cooler removal
• Charge-air cooler installation
• Inlet and exhaust system information
• Related technical specifications

6. ENGINE COOLING AND LUBRICATION

The manual covers both routine inspection and component replacement in the cooling and lubrication systems.

Cooling system procedures:

• Cooling system pressure checking
• Coolant pump replacement
• Radiator removal
• Radiator installation
• Cooling fan system description
• Reversible fan operation
• Cooling fan speed specifications

Lubrication procedures:

• Engine lubrication oil pressure checking
• Crankcase ventilation separator replacement
• Lubrication system inspection references
• Lubrication system specifications
• Lubrication system tightening torques

7. ELECTRONIC CONTROL UNITS

The electrical documentation describes the electronic modules used for machine operation and monitoring.

Control units identified in the manual:

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

The manual includes input/output lists for these units, software parameter descriptions, and electrical communication information.

Control module service procedures include:

• E-ECU MID 128 replacement
• ACM replacement
• V-ECU MID 187 replacement
• V2-ECU MID 249 replacement
• I-ECU MID 140 replacement
• ECC MID 146 replacement

Programmed and non-programmed replacement procedures are identified for several of these modules.

8. VCADS PRO DIAGNOSTICS

The publication contains references to Volvo VCADS Pro diagnostic operations.

Diagnostic subjects include:

• Engine service operations
• Transmission service operations
• Brake system operations
• Steering system operations
• Hydraulic system operations
• Electronic control unit servicing
• VCADS Pro connection troubleshooting
• Software parameter settings
• Control module information

Important: The product contains technical documentation, not a VCADS Pro software license, diagnostic interface, or electronic service tool.

9. INSTRUMENT PANEL AND INFORMATION DISPLAY

The manual explains the machine's display functions and electronic monitoring features.

Display categories:

• Engine information
• Transmission information
• Axles and brakes
• Hydraulic system
• Electrical system
• Vehicle information
• Vehicle messages
• Service mode
• Machine settings
• Start lockout
• Operating display

The electrical section also includes alarm descriptions, central warnings, electronic startup sequences, and communication between control units.

10. ELECTRICAL SYSTEM SERVICE

The electrical chapters provide information about major electrical components and circuits.

Included subjects:

• Alternator
• Batteries and charging
• Battery disconnector switch
• Starter lock
• Engine preheating
• Lighting
• Electrical connectors
• Cable identification
• Chassis connections
• System voltage
• Electronic software parameters
• Data bus communication
• Intermittent wiper and washer
• Engine hood opening control

Electrical repair operations:

• Battery condition checking
• Battery replacement
• CareTrack battery replacement
• Starter lock replacement
• Electronic control module replacement

11. ELECTRICAL WIRING DIAGRAMS

The manual provides an extensive set of wiring diagrams for the Volvo L90G electrical system.

Dedicated diagrams include:

• Exhaust aftertreatment
• Brake system
• Boom Suspension System (BSS)
• Electrically controlled battery disconnector
• Gear system
• Starting system

Additional diagram references include:

• WD201–WD202
• WD260–WD267
• WD301–WD304
• WD306 and WD308
• WD320–WD326
• WD330–WD331
• WD333–WD335 and WD337
• WD350–WD352
• WD360–WD364
• WD371–WD376
• WD401–WD405 and WD407
• WD501
• WD601–WD602 and WD604
• WD801–WD802
• WD804–WD808
• WD831
• WD901–WD906
• WD908, WD911, WD913 and WD915

Several wiring diagrams are identified with Update G versions.

These diagrams provide references for electrical circuit tracing and component connection checks.

12. HYDRAULIC TRANSMISSION

The drivetrain chapters address transmission operation, testing, and mechanical repairs.

Transmission procedures include:

• Transmission functional checking
• Transmission oil pressure checking
• Transmission removal
• Transmission installation
• Gear selector solenoid replacement
• Transmission heat exchanger replacement
• Front output shaft seal replacement
• Rear output shaft seal replacement
• Transmission calibration error code references

The publication also contains transmission specifications, oil capacity information, and tightening torques.

13. DRIVE AXLES AND DIFFERENTIALS

The axle section provides technical descriptions and workshop procedures for the drivetrain.

Components covered:

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

Repair procedures:

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

14. SERVICE BRAKING SYSTEM

The braking section addresses the hydraulic brake equipment, accumulators, and wheel brake assemblies.

Brake service procedures:

• Brake accumulator checking
• Removed accumulator charging pressure checking
• Accumulator removal and installation
• Brake system charging check
• Brake circuit pressure checking
• Brake circuit pressure adjustment
• Brake system bleeding
• Brake retardation functional checking
• Wheel brake functional checking
• Brake disc wear measurement
• Brake disc replacement
• Brake piston seal replacement

15. PARKING BRAKE REPAIRS

The parking brake documentation includes both adjustment and component-level repair procedures.

Included operations:

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

16. HYDRAULIC STEERING SYSTEM

The steering chapters describe the steering valve, steering cylinders, pressure monitoring, and secondary steering arrangement.

Steering repair topics:

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

17. COMFORT DRIVE CONTROL (CDC)

The manual includes specific procedures for the optional CDC lever steering system.

CDC information includes:

• CDC system description
• CDC valve description
• CDC angle sensor replacement
• CDC solenoid valve replacement
• CDC servo pressure checking
• CDC lever steering functional checking
• CDC calibration error codes

18. FRAME, WHEELS AND COUNTERWEIGHT

The structural repair section includes:

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

Technical references cover counterweight weight, frame joint tightening torques, and wheel tightening torques.

19. OPERATOR CAB AND CLIMATE CONTROL

The cab section covers operator environment components, air conditioning, and body repairs.

Cab repair operations:

• Cab removal and installation
• Engine hood removal and installation
• Manual engine hood operation
• Engine hood raising and securing
• Door lock cylinder replacement
• Electric door opener repairs
• Side window replacement
• Windscreen replacement
• Plastic hood repair
• Operator seat securing

Climate control repairs:

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

20. WORKING HYDRAULIC SYSTEM

The hydraulic documentation covers the machine's lifting, tilting, servo control, and auxiliary hydraulic functions.

System descriptions include:

• Hydraulic oil tank
• Hydraulic pumps
• Hydraulic pump flow regulation
• Central control valve
• Servo valve
• Servo system
• Hydraulic pressure monitor
• Shift valve
• Working hydraulic circuits
• Hydraulic attachment bracket
• TP-Linkage bearing points

21. HYDRAULIC PUMPS P2 AND P3

The repair section identifies specific procedures for pumps P2 and P3.

Pump P2:

• Removal
• Installation
• Technical specifications

Pump P3:

• Functional checking
• Removal
• Installation
• Technical specifications

Hydraulic pressure operations:

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

22. LIFT AND TILT CYLINDER REPAIRS

An especially useful part of the manual concerns hydraulic cylinder servicing without removing the entire cylinder from the machine.

Included procedures:

• Lift cylinder repacking in the machine
• Tilt cylinder repacking in the machine
• Hydraulic cylinder piston lock brace installation
• Lift/lower function checking
• Lifting time checking
• Tilt function checking
• Lift shock valve checking
• Tilt shock valve checking

23. HYDRAULIC SERVO SYSTEM

The servo system section includes:

• Servo pressure checking
• Servo pressure adjustment
• Servo pressure measurement at the control valve spool
• Servo accumulator removal
• Servo accumulator installation
• Hydraulic control system testing

24. BOOM SUSPENSION SYSTEM (BSS)

The manual includes component descriptions, functional information, and workshop procedures for the Boom Suspension System.

BSS service operations:

• Boom Suspension System checking
• Accumulator pressure checking
• Accumulator pressure adjustment
• Accumulator reconditioning
• Accumulator depressurization
• Left accumulator removal
• Left accumulator installation
• Pressure reduction valve checking
• Safety valve checking
• Safety valve adjustment

25. AUXILIARY HYDRAULIC FUNCTIONS

The documentation covers third and fourth hydraulic functions used with compatible attachments.

Included topics:

• Auxiliary hydraulic valve operation
• Third hydraulic function
• Third and fourth hydraulic functions
• Auxiliary hydraulic pressure checking
• Auxiliary hydraulic pressure adjustment
• Shock valve checking
• Auxiliary hydraulic functional testing
• Attachment locking checking

26. AUTOMATIC LUBRICATION SYSTEM

The manual includes information about the machine's central lubrication equipment.

Subjects covered:

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

27. FIRE SUPPRESSION SYSTEM

The fire suppression section contains:

• Fire suppression system component descriptions
• Maintenance and safety references
• Actions following automatic system activation
• Actions following manual activation
• Fire suppression technical specifications

28. HYDRAULIC DIAGRAMS

The publication includes complete hydraulic system diagrams and explanations.

These schematics can be consulted when working with:

• Hydraulic pressure circuits
• Hydraulic pumps
• Servo controls
• Working hydraulics
• Boom suspension
• Auxiliary hydraulic equipment

29. OPTIONAL EQUIPMENT INSTALLATION

The installation section contains instructions for selected machine accessories and optional systems.

Hydraulic and control equipment:

• Third hydraulic function
• Third and fourth hydraulic functions
• Attachment locking
• Boom Suspension System
• Electric CDC lever steering
• Single-lever control for second hydraulic function

Engine and service equipment:

• Engine heater, 120V
• Engine heater, 240V
• Extra fuel filter
• High Sulphur Fuel Conversion Kit
• Cyclone pre-cleaner
• Oil-bath pre-cleaner
• Reversible cooling fan
• Hand throttle

Electrical and monitoring equipment:

• CareTrack
• Anti-theft device
• Battery main switch
• Back-up alarm
• Forward-view camera
• Rear-view camera

Lighting and protection equipment:

• LED cab front work lights
• LED cab rear work lights
• LED cab side work lights
• LED front work lights
• LED grille work lights
• Front and rear work lights
• Rotating beacon
• Front lighting protection
• Radiator grille guard
• Windscreen guard

Cab equipment:

• Radio installation
• Cab air pre-cleaner

The installation instructions refer to specific equipment configurations and should be checked against the machine's actual setup.

30. WORKSHOP SAFETY

The safety documentation includes procedures and precautions for servicing heavy machinery.

Included topics:

• General workshop safety
• Machine service positions
• Hydraulic system safety
• Hydraulic accumulator handling
• Electrical system safety
• Battery handling
• Air conditioning refrigerant safety
• Oil and fuel handling
• Tyre safety
• Fire prevention
• Checks following fire or heat exposure
• Environmental handling
• Decontamination
• Waste disposal
• Safe lifting and supporting
• Working under a raised boom
• Booster battery starting

31. TECHNICAL SPECIFICATIONS

The manual contains reference tables for the machine's major assemblies.

Machine System	Technical Information
Engine	Specifications, fluid quantities, software data, tightening torques
Fuel system	Fuel system specifications and tightening torques
Exhaust aftertreatment	Aftertreatment system specifications
EGR	Component tightening torques
Cooling	Fan speeds, thermostat data, temperature limits
Lubrication	Oil pressure and lubrication specifications
Electrical	Alternator, battery, starter motor, lighting
Transmission	Transmission specifications, capacity, tightening torques
Drive axles	Axle specifications, oil volumes, tightening torques
Brakes	Brake accumulator, wheel brake, parking brake
Steering	CDC, steering system, secondary steering pump
Frame	Counterweight, frame joint, wheels
Cab	Air conditioning, refrigerant weight, tightening torques
Hydraulic pumps	Pump P2 and Pump P3 specifications
Hydraulic equipment	System volume, control valves, servo system
Auxiliary hydraulics	Third and fourth function specifications
Boom suspension	BSS specifications and tightening torques
Lubrication equipment	Automatic lubrication specifications
Fire suppression	System specifications

WHY CHOOSE THIS VOLVO L90G MANUAL?

This publication offers workshop information for a wide range of service activities, including:

• Diesel engine mechanical repairs
• High-pressure fuel injection system maintenance
• DPF cleaning and DOC replacement
• Exhaust regeneration equipment servicing
• EGR component replacement
• Electronic control module replacement
• VCADS Pro diagnostic references
• Electrical wiring fault investigation
• Transmission servicing
• Axle and hub reduction repairs
• Brake accumulator testing
• Parking brake repairs
• CDC steering maintenance
• Hydraulic pump pressure adjustments
• Lift and tilt cylinder repacking
• Boom Suspension System repairs
• Auxiliary hydraulic function testing
• Air conditioning servicing
• Optional equipment installation

The combination of mechanical, electrical, hydraulic, and aftertreatment documentation makes this manual a useful technical resource for Volvo L90G maintenance and repair.

WHO CAN USE THIS MANUAL?

The manual is intended for:

• Volvo construction equipment service technicians
• Heavy machinery repair workshops
• Diesel engine mechanics
• Construction equipment fleet maintenance teams
• Electrical diagnostics specialists
• Hydraulic repair technicians
• Experienced Volvo L90G owners

IMPORTANT MODEL COMPATIBILITY INFORMATION

This manual is identified for the Volvo L90G Wheel Loader.

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

Certain electrical diagrams, aftertreatment components, hydraulic circuits, and optional equipment instructions may apply only to specific configurations.

Technical Information Updated: 2022 refers to the documentation update year and does not necessarily indicate when the wheel loader was manufactured.

DIGITAL PDF PRODUCT

You are purchasing a digital technical manual containing 2,132 pages of service and repair documentation.

The publication includes descriptions, repair procedures, electrical wiring diagrams, hydraulic schematics, installation instructions, safety information, and specifications.

No printed manual or physical product will be shipped.

A PDF reader is required to view the document.

IMPORTANT DOWNLOAD INFORMATION

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

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Detailed contents: 

Descriptions
(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
CareTrack W-ECU, description
Central warning
Alarm, description 2
Alarm, description
Information display, check
Information display, settings
Information display, service mode
Information display, service
Information display, vehicle messages
Information display, vehicle info
Information display, electrical system
Information display, axles brakes
Information display, hydraulics
Information display, transmission
Information display, engine
Information display, operating display
Information display, start lockout
Information display, general
Middle instrument panel with warning lights
Instrument panels
Branching in cables
Chassis connection
Battery disconnector switch, description
W-ECU, I O list
V2-ECU, I O list
V-ECU, I O list
I-ECU, I O list
E-ECU, I O list
ECC, I O list
ACM, I O list
Components list
Cable and component marking explanations
Cable and component designations
Electrical symbols and designations
Hood opening
Engine control unit E-ECU, description
Vehicle control unit V2-ECU, description
Vehicle control unit V-ECU, description
Connectors, overview
Intermittent wiper and washer
Lighting, description
Preheating, description
Booting sequence
Alternator, description 2
Alternator, description
Battery, charging
Battery, description
Key feed
System voltage
Software parameters, description
Communication with data buses
Electronic control system, description
Software, description
Electrical system, description
Electrical system, work instructions
(4) POWER TRANSMISSION
Oil cooler, component description
Differential lock, description
Automatic differential brake, Limited Slip, description
Rear axle mounting, component description
Rear axle, component description
Front axle, component description
Drive axles, description
Propeller shaft, component description
Hydraulic transmission, 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, alternatively 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) POWER TRANSMISSION
(9) HYDRAULIC SYSTEM;DIGGING HANDLING GRADING EQUIPM.; MISC. EQUIP
Explanations to hydraulic diagram
Hydraulic diagram, complete
Installation Instruction
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 2
Pre-cleaner oil bath 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, 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
w plug control unit, replacing
Wastegate, checking
(3) ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Batteries, replacing
Battery condition, checking
CareTrack battery, replacing
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) 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
Hub reduction, installing2
Hub reduction, removing
Hub reduction, removing2
Hub seal, replacing
Hub seal, replacing2
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
Brake piston seals, replacing2
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
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
Door lock cylinder, replacing2
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
Side window, replacing2
Window pane, installing
Windscreen, replacing
(9) HYDRAULIC SYSTEM;DIGGING HANDLING GRADING EQUIPM.; MISC. EQUIP
3rd th 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
Accumulator, discarding2
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 power control valve, replacing
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 cylinder, repacking in machine2
Lifting time, checking
Liftlower function, checking
Servo accumulator, installing (2)
Servo accumulator, installing
Servo accumulator, removing
Servo accumulator, removing2
Servo pressure, at the spool in control valve, checking
Servo pressure, checking and adjusting
Servo pressure, checking and adjusting2
Shock valve lift function, checking
Shock valve, tilt function, checking
Shock valve, tilt function, checking2
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
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
Engine, tightening torques
Engine, specifications
Lubrication system, specifications 1
Lubrication system, specifications
Fuel system, specifications
EGR system, tightening torques
Conversion tables
Thermostat, specifications
Engine, software specifications
Tightening torques
(1) STANDARD PARTS, SERVICE
Wheel brake, specification
Alternative fuels
Recommended lubricants
Coolant
(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, specifications
Engine, tightening torques
Exhaust aftertreatment system, specifications
Fuel system, specifications
Fuel system, tightening torques
ine, software specifications
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
lectrical system, specifications
Lighting, specifications
Preheating, specifications
Starter motor, specifications
(4) POWER TRANSMISSION
Transmission, tightening torques
Transmission, specifications
Transmission, specifications 4
Transmission, specifications 3
Transmission, specifications 2
Propeller shaft, tightening torque
Hydraulic transmission, capacity
Front and rear axles, volume
Front and rear axles, tightening torque
Front and rear axles, specifications
(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
Attachment bracket, rotary, 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