Preview

L60H, L70H, L90H
VOLVO WHEEL LOADERS 13.0-18.3 t / 24,250-38,140 lb 165-184 hp

A passion for performance.
At Volvo Construction Equipment, we’re not just coming along for the ride. Developing products
and services that raise productivity – we are confident we can lower costs and increase profits
for customers around the globe. Part of the Volvo Group, we are passionate about innovative
solutions to help you work smarter – not harder.
Helping you to do more

Doing more with less is a trademark of Volvo Construction The strength of our dealer network is enhanced with extensive
Equipment. High productivity has long been married to low energy individualized product support training at our best-in-class Customer
consumption, ease of use and durability. When it comes to lowering Center in Shippensburg and through hands-on training. Using a
life-cycle costs, Volvo is in a class of its own. great Product Demonstration Center featuring a dedicated area for
most commons applications, visitors operate equipment from our
Designed to fit your needs entire product line under a variety of simulated working conditions.
There is a lot riding on creating solutions that are suited to the This facility is in year-round use by our dealers and customers.
particular needs of different industry applications. Innovation often Building the best starts right here.
involves high technology – but it doesn’t always have to. Some
of our best ideas have been simple, based on a clear and deep The products designed and manufactured by Volvo Construction
understanding of our customers’ working lives. Equipment have their beginnings at the most advanced Research &
Design centers in the industry. Volvo CE machines are designed in
11 R&D centers and produced in 15 manufacturing facilities across
the world.
The major R&D center and manufacturing plant in the Americas

is located in Shippensburg, Pennsylvania. This facility has been in
operation for over 30 years and – with its recently added 200,000
You learn a lot in 180 years sq. ft. expansion – now covers 570,000 sq. ft. on an 80 acre campus.
Over the years, Volvo has advanced solutions that have revolutionized Dedicated work teams and highly advanced technologies and
the use of construction equipment. No other name speaks Safety techniques using the Volvo Production System ensure continuous
louder than Volvo. Protecting operators, those around them and quality improvements, labor savings and cost control to reach the
minimizing our environmental impact are traditional values that high quality that our customers have come to expect from Volvo.
continue to shape our product design philosophy.
We’re on your side

We back the Volvo brand with the best people. Volvo is truly a global
enterprise, one that is on standby to support customers quickly and
efficiently – wherever they are.
We have a passion for performance.
A strong, dedicated, capable dealer network.

Our dealers are strategically located throughout North America to
provide the equipment you need and the parts and service support
you demand for a productive and profitable operation.
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Volvo Trucks Renault Trucks Mack Trucks UD Trucks
Volvo Buses Volvo Construction Equipment Volvo Penta Volvo Financial Services
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See clearer in comfort.
The Volvo L60H, L70H and L90H wheel loaders are versatile machines that can take on any task
with a wide range of perfectly matched attachments. From the comfort of your wheel loader, sit back
and enjoy a clear view of the site while increasing your productivity and uptime.
HMI – New display and controls

Operator ergonomics is at the forefront of Volvo’s HMI (Human
Seat
Machine Interface) design. The information display, controls, setting
switches, hydraulic control levers and steering wheel, are all designed The operator’s seat has several adjustment possibilities for maximum
and placed in the cab for easy and comfortable operation. The comfort. Suspension and damping are adjustable according to body
information display informs the operator about all necessary machine weight and both the seat cushion and backrest can be positioned at
information for peace of mind, control and less fatigue. The new various angles. Well placed instruments and adjustable lever console
display has better visibility even when exposed to direct sunlight. make your long day a lot more comfortable.
Heating, ventilation and air conditioning Industry leading air-filtration

The standard Automatic Heat Control (AHC) system ensures a Volvo’s industry-leading air filtration system allows 90% of the cab air
comfortable environment inside the cab. Air conditioning is also to be recirculated through the main filter for continuous dust removal
available so the operator can work in comfortable conditions, in any and a cleaner environment. The cab air intake is located in a high
climate. position where the air is cleaner. An easily replaceable external pre-
filter effectively separates coarser dust and particles before entering
the main filter and cab.
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Cab
Volvo continues to provide the industry-leading cab for
maximum comfort, visibility and productivity. The cab is
consistent across all Volvo wheel loaders and boasts unparalleled all-
round visibility, space, climate control, safety and vibration levels. The
Volvo cab is also renowned for its effective sound proofing, protecting
the operator from noise for a more productive environment.
TP linkage
The TP linkage combined with the new and improved Volvo
attachment bracket offers industry leading versatility and
unparalleled front visibility. The TP linkage combines the benefits of the
Z-bar and parallel linkage to deliver high breakout torque and excellent
parallel movement throughout the entire lifting range. The bracket
allows attachments to be changed quickly and safely so the machine
can perform a wide range of tasks.
An up-front approach.
The wheel loaders are especially designed to match a number of attachments so that you can handle
a variety of tasks on your job site with the same machine. The TP linkage together with the improved
Volvo attachment bracket provides excellent versatility and visibility.
Double sealed joints

Attachment Bracket The Volvo TP linkage features double sealed joints for all linkage pins.
Want to switch between different attachments quickly and easily? The double sealing system retains lubricating grease and prevents
Then look no further than the market-leading attachment bracket dust or other contaminants from getting in. The double sealing system
from Volvo Construction Equipment. The smart design of the interface results in a longer life for the lift arm system. The high quality and
enables safe connection to a wide range of attachments that meet the durable components last longer, reduce maintenance and increase
International Standardization Organization (ISO) standard. uptime.
Roll back angle Parallel movement

The Volvo TP linkage geometry, along with the Volvo bucket design, The TP linkage allows excellent parallel movement, which means the
provides excellent bucket roll-back angles. The superior roll-back load stays level throughout the entire lifting range. This allows the
angle increases the amount of retained material in the bucket and operator to have full control over the load, which increases safety and
keeps the load closer to the front axle for increased stability and less productivity.
spillage. As a result, the roll back angle increases productivity.
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A multiple of talents.
Volvo offers the most durable and effective Volvo attachments, which work in harmony with your
machine for increased productivity and versatility. They are designed for improved visibility and ease
of use, so you can swap and change your Volvo attachments quickly and safely.
New General Purpose (GP) bucket

Pallet forks
The improved Volvo general purpose bucket is designed for higher
productivity and increased fuel efficiency. The bucket – when fitted Volvo’s pallet fork frame with pallet fork tines allow the machine to
with bolt-on edges – handles loose material, such as gravel and handle, load and move pallets of building material, drainage pipe,
aggregates in both short cycle or load and carry operations. It can lumber, or loose items around the uneven terrain of a construction
be fitted with optional welded teeth and segments to load harder site. The Volvo pallet fork and attachment bracket has been designed
banked material with ease. It provides excellent support on your job for industry-leading visibility at different working heights while moving
site and the wear resistant steel is used in the most exposed areas for and lifting materials. Volvo’s durable TP linkage, attachment bracket
increased durability and long life. and pallet forks increase safety.
Material handling arm Light Material (LM) bucket

Volvo’s material handling arm extends your machine’s versatility. The Volvo light material bucket with a robust light weight design and
Designed to work with Volvo wheel loaders and with an approved lift high capacity, secures the highest productivity for your machine. The
capacity set for each arm and machine, you’ll know exactly how much bucket is designed for efficient handling low density material, such as
you can lift safely. The extendable arm consists of three sections, snow, sawdust, wood chips and compost. It’s delivered with a standard
providing increased flexibility and greater reach. Safety Mechanical bolt-on edge.
stops also prevent the material handling arm from overextending – a
safety hook at the end of the arm is fitted as standard.
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Attachment offer
Volvo attachments give you more flexibility. Each
attachment from the extensive range is perfectly matched
to the machine’s link-arm geometry and breakout, rim pull and lifting
force. All attachments can be fastened and removed quickly thanks to
Volvo’s attachment bracket so you can ‘connect and go’.
Volvo Powertrain
These machines feature entirely Volvo designed and built
Powertrain components, which have been created to
work together in harmony. Thanks to years of development, the Volvo
Powertrain offers unrivalled durability and performance for increased
uptime, as well as longer component life and higher fuel efficiency.
Made to last.
Quality is key at Volvo, which is why only the best components, technology and systems are used in
the Volvo wheel loaders. All parts work with each other for increased reliability and a long cycle life,
saving you long term costs and downtime.
Counter shaft transmission

Axles
The Volvo counter shaft transmission offers a heavy duty solution
for proven reliability and durability. The machines are equipped with Volvo axles provide longer service life as a result of the free-floating
a counter shaft transmission that can endure more stress. Various shaft design, durable components, circulating lubrication oil and wet-
tailored settings can be selected by the operator to match all disc brakes. The outboard service brakes are easily maintained for
applications whether it’s short cycle truck loading or medium to long greater uptime and can also be easily monitored using the brake wear
distance load and carry. indicators.
Differential lock Intelligent hydraulic system

The differential lock provide outstanding traction and rimpull on soft The load sensing hydraulic system increases fuel efficiency and
and slippery ground conditions. The front axle is mounted to the front provides perfect control of the load. It also allows for more engine
frame and equipped with an electro-hydraulically operated differential power to be available for rimpull, providing easier penetration for
lock. The differential lock is a dog-clutch type which can secure 100% increased performance. With help from the variable displacement
locking, which minimizes wheel spin and tire wear. piston pumps and precision control levers, hydraulic power is delivered
according to demand.
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Strongly attached.
Environmental care is at the forefront of Volvo’s core values and to show its passion and dedication,
Volvo thinks about all aspects of the machine which can impact on the environment.
Eco-pedal
This unique feature keeps operators aware of whether they are
operating in the most economical way in order to increase fuel
efficiency. The Eco-pedal with a mechanical push-back mechanism
Tier 4 Final
engages when the engine rpm is about to exceed the economic
Volvo’s 6 litre diesel Tier 4 Final engine complies with the latest operating range. The operator senses the resistance and then
emissions legislation and delivers high torque at low engine rpm. The operates within the optimal operating range. If full engine speed
engine delivers industry-leading performance and impressive fuel is needed, this mechanical push-back mechanism can easily be
efficiency. overridden.
Service access 95% of the machine is recyclable

The service friendly design keeps your routine maintenance quick and Planned recycling of the machine is the last stage of its life cycle.
efficient. The one piece motorized engine hood opens up at a large Being able to recycle machine parts and materials for use in new
angle, providing full access to the engine compartment and engine Volvo wheel loaders or other products is part of Volvo’s responsibility
maintenance points are strategically grouped together for quick and to environmental care. According to our calculations, the machine is
easy service checks. The machine also features fluid drain ports which up to 95% recyclable by weight. Volvo thrives to build a sustainable
simplifies the oil changing. This prevents oil spillages that impacts the environment and reuse parts whenever possible.
environment.
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Low Emissions Level
The H-series wheel loaders are equipped with the latest
technology dedicated to protecting the environment.
Eco-pedal, recyclable materials usage, and our latest Tier 4 final
compliant engine technology are only examples of features showing
our commitment to sustainable development. In addiction, remote oil
drains, CareTrack telematics and MATRIS reports are also offered
by Volvo to help you limit your fuel consumption, greenhouse gas
emissions or fluid spillage.
An application for any occasion.
Cab
Volvo continues to provide the industry-leading cab
for maximum comfort, visibility and productivity.
Human Machine Interface

The information display, controls, setting switches,
hydraulic control levers and steering wheel, are
all designed and placed in the cab for easy and
comfortable operation.
TP linkage
The TP linkage combines the benefits of Z-bar and
parallel linkage in one to deliver high breakout torque
and excellent parallel movement through the entire
lifting range.
Attachment bracket
The Volvo attachment
bracket is the most
commonly used
attachment bracket
in the world with a
compact and robust
design for outstanding
visibility.
Attachment offer Eco pedal

Volvo’s wide range of high quality attachments are perfectly This unique feature keeps operators
matched to the machine’s linkage, hydraulics and driveline to aware of whether they are operating
work as one unit and increase productivity. in the most economical way in order to
increase fuel efficiency.
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Volvo Powertrain
These machines feature entirely Volvo designed
and built Powertrain components, which have been
created to work together in harmony.
Hydraulic cooling fan

Hydraulically driven, electronically controlled
cooling fan, located between the engine and
radiator, speeds-up only when necessary to
lower fuel consumption and sound levels.
Tier 4 Final/Stage IV
engine technology
Volvo’s 6 litre diesel Tier
4 Final/ Stage IV engine
complies with the latest
emissions legislation
and delivers high torque
at low engine rpm.
Intelligent hydraulic system

The load sensing hydraulic system
increases fuel efficiency and provides
perfect control of the load.
Service access
The service friendly design increases your uptime
by allowing easy access and quick service.
CareTrack*
CareTrack provides information for better
planning and smarter working, including fuel
consumption reports, location reports and
service reminders.
Low Emissions Level

Lifetime Frame Warranty:
The wheel loaders are equipped
with the latest technology dedicated Find out more on volvoce.com/structureandframe
to protecting the environment.
* In markets where CareTrack is available

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Volvo L60H, L70H, L90H in detail.
Engine
6-cylinder, 6 liters in-line turbocharged diesel engine with
an advanced fuel injection system with the common rail.
Fuel is distributed under high pressure from a high-pressure
accumulator, the rail. One belt driven high pressure pump deliver
the fuel to the rail and then further on via high-pressure pipes to
the electronically operated fuel injectors. Engine meets
Tier 4 Final emission legislation.
L60H L60H
D6J
Engine
(Tier 4 Final) 175 130 700
120 900
Max power at r/s (r/min) 23.3-30.0 (1,400-1,800) 155
110
800 600
SAE J1995 gross kW hp 123 165 135 100
90 700
ISO 9249, SAE J1349 net kW hp 123 165 115
80
500
Max torque at r/s (r/min) 23.3 (1,400) 95 70 600

60 400
SAE J1995 gross Nm lbf ft 820 605 75
50
500
ISO 9249, SAE J1349 net Nm lbf ft 820 605 55 40 400 300
800 1 000 1 200 1 400 1 600 1 800 2 000
Economic working range r/s (r/min) 13.3-26.6 (800-1,600)
r/s
Displacement l in3 5.7 348
L70H L70H
D6J
Engine
(Tier 4 Final) 175 130 700
120 900
110
800 600
SAE J1995 gross kW hp 127 170 135 100
90 700
ISO 9249, SAE J1349 net kW hp 127 170 115
80
500

60 400
50
500
800 1 000 1 200 1 400 1 600 1 800 2 000
r/s
L90H L90H
D6J
Engine
(Tier 4 Final) 175 130 700
120 900
110
800 600
SAE J1995 gross kW hp 137 184 135 100
90 700
ISO 9249, SAE J1349 net kW hp 137 184 115
80
500

60 400
50
500
800 1 000 1 200 1 400 1 600 1 800 2 000
r/s
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Drivetrain Electrical system
Torque converter: Single-stage Contronic electrical system with central warning light
Transmission: Volvo countershaft transmission with single lever and buzzer for following functions: - Serious engine fault,
control. Fast and smooth shifting of gears with Pulse Width Low steering system pressure, Over speed warning engine,
Modulation (PWM) valve. Interruption in communication (computer fault), Central warning
Transmission: Volvo Automatic Power Shift (APS) gear shifting light and buzzer with the gear engaged for the following
system with fully automatic shifting 1-4 and mode selector with 4 functions: Low engine oil pressure, High engine oil temperature,
different gear shifting programs, including AUTO mode. High charge air temperature, Low coolant level, High coolant
Axles: Volvo fully floating axle shafts with planetary hub temperature, High crank case pressure, Low transmission oil
reductions and cast steel axle housing. Fixed front axle and pressure, High transmission oil temperature, Low brake pressure,
oscillating rear axle. 100% differential lock on the front axle. Engaged parking brake, Fault on brake charging, Low hydraulic
L60H oil level, High hydraulic oil temperature, Overspeeding in engaged
gear, High brake cooling oil temperature front and rear axles, etc.
Transmission Volvo HTE 125
L60H, L70H, L90H
Torque multiplication, stall ratio 2.5:1
Batteries V 2 x 12
1st gear km/h mph 7 4.3
Battery capacity Ah 2 x 110
Maximum speed, 2nd gear km/h mph 14 8.7
Cold cranking capacity, approx A 680
forward/reverse 3rd gear km/h mph 27 16.8
Alternator rating W/A 3 135/80
4th gear* km/h mph 44 27.3
Starter motor output kW 5.5
Measured with tires 20.5R25
Brake system
Front axle/rear axle AWB 15/AWB 15
Rear axle oscillation ± ° ± 13 Service brake: Volvo dual-circuit system with outboard mounted,
hydraulically operated, fully sealed and circulating oil cooled wet
Ground clearance at 13° osc. mm in 470 18.5 disc brakes. Operator selectable, four transmission de-clutch
L70H settings while braking.
Transmission Volvo HTE 125 Parking brake: Dry disc brake mounted on the transmission
Torque multiplication, stall ratio 2.5:1 output shaft. Applied by spring force, electro-hydraulically
released with a switch on the instrument panel.
1st gear km/h mph 7 4.3 Secondary brake: Dual brake circuits with rechargeable
Maximum speed, 2nd gear km/h mph 14 8.7 accumulators.
forward/reverse 3rd gear km/h mph 27 16.8 Standard: The brake system complies with the requirements of
ISO 3450, 71/320/EEC
Measured with tires 20.5R25 L60H
Front axle/rear axle AWB 25/AWB 20 Number of brake discs per wheel front 1
Rear axle oscillation ± ° ± 13 Accumulators l gal 3 x 0.5 3 x 0.13
Ground clearance at 13° osc. mm in 470 18.5 L70H
L90H Number of brake discs per wheel front 1
Transmission Volvo HTE 125 2 x 0.5 2 x 0.13
Accumulators l gal
+1 x 1.0 +1 x 0.26
Torque multiplication, stall ratio 2.5:1
1st gear km/h mph 7 4.3 L90H
2nd gear km/h mph 13 8.1 Number of brake discs per wheel front 1
Maximum speed,
forward/reverse 3rd gear km/h mph 25 15.5 2 x 0.5 2 x 0.13
Accumulators l gal
+1 x 1.0 +1 x 0.26
Measured with tires 20.5R25
Front axle/rear axle AWB 25/AWB 20
Rear axle oscillation ± ° ± 13
Ground clearance at 13° osc. mm in 470 18.5
*limited by ECU
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Volvo L60H, L70H, L90H in detail.
Cab Hydraulic system
Instrumentation: All important information is centrally located Closed center load sensing hydraulic system with non pressurised
in the operator’s field of vision. Display for Contronic monitoring hydraulic tank and pilot operated control valves.
system System supply: Variable displacement axial piston pump supply
Heater and defroster: Heater coil with filtered fresh air and fan the hydraulic system.
with auto and 11 manual speed settings. Defroster vents for all Valves: The central valve distributes pressure and flow out to the
window areas. cooling fan, steering, brake, pilot and hydraulic system. Steering
Operator’s seat: Operator’s seat with adjustable air suspension system gets priority over others.
and retractable seat belt. The seat is mounted on a bracket on Lift function: The valve has four positions; raise, hold, lower and
the rear cab wall and floor. The forces from the retractable seat float position. Automatic boom kick-out position can be set to any
belt are absorbed by the seat rails. position between maximum reach and full lifting height.
Standards: The cab is tested and approved according to ROPS Tilt function: The valve has three functions; rollback, hold and
(ISO 3471), FOPS (ISO 3449). The cab meets with requirements dump. Automatic tilt-back can be adjusted to the desired bucket
according to ISO 6055 (Operator overhead protection - Industrial angle.
trucks) and SAE J386 (Operator Restraint System). Cylinders: Double-acting cylinders for all functions.
L60H L70H L90H Filter: Full flow filtration through 10 micron (absolute) filter
cartridge.
Emergency exit: Use emergency hammer to break window
L60H L70H L90H
Sound level in cab according to ISO 6396/SAE J2105
Working pressure
LpA dB(A) 68 68 68 maximum, pump 2
External sound level according to ISO 6396/SAE J2105 for steering-, brake-, MPa bar 26.0 260 26.0 260 31 310
LwA dB(A) 104 105 105 pilot- and working
Ventilation m3/min yd3/min 9.0 11.8 9.0 11.8 9.0 11.8 hydraulic system
gal/
Heating capacity kW 16 16 16 Flow l/min 145 38.3 154 40.7 171 45.2
min
Air conditioning (optional) kW 7.5 7.5 7.5 at MPa bar 10 100 10 100 10 100
Lift arm system engine speed r/s(r/min) 32 (1,900) 32 (1,900) 32 (1,900)
Torque parallel linkage (TP-linkage) with high breakout torque Working pressure
and parallel lift-arm action. maximum, pump
MPa bar 21.0 210 21.0 210 21.0 210
L60H L70H L90H 3 for brake- and
Lift cylinders 2 2 2 cooling fan system
gal/
Cylinder bore mm in 110 4.3 110 4.3 120 4.7 Flow l/min 33 8.7 33 8.7 33 8.7
min
Piston rod diameter mm in 70 2.8 70 2.8 70 2.8 at MPa bar 10 100 10 100 10 100
Stroke mm in 665 26.2 756 29.8 733 28.9 engine speed r/s (r/min) 32 (1,900) 32 (1,900) 32 (1,900)
Tilt cylinder 1 1 1 Pilot system,
Cylinder bore mm in 150 5.9 160 6.3 180 7.1 MPa bar 3.5 35 3.5 35 3.5 35
working pressure
Piston rod diameter mm in 80 3.1 90 3.5 90 3.5 Cycle times
Stroke mm in 444 17.5 432 17.0 430 16.9 Lift s 4.5 5.1 5.4
Service / Refill capacity Tilt s 2.3 1.3 1.9
Service accessibility: Large, electrically operated easy-to-open Lower, empty s 2.9 2.7 3.2
hood covering whole engine compartment. Fluid filters and Total cycle time s 9.7 9.1 10.5
component breather air filters are located from ground level
Steering system
access and promote long service intervals. Machine contronics
have possibility to monitor, log and analyze data to facilitate System supply: The steering system has priority feed from a
troubleshooting. load-sensing axial piston pump with variable displacement.
Steering cylinders: Two double-acting cylinders.
L60H L70H L90H
L60H L70H L90H
Fuel tank l gal 222 58.6 222 58.6 222 58.6
Steering cylinders 2 2 2
DEF tank l gal 20 5.3 20 5.3 20 5.3
Cylinder bore mm in 70 2.76 70 2.76 80 3.1
Engine coolant l gal 30 7.9 30 7.9 30 7.9
Rod diameter mm in 45 1.77 45 1.77 50 2.0
Hydraulic oil tank l gal 90 23.8 90 23.8 90 23.8
Stroke mm in 386 15.2 386 15.2 345 13.6
Transmission oil l gal 21 5.5 21 5.5 21 5.5
Working pressure MPa bar 21 210 21 210 21 210
Engine oil l gal 19.5 5.2 19.5 5.2 19.5 5.2
gal/
Axle oil front l gal 25 6.6 35 9.2 35 9.2 Maximum flow l/min 60 15.9 60 15.9 60 15.9
min
Axle oil rear l gal 25 6.6 27 7.1 27 7.1
Maximum
±° 40 40 40
articulation
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Dimensions.
Where applicable,
specifications and
dimensions are according
to ISO 7131, SAE J732,
ISO 7546, SAE J742,
ISO 14397, SAE J818.
Tires 20.5 R25 L3

Standard boom Long boom
L60H L70H L90H L60H L70H L90H
B mm ft in 6 040 19' 10" 6 080 19' 11" 6 160 20' 3" 6 550 21' 6" 6 560 21' 6" 6 590 21' 8"
C mm ft in 3 000 9' 10" 3 000 9' 10" 3 050 10' 0" 3 000 9' 10" 3 000 9' 10" 3 050 10' 0"
D mm ft in 440 1' 5" 450 1' 6" 450 1' 6" 440 1' 5" 450 1' 6" 450 1' 6"
F mm ft in 3 270 10' 9" 3 280 10' 9" 3 280 10' 9" 3 270 10' 9" 3 280 10' 9" 3 280 10' 9"
G mm ft in 2 134 7' 0" 2 134 7' 0" 2 132 7' 0" 2 134 7' 0" 2 134 7' 0" 2 132 7' 0"
J mm ft in 3 570 11' 9" 3 590 11' 9" 3 660 12' 0" 4 150 13' 7" 4 100 13' 6" 4 090 13' 5"
K mm ft in 3 870 12' 8" 3 870 12' 9" 3 970 13' 0" 4 380 14' 4" 4 390 14' 5" 4 400 14' 5"
O ° 56 56 57 58 52 57
Pmax ° 46 46 44 42 43 45
R ° 43 43 44 43 43 46
R1* ° 47 48 49 50 49 51
S ° 79 68 67 78 73 66
T mm ft in 103 0' 4" 101 0' 4" 107 0' 4" 79 0' 3" 107 0' 4" 102 0' 4"
U mm ft in 450 1' 6" 440 1' 3" 470 1' 6.5" 540 1' 9" 500 1' 8" 510 1' 8"
X mm ft in 1 900 6' 3" 1 930 6' 4" 1 960 6' 5" 1 900 6' 3" 1 930 6' 4" 1 960 6' 5"
Y mm ft in 2 430 8' 0" 2 460 8' 1" 2 490 8' 2" 2 430 8' 0" 2 460 8' 1" 2 490 8' 2"
Z mm ft in 3 210 10' 6" 3 160 10' 4" 3 290 10' 9" 3 590 11' 10" 3 500 11' 6" 3 660 12' 0"
a2 mm ft in 5 340 17' 6" 5 350 17' 7" 5 430 17' 10" 5 340 17' 6" 5 350 17' 7" 5 430 17' 10"
a3 mm ft in 2 900 9' 6" 2 890 9' 6" 2 950 9' 8" 2 900 9' 6" 2 890 9' 6" 2 950 9' 8"
a4 ±° 40 40 40 40 40 40
Tires: 20.5R25 L3
L60H L70H L90H
Grapple sales code 82194 80153 80832
SAE-Load kg lb 3 450 7,610 3 990 8,800 4 600 10,140
Operating weight
kg lb 12 380 27,310 14 110 31,110 16 100 35,510
without load*
A m2 yd2 1.3 14 1.5 16.1 2.4 25.8
B mm ft in 3 410 11' 2" 3 380 11' 1" 3 420 11' 3"
C mm ft in 1 480 4' 10" 1 590 5' 3" 1 790 5' 11"
D mm ft in 2 930 9' 7" 2 870 9' 5" 2 790 9' 2"
E mm ft in 1 170 3' 10" 1 260 4' 2" 1 410 4' 7"
F mm ft in 1 530 5' 0" 1 510 4' 11" 1 440 4' 9"
G mm ft in 2 350 7' 8" 2 440 8' 0" 2 740 9' 0"
H mm ft in 4 330 14' 3" 4 380 14' 5" 4 540 14' 11"
I mm ft in 5 880 19' 3" 6 030 19' 9" 6 590 21' 7"
J mm ft in 2 000 6' 7" 2 140 7' 0" 2 790 9' 2"
K mm ft in 2 080 6' 10" 2 370 7' 9" 2 990 9' 10"
L mm ft in 1 710 5' 7" 1 790 5' 11" 2 130 7' 0"
M mm ft in 7 890 25' 11" 7 990 26' 2" 8 460 27' 9"
* Including logging counterweight
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Dimensions.
Tires: 20.5R25 L3
L60H L70H L90H
MHA sales code 92007 92007 92008
A* kg lb 1 800 3,969 2 150 4,741 2 760 6,086
B* kg lb 1 400 3,087 1 710 3,771 2 130 4,697
C* kg lb 1 150 2,536 1 400 3,087 1 740 3,837
Static tipping load,
kg lb 3 070 6,780 3 430 7,560 4 080 9,000
straight
35deg. turn kg lb 2 760 6,090 3 090 6,800 3 650 8,040
at full turn kg lb 2 670 5,880 2 980 6,580 3 520 7,760
D mm ft in 2 590 8' 6" 2 710 8' 11" 2 610 8' 7"
E mm ft in 2 000 6' 7" 2 100 6' 11" 2 010 6' 7"
F mm ft in 1 460 4' 10" 1 540 5' 1" 1 410 4' 7"
G mm ft in 3 270 10' 9" 3 320 10' 11" 3 250 10' 8"
H mm ft in 4 300 14' 1" 4 350 14' 3" 4 380 14' 5"
I mm ft in 5 430 17' 10" 5 490 18' 0" 5 520 18' 1"
J mm ft in 900 2' 11" 1 260 4' 2" 1 340 4' 5"
K mm ft in 1 220 4' 0" 1 740 5' 9" 1 890 6' 2"
L mm ft in 1 580 5' 2" 2 260 7' 5" 2 430 8' 0"
M mm ft in 2 260 7' 5" 2 170 7' 2" 2 040 6' 8"
N mm ft in 3 240 10' 8" 3 090 10' 2" 3 030 9' 11"
O mm ft in 4 320 14' 2" 4 100 13' 5" 4 020 13' 2"
P mm ft in 1 510 4' 11" 1 530 5' 0" 1 530 5' 0"
Q mm ft in 5 290 17' 4" 5 300 17' 5" 5 340 17' 6"
R mm ft in 6 170 20' 3" 6 180 20' 3" 6 300 20' 8"
S mm ft in 7 140 23' 5" 7 130 23' 5" 7 260 23' 10"
Operating weight
kg lb 11 670 25,720 13 160 29,020 14 520 32,010
without load
* Op. load at full turn + tipping position
Tipping loads calculated for max. arm length
Tires: 20.5R25 L3
L60H L70H L90H
Fork frame sales code 83 768 83 769 83770
Fork tines sales code (R/L) 80042/80043 80042/80044 80106/80107
Static tipping load,
kg lb 6 570 14,490 7 250 15,990 8 470 18,670
straight
35deg. Turn kg lb 5 900 13,020 6 510 14,370 7 550 16,650
at full turn kg lb 5 710 12,580 6 300 13,890 7 280 16,050
at load center
mm in 600 2' 0" 600 2' 0" 600 2' 0"
distance*
A mm ft in 790 2' 7" 840 2' 9" 930 3' 1"
B mm ft in 1 560 5' 2" 1 610 5' 3" 1 670 5' 6"
C mm ft in -37 -0' 1.5" -55 -0' 2.1" -8 -0' 0.3"
D mm ft in 1 830 6' 0" 1 860 6' 1" 1 800 5' 11"
E mm ft in 3 710 12' 2" 3 740 12' 3" 3 780 12' 5"
F mm ft in 700 2' 3" 760 2' 6" 730 2' 5"
Operating weight
kg lb 11 750 25,900 13 240 29,200 14 610 32,220
without load
* Firm and level ground
20
Specifications.
L60H
LONG
GENERAL PURPOSE GRADING LIGHT MATERIAL
BOOM
Tires 20.5R25 XHA2 L3
1.9 m³ 2.1 m³ 2.1 m³ 2.3 m³ 2.3 m³ 1.7 m³

1.8 m³ 3.1 m³ 5.0 m³
2.5 yd3 2.7 yd3 2.7 yd3 3.0 yd3 3.0 yd3 2.2 yd3
2.4 yd3 4.1 yd3 6.5 yd3
STE H STE P STE H STE P STE H GRB H
BOE STE H T LM H LM H
BOE BOE BOE BOE BOE
Volume, heaped ISO/SAE m3 yd3 1.9 2.5 1.8 2.4 2.1 2.7 2.1 2.7 2.3 3 2.3 3 1.7 2.2 3.1 4.1 5 6.5 – –
Volume at 110% fill factor m3 yd3 2.1 2.7 2 2.6 2.3 3 2.3 3 2.5 3.3 2.5 3.3 1.9 2.4 3.4 4.5 5.5 7.2 – –
Static tipping load, straight kg lb 8 460 18,650 8 630 19,030 8 820 19,450 8 370 18,460 8 740 19,270 8 290 18,280 7 320 16,150 7 990 17,610 7 970 17,580 -1710 -3,770
at 35° turn kg lb 7 560 16,660 7 720 17,020 7 900 17,420 7 470 16,470 7 820 17,250 7 390 16,290 6 540 14,430 7 110 15,690 7 070 15,590 -1570 -3,460
at full turn kg lb 7 290 16,070 7 450 16,430 7 630 16,820 7 210 15,890 7 550 16,660 7 120 15,710 6 310 13,920 6 860 15,120 6 810 15,010 -1540 -3,380
Breakout force kN lbf 81.9 18,410 83.9 18,870 84.9 19,090 78.5 17,650 80.9 18,200 75.1 16,900 60.2 13,540 61.7 13,880 53.8 12,100 2 390
A mm ft in 7 350 24' 1" 7 380 24' 3" 7 310 24' 0" 7 410 24' 4" 7 370 24' 2" 7 470 24' 6" 7 690 25' 3" 7 720 25' 4" 7 940 26' 1" 520 1' 8"
E mm ft in 1 120 3' 8" 1 140 3' 9" 1 080 3' 7" 1 180 3' 10" 1 140 3' 9" 1 230 4' 0" 1 400 4' 7" 1 480 4' 10" 1 700 5' 7" 30 0' 1"
H mm ft in 2 830 9' 3" 3 040 10' 0" 2 840 9' 4" 2 790 9' 2" 2800 9' 2" 2 750 9' 0" 2 510 8' 3" 2 570 8' 5" 2 430 8' 0" 540 1' 9"
L mm ft in 5 020 16' 6" 5 020 16' 6" 4 800 15' 9" 5 100 16' 9" 5 120 16' 9" 5 170 17' 0" 4 520 14' 10" 5 280 17' 4" 5 480 18' 0" 520 1' 8"
M mm ft in 1 050 3' 6" 1 400 4' 7" 990 3' 3" 1 090 3' 7" 1 040 3' 5" 1 130 3' 9" 1 130 3' 8" 1 310 4' 3" 1 500 4' 11" 0 0
N mm ft in 1 570 5' 2" 2 030 6' 8" 1 560 5' 1" 1 590 5' 3" 1 580 5' 2" 1 600 5' 3" 1 480 4' 10" 1 620 5' 4" 1 670 5' 6" 450 1' 6"
V mm in 2 500 98" 2500 98" 2500 98" 2 500 98" 2 500 98" 2 500 98" 2 500 98" 2 550 100" 2 650 104" 0 0
a1 clearance circle mm ft in 11 570 37' 11" 11 620 38' 2" 11 580 38' 0" 11 600 38' 1" 11 610 38' 1" 11 620 38' 2" 11 970 39' 3" 11 840 38' 10" 12 060 39' 7" 440 1' 5"
Operating weight kg lb 12 100 26,670 12 040 26,540 11 870 26,170 12 150 26,800 11 900 26,250 12 200 26,900 12 040 26,550 12 230 26,970 12 520 27,610 120 260
L60H
Bucket Selection Chart 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
The chosen bucket is determined by the density of the material (674) (1,011) (1,348) (1,686) (2,023) (2,360) (2,697) (3,035) (3,371)
and the expected bucket fill factor. The actual bucket volume H 1.8 m3
is often larger than the rated capacity, due to the features of (2.3 yd3)
the TP linkage, including an open bucket design, good rollback
angles in all positions and good bucket filling performance. The H 1.9 m3
example represents a standard boom configuration. (2.4 yd3)
Example: Sand and gravel. Fill factor ~ 105%. Density 1.6 t/m3
P 2.1 m3
(2,700 lb/yd3). (2.7 yd3)
Result: The 3.4 m3 (4.5 yd3) bucket carries 3.6 m3 (4.7 yd3). For
optimum stability always consult the bucket selection chart. H 2.1 m3
(2.7 yd3)
ISO/SAE
Material Actual
Bucket fill, bucket
Material density volume P 2.3 m3
% volume (3.0 yd3)
t/m lb/yd m3 yd3 m3 yd3

3 3
H 2.3 m3
(3.0 yd3)
~ 1.55 ~ 2,610 1.9 2.5 2.1 2.8
Earth/Clay ~ 110 ~ 1.40 ~ 2,360 2.1 2.8 2.3 3.0
~ 1.30 ~ 2,190 2.3 3.0 2.5 3.3 H 3.1 m3
(4.0 yd3)
~ 1.65 ~ 2,780 1.9 2.5 2.0 2.6
Sand/
~ 105 ~ 1.50 ~ 2,530 2.1 2.8 2.2 2.9 H 5.0 m3
Gravel ~ 1.35 ~ 2,280 2.3 3.0 2.1 2.8 (6.5 yd3)
~ 1.75 ~ 2,950 1.9 2.5 1.9 2.5

Aggregate ~ 100 ~ 1.55 ~ 2,610 2.1 2.8 2.1 2.8 H 1.7 m3
(2.2 yd3)
~ 1.55 ~ 2,610 2.3 3.0 2.3 3.0
H 3.1 m3
Rock ≤100 ~ 1.70 ~ 2,870 1.7 2.2 1.7 2.2 (4.0 yd3)
The size of rock buckets is optimized for optimal penetration and filling
capability rather than the density of the material.
Supplemental Operating Data

Standard boom
Tires 20.5 R25 L2 17.5 R25 L2 20.5 R25 L2 600/65 R25 L3
Width over tires mm in -122 -4.8 +10 + 0.4 +100 +4
Ground clearance mm in -72 -2.8 -10 - 0.4 -30 - 1.2
Tipping load, full turn kg lb -328 -723 -120 - 265 -20 - 44
Operating weight kg lb -589 -1,299 -90 - 198 +30 + 66
21
Specifications.
L70H
LONG
BOOM
2.1 m³ 2.3 m³ 2.3 m³ 2.4 m³ 2.4 m³ 2.2 m³

2.0 m³ 3.4 m³ 6.4 m³
2.7 yd3 3.0 yd3 3.0 yd3 3.1 yd3 3.1 yd3 2.9 yd3
2.6 yd3 4.4 yd3 8.4 yd3
BOE BOE BOE BOE BOE
Volume, heaped ISO/SAE m3 yd3 2.1 2.7 2.0 2.6 2.3 3.0 2.3 3.0 2.4 3.1 2.4 3.1 2.2 2.9 3.4 4.4 6.4 8.4 - -
Volume at 110% fill factor m3 yd3 2.3 3.0 2.2 2.9 2.5 3.3 2.5 3.3 2.6 3.5 2.6 3.5 2.4 3.2 3.7 4.9 7.0 9.2 - -
Static tipping load, straight kg lb 9 330 20,570 9 520 20,990 9 860 21,750 9 270 20,430 9 830 21,670 9 230 20,350 7 550 16,650 8 820 19,450 8 380 18,480 -1 740 -3,840
at 35° turn kg lb 8 340 18,380 8 520 18,790 8 840 19,490 8 280 18,250 8 800 19,410 8 240 18,170 6 700 14,780 7 850 17,320 7 390 16,290 -1 600 -3,520
at full turn kg lb 8 040 17,730 8 230 18,140 8 540 18,820 7 980 17,600 8 500 18,740 7 950 17,520 6 460 14,230 7 570 16,690 7 090 15,640 -1 550 -3,410
Breakout force kN lbf 92.8 20,860 94.8 21,320 98.8 22,210 89.4 20,110 96.5 21,700 87.6 19,690 62.7 14,100 71.7 16,130 53.9 12,110 -2.0 -380
A mm ft in 7 440 24' 5" 7 590 24' 11" 7 370 24' 2" 7 490 24' 7" 7 400 24' 3" 7 520 24' 8" 7 950 26' 1" 7 780 25' 6" 8 330 27' 4" 460 1' 6"
E mm ft in 1 150 3' 9" 1 290 4' 3" 1 080 3' 7" 1 190 3' 11" 1 110 3' 8" 1 220 4' 0" 1 670 5' 6" 1 470 4' 10" 1 970 6' 5" 20 0' 1"
H mm ft in 2 780 9' 2" 2 690 8' 10" 2 830 9' 3" 2 750 9' 0" 2 810 9' 2" 2 730 8' 11" 2 350 7' 9" 2 530 8' 4" 2 150 7' 1" 560 1' 10"
L mm ft in 5 100 16' 9" 5 150 16' 11" 5 090 16' 9" 5 170 16' 11" 5 130 16' 10" 5 200 17' 1" 4 720 15' 6" 5 450 17' 11" 5 790 19' 0" 510 1' 8"
M mm ft in 1 110 3' 8" 1 240 4' 1" 1 060 3' 6" 1 140 3' 9" 1 070 3' 6" 1 160 3' 10" 1 350 4' 5" 1 340 4' 5" 1 720 5' 8" -60 -0' 2"
N mm ft in 1 630 5' 4" 1 710 5' 7" 1 610 5' 3" 1 650 5' 5" 1 610 5' 4" 1 660 5' 5" 1 570 5' 2" 1 680 5' 6" 1 720 5' 8" 400 1' 4"
V mm in 2 650 104" 2 500 98" 2 650 104" 2 650 104" 2 650 104" 2 650 104" 2 650 104" 2 650 104" 2 750 108" 0 0
L70H
angles in all positions and good bucket filling performance. The H 2.1 m3
example represents a standard boom configuration. (2.7 yd3)
Example: Sand and gravel. Fill factor ~ 105%. Density 1.65 t/m3
P 2.3 m3
(2,780 lb/yd3). (3.0 yd3)
Result: The 2.5 m3 (3.3 yd3) bucket carries 2.6 m3 (3.4 yd3). For
optimum stability always consult the bucket selection chart. H 2.3 m3
(3.0 yd3)
ISO/SAE
Material Actual
Bucket fill, bucket
Material density volume P 2.4 m3
% volume (3.1 yd3)

3 3
H 2.4 m3
(3.1 yd3)
~ 1.55 ~ 2,610 2.5 3.3 2.7 3.5
Earth/Clay ~ 110 ~ 1.45 ~ 2,440 2.6 3.4 2.9 3.8
~ 1.40 ~ 2,360 2.8 3.7 3.1 4.0 H 3.4 m3
(4.4 yd3)
~ 1.65 ~ 2,780 2.5 3.3 2.6 3.4
Sand/
~ 105 ~ 1.55 ~ 2,610 2.6 3.4 2.7 3.5 H 6.4 m3
Gravel ~ 1.50 ~ 2,530 2.8 3.7 2.9 3.7 (8.3 yd3)
~ 1.75 ~ 2,950 2.5 3.3 2.5 3.3

Aggregate ~ 100 ~ 1.65 ~ 2,780 2.6 3.4 2.6 3.4 H 2.1 m3
(2.7 yd3)
~ 1.60 ~ 2,700 2.8 3.7 2.8 3.7
H 3.4 m3
Rock ≤100 ~ 1.80 ~ 3,030 2.2 2.9 2.2 2.9 (4.4 yd3)

Standard boom
Tires 20.5 R25 L2 20.5 R25 L2 600/65 R25 L3
Width over tires mm in +10 + 0.4 +100 +4
Ground clearance mm in -20 - 0.8 -30 -1.2
Tipping load, full turn kg lb -180 -397 -10 -22
Operating weight kg lb -90 -198 +30 + 66
22
L90H
LONG
BOOM
2.3 m³ 2.5 m³ 2.5 m³ 2.6 m³ 2.8 m³ 2.8 m³

2.5 m³ 4.1 m³ 7.0 m³
3.0 yd3 3.3 yd3 3.3 yd3 3.4 yd3 3.7 yd3 3.7 yd3
3.3 yd3 5.4 yd3 9.2 yd3
BOE BOE BOE BOE BOE
Volume, heaped ISO/SAE m3 yd3 2.3 3.0 2.5 3.3 2.5 3.3 2.5 3.3 2.6 3.4 2.8 3.7 2.8 3.7 4.1 5.4 7.0 9.2 - -
Volume at 110% fill factor m3 yd3 2.5 3.3 2.8 3.6 2.8 3.6 2.8 3.6 2.9 3.7 3.1 4 3.1 4 4.5 5.9 7.7 10.1 - -
Static tipping load, straight kg lb 10 930 24,110 11 090 24,450 11 470 25,290 10 860 23,940 11 430 25,210 11 350 25,020 10 740 23,690 10 240 22,570 9 940 21,920 -1 680 -3,710
at 35° turn kg lb 9 700 21,380 9 850 21,710 10 200 22,480 9 620 21,220 10 160 22,410 10 080 22,220 9 510 20,970 9 030 19,910 8 720 19,220 -1 530 -3,370
at full turn kg lb 9 330 20,580 9 480 20,900 9 820 21,660 9 260 20,420 9 790 21,580 9 700 21,400 9 150 20,170 8 670 19,130 8 360 18,430 -1 490 -3,270
Breakout force kN lbf 138 31,020 137.6 30,940 145.5 32,720 133 29,900 142.9 32,120 137.7 30,960 126.4 28,420 100.5 22,590 86.9 19,540 2.0 390
A mm ft in 7 560 24' 10" 7 790 25' 7" 7 510 24' 7" 7 610 25' 0" 7 530 24' 8" 7 580 24' 10" 7 690 25' 3" 8 040 26' 4" 8 340 27' 4" 410 1' 4"
E mm ft in 1 170 3' 10" 1 370 4' 6" 1 110 3' 8" 1 210 4' 0" 1 140 3' 9" 1 180 3' 10" 1 280 4' 2" 1 590 5' 3" 1 850 6' 1" -10 -0.4"
H mm ft in 2 840 9' 4" 2 700 8' 10" 2 880 9' 6" 2 810 9' 3" 2 870 9' 5" 2 830 9' 4" 2 750 9' 0" 2 540 8' 4" 2 340 7' 8" 430 1' 5"
L mm ft in 5 230 17' 2" 5 320 17' 6" 5 220 17' 2" 5 290 17' 4" 5 250 17' 3" 5 310 17' 5" 5 380 17' 8" 5 570 18' 3" 5 770 18' 11" 420 1' 5"
M mm ft in 1 070 3' 6" 1 270 4' 2" 1 030 3' 5" 1 110 3' 8" 1 050 3' 5" 1 080 3' 7" 1 140 3' 9" 1 440 4' 9" 1 650 5' 5" -30 -0' 1"
N mm ft in 1 660 5' 5" 1 760 5' 9" 1 640 5' 4" 1 680 5' 6" 1 640 5' 5" 1 660 5' 5" 1 700 5' 7" 1 710 5' 7" 1 710 5' 7" 360 1' 2"
V mm in 2 750 108" 2 750 108" 2 750 108" 2 750 108" 2 750 108" 2 750 108" 2 750 108" 2 750 108" 3 000 118" 0 0
L90H
H 2.5 m3
angles in all positions and good bucket filling performance. The (3.2 yd3)
example represents a standard boom configuration.
Example: Sand and gravel. Fill factor ~ 105%. Density 1.6 t/m3 P 2.5 m3
(3.2 yd3)
(2,700 lb/yd3).
Result: The 3.4 m3 (4.5 yd3) bucket carries 3.6 m3 (4.7 yd3). For H 2.5 m3
(3.2 yd3)
optimum stability always consult the bucket selection chart.
ISO/SAE P 2.6 m3
Material Actual (3.4 yd3)
Bucket fill, bucket
Material density volume
% volume P 2.8 m3
(3.6 yd3)

3 3
H 2.8 m3
(3.6 yd3)
~ 1.55 ~ 2,610 2.5 3.3 2.7 3.5
Earth/Clay ~ 110 ~ 1.45 ~ 2,440 2.6 3.4 2.9 3.8
~ 1.40 ~ 2,360 2.8 3.7 3.1 4.0 H 4.1 m3
(5.3 yd3)
~ 1.65 ~ 2,780 2.5 3.3 2.6 3.4
Sand/
~ 105 ~ 1.55 ~ 2,610 2.6 3.4 2.7 3.5 H 7.0 m3
Gravel ~ 1.50 ~ 2,530 2.8 3.7 2.9 3.7 (9.1 yd3)
~ 1.75 ~ 2,950 2.5 3.3 2.5 3.3

Aggregate ~ 100 ~ 1.65 ~ 2,780 2.6 3.4 2.6 3.4 H 2.3 m3
(3.0 yd3)
~ 1.60 ~ 2,700 2.8 3.7 2.8 3.7
H 4.1 m3
Rock ≤100 ~ 1.80 ~ 3,030 2.2 2.9 2.2 2.9 (5.3 yd3)

Standard boom
Tires 20.5 R25 L2 20.5 R25 L2 600/65 R25 L3
Width over tires mm in 0 0 +160 + 6.3
Ground clearance mm in -10 -0.4 -10 -0.4
Tipping load, full turn kg lb -110 -243 +310 +683
Operating weight kg lb -100 -220.5 +560 +1,235
23
Equipment.
STANDARD EQUIPMENT
Service and maintenance Contronic monitoring system
Engine oil remote drain and fill • • • Monitoring and logging of machine data • • •
Transmission oil remote drain and fill • • • Contronic display • • •
Lubrication manifolds, ground accessible • • • Fuel consumption • • •
Pressure test ports: transmission and Diesel Exhaust Fluid/AdBlue consumption • • •
hydraulic, quick connects
• • •
Service platforms with anti-slip surfaces • • •
Ambient temperature • • •
CareTrack • • •
Clock • • •
Test function for warning and indicator
Telematics, 6 -Year Subscription • • • lights
• • •
Toolbox, lockable • • • Brake test • • •
Engine
Warning and indicator lights:
Exhaust after-treatment system • • • Battery charging • • •
Three stage air cleaner, pre-cleaner,
primary and secondary filter
• • • Parking brake • • •
Warning and display message:
Indicator glass for coolant level • • •
Preheating of induction air • • •
Regeneration • • •
Fuel pre-filter with water trap • • •
Engine coolant temperature • • •
Fuel filter • • •
Charge air temperature • • •
Crank case breather oil trap • • •
Engine oil temperature • • •
Exhaust heat ventilation • • •
Engine oil pressure • • •
Electrical system
Transmission oil temperature • • •
24 V, pre-wired for optional accessories • • •
Transmission oil pressure • • •
Alternator 80A/3 135W • • •
Hydraulic oil temperature • • •
Battery disconnect switch • • •
Brake pressure • • •
Maintenance free batteries • • •
Parking brake applied • • •
Battery box, steel • • •
Brake charging • • •
Fuel gauge • • •
Overspeed at direction change • • •
Hour meter • • •
Axle oil temperature • • •
Electric horn • • •
Steering pressure • • •
Instrument cluster:
Crank case pressure • • •
Fuel level • • •
Attachment lock open • • •
Level warnings:
Diesel Exhaust Fluid/AdBlue level • • •
Transmission temperature • • •
Fuel level • • •
Coolant temperature • • •
Diesel Exhaust Fluid/AdBlue level • • •
Instrument lighting • • •
Engine coolant level • • •
Lighting:
Transmission oil level • • •
Twin halogen front headlights with high
Hydraulic oil level • • •
and low beams
• • • Washer fluid level • • •
Parking lights • • • Engine torque reduction in case of
malfunction indication:
Double brake and tail lights • • •
Turn signals with flashing hazard light
High engine coolant temperature • • •
function
• • • High engine oil temperature • • •
Halogen work lights (2 front and 2 rear) • • • Low engine oil pressure • • •
High crank case pressure • • •
High charge air temperature • • •
Engine shutdown to idle in case of
malfunction indication:
High transmission oil temperature • • •
Slip in transmission clutches • • •
Key pad, background lit • • •
Start interlock when gear is engaged • • •
24
Drivetrain Hydraulic system
Automatic Power Shift • • • Main valve, double acting 2-spool with
• • •
Fully automatic gear shifting, 1-4 • • • hydraulic pilots
PWM-controlled gear shifting • • • Variable displacement axial piston
Forward and reverse switch by hydraulic pumps (2) for:
lever console
• • • Working hydraulics, pilot hydraulics,
steering system, brakes
• • •
Indicator glass for transmission oil level • • •
Differentials: Cooling fan, brakes • • •
Front: 100% hydraulic locking • • • Hydraulic control levers • • •
Rear: Conventional • • • Mechanical hydraulic lever lock • • •
Tires Automatic boom kick-out • • •
17.5R25 • automatic bucket positioner • • •
20.5R25 • • • Double acting hydraulic cylinders • • •
Brake system Indicator glass for hydraulic oil level • • •
Dual brake circuits • • • Hydraulic oil cooler • • •
Dual brake pedals • • • External equipment
Secondary brake system • • • Basic fenders, front and rear • • •
Parking brake, electrical-hydraulic • • • Viscous cab mounts • • •
Brake wear indicators • • • Rubber engine and transmission mounts • • •
Outboard mounted circulating oil cooled Engine hood, electronically openable • • •
wet disc brakes on all four wheels
• • • Frame, joint lock • • •
Cab Vandalism lock for engine compartment • • •
ROPS (ISO 3471), FOPS (ISO 3449) • • • Lifting eyes • • •
Single key kit door/start • • • Tie down eyes • • •
Acoustic inner lining • • • Tow hitch • • •
Counterweight, pre drilled for optional
Cigarette lighter, 24 V power outlet • • • • • •
guards
Lockable door • • •
Cab heating with fresh air inlet and
defroster
• • •
Fresh air inlet with two filters • • •
Automatic heat control • • •
Floor mat • • •
Dual interior lights • • •
Interior rearview mirrors • • •
Dual exterior rearview mirrors • • •
Sliding window, right side • • •
Tinted safety glass • • •
Retractable seat belt (SAE J386) • • •
Adjustable steering wheel • • •
Storage compartment • • •
Document pocket • • •
Sun visor • • •
Beverage holder • • •
Windshield washer front and rear • • •
Windshield wipers front and rear • • •
Interval function for front and rear wipers • • •
Foot step, left side (toolbox lockable
included)
• • •
25
Equipment.
OPTIONAL EQUIPMENT
Service and maintenance Cab
Automatic lubrication System • • • Lunch box holder • • •
Automatic lubrication system for long boom • • • Operator’s seat, Volvo air susp, heavy-duty,
• • •
Oil sampling valve • • • high back, heated
Refill pump for automatic lubrication system • • • Operator’s seat, ISRI, air susp, heavy-duty,
• • •
Grease nipple guards • • for CDC
Tool kit • • • Operator’s seat, ISRI, heated, high back • • •
Wheel nut wrench kit • • • Operator’s seat, ISRI, low back • • •
Engine Seat belt (width 75 mm / 3") • • •
Air pre-cleaner, cyclone type • • • Radio installation kit incl. 12 volt outlet,
left-side • • •
Air pre-cleaner, oil-bath type • • •
Air pre-cleaner, turbo type • • • Radio installation kit incl. 12 volt outlet,
right-side • • •
Engine auto shut down • • •
Engine block heater, 120 V / 230 V • • • Radio installation kit, 12 V, for USA • • •
Fuel heater • • • Radio with CD player • • •
Fuel fill strainer • • • Forward view mirror • • •
Hand throttle control • • • Rear view mirrors, el. adjusted and heated • • •
Max. fan speed, hot climate • • • Rear view mirrors, long arm right • • •
Reversible cooling fan • • • Rear view mirrors, el. adjusted and heated,
long arm right • • •
High altitude kit, 2 000 m / 6,560 ft up • •
Electrical Steering wheel knob • • •
Battery disconnect switch • • • Sun blinds, rear windows • • •
Anti-theft device • • • Sun blinds, side windows • • •
Headlights, assym. left • • • Timer cab heating • • •
Emergency stop • • • Universal door/ignition key • • •
License plate holder, lighting • • • Window, sliding, door • • •
Reduced function working lights when Drivetrain
reverse gear activated • • • Rear axle with limited slip • • •
Side marker lamps • • • Speed limiter, 20 km/h / 12 mph • • •
License plate holder, lighting • • • Speed limiter, 30 km/h / 19 mph • • •
Forward camera, color • • • Speed limiter, 40 km/h / 25 mph • • •
Rear view camera incl. Monitor, color • • • Brake system
Rear view mirrors, Long arm, right side • • • Stainless steel, brake lines • •
Rearview mirrors, adjustable, el. heated • • • Parking brake alarm, audible • • •
Reverse alarm • • • Hydraulic system
Reverse lights • • • Arctic kit: Attachment locking, pilot hoses
and hydraulic oil • • •
Reversing warning light • • •
Reverse warning light, strobe lightning • • • Attachment bracket, cast, visibility-optimized • • •
Warning, collapsible, rotating beacon • • • Attachment bracket, side-tilting • • •
Warning beacon, flashing strobe light • • • Separate attachment locking, long boom • • •
Working lights, attachments • • • Separate attachment locking, standard boom • • •
Working lights front, high intensity Single acting lifting function • • •
discharge (HID) • • • Boom suspension system • • •
Working lights front, on cab, dual • • • HD LS hydraulics, pump kit included •
Working lights rear, on cab • • • Hydraulic fluid, biodegradable, Volvo • • •
Working lights rear, on cab, dual • • • Hydraulic fluid, fire resistant • • •
Working lights front, extra • • • Hydraulic fluid, for hot climate • • •
Working lights, front on cab, 2 LED lamps • • • Hydraulic function, 3rd • • •
Working lights, rear on cab, 2 LED lamps • • • Detent for 3rd hydraulic function • • •
Working lights, front on cab, 4 LED lamps • • • Adjustable flow for 3rd hydraulic function •
Working lights, rear on cab, 4 LED lamps • • • Hydraulic function, 3rd-4th • • •
Working lights, side on cab, 4 LED lamps • • • Single lever control • • •
Working lights, rear in grille, 2 LED lamps • • • Single lever control for 3rd hydr. Function • • •
Working lights, front above head lamps, 2 External equipment
LED lamps • • • Deleted front mudguards • • •
Taillight, LED lamp • • • Fire extinguisher • • •
Cab Bracket for fire extinguisher • • •
ACC control panel, with Fahrenheit scale • • • Fire suppression system • • •
Anchorage for Operator´s manual • • • Mudguards, full cover, rear for 80-series tires • • •
Armrest, operator’s seat, ISRI, left only • • • Mudflap kit for mudguards, full cover for
80-series tires • • •
Armrest, operator’s seat, Volvo, left • • •
Asbestos dust protection filter • • • Mudguards, full cover, rear and front/rear
for 65-series tires • • •
Automatic Climate Control, ACC • • •
Automatic Climate Control, ACC, corr prot. Mudflap kit for mudguards, full cover for
• • • 65-series tires • • •
Condenser
Cab air pre-cleaner, cyclone type • • • Footsteps front frame • • •
Carbon filter - cab • • • Footsteps, right-hand side • • •
Foot steps, front frame • • • Flexible rear step • • •
Remote door opener • • • Cab ladder, rubber suspended • • •
26
Protective equipment Tires and Rims
Anti-theft device • • • 17.5R25 •
Belly guard front • • • 20.5R25 • • •
Belly guard rear • • • 600/65R25 • • •
Boom cylinder hose and tube guards • • • 650/65R25 •
Cab roof, heavy duty • • • Attachments
Center hinge and rear frame guard • • • Buckets:
Corrosion protection, painting • • • Straight • • •
Cover plate front frame, heavy-duty • • • Spade nose • • •
Cover plate, under cab • • • High tipping • • •
Cover plates rear frame • • • Light material • • •
Guards for front head lights • • • Grading • • •
Guards for grease nipples • • Wear parts:
Guards for radiator grill • • • Bolt-on edge • • •
Guards for tail lights, heavy-duty • • • Bolt-on or weld-on bucket teeth • • •
Wheel/axle seal guards • • • Segments • • •
Window guards, side and rea • • • Log grapples • • •
Windshield guard • • • Fork equipment • • •
Other equipment Material handling arm • • •
CareTrack, GSM/Satellite • • • Snow blade • • •
CE-marking • • • Broom • • •
Secondary steering • • • Sand spreading bucket • • •
Counterweight, logging • • • Bale clamp • • •
Noise reduction kit, Blauer Engel incl. Decal • • • Drum rotator • • •
Noise reduction kit, EU excl. Decal • • •
Sign, 50 km/h / 31mph • • •
Sign, slow moving vehicle • • •
Selection of Volvo optional equipment
Boom suspension system 3rd and 4th hydraulic function LED lights
Rear view camera Reversible fan Fire suppression system
Not all products are available in all markets. Under our policy of continuous improvement, we reserve the right to change specifications and design without prior notice.
The illustrations do not necessarily show the standard version of the machine.
27
Ref. No. VOE2210009367English-22
Printed in USA, 2/2015 WLC
Volvo, Shippensburg
Copyright © 2015 Volvo
3rd/4th hydraulic function, valve, description
Figure 1
1. Connecting block
2. Anti-cavitation valve
3. Pressure-reducing valve
4. Spring + spool
5. Air nipple
6. Housing
7. Compensator
8. Bush and nipple
9. Stroke limiter (is not used)
3rd, or 3rd/4th hydraulic function, component location
Figure 1
1. Main control valve

2. Valve, 3rd hydraulic function
3. Central valve
4. Lever carrier
For description of components, see:
 3rd, or 3rd/4th hydraulic function, description

 Control valve, description
 Central valve, description
3rd, or 3rd/4th hydraulic function, description
In addition to the ordinary main control valve for lift and tilt function, the machine can be equipped with one or two additional hydraulic
functions. These extra functions are double-acting and the connection points are located on the boom.
For information on other systems affecting the 3rd or 3rd/4th hydraulic function, see:
Working hydraulic system, description
Servo system, description
General function
For control of function spools, hydraulic servo pressure is distributed from the boom lowering valve to both the servo valve and the
control valve for 3rd/4th function, which is found on its inlet port PS, see figure below.
Figure 1
Control valve for 3rd/4th hydraulic function in neutral position, not activated.
Green Pressureless oil

Orange Servo pressure, standby pressure
1 Central valve
2 Servo valve
3 Main control valve
4 Control valve 3rd/4th hydraulic function
5 Boom lowering valve
SW9141 Switch, automatic tilt-in
SW9142 Switch, automatic lift
SW9144 Switch, control lever lockout
SW9174 [1] Switch, control lever lockout
MA9112 [2] Control lever lockout
MA9144 Hold solenoid, 3rd function
MA9141 Hold solenoid, bucket positioner
MA9142 Hold solenoid, boom kick-out
MA9143 Hold solenoid, float mode
SE9156 Position sensor, automatic tilt-in
SE9157 Position sensor, automatic lift
Working hydraulic pressure is directed from the main control valve to inlet port P1 on the hydraulic control valve for 3rd/4th function.
Figure 2
Oil from pump P2 is supplied to the 3rd/4th hydraulic valve via the main control valve.

Red Working pressure
Purple Trapped oil
The control valve's valve sections are provided with flow compensators for each control spool, which have the function to give priority
to the machine’s primary hydraulic functions such as lift, lower, and tilt functions if they are used simultaneously, see 3rd/4th hydraulic
function, valve, description.
Enabled 3rd hydraulic function
When the 3rd function's control lever is moved backwards (from the operator's viewpoint), positive direction, servo pressure oil is
directed to the 3rd hydraulic function’s control spool according to the figure below.
Figure 3
Applied servo pressure for 3rd hydraulic function from engaged lever, directing working hydraulic pressure for 3rd
hydraulic function.

Blue Servo pressure
Pink LS–pressure
The spool will move downwards due to the servo pressure applied on top, creating a hydraulic connection to its flow compensator.
When the spool changes position, an LS-connection is created where an LS-pressure is generated. The LS-pressure affects pump
P2, increasing its oil displacement to meet the need for increased oil flow.
The LS-pressure passes the control spool’s restriction to the bottom of its flow compensator. When the flow compensator changes
position, moves upwards, due to the applied LS-pressure, working oil pressure is directed to outlet port A (connection A3).
The top side of the compensator spool is always affected by the highest available LS-pressure in the machine’s hydraulic system. If a
higher LS-pressure is required, e.g., for lift function, the flow compensator will limit the oil flow through the control spool for 3rd and
4th hydraulic function, hence priority is given to the lift function.
The principal sequence of events for using the 4th hydraulic function is as stated for the 3rd hydraulic function above.
Servo circuit
The servo circuit controls the working hydraulic system via servo valves, Servo system, description.
Hydraulic safety features
For more information about safety when working with hydraulic systems, see Safety when working on hydraulic systems.
Parameters
Relevant parameters for 3rd and 4th hydraulic function
Parameter (code) Setting

- -
Supplementary information
 Braking system, description

 Steering system, description
 Working hydraulic system, component location
 Servo system, description
 Boom Suspension System, component description
 Hydraulic diagram, complete
Function check
 3rd/4th hydraulic, functional check
Diagnostics
Detailed information about relevant warnings and error codes are available under the diagnostics tab.
[1]Only for machines equipped with 4th hydraulic function or single lever.
[2]Only for machines equipped with 4th hydraulic function or single lever.
ACM, I/O list
In case of electric failure, the information display unit shows “o” for open circuit and “s” for short-circuiting. “–” is shown if input or
output is not used.
Pin Component Function Wiring diagram

A:1 CAN7L Engine subnet Wiring diagram WD265
A:2 CAN L Backbone 2(L) Wiring diagram WD321
A:3 ACM Key feed Wiring diagram WD264
A:4 MA2517 AdBlue®/DEF coolant valve Wiring diagram WD270
A:5 CAN7H Engine subnet Wiring diagram WD265
A:6 CAN H Backbone 2(H) Wiring diagram WD321
A:7 FX1074 AdBlue®/DEF pump unit Wiring diagram WD270
A:9 — — —
A:10 CAN L Backbone 1(L) Wiring diagram WD320
A:11 — — —
A:13 — — —
A:14 CAN H Backbone 1(H) Wiring diagram WD320
A:15 — — —
A:16 — — —
A:17 — — —
A:18 — — —
A:19 — — —
A:20 — — —
A:21 — — —
A:22 SE2544 Exhaust gas pressure sensor before SCR catalyst Wiring diagram WD266
A:23 — — —
A:24 HE2513 AdBlue®/DEF hose (supply/return) Wiring diagram WD269
A:25 — — —
A:26 SE2519 DPF Differential pressure sensor Wiring diagram WD266
A:27 — — —
A:29 — — —
A:31 — — —
A:33 — — —
A:34 SE2522 Exhaust gas temperature sensor before DPF Wiring diagram WD266
A:35 — — —
A:36 — — —
A:37 — — —
A:38 — — —
A:39 SE2543 Exhaust gas temperature sensor after DPF Wiring diagram WD266
A:40 MA2519 AdBlue®/DEF dosing injector Wiring diagram WD269
A:41 — — —
A:42 SE2521 Exhaust gas temperature sensor before DOC Wiring diagram WD266
A:43 — — —
A:44 MA2519 AdBlue®/DEF dosing injector Wiring diagram WD269
A:45 — — —
A:46 — — —
A:47 — — —
A:48 — — —
A:49 FX1079 Voltage feed (supply) Wiring diagram WD269
A:50 SE2519 DPF Differential pressure sensor Wiring diagram WD266
SE2544 Exhaust gas pressure sensor before SCR catalyst
A:52 — — —
A:53 FU77 EGR (FX1040), voltage feed Wiring diagram WD264
Wiring diagram WD303
SE2519 Wiring diagram WD270
SE2544
A:55 31C1 ACM, ground Wiring diagram WD264
A:56 SE2521 Ground Wiring diagram WD266
SE2522
SE2543
A:59 HE2511 Ground Wiring diagram WD269
HE2512
HE2513
Air conditioning, function description
Figure 1
1. Compressor
2. Safety valve
3. Fan in cab
4. Evaporator
5. Temperature sensor
6. Expansion valve
7. Pressure monitor
8. Drain and fill point
9. Cooling fan, engine
10. Condenser
11. Receiver drier
A. Warm refrigerant in liquid phase
B. Refrigerant in liquid phase. Cooled by ambient temperature.
C. Refrigerant in gaseous phase.
D. CCM (Climate Control Module)
E. Cold gas phase. Affected by ambient temperature.
Function description
The compressor is driven by the diesel engine via a fan belt.
The refrigerant, which now is in warm liquid phase, is pumped from the compressor to the condenser and increases the pressure so
that the refrigerant is condensed.
Compression of the refrigerant generates heat. The heat is dissipated from the condenser by the diesel engine's standard cooling fan
and now converts to cooled liquid phase.
At the expansion valve there is a pressure sensor that cuts out at too high and too low pressure and controls the compressor's
activity. The system also features a safety valve that is located by the compressor. For cut-out values, see: Air conditioning,
specifications
The refrigerant passes the receiver drier where any moisture is absorbed.
Now the refrigerant continues to the expansion valve where the restriction lowers the pressure so that the refrigerant converts from
liquid to gas. Then the gas is pumped into the evaporator. Evaporation results in a significant reduction of the refrigerant's
temperature.
The size of the refrigerant flow through the evaporator is controlled by the expansion valve which senses the temperature at the
outlet from the evaporator using the temperature sensor. When too much ice has forms in the evaporator, the temperature sensor
ensures that the compressor cuts out until the temperature has increased.
The cold refrigerant passes through the evaporator and cools the evaporator's fins. The cab fan blows through the fins and cold air is
forced into the cab.
There are three drain and fill points on the system. One on the receiver drier and two by the condenser.
Air conditioning, tightening torques
Part Tightening torques

Pressure sensor 8 ±1 Nm (5.9 lbf ft)
Safety valve 18 ±2 Nm (13.3 lbf ft)
Hose connections with M8 24 ±4 Nm (17.7 lbf ft)
Bolt for compressor bracket to engine 65 ±6 Nm (48 lbf ft)
Bolt for compressor to compressor bracket 65 ±6 Nm (48 lbf ft)
Air conditioning, tightening torques
Part Tightening torques

Pressure sensor 8 ±1 Nm (5.9 lbf ft)
Safety valve 18 ±2 Nm (13.3 lbf ft)
Hose connections with M8 24 ±4 Nm (17.7 lbf ft)
Bolt for compressor bracket to engine 65 ±6 Nm (48 lbf ft)
Bolt for compressor to compressor bracket 65 ±6 Nm (48 lbf ft)
Alternator 80 A, description
The alternator is a 80 A alternating current generator with a normal charge voltage of 28.3 V and a built-in charging regulator.
When the engine is turned off, the batteries normally give a voltage of approx. 24-26 V, depending on their charging status. When the
engine is running, the batteries are normally charged by the alternator, since the alternator's normal charging voltage is higher than
the battery voltage.
If the batteries do not seem to take a charge, this may be due to incorrect charge voltage from the alternator. Also see Battery,
charging and Alternator 80 A, specification.
See Wiring diagram WD306.
Automatic differential brake, "Limited Slip", description
As soon as the wheels begin to rotate at different speeds, the automatic differential brake strives to make the wheels rotate at the
same speed.
In order to achieve this, the differential shaft's bevelled ends are pressed against the thrust plate's bevelled slots, and that force
results in the thrust plates being pressed outward against the discs.
The discs transmit the force and the half shafts are locked together. This forces the wheels to rotate at the same speed. When the
torque reaches approx. 80% of the incoming power, the discs begin to slip.
The difference between a conventional differential lock and a differential brake is that the first locks to 100% while the latter locks up
to 80% of the incoming power.
Figure 1
Automatic differential brake
A The differential shaft is pressed outward against the bevelled surface when the wheels rotate at different speeds.
B Thrust plates slide outward.
1. Crown wheel 6. Half shaft

2. Differential side gear 7. Differential shaft
3. Thrust plate 8. Half shaft
4. Discs 9. Bevelled contact surfaces which allow sliding
5. Half shaft's differential gears
Parameters
-
- Drive axles, description
- Front axle, component description
- Rear axle, component description
Relevant Tech Tool operations
-
Function check
-
Diagnostics
-
Auxiliary brake (engine braking), description
The machine is equipped with auxiliary brake, which:
 helps the engine to brake the machine on downhill grades

 prevents upshifting when the machine is operated downhill
For more information, see
 Cooling fan, description

 Hydraulic transmission, description
The auxiliary brake is not activated when the directional gear is in position N.
To prevent too high engine speed in an engine brake situation, the engine's load is increased when the engine speed exceeds 1300
rpm by the cooling fan's speed increasing to max.
The maximum fan speed that the fan can reach depends on the engine's current load, see Cooling fan rpm, specifications.
Parameters
There are no parameters for the function in question
 Cooling fan rpm, specifications
Diagnostics
Detailed information about relevant warnings and error codes below are available under the diagnostics tab
Battery, charging
WARNING
Hydrogen gas is formed during battery charging. Hydrogen gas is flammable and may be explosive. A short circuit, open
flame or spark near the battery can cause a powerful explosion. Therefore, ventilate well. Never smoke near batteries.
 Batteries must only be charged using battery charger.

 Check the battery terminal connections and make sure that they are adequately tightened and free from corrosion and dirt.
 Check the battery voltage when the batteries are at rest (before starting). Each battery must be at least half-charged.
NOTICE
Always turn off the current to the battery charger before disconnecting the charging clamps.
WARNING
Risk of chemical burns.
Contact with battery acid causes serious chemical burns.
Always wear personal protective gloves, goggles and clothing when handling batteries.
Battery, description
The battery consists of two series-connected 12 V batteries, which together give 24 V. The batteries are located in a battery box on
the right side of the cab. The battery disconnector is located on the left side of the cab by the steps.
The batteries should be in good condition when troubleshooting the system. If needed, charge the batteries with a battery charger. If
the batteries do not take the charge, replace the batteries.
For checking battery status, see Battery condition, check.
Boom Suspension System, component description
Piston type accumulator
Figure 1
Piston type accumulator
1. Gas valve screw

2. Piston
Valve block
Figure 2
Valve block 1 (V1)
Figure 3
Valve block 2 (V2)
Boom suspension system, component location
Figure 1
1. Accumulator, Boom Suspension System

2. Valve for Boom Suspension System, V1
3. Valve for single-acting lift, V2
 Accumulator and valve block, see Boom Suspension System, component description
Boom Suspension System, description
The Boom Suspension System (BSS) [1] means that the boom is allowed to swing more freely, whereby its vertical forces are
absorbed. The benefits are improved operator’s comfort, reduced spill, and less mechanical stress on the machine when operating
over rough ground surfaces.
Main components for the BSS are two BSS-valves, V1 and V2, with solenoids, BSS-accumulator, and hydraulic pump P1 and P2.
The BSS-equipment is supplied with oil at its inlet port P from the main control valve’s outlet port P (working hydraulic oil pressure),
see figure below. For a more detailed hydraulic diagram, see Hydraulic diagram, complete.
Figure 1
BSS, electric and hydraulic overview.
1. V1 – BSS-valve 1
2. V2 – BSS-valve 2
3. Boom lift cylinder
MA9103 BSS (CT4)

MA9104 Single-acting lift function (CT1 in V2)
MA9114 BSS (CT1 in V1)
RE08 Relay, engagement BSS
SW4209 Kick-down, lever carrier
SW4211 FAPS
SW4220 Kick-down, CDC [2]
SW9148 BSS, activating/mode selection
SW9149 Single-acting lift function
GPMECU1 General Purpose Machine Electronic Control Unit 1
The operator can select one of the three following different modes for engaging BSS:
 Gear-dependent mode.
 Speed-dependent mode without FAPS.
 Speed-dependent mode with FAPS.
FAPS (Fully Automatic Power Shift) means that the machine uses all gears, 1st-4th gear, where gears can be skipped in case of fast
speed changes.
The operator can also partly activate the BSS-related function, called single-acting lift. This functionality allows the boom to be raised
by an external force, returning to earlier set position.
For information about other systems related to BSS, see:

 Working hydraulic system, description
Function of the BSS-accumulator

When the engine starts, V1 is supplied with oil via its inlet port P. The copying valve CT7 ensures that oil pressure at the lift cylinders'
piston end, (+) side, corresponds to accumulator pressure of the BSS, see figure below.
Figure 2
Charging accumulator.

Green Return oil
Purple Trapped oil
The pressure limiting valve CT8 ensures that maximum accumulator charging pressure is not exceeded, which corresponds to the
approximate oil pressure with a fully loaded bucket.
If BSS is engaged and the internal oil accumulator pressure is higher than the pressure in the lift cylinders' piston end, (+) side, then
CT3 in V1 opens, which drains oil to tank via CT1. As soon as the oil pressure between the lift cylinders and BSS-accumulator is
balanced, CT3 in V1 closes and CT2 in V1 opens a connection between the BSS-accumulator and lift cylinders. Without pressure-
balancing, pressurized oil from the BSS-accumulator would result in involuntary lifting of the boom as CT2 in valve V1 opens.
Engaging BSS
BSS functionality will only be available when its prerequisites are met even though its enabled functionality can be seen in the
operator’s display. If any BSS errors are detected, to activate its functionality, an alarm is shown on the operator’s display.
The BSS functionality is engaged with SW9148 which, via control unit GPMECU1, activates relay RE08, which in turn activates
MA9103, MA9104 and MA9114, see figure below.
Figure 3
BSS signal diagram, overview.

BUS COM Bus communication
SW9148 BSS, activation select
SW9149 BSS, single-acting lift
SW4209 Kick-down, lever carrier
SW4211 FAPS, activation select
SW4220 Kick-down, CDC [3]
MA9103 BSS
MA9104 Single-acting lift
MA9114 BSS
When MA9103 is energized and changes position, the hydraulic connection is cut off between the lift cylinders' piston end, (+) side,
and copying valve CT7, see figure below. Also, when MA9114 is energized, the top of CT2 in valve V1 is drained to tank, allowing oil
flow between lift cylinders' piston end (+) and BSS-accumulator.
When energized, MA9104 will allow oil to be drained from top of CT3 in V2 to tank. When CT3 in V2 is drained, a hydraulic
connection is opened between the lift cylinders' rod end, (-) side, to tank. To dampen any boom oscillations, restrictions in CT3 in V2
and CT1 in V2 limit the oil flow. The anti-cavitation valves in the main control valve ensure that the lift cylinders' rod ends, (-) sides,
are refilled with oil if needed, see also Working hydraulic system, description.
Figure 4
Engagement of BSS

Green Return oil
Conditions for engagement and disengagement

Input conditions to the machine’s electrical system must be fulfilled to engage BSS functionality, such as: parameter settings,
directional gear, FAPS activated or not activated, gear-dependent mode or speed-dependent mode selected. See figure below.
BSS functionality is always deactivated when downshift to first gear is activated and obtained or if operator locks the transmission to
first gear.
NOTE!
If first gear is engaged as a protective action by the transmission control system, then BSS will remain engaged.
Figure 5
Conditions and machine status for engaging BSS functionality.
1 BSS parameters
2 Gear
FAPS Fully Automatic Power Shift activated
3 Operator feedback:
– Engaged BSS
– Alarms (error)
4 Machine’s electrical system
5 Transmission:
– machine speed
– current gear
– kick-down status
6 Hydraulics, BSS active
7 Engine running
Gear-dependent mode
If gear-dependent BSS mode is selected with SW9148, then boom suspension will be engaged continuously for as long as the
transmission has not been limited to first gear or set to first gear by kick-down request. FAPS selection will have no effect.
Speed-dependent mode
When BSS is set to be speed-dependent mode, its functionality is activated as soon as machine speed exceeds a certain set level.
Set level may differ depending on which directional gear is selected, Forward, Neutral, or Reverse (F, N, or R) as well as if FAPS is
activated.
Speed-dependent mode without FAPS
Conditions for speed-dependent mode without FAPS are set by software parameter P1K12 and P1K11 which need to be fulfilled.
Parameter P1K12 is for directional gear R and parameter P1K11 is for machine speed for engagement plus 1 km/h (0.6 mph) for
directional speed F.
BSS will be disengaged as soon as first gear is obtained or if machine speed is below 2 km/h (1 mph) for directional gear R and N,
and its limit is set by parameter P1K11 for directional gear F.
Speed-dependent mode with FAPS
BSS will be engaged for directional gear F or N when the speed exceeds parameter value P1K1Z plus 1 km/h (0.6 mph). For
directional gear R, enabled BSS will be available if parameter P1K10 is equal to 0 km/h (0 mph). If parameter P1K10 is not 0, then
BSS will be engaged when exceeding the set parameter value plus 1 km/h (0.6 mph).
BSS will be engaged when first gear is obtained and the speed for gear F or N is lower than the set parameter value P1K1Z. Default
parameter value for P1K1Z is 8 km/h (5 mph). Disengaging speed for gear R and activated kick-down is set by parameter P1K10. If
parameter P1K10 is set to 0 km/h (0 mph), then no disengagement will take place, otherwise it takes place when the speed is lower
than the set parameter value.
Single-acting lift
For single-acting lift only solenoid MA9104 will be energized with switch SW9149, which disables topping up the lift cylinders' piston
end, (+) side, with oil, see figure above "BSS, electric and hydraulic overview". CT1 in BSS-valve (V2), controlled by MA9104, drains
the top of CT3 in V2 to tank. When CT3 in V2 is drained, a connection opens between the lift cylinders’ rod end, (-) side, to tank. The
restriction in CT3 in V2 slows the oil flow coming from the lift cylinders’ rod end, (-) side, and dampens any boom oscillations.
Servo circuit
The servo circuit controls the working hydraulic system via servo valves. For more information about the servo system, see Servo
system, description.
Parameters
Relevant parameters for BSS function.

P1K1Y Boom Suspension Installed
P1K11 Boom Suspension Disengagement, Forward, FAPS Off
P1K12 Boom Suspension Engagement, Reverse, FAPS Off
P1K1Z Boom Suspension Disengagement, Forward, FAPS On
P1K10 Boom Suspension Disengagement, Reverse, FAPS On

 Hydraulic pumps, description
 Boom suspension system, component location
 Boom Suspension System, component description
 Boom Suspension System, specifications
Function check
 Boom suspension system, functional check
Diagnostics
Component Method
MA9103 MA9103, description and measuring
SW4209 SW4209, description and measuring
[1]Optional equipment
Booting sequence
Figure 1
Ignition (SW3301)
1. Battery disconnector on.

2. Set the gear selector in neutral position.
3. Turn the key in the ignition to running position (1) so that system test takes place for 4–5 seconds.
(If the machine is equipped with theft protection, deactivate the theft protection by entering the code. See Operator's Manual.
4. Turn the key in the ignition to start position (2) and the starter motor will be engaged, and the engine starts.
If starting fails, the start key must be turned back to position 0 before a new start attempt can be made.
Error messages
 When Forward or Reverse gear is engaged, engagement of the starter motor is prevented and the message “Information
Gear selector not in neutral” will be shown on the information panel in case of start attempt.
 If the starter motor is overheated, the message “Check High temp. starter motor Wait 5 min. before start” will be shown on the
information panel.
 In case of any other malfunction in the start circuit, the message “Check Engine failure” will be shown on the information
panel.
See Wiring diagram WD301, Wiring diagram WD304 and Wiring diagram WD306.
Brake accumulator, description
Figure 1
1. SE5201, sensor, brake pressure charging

2. Measuring nipple, pressure checking point
3. Accumulator, rear circuit
4. Accumulator, front circuit
5. Accumulator, in common
The accumulators are precharged with nitrogen gas. Their function is to store pressure and provide safe braking capacity by a wide
margin. One accumulator is for the front circuit, one accumulator is for the rear circuit, and one accumulator is in common.
Brake system, component location
Figure 1
Brake system
1. Foot brake valve

2. Accumulator block, brake
3. Hydraulic pump P2
4. Hydraulic oil tank
6. Brake, rear axle
7. Central block
8. Brake, front axle
For description of components, see
 Drive axles, description

 Foot brake valve, description
 Brake accumulator, description
 Hydraulic oil tank, description
Braking system, description
The machine can be braked in three ways:
 the wheel brake applies the discs (disc brakes) in the axles
 the parking brake applies the disc brake in the transmission
 the auxiliary brake (engine brake) increases the engine's resistance through increased load on fan pump P3.
If the machine is moving at 5 km/h or above, neutral gear is not activated when parking brake is applied. This is to reinforce braking
power with engine braking when the parking brake is used as a supplementary brake.
The brake system is integrated with the cooling fan system and the parking brake.
Other systems that can affect the braking system are:

 Auxiliary brake (engine braking), description
 Drive axles, description
 Parking brake, function description
The machine can also be equipped with various optional equipment that affects the braking system:
 Hydraulic attachment locking, description
Figure 1
Brake system with attachment lock
Red = working pressure

Green = return oil
Grey = electrical
1. Axle, rear
2. Axle, front
3. Foot brake valve
4. Brake accumulator block
5. Central valve
6. Cooling fan motor
7. Attachment lock
8. Differential lock
MA4603 differential lock

MA5503 brake pressure charging
MA9106 attachment lock, close
MA9127 attachment lock, open
PWM2602 control pump P3
SE5203 output brake pressure
SE5201 accumulator brake pressure
FX1009 (temperature hydraulic oil tank, level hydraulic oil tank)
SW3801 keypad
SW9143 attachment lock
Figure 2
Signal diagram for brake pressure charging
GPMECU1 General purpose machine electronic control unit

SE5201 Accumulator brake pressure
MA5503 Brake pressure charging
PWM2602 Control, pump P3
Hydraulic (passive) brake pressure charging

Brake pressure charging takes place passively with hydraulic pump P2, which has priority for the steering. When the pressure in the
working hydraulic system or steering system is higher than the pressure in the brake system, the brake accumulators are charged
passively via the shuttle valve in the central block.
If the pressure in the cooling fan circuit becomes high enough, the brake accumulators are charged passively by the cooling fan
system with hydraulic pump P3. The maximum pressure in the brake accumulator block is controlled by the pressure reducing valve
in the central valve.
Figure 3
Hydraulic (passive) brake pressure charging
Electrically controlled (active) brake pressure charging
Electrically controlled (active) brake pressure charging is provided by hydraulic pump P3.
Brake pressure charging starts when the control unit registers a pressure below the cut-in level in the brake accumulator block from
brake pressure sensor SE5201. The control unit decreases the current to the valve for cooling fan control, PWM2602, which
increases the pump's displacement. The valve for brake pressure charging, MA5503, limits the hydraulic oil flow to the fan.
When the brake pressure at SE5201 has increased to the cut-out pressure, active brake pressure charging ends and control of the
pump is returned to the cooling system. (Then the control unit permits the cooling system to take over control of the pump's control,
and the valve for brake pressure charging opens to the fan again). See Brake system, specifications.
Figure 4
Electrically controlled brake pressure charging
Braking
The axles have built-in oil cooled disc brakes which are hydraulically-controlled by the pressure from the foot brake valve. The brake
system is divided into two circuits, one front circuit and one rear circuit.
When the brake pedal is depressed, two parallel connections are opened between the accumulator block and the front and rear
axles. The output pressure is proportional to the pedal angle.
The brake piston and the thrust plate are fixed to the axle housing and do not rotate. The brake disc is located between these two
parts, and the brake disc is connected to the half shaft and rotates when the machine is moving. When the brake pedal is pressed
down, the oil pressure from the foot brake valve enters behind the brake piston, which presses the brake disc against the thrust plate
and the wheel speed is braked.
The hub is equipped with an indicator (see figure below) that is used to check brake disc wear.
When rotating, the brake disc also works as an oil pump, which throws the oil out over the surface of the brake disc and into a pipe
and the oil then flows back to the differential carrier assembly. This function circulates the oil and cools the brakes.
Figure 5
Axle with disc brake
1. Wear indicator, brake disc

2. Wheel hub
3. Automatic clearance adjusters
4. Air nipple, brakes
5. Thrust plate
6. Brake disc
7. Brake piston
Parameters
 -
Summary
 The brake system and the cooling fan share the same hydraulic pump P3.
 Brake pressure charging takes place passively by P2 and actively by P3.
 Front axle, component description

 Rear axle, component description
 Wheel brake, specification
 Brake system, specifications
 Brake system, component location
Function check
 Brake system, check and adjusting pressure in circuit

 Brake system, checking function, retardation
 Brake system charging, checking
 Brake discs, measuring wear
 Accumulators, checking in machine
 Accumulator removed, checking charging pressure
 Tech Tool52005-3 Brake pressure charging, test
 Tech Tool52003-3 Sensor braking system, check
Diagnostics
Detailed information about relevant symptoms is available under the diagnostics tab.
Cab and air conditioning
The machine is equipped with an advanced climate control system where heating and cooling (optional equipment) are integrated in
a single unit and designed to offer a comfortable cab environment during all seasons and in all conditions. For more information
about, e.g., cab fan, air conditioning, or control panel, see Climate control system, description.
Cab, description
Figure 1
Cab
The cab is mounted on the frame using four viscous cab suspension. The pads dampen noise and vibrations that otherwise would be
propagated to the cab. The cab consists of a frame structure that is designed so that it is not crushed in case the machine rolls over.
In addition to frame strength, the cab is adapted to the operator's need for good visibility. Not only visibility of the attachment, but also
all around the machine.
The inside of the cab is spacious with good storage compartments. The instruments are located at the front and on the right side in
the cab. An information display continuously shows information about the machine's different functions.
For operator comfort there is, e.g., an adjustable steering wheel that can be adjusted fore-aft.
The air in the cab is filtered twice when fresh air enters the cab and once more during recirculation. The climate in the cab is
controlled by the ECC (electronic climate control) and can be equipped with AC (air conditioning).
Cable and component designations
Leads and components
Cables and components on wiring diagrams are designated by function group division.
Lead marked, e.g., 3033, indicates that it is function group 3 and running number is 033.
Component marked, e.g., SW3601, means that it is a switch (SW), function group 36 and running number is 01.
NOTE!
Relays and fuses located on the circuit board are not marked according to function group division.
Function group division
2 Engine
3 Electrical system, lighting, etc.
4 Power transmission
5 Brakes
6 Steering
8 Cab
9 Hydraulics
Voltage feed (supply)
30 Battery feed
30A Battery feed via main fuse FU70
30AL Charging voltage to battery from alternator
30C Battery feed via main fuse FU70 (not used)
30K Battery feed to electrical distribution box via main fuse FU70
15A Ignition-dependent voltage feed via relay RE16
15B Ignition-dependent voltage feed via relay RE17
15 EECU Ignition-dependent voltage feed for ECM via relay RE13 with delayed cut-out
15EA Ignition-dependent voltage feed for ECU-controlled functions via RE18
15RA Ignition-dependent voltage feed to radio
58A Voltage feed for instrument lighting in switches via dimmer R3501
Ground connection
Ground connections designation 31xx, e.g., 31C, 31CR, 31F, 31FR, 31FL, 31R, and 31K. For ground connections' location, see
Chassis connection. The leads from ground connections are black.
Colour marking of leads
Leads in wiring diagrams have colour codes with meaning as follows.
BL Blue OR Orange VO Violet

BN Brown P Pink W White
GN Green R Red Y Yellow
GR Grey SB Black
Cable and component marking explanations
Figure 1
Principle diagram, wiring diagram
1 Voltage feed (30=battery voltage, K=circuit board). 11 A lead drawn with a thick line means that it is a printed circuit
See also Cable and component designations. on circuit board
2 Connector, connector pin, male/female 12 Twisted signal cable to reduce the risk of interference in the
signals.
3 Example of designation of switches. The first digit 13 Shielded cable for, e.g. video signal
indicates main group, the second digit subgroup, and
the last two = running number.
4 Reference to other wiring diagram (diagram, 14 Lead number, made up of function group (e.g., 3) and running
coordinates, and connection/split/component) number (e.g., 033)
NOTE!
The arrow does not indicate the current direction.
5 Component designation Cable and component 15 SB = leads with this colour-marking are connected to ground
designations
6 Ground connection (31K, 31F, etc.) Chassis 16 FX = unit that consists of several components.
connection
7 The diagram shows two connections (30:1 and 30:2) 17 Ignition-dependent voltage feed for E-ECU
but the component only has one physical connection
where it should be possible to connect cables of
different cross-sectional areas.
8 Cable split 18 Cables present in the cable harness but that are not used on
this machine model
9 Circled digit indicates that there is information about 19 Coordinates
model versions noted under the diagram.
10 Cable colour. Cable and component designations
Calibration of Comfort Drive Control (CDC), function description
The main purpose of the calibration with Tech Tool is to find the start-current and end-current within the tolerance interval, and also to
find the different mechanical end-positions to ensure good harmony and control lever feeling in the system.
The calibration compensates for component manufacturing tolerances and component wear, and therefore it is necessary to perform
a calibration in any of the following cases:
 Replaced PWM-valves
 Replaced main spool in valves
 Replaced springs for valve spools
 Replaced valve housing
 Replaced complete valve housing
 Replaced angle sensor
 Replaced angle sensor linkage
 Dismantling and reassembly of the angle sensor or angle sensor linkage
 Incorrect lever response
Tech Tool, operations

For adjusting or calibrating the CDC-function, the following operations are available in Tech Tool:
 64186-3 Lever steering, calibration complete

Shall be used to calibrate the end-positions, start-current and end-current.
 64187-3 End position lever steering right/left, calibration
Shall be used to calibrate end-positions.
 64101-3 Lever steering, current values, adjust
Shall be used when fine-tuning the machine or when troubleshooting.
End-position calibration
Calibration of the end-position is performed to find the mechanical limits for the left and right end-position.
The procedure for this is to steer the machine to left and right full lock (end-position). Then the angle value will be read out from
angle sensor SE6411. The calibrated end-position value is only a calculated value, not to be mixed up with the measured angle
value.
 Left end-position
Make sure that the machine is against the left end-position.
Figure 1
Left end-position
 Right end-position
Make sure that the machine is against the right end-position.
Figure 2
Right end-position
Error codes presented inTech Tooland recommended actions

Any deviations from ongoing calibration procedure with Tech Tool will be presented as error codes in messages from control unit
GPMECU2. For more information about error codes, see Error codes when calibrating.
Start-current calibration
Start-current calibration is done to obtain smooth start and stop for the hydraulic function.
In short, the calibration sequence is meant to pinpoint the minimum current signal from GPMECU2 to the valves PWM6601 and
PWM6602, respectively, where the hydraulic control spool just opens. As the current is increased an angle change will be detected
by SE6411, see figure “Start-current characteristics”.
The control unit GPMECU2 will send the PWM’s start-current value, triggering an angle change to Tech Tool. Tech Tool calculates a
current adjustment based on the GPMECU2 values, which is later programmed as starting points for the GPMECU2.
Figure 3
Start-current characteristics
1. Point to be found
X= Current
Y= Angle change
Minimum and maximum start-current during calibration

There is a current limit interval within which an angle change must be obtained, otherwise error codes 88 and 96 will be shown in
Tech Tool, see Error codes when calibrating.
For more information about the angle change limit, minimum and maximum start-current, see Calibration of Comfort Drive Control
(CDC), specification.
Error codes presented in Tech Tool and recommended actions

During calibration of start-current, error codes can be received from control unit GPMECU2.
For more information about error codes and recommended actions, see Error codes when calibrating.
End-current calibration
Calibration of the end-current is performed to find the maximum allowed speed for the CDC steering function. This means that CDC
steering should correspond to the maximum allowed speed of the function.
Calibrating step 1, 2, and 3
NOTE! The speed is controlled by control unit GPMECU2 during calibration regardless of lever position.
When calibrating the end-current for functions that require the angular speed to be measured, the peak of the curve in step 3 is
relevant, see figure “End-current calibration step 1, 2, and 3”.
Figure 4
End-current calibration step 1, 2, and 3
1. Step 1
2. Step 2
3. Step 3
X= Speed
Y= Current
Control unit GPMECU2 will send the speed value to Tech Tool. Tech Tool will then calculate the correct end-current to set the allowed
speed for the function. Then the end-current is programmed into GPMECU2 for the steering directions.
When running step 1, the maximum end-current to the PWM-valve PWM6601 or PWM6602 is high enough to ensure that the control
spool is fully open. See figure “End-current calibration step 1, 2, and 3”.
When running step 2, the minimum end-current to the PWM-valve PWM6601 or PWM6602 is as low as possible to ensure that the
control spool always is slightly open. See figure “End-current calibration step 1,2, and 3”.
The measured speed in step 1 must always be higher than in step 2, otherwise messages 510, 511, or 512 can be received. See
Error codes when calibrating.
When running step 3, see figure “End-current calibration step 1, 2, and 3”, the current to PWM-valve PWM6601 or PWM6602 is
calculated by the result from step 1 and 2 and must be close to the correct end-current. The measured speed in step 1 must always
be higher than in step 3, otherwise error codes 513 or 514 can be received, see Error codes when calibrating.
If the angular steering speed in step 3 is higher than in step 1, a re-run of step 3 is required according to the instruction shown in
Tech Tool.
For more information about the calibration specification, see Calibration of Comfort Drive Control (CDC), specification.
Control current
When the machine is calibrated with Tech Tool , the calibrated value can never be outside the control current limit. When using the
parameter programming operations in Tech Tool the values can be programmed outside the control current limits without notification.
Calibrated parameter values can be set out of range.
For more information about the calibration specification, see Calibration of Comfort Drive Control (CDC), specification When the
ignition key is in position 1, the GPMECU2 checks the parameter value for all start-currents and end-currents. If the parameter value
is outside the limit, GPMECU2 will use the default value for the parameter.
For more information about the control current specification, see Calibration of Comfort Drive Control (CDC), specification.
Parameters
Parameter Name
P1KHZ CDC Left End Angle Calibrated Value
P1KH0 CDC Right End Angle Calibrated Value
P1KJ3 CDC Left, start current calibration value
P1KJ5 CDC Right, Start Current Calibration Value
P1KJ4 CDC Left, end current calibration value
P1KJ6 CDC Right , End current calibration value
 PWM6601, description and measuring

 PWM6602, description and measuring
 SE6411, description and measuring
 Tech Tool operation 64595-3 Electric servo lever steering, test
 Tech Tool operation 64528-3 Angle sensor value, Lever steering CDC, check
 Comfort Drive Control (CDC), description
 Comfort Drive Control (CDC), component location
CareTrack W-ECU, description
General
CareTrack is a telematics system enabling machine owners to track and monitor machines from a computer with connection to the
Internet, regardless of how far away the machine is. By logging in to the CareTrack portal, it is possible to get information about the
machines' condition, at any time. For example, when they have been used, at what speed they have been operated, how much fuel
they have consumed, or the exact positions of the machines.
CareTrack uses GSM (Global System for Mobile communication, same as is used for mobile telephones) for direct connection to the
machines' built-in computers (ECUs). By using a combination of the GSM-net and the satellite-based GPS-system (Global
Positioning System), CareTrack can move information from a machine to a computer connected to the Internet, via the CareTrack
portal.
The CareTrack unit consists of a built-in GPS receiver, satellite modem, and two antennas. The CareTrack unit is connected with the
machine's electronic system, which gives access to read-offs of, e.g., the instrument control unit. When the machine is running, it is
online, and can be localized - at any time and in any place.
After having logged in via the secure CareTrack portal, the machines can be tracked and monitored online, in real-time. However, the
machine must be running to send real-time information, all other information is sent within 24 hours.
CareTrack is available on several continents, but in principle CareTrack works everywhere there is GSM coverage. Where there is no
coverage, satellite link can be used.
CareTrack is available in two versions, “Basic” and “Advanced”.
Figure 1
CareTrack unit
1. W-ECU
2. Satellite modem
Figure 2
1. GSM and GPS antenna.
2. Antenna for satellite communication.
CareTrack “Basic”
 Machine position: the exact position in latitude and longitude

 Real-time machine data: total number of machine hours
 Geographic restriction: The user indicates the geographic limits within which the machine must stay. If it wanders outside the
limits, an alarm is sent via e-mail and an SMS to mobile telephone.
 Time limit: the uses determines between what times and on what days the machine may be used. Here as well, an alarm via
e-mail and to mobile telephone is sent if the time limit is exceeded.
 Position report: summary of the machine's geographic movements
 Reports on daily use: shows how many hours the machine has operated and when it was started and stopped. Reports are
available per day, week, or month.
 Service reminders: send via e-mail and on the mobile telephone
 Service history: every machine's service history can be seen on the secure web portal
 Forwarding of service reminders: to co-workers or service provider
 Service reports: summary of current service
 Message when it's time to replace parts: informs about replacement of certain wear parts that are not included in the normal
service program, and reminds when it's time for replacement
CareTrack “Advanced”
Contains everything in CareTrack “Basic” as well as the following functions:
 Machine utilization: for example, daily reports on the previous 24 hours activities for all machines
 Incident reports: summary of events that are outside certain limits
 Performance report and productivity report: compare the individual machines' (or different shifts) performance and
productivity
 Alarms and warnings: alarm on the instrument panel can be sent via e-mail and mobile telephone as soon as they occur
 History of alarms and warnings: summaries of alarms and warnings
 Error codes: summaries of error codes
 History of error codes
 Forwarding of alarms, warnings, and error codes: enables the dealer to check the machine before it arrives. This can lead to
fewer service trips, that the service technician can bring the right parts the first time, and it can minimize downtime.
 Matris, complete download
 Matris, partial download
 Fuel consumption in real-time: available on the web portal and is shown in simple graph form
System description
Figure 3
1. Network node, control station.

2. CareTrack portal, for users.
3. E-mail, Matris, and Internet.
4. Satellite link for machine data.
5. Satellite for communication.
6. GSM-link for machine data.
7. Machine.
8. Satellite for GPS positioning.
Satellite communication
Satellite communication consists of a number of satellites that orbit the Earth at low altitude. Each satellite's coverage is a few
thousand kilometres in diameter. However, since satellites move quickly across the Earth's surface a powerful signal may be lost just
a few minutes later.
Signal-noise ratio
Signal-noise ratio, often abbreviated SNR or S/N, is a term that defines the relationship between the signal and the noise effect that
distorts the signal, that is, SNR compares the level of the useful signal (, e.g., music) with the background noise. The higher the ratio
the less one is disturbed by the background noise. For example, a CD-player has a ratio (= dynamics) of approx. 90 dB. A record
player may be able to handle 25 dB.
There are many factors that may give CareTrack a low S/N ratio: sources of interference close by, high buildings, thick forests, high
mountains, operating in a tunnel, thunderstorm, long distance to ground station (GSM), or that the communication satellite is at the
outer limit of its range.
Doppler effect
The Doppler effect is a phenomena that entails a change of the frequency (oscillation rate) of a signal, e.g., sound or noise,
depending on if the source is getting closer to or is moving away from the observer. An example of eh Doppler effect are sirens on
ambulances or police cars, that seem to increase (= a higher tone) when approaching the observer, and decrease in frequency (= a
lower tone) when they have passed.
The software in CareTrack uses the Doppler effect to calculate if a communication satellite is approaching the machine or moving
away from the machine.
Activation of CareTrack
The W-ECU (the CareTrack unit) is installed in the vehicle and Tech Tool is connected. The the W-ECU is configured with, e.g.,
chassis-ID, thereafter the W-ECU is restarted and now the vehicle sends an activation message via GSM (SMS) or satellite to the
network node for CareTrack. A machine card is now created in the network node and the user can log in to the CareTrack portal and
enter information about the vehicle, among other things, chassis-ID. Then the settings are sent to the vehicle which then is ready
monitor and track in CareTrack.
More detailed information about settings and configuration is available in Tech Tool or in the installation instructions for CareTrack.
CCM, I/O list
output is not used.

1 SE8709 Pressure, refrigerant Wiring diagram WD805
2 — — —
3 — — —
4 — — —
5 SW3528 Guide lights Wiring diagram WD335
6 — — —
7 SE8301 Position monitor, door Wiring diagram WD333
8 — — —
9 — — —
10 — — —
11 — — —
12 — — —
13 — — —
14 — — —
15 — — —
16 — — —
17 — — —
18 SW8701 Voltage feed, controls Climate Control Module Wiring diagram WD805
19 FU51 Voltage feed (15EA), Climate Control Module Wiring diagram WD305
20 SE8709 Pressure, refrigerant Wiring diagram WD805
21 — — —
22 MO8703 Actuator air mixing damper Wiring diagram WD806
23 MA8701 AC Compressor Wiring diagram WD806
24 — — —
25 — — —
26 SE8706 Temperature, cab Wiring diagram WD805
27 MO8707 Actuator heat valve Wiring diagram WD806
28 — — —
29 — — —
30 — — —
31 — — —
32 — — —
33 — — —
34 CANL Communication, BB2 Wiring diagram WD321
35 — —
36 RE14 Voltage feed CCM, magnet clutch AC compressor, Wiring diagram WD302
pause coolant pump
37 RE8712 Water pump, pause heat Wiring diagram WD806
38 — — —
39 — — —
40 — — —
41 SW8701 Controls, Climate Control Module Wiring diagram WD805
42 — — —
43 — — —
44 — — —
46 MO8701 Cab fan Wiring diagram WD806
47 MO8701 Cab fan Wiring diagram WD806
48 MO8707 Voltage feed, sensors. Wiring diagram WD805
SE8702
SE8706
SE8708
SE8709
49 SE8708 Temperature, air channel Wiring diagram WD805
50 SE8702 Evaporator, temperature Wiring diagram WD805
51 — — —
52 — — —
53 — — —
54 — — —
55 — — —
56 — — —
57 — — —
58 CANH Communication, BB2 Wiring diagram WD321
59 — — —
64 — — —
65 SW8701 Ground, controls Climate Control Module Wiring diagram WD805
66 FU27 RE14, voltage feed CCM, magnet clutch AC Wiring diagram WD302
compressor, pause coolant pump
69 Ground Ground connection 31C1 Wiring diagram WD302
70 Ground Ground connection 31C1 Wiring diagram WD302
CDC valve, lever steering, description
Figure 1
1. Priority slide, steering wheel steering / Comfort Drive Control CDC (lever steering)
2. Filter
3. Non-return valve
4. PWM6601, lever steering CDC, left
5. PWM6602, lever steering CDC, right
6. Pressure limiter
Figure 2
1. Priority slide, steering wheel steering / Comfort Drive Control CDC (lever steering)
2. Filter
3. Non-return valve
4. PWM6601, lever steering CDC, left
5. PWM6602, lever steering CDC, right
6. Pressure limiter
7. Shuttle valve
8. Directional slide, lever steering CDC
9. Non-return valve
Central lubrication system, description
The central lubrication system TWIN3 consists of a pump unit, main line A and main line B, distribution block with metering valves,
secondary line, and a lubrication pressure sensor.
A control unit (CU9901), integrated in the pump unit, activates the pump according to a preset lubrication cycle. Three different pre-
programmed lubrication cycles can be selected, LIGHT, NORMAL, and HEAVY, to obtain correct lubrication according to the existing
operating and load conditions. Selection of lubrication cycle takes place using the keypad and the machine's display. See Change of
lubrication interval.
How often the pump greases depends on the selected lubrication cycle.
Lubricant is pumped out through the two separate channels (A and B), leading to the distribution blocks with metering valves. The
channels are pressurized alternately. In a lubrication cycle one channel is pressurized and the other is depressurized. During every
lubrication cycle, each grease point receives a specific amount of grease regardless of if channel A or B is pressurized.
The delivered amount of lubrication is determined by the size of the dosage valves and is not affected by back-pressure,
temperature, or the distance between grease point and pump.
Figure 1
1. Electric grease pump with integrated grease reservoir and digital control unit.
2. Main line, channel A
3. Main line, channel B
4. Distribution block
5. Metering valve
6. Lubrication pressure sensor, PS
7. Secondary line
Figure 2
Lubrication cycles
1. Pump unit
2. Main line, channel A and channel B
4. Metering valve
5. Secondary line
6. Lubrication pressure sensor, PS
Connections on circuit board.
Lubrication cycles
The programmable control unit integrated in the pump unit determines the progress of each lubrication cycle that takes place during
four different phases, pump phase, pressure retaining phase, pressure reduction phase, and pause. It also decides how often a
lubrication cycle should be performed. In addition, there are protective functions that ensure lubrication if there are problems in the
systems.
A complete lubrication cycle consists of a cycle where all grease points are supplied with lubricant through one of the channels in the
main line.
A lubrication cycle is initiated by the control unit (CU9901) that activates the pump. The pump delivers pressure to line A. The
pressure builds up until lubrication pressure monitor (SE9901) sends a signal that desired pressure is reached. The pressure signal
stops the pump and after some time, channel A is depressurized. At the next lubrication cycle, the pump is activated via the control
unit (CU9901). At the same time, the shift valve is activated and channel B is pressurized.
Figure 3
1. Pump a. Pressure retaining phase

2. Shift valve b. Pump phase
3. Pressure curve main line A c. Pressure reduction phase
4. Pressure curve main line B d. Pause
Cycle A
During the pump phase lubricant is pumped in to the main line's channel A and on to the distribution block and metering valves that
deliver a determined amount of grease to each grease point. During that time channel B is connected to tank. When full pressure has
been reached the lubrication pressure sensor (6) is affected so that the pump motor turns off, the pressure retaining phase finishes.
See Pressure switch
During the pressure retaining phase the pump motor is off. The pressure is maintained in the line to ensure lubrication to all grease
points.
During the pressure reduction phase, the pressure is relieved in channel A through activation of the shift valve.
The lubrication cycle ends with pause.
Cycle B
During the next lubrication cycle, lubricant is pumped in through channel B. In other aspects the lubrication cycle is the same as in
channel A.
The pressure builds up in one channel, at the same time as it is released in the other. A shift valve in the pump unit opens and closes
the pump connection with both channels.
Channel A and B alternate in supplying the metering valve with lubricant, which then is metered out to the grease point.
Then the metering valve's piston returns and the metering valve is filled with new lubricant for the next lubricant cycle. See Metering
unit
Since the return stroke of the metering valve's piston always takes place affected by the pressure in the channel, A or B, the metering
valves work regardless of, e.g., temperature and type of lubricant.
This means that the pressure lines A and B never are in direct contact with the secondary line out to each grease point.
For description of lubrication cycles, see: Lubrication cycles
Different function parameters can be set in the control unit with a software installed on a laptop PC. With the PC-tool it is also
possible to read function data, for example, error indications that are registered in the control unit's memory.
Circuit board connection, see: Pump unit, circuit board
Central valve, description
The purpose of the central block is to distribute oil and pressure to the cooling fan, brakes, steering, servo system, and working
hydraulics. Pressure and flow from P2 and P3 is distributed by the central block to the different subsystems. The central block gives
priority to oil flow between the steering and working hydraulics and also gives priority to the LS-pressure from the different
subsystems.
Figure 1
Figure 1 Central block
1. Pressure reducing valve: brake pressure

2. Pressure reducing valve: max. servo pressure
3. Pressure limiting valve: max. steering pressure
4. —.
5. Shuttle valve: selects the highest LS-pressure from steering or working hydraulics and leads it to the flow compensator on P2
6. Brake charging takes place via the shuttle valve that selects the highest pressure from either P3, or P2.
7. MA5503 Brake charging valve: limits the flow to the fan to ensure brake charging. Controlled by V-ECU
8. Pressure check connection for P2
9. Priority valve: makes sure that the steering is supplied with oil before the working hydraulics
10. Restriction LS-pressure steering
Port designations on central block
1. PFF Output flow, hydraulic fan.

2. PF Input flow, P3
3. PB Brake charging pressure, output.
4. P Input flow, P2
5. PR Servo pressure, output
6. LSS Input LS-signal from steering
7. PS Output flow to steering valve.
8. LSW input LS-signal from working hydraulics
9. LSP Output LS-pressure to P2
10. PW Output work pressure, working hydraulics
Diagnostics
Detailed information about relevant warnings and error codes below is available under the diagnostics tab.
Component MID Message ID

MA5503 187 PPID1048
Change of lubrication interval
1. Turn the ignition key to position 1 (operating position).
2. Select "Service" with the keypad.
3. Select "Central lubrication" with the arrow keys and press SELECT.
4. Select "Interval" with the arrow keys and press SELECT.
5. Select the lubrication interval you want to change to with the arrow keys and press SELECT.
6. Wait 45 seconds before turning the start key to 0 (selected interval in display may go back to earlier interval, but the change
will be in effect after 45 seconds).
NOTE!
If the start key is turned to position 0 within 45 seconds after the lubrication interval has been changed, then the latest
selection of lubrication interval will be erased. Therefore, wait for at least 45 seconds after the setting has been made, before
turning the start key to position 0.
7. Turn the start key to position 0 and wait until the display shuts down.
8. Turn the start key to position 1 (running position) and check that the correct lubrication interval is shown in the display.
To change lubrication interval again, the start key must be turned to position 0 and when the display shuts down, the start key can
once again be turned to position 1 and new lubrication interval can be selected.
Chassis connection
Pos. Serves
1 Battery. (31R1)
2 Engine, starter motor, and alternator. (31E1)
3 Front frame. (31F1)
4 Rear frame and secondary steering pump. (31R2)
5 Cab. (31C1)
6 Cab. (31C2)
7 Rear frame. (31R2)
Figure 1
Frame ground connections
Climate control system, description
General
The machine features an advanced Electronic Climate Control (ECC) system where heating and cooling (optional equipment) are
integrated in a single unit. It is designed to provide a comfortable cab climate during all seasons of the year and in all conditions.
The cab fan can maintains a constant over-pressure to shut out impurities where all air, including the recirculated air, is filtered.
The cab is standard-equipped with a heating system. Air conditioning (AC) is available as optional equipment.
All controls for the climate control system are located above the right side panel.
During recirculation, most of the air volume will flow through the recirculation damper. With the control set to max. recirculation, most
of the air will be recirculated and only a small amount of air will come from the outside in order to maintain the over-pressure in the
cab.
Heating system
The air that is drawn into the cab is routed via the air inlet through the prefilter and the main filter. The prefilter and main filter are
replaced at different intervals (see Service Program).
After the air has passed through the cab filters it is drawn into the fan through the heating coil where the warm coolant from the
engine circulates. Then the air is distributed throughout the cab through different channels and individually adjustable air vents to
direct the airflow. The air vents can be closed. There are 10 air vents at the front in the cab and 2 air vents on the right side behind
the operator's seat.
Air conditioning (AC)
After the air has passed the prefilter and main filter, it is drawn through the evaporator, which is located behind the main filter, on
through the heater core and out into the cab through the same air channels and air vents as the warm air system.
Control panel
Figure 1
1. 1. Switch, air conditioning (optional equipment).

The switch is also found on machines without an AC-system. The control light in the switch shows that the function is active.
If the control light starts to flash the AC has been turned off due to too high system pressure, and then the AC-system has to
be reactivated or checked for any malfunctions.
2. 2. Cab ventilation/pause heater (interval heating, option)
3. Fan control
If the fan control is in AUT-mode, fan speed is controlled automatically.
4. Temperature control
5. 5. Recirculation control and defroster
In defroster position, max. fan and air conditioning are turned on. For more detailed information, see the Operator's Manual.
Temperature control of the ECC consists of a control panel, SW8701, and a control unit, CCM (Climate Control Module).
The CCM controls the temperature in the cab using an electrically controlled coolant flow valve, MO8707, as well as temperature
sensors SE8706, SE8708, SE8702, and SE8705. The CCM communicates with the HMICU (Human Machine Interface Control Unit).
If the fan control is in AUT-mode, the system strives to reach the selected temperature as quickly as possible, working together with
the coolant flow valve and lowest possible fan speed.
If the recirculation control is in AUT-mode, the damper is controlled according to ambient temperature and selected temperature.
The temperature sensors sense:
 SE8702 – Evaporator temperature (only with installed AC)

 SE8708 – Air temperature in air channel
 SE8706 – Air temperature in cab behind operator's seat
 SE8705 – Ambient temperature via HMICU
The sensor that primarily controls the cab temperature is SE8706. SE8708 is a reference sensor with the purpose of providing as
uniform temperature as possible in the air channel. The ECC receives information about the ambient temperature via SE8705.
The electrically controlled coolant flow valve remains in its latest position when the engine is turned off. If the pause heater function
(optional equipment) is enabled, the coolant flow valve and sensors are active in the ECC.
Climate control system with components
Figure 2
1. Primary filter
2. Air mix door
3. Hot coolant valve
4. Hot coolant from engine
5. Hot coolant to radiator
6. Main filter
7. Drain
8. Evaporator
9. Heater unit
10. Fan
11. Return hot coolant to engine
A. Inlet air
B. Recirculated air from cab
C. Air from fan to cab
Air conditioning
When the AC-switch on the panel is pressed, the AC-compressor starts if the pressure and temperature are within the limit values,
see software description.
The evaporator's temperature is monitored by the CCM and the compressor's cycles. The air conditioning controls the engine's
cooling fan endlessly as needed.
When the AC-compressor runs the evaporator gets cold. The temperature sensor SE8702 sends a signal to the CCM. If the
evaporator gets colder than 3 °C (37.4 °F), the CCM cuts off the ground connection to the electromagnetic compressor clutch . When
the AC-compressor stops, the evaporator temperature increases and at approx. 7 °C (45 °F), the CCM activates the AC-compressor
again. This is done in order to prevent ice formation on the evaporator. The AC will turn off when the temperature falls below the “low”
level and the AC will turn on again when temperature increases above the “high” level. The “low” and “high” levels are defined with
the parameter “AC Cycling level”.
The following must occur for the AC-compressor to start, that is, for the magnet clutch to be activated:
 The AC-switch on the panel must be pressed in or soft-start AC activated, see next paragraph
 The pressure in the system must be within the limit values, see software description
 The engine must be running
 The evaporator temperature must be above approx. 3 °C (37.4 °F)
 Reversing of cooling fan (optional equipment) must not be active. Affected by the air conditioning's cooling need.
Soft-start AC
At engine start, the CCM grounds RE14 which closes the circuit. MA8701 receives voltage from FU27 and ground via the CCM,
which means that the AC-compressor starts. The AC-compressor also rotates along when the starter motor rotates to obtain slow
pressure build-up. This prevents fluid shocks in the compressor at the same time as the compressor's shaft seal is lubricated.
Soft-start is not activated if:
• Less than four hours have passed since the engine was turned off
• The system has the wrong pressure, see software description
• The temperature in the evaporator is too low, see software description.
Monitoring AC
If the pressure sensor SE8709, high-pressure side of the AC-unit, indicates <155 kPa (1.55 bar) (22.5 psi) at engine start and the
ambient temperature is above +10 °C (50 °F), "ERROR AC-system" is shown on the operator's information display and the control
light in the AC-switch flashes. The problem may be due to the AC-system not having enough refrigerant in it or the pressure sensor
has failed.
Air conditioning's impact on engine cooling fan's speed
The machine features a hydraulic engine cooling fan which also cools the condenser. The air conditioning controls the engine's
cooling fan endlessly according to the air conditioning's cooling need. This means that the cooling fan increases in speed without the
engine needing cooling.
Parameters
Relevant parameters for climate control function.

P1KQI AC Installed
P1KQW Climate control system heating coil installed
P1KQU Cab fan speed limitation with open door installed
P1KQL§ Cab pause heating installed
P1KQT AC cycling level
P1JKS Attachment bracket installed
Tech Tool parameters are found in this list: Software parameters, description.
In case of malfunction of any Tech Tool parameter, it is considered to be "OFF" or "0"
In case of malfunction of pressure sensor SE8709, it is considered to be outside the working values.
In case of malfunction of the climate system's control panel SW8701, the AC is considered to be "OFF"
In case of incorrect input signal Engine On/Off, it is considered to be "On".
In case of malfunction of switch attachment lock SW9143, it is considered to be Locked.
In case of malfunction of ambient temperature, SE8705, it is considered to be >25 °C (77 °F)
In case of incorrect input signal Key-feed, no soft-start shall be performed.
 Wiring diagram WD302

Diagnostics
Comfort Drive Control (CDC), component location
Figure 1
1. Central valve
2. CDC valve
4. Angle sensor
5. Steering valve
6. Steering cylinder
8. Hydraulic pump 2
9. Pressure monitor

 Hydraulic oil tank, description
 Pressure monitor, description
Comfort Drive Control (CDC), description
Comfort Drive Control (CDC) is optional equipment which allows steering, gearshifting between Forward and Reverse, and kick-down
function to be operated by controls on the left armrest. The main components for the CDC-system are the CDC hydraulic valve, the
electronic control units, the steering angle sensor, and the armrest which is equipped with a steering lever and switches for
gearshifting and kick-down function. These components are all integrated with the standard steering system.
Other systems that can affect the CDC system’s function are:
 Steering system, description

 Working hydraulic system, description
 Servo system, description
General function
The steering is controlled with the steering lever, SE6601, and gearshifting and kick-down function are controlled with switches that
are located on the left armrest close to the steering lever, see figure below.
Figure 1
Left armrest with component positions
1 Activation switch CDC-function, SW4216

2 Control lever CDC-function, SE6601
3 Switch Forward-Neutral-Reverse gearshifting, SW4217
4 Switch Kick-down function, SW4220
5 Position sensor armrest, SE4227
The machine speed can be limited when CDC is activated by adjusting the software parameter P1KLN with Tech Tool. As long as the
CDC is activated it is not possible to exceed the set speed limit.
NOTE!
Steering with the steering wheel always has a higher priority than CDC.
If the steering wheel is used when CDC is activated, the CDC-system is given lower priority in relation to the steering wheel. The
CDC-system’s function becomes available as soon as use of the steering wheel ceases. See more in the section Steering function.
A complete calibration of the CDC-system is performed with Tech Tool Service Tool op. 64186-3 Lever steering, calibration complete.
Engagement of Comfort Drive Control (CDC)
The left armrest needs to be in lowered position so that SE4227 is closed before the CDC-system can be activated. The CDC-system
is activated with switch SW4216. When the CDC-system is activated, a CDC symbol/control light will be active together with the
message "CDC" in the operator's display.
NOTE!
All gear selector controls must be in neutral position to enable activation of the CDC-system.
Steering function
When the steering lever SE6601 is actuated, a signal is sent to control unit GPMECU2. The signal is monitored by the control unit
CU6601 to make sure that the signal input to GPMECU2 corresponds with the PWM current output. Then the proportional valve
PWM6601 or PWM6602, depending on steering direction, allows oil to flow from pump P2 via the central valve’s priority spool, the
CDC hydraulic valve, the steering valve, and the anti-cavitation valve to the steering cylinders. See overview below.
Figure 2
Overview, hydraulic diagram for CDC and related systems
1 Central valve
2 Steering valve
3 Anti-cavitation valve
4 Steering cylinders
5 CDC hydraulic valve
The CDC hydraulic valve is supplied with oil at its inlet port P1, which pressurizes the proportional valve PWM6601 (steering left) or
PWM6602 (steering right) and the directional spool. In unaffected state the PWM-valves block any oil flow to the directional spool
and no CDC-steering will occur. An energized PWM-valve will direct servo pressure oil to the directional spool, which allows oil to be
directed to the steering cylinders via the shift valve, see Steering system, description. A corresponding LS-pressure is also generated
at the CDC hydraulic valve’s outlet port PL as the position of the directional spool changes. This affects hydraulic pump P2 to
increase its oil displacement to meet the increased oil need for the steering function, see figure below.
Figure 3
Example of pressurized CDC hydraulic valve when steering right
Red High pressure

Orange Reduced pressure
Just as the steering function is prioritized in the central valve, the steering wheel is prioritized before the CDC-function. The
prioritizing function spool for the steering wheel in relation to CDC is located in the CDC hydraulic valve, which drains the CDC-valve
whenever a hydraulic signal output pressure is generated from the steering valve. The CDC-function becomes available as soon as
the steering wheel is not used.
Depending on the machine's travel speed, the steering lever's sensitivity varies. When operating the machine at low speed the
steering lever's sensitivity is high, e.g., small lever adjustments give steering response. This sensitivity decreases with increasing
travel speed. When operating the machine at higher speed, only big movements of the steering lever will affect the machine's
steering. The steering lever's sensitivity is specific to the machine model and can not be changed.
Stroke-end damping
When close to its end-of-stroke position, the steering speed is reduced to obtain a smooth stop. The calibrated angle sensor SE6411,
which monitors the position of the steering joint, sends a signal to the control unit GPMECU2. This restricts the oil flow to the steering
cylinders by decreasing the current output to PWM6601 or PWM6602. Subsequently the CDC's PWM-valve limits oil flow to the
steering cylinders from pump P2.
Tech Tool is used to calibrate and adjust the angle value for SE6411.
CDC supervision
To ensure safe operation the supervision function makes sure that requested input via the steering lever, and other CDC-related
sensors, corresponds to the output via PWM6601 or PWM6602 to the hydraulic steering function.
The electronic control unit CU6601 contains a relay mechanism which allows a signal from GPMECU2 to control PWM6601 or
PWM6602. The relay is controlled by an enable signal from GPMECU1, where the relay will be disabled if the power is cut off.
Supervising GPMECU1 also receives steering position signals of steering lever from controlling GPMECU2 via CU6601, see signal
diagram below.
Figure 4
CDC-system signal diagram, overview
1 Measured CDC-lever, CDC left/right, armrest position

2 CDC-relay feed signal
3 PWM6601/PWM6602 request
CU6601 CDC supervision control unit
SE4227 Armrest sensor
SE6601 Steering lever
SW4216 Activation CDC-function
SE6411 Steering angle
SW4220 Kick-down armrest
SW4217 Forward-Neutral-Reverse gearshifting
PWM6601 Return status
PWM6602 Return status
For any incorrect signal detected by the CDC supervision system, the CDC-function will be disabled and a warning will be shown in
the operator’s display.
If any of the cylinders are forced in any direction by external forces, increased oil channel pressure is generated. This pressure must
be released in a safe way to protect hydraulic components. For more information, see Steering system, description and Safety when
working on hydraulic systems.
Parameters
Relevant parameters for CDC-function.

P1JMC CDC Installed
P1KHZ CDC left end angle calibrated value
P1KH0 CDC right end angle calibrated value
P1KJ3 CDC steering start current positive solenoid
P1KJ4 CDC steering end current positive solenoid
P1KJ5 CDC steering start current negative solenoid
P1KJ6 CDC steering end current negative solenoid
P1KLN CDC Speed Limit
P1K81 Serial number CDC-valve
 Braking system, description

 Steering system, description
 Central valve, description
 Hydraulic pumps, description
 Servo system, description
 Hydraulic diagram, complete
Function check
 Lever steering (CDC), functional check

 640 Tech Tool op. 64595-3 Electric servo, Lever steering, test
 640 Tech Tool op. 64528-3 Angle sensor, Lever steering, check
Diagnostics
Component
CU6601 See CU6601, description and measuring
Components list
Figure 1
Figure 2
Position of relays and fuses outside circuit board
Figure 3
Position of control units
1. Engine Control Module (ECM)

2. Aftertreatment Control Module (ACM)
3. General Purpose Machine Electronic Control Unit 1 (GPMECU1)
6. Human Machine Interface Control Unit (HMICU)
7. Telematics ECU (WECU)
8. Climate Control Module (CCM)
9. Instrument cluster (IC)
Component Designation Function Wiring diagram

Antenna
AN3903 Aerial, GPS (CareTrack) Wiring diagram WD326
AN3904 Aerial, satellite (CareTrack) Wiring diagram WD326
Alternator
AL3201 Alternator Wiring diagram WD306
Battery
BA3101 Battery 1 Wiring diagram WD301
BA3102 Battery 2 Wiring diagram WD301
Radio
CR3901 Radio Wiring diagram WD326
Diodes
DI01 Diode, control voltage RE13 Wiring diagram WD302
DI06 Diode, Parking lights Wiring diagram WD331
DI10 Lock-out diode Wiring diagram WD911
DI20 Diode, single acting lift function Wiring diagram WD903
DI21 Diode, BSS and single acting lift function Wiring diagram WD903
DI22 Diode, windshield wiper Wiring diagram WD801
DI23 Diode, windshield wiper Wiring diagram WD801
DI3301 Diode, starter motor Wiring diagram WD304
DI3701 SW3102, emergency stop Wiring diagram WD304
DI3703 SW3102, emergency stop Wiring diagram WD304
DI3705 Diode unit, RE3102 Wiring diagram WD304
DI9101 MA9144, ratchet, 3rd Wiring diagram WD902
DI9102 MA9113, single lever control, lever lock Wiring diagram WD902
DI9103 MA9142, lift auto, 4th lever lock Wiring diagram WD902
DI9104 Timber shovel, relaybox Wiring diagram WD902
DI3703 Emergency stop Wiring diagram WD304
DI9101 MA9144, ratchet, 3rd function Wiring diagram WD902
DI9102 MA9113, lever lock−out, single lever Wiring diagram WD902
DI9103 MA9142, holding magnet, automatic lift Wiring diagram WD902
DI9104 MA9144, holding magnet, float position Wiring diagram WD902

Fuses
FX1026 Main fuse box Wiring diagram WD301
FU70 Secondary steering
FU71 Charging
FU72 Cab
FU73 –
FX1027 Extra fuse box Wiring diagram WD807

FU85 Fan cyclone filter
FU86 —
FU87 —

FU61 Electric heat fuel filter
FU64 Electric door
–
FU01 Brake lights Wiring diagram WD501

FU02 HMICU, IC (Instrument Cluster) Wiring diagram WD302
FU03 Work lights cab front Wiring diagram WD331
FU04 Voltage feed RE14 Wiring diagram WD302
FU05 Parking light left front Wiring diagram WD330
Side light, left front
Parking light right rear
FU06 Parking light right front Wiring diagram WD330

Side light, right front
Parking light left rear
Lighting license plate
FU07 Low beam, left Wiring diagram WD330

FU08 Low beam, right Wiring diagram WD330
FU09 Voltage feed RE02 Wiring diagram WD324
FU10 High beam, right Wiring diagram WD330
FU11 High beam, left Wiring diagram WD330
FU12 Reversing camera Wiring diagram WD804
FU13 Work lights front Wiring diagram WD331
FU14 Hazard flashers Wiring diagram WD363
FU15 Work lights cab, rear Wiring diagram WD334

FU16 Work lights roof, front Wiring diagram WD334
FU17 HMICU voltage feed, hold voltage RE13 Wiring diagram WD302
FU18 24 V socket Wiring diagram WD301

FU19 Parking light Wiring diagram WD330
High- and low beam
FU20 Starter lock, voltage feed Wiring diagram WD304
HMICU
FU21 Rotating beacon Wiring diagram WD363

Interior lighting
Entry light
Extended light around the machine
FU23 – Wiring diagram WD325

FU24 ECM, FU30 voltage feed Wiring diagram WD302
FU25 GPMECU1, CDC voltage feed Wiring diagram WD302
FU26 GPMECU2, CU6601, CDC voltage feed Wiring diagram WD302
FU27 CCM, magnet clutch, AC compressor, pause Wiring diagram WD302
coolant pump
FU28 — Wiring diagram WD302

FU29 — Wiring diagram WD302
FU30 Power supply, aftertreatment Wiring diagram WD302
FU31 Travel direction, gear shifting Wiring diagram WD302
FU32 Boom Suspension System BSS Wiring diagram WD362
BSS, single acting lift
Emergency stop, 3rd function
FU33 Electric lever lock Wiring diagram WD362

Aftertreatment (ASU), switch
Lift / tilt function
FU34 Headlight flasher Wiring diagram WD362
Windshield wiper and windshield washer front
FU35 Windscreen wiper and washer rear Wiring diagram WD362

Washer fluid level
FU36 RE3601, voltage feed Wiring diagram WD306
FU37 Direction indicators Wiring diagram WD362

FU38 Work lights Wiring diagram WD362
Fuel heater
FU39 Horn Wiring diagram WD361
Kick-down (CDC)
Electric heat rear-view mirrors
Operation rear-view mirrors
FU40 Reversing camera, voltage feed Wiring diagram WD361

FU41 Seat heating Wiring diagram WD802
Position monitor loading operator's seat
FU42 Fully automatic gearshifting (FAPS) Wiring diagram WD360

Gear selector lever carrier
CDC (armrest)
Boom Suspension System, activation /
function selection
Differential lock, feedback
FU43 Central lubrication Wiring diagram WD913

FU44 Floating position Wiring diagram WD360
FU46, FU47 — Wiring diagram WD325

FU48 Parking brake Wiring diagram WD501
FU49 Secondary steering Wiring diagram WD604
FU50 Voltage feed TechTool communication socket Wiring diagram WD360
Attachment locking
FU51 Ignition-dependent voltage feed to ECU:s and Wiring diagram WD305
TechTool communication socket
FU61 Electric heat fuel filter (FX1028) Wiring diagram WD807

FU64 Electrical doorlock control unit (FX1028) Wiring diagram WD807
FU70 Secondary steering (FX1026) Wiring diagram WD301
FU71 Charging (FX1026) Wiring diagram WD301
FU72 Cab (FX1026) Wiring diagram WD301
FU73 – (FX1026) Wiring diagram WD301
FU74 Alternator, magnetization Wiring diagram WD301
Voltage converter
Ignition, key controlled
WECU
Fire suppression system
FU75 Hood motor Wiring diagram WD807

Battery disconnection switch
FU77 ACM Wiring diagram WD303
FU78 ECM, FX1041 Wiring diagram WD303
FU83 NOx sensors Wiring diagram WD303
FU85 Fan cyclone filter Wiring diagram WD807
FU88 RE2501 preheating. MO2505. Wiring diagram WD303
FU89 FU75 engine hood Wiring diagram WD303
FU2501 Preheating Wiring diagram WD264

Multi-function components
FX1001 Interior lighting, cab (front) Wiring diagram WD333
Component including LA3501, LA3516,
SW3503, and SW3507
FX1002 Interior lighting (right) Wiring diagram WD333

SW3508, and SW3509
FX1005 SE2302, Water in fuel sensor Wiring diagram WD202

HE2301 Electric heat fuel/water bowl Wiring diagram WD263
FX1007 SE2507 Inlet manifold temperature sensor Wiring diagram WD262

SE2508 Inlet manifold pressure sensor
FX1008 SE2501 Inlet air temperature sensor Wiring diagram WD263

SE2502 Air cleaner pressure sensor
FX1009 SE9104 Level hydraulic oil tank Wiring diagram WD903

SE9105 Temperature, hydraulic oil tank
FX1020 Combination light left rear Wiring diagram WD333

LA3510 Tail light
LA3606 Direction indicator
LA5202 Brake light
FX1021 Combination light right rear Wiring diagram WD333
LA3511 Tail light
LA5201 Brake light
FX1026 Main fuse box Wiring diagram WD301

FU71 Charging
FU72 Cab
FU73 –

FU85 Fan cyclone filter
FU86 —
FU87 —

FU61 Electric heat fuel filter Wiring diagram WD807
FU64 Electric door
–
FX1029 SW3602 Windshield wiper front and Wiring diagram WD801

windshield washer front
SW3608 Windshield washer front
FX1036 MO3605, electrically controlled rear-view Wiring diagram WD804

mirror, left horizontal
MO3606, electrically controlled rear-view
mirror, left vertical
HE3602, electric heat left rear-view mirror

mirror, right horizontal
mirror, right vertical
HE3604, electric heat right rear-view mirror
FX1040 ACM, ECM, (FU77, FU78, FU79) Wiring diagram WD303
FX1041 EGR on/off, preheating, induction air (FU83, Wiring diagram WD303
FU88, FU89)
FX1072 LA3602 Direction indicator Wiring diagram WD333
FX1073 LA3603 Direction indicator Wiring diagram WD333
FX1074 AdBlue®/DEF pump unit Wiring diagram WD270
FX1079 SE2536 AdBlue®/DEF temperature sensor Wiring diagram WD265

SE2537 AdBlue®/DEF level sensor Wiring diagram WD269
SE2541 AdBlue®/DEF quality sensor
Heating coil
FX1005 HE2301 Electric heat fuel/water bowl Wiring diagram WD202
SE2302, Water in fuel sensor Wiring diagram WD263
HE2301 Electric heat fuel/water bowl (FX1005) Wiring diagram WD263

HE2501 Preheater element Wiring diagram WD264
HE2511 AdBlue®/DEF hose (supply/return) Wiring diagram WD269
HE3602 Electric heat left rear-view mirror (FX1036) Wiring diagram WD804
HE3604 Electric heat right rear-view mirror (FX1037) Wiring diagram WD804
HE8501 Seat heating Wiring diagram WD802

Lighting
FX1001 Interior lighting, cab Wiring diagram WD333
SW3503, and SW3507
FX1002 Interior lighting right Wiring diagram WD333

SW3508, and SW3509
FX1020 Combination light left rear Wiring diagram WD333

LA3510 Tail light
LA5201 Brake light
FX1021 Combination light right rear Wiring diagram WD333

LA3511 Tail light
LA5202 Brake light
FX1072 Combination light left front Wiring diagram WD330

LA3502 Low beam Wiring diagram WD333
LA3504, High beam
LA3506 Parking light
FX1073 Combination light right front Wiring diagram WD330

LA3503 Low beam Wiring diagram WD333
LA3505 High beam
LA3507 Parking light
LA3502 Low beam left (FX1072) Wiring diagram WD330
LA3503 Low beam right (FX1073) Wiring diagram WD330
LA3504 High beam left (FX1072) Wiring diagram WD330
LA3505 High beam right (FX1073) Wiring diagram WD330
LA3506 Parking light left front (FX1072) Wiring diagram WD330
LA3507 Parking light right front (FX1073) Wiring diagram WD330
LA3508 Left front side light Wiring diagram WD330
LA3509 Right front side light Wiring diagram WD330
LA3510 Tail light (FX1020) Wiring diagram WD333
LA3511 Tail light (FX1021) Wiring diagram WD333
LA3512 Work light left front Wiring diagram WD331
LA3513 Work light right front Wiring diagram WD331
LA3514 Work light left rear Wiring diagram WD334
LA3515 Work light right rear Wiring diagram WD334
LA3516 Interior lighting, cab (FX1001) Wiring diagram WD333
LA3521 Work light cab front left Wiring diagram WD331
LA3522 Work light cab front right Wiring diagram WD331
LA3523 Work light cab, left front (optional equipment) Wiring diagram WD331
LA3524 Work light cab, right front (optional Wiring diagram WD331
equipment)
LA3525 Work light, cab, rear left Wiring diagram WD334

LA3526 Work light, cab, rear right Wiring diagram WD334
LA3527 Work light cab, left rear (optional equipment) Wiring diagram WD334
LA3528 Work light cab, right rear (optional equipment) Wiring diagram WD334
LA3529 Work lights attachment Wiring diagram WD331

LA3530 Number plate lighting Wiring diagram WD330
LA3548 Work lights Wiring diagram WD337
LA3601 Rotating beacon Wiring diagram WD324
LA3602 Direction indicator (FX1072) Wiring diagram WD333
LA3603 Direction indicator (FX1073) Wiring diagram WD333
LA3612 Back-up warning, strobe light Wiring diagram WD324
LA5201 Brake light right (FX1020) Wiring diagram WD333
LA5202 Brake light left (FX1021) Wiring diagram WD333
LA9901 Beacon, fire supression system Wiring diagram WD915

Indicators
LC3701 Fuse tester Wiring diagram WD325

Solenoid valves
MA2301 Fuel injector 1 Wiring diagram WD260
MA2517 AdBlue®/DEF coolant valve Wiring diagram WD270
MA2519 AdBlue®/DEF dosing injector Wiring diagram WD269
MA2601 Cooling fan, braking Wiring diagram WD201
MA2602 Cooling fan, rotational direction (reversible Wiring diagram WD201
fan)
MA4603 Differential lock Wiring diagram WD404
MA5501 Parking brake Wiring diagram WD501
MA5503 Brake pressure charging Wiring diagram WD501
MA8701 AC Compressor Wiring diagram WD806
MA9103 Boom Suspension System CT4 (BSS) Wiring diagram WD903
MA9104 Single-acting lift CT1 (valve block 2) Wiring diagram WD903
MA9106 Attachment lock, close Wiring diagram WD904
MA9112 Lever lock−out Wiring diagram WD902
MA9113 Lever lock−out, single lever Wiring diagram WD902
MA9114 Boom Suspension System CT1 (BSS) Wiring diagram WD903
MA9127 Attachment lock, open Wiring diagram WD904
MA9141 Holding magnet, automatic tilt Wiring diagram WD902
MA9142 Holding magnet, automatic lift Wiring diagram WD902
MA9143 Holding magnet, float position Wiring diagram WD902
MA9144 Holding magnet, 3rd function Wiring diagram WD902
MA9145 Hydraulic servo, adjustable flow, 3rd function Wiring diagram WD905
MA9903 Propellant charge solenoid Wiring diagram WD915
Motors
mirror, left horizontal
mirror, left vertical

mirror, right horizontal
mirror, right vertical
MO2503 Air intake throttle Wiring diagram WD268

MO2505 EGR actuator Wiring diagram WD264
MO2509 EGR, exhaust gas throttle Wiring diagram WD264
MO3301 Starter motor Wiring diagram WD301
MO3601 Windshield washer front Wiring diagram WD801
MO3602 Windshield wiper front Wiring diagram WD801
MO3603 Windshield washer rear Wiring diagram WD801
MO3604 Windshield wiper rear Wiring diagram WD801
MO3605 Electrically controlled rear-view mirror, left Wiring diagram WD804
horizontal (FX1036)
MO3606 Electrically controlled rear-view mirror, left Wiring diagram WD804

vertical (FX1036)
MO3607 Electrically controlled rear-view mirror, right Wiring diagram WD804

horizontal (FX1037)
MO3608 Electrically controlled rear-view mirror, right Wiring diagram WD804

vertical (FX1037)
MO3611 Hood motor Wiring diagram WD807

MO3612 Electrical doorlock opening support motor Wiring diagram WD831
MO3613 Electrical doorlock motor Wiring diagram WD831
MO6402 Motor for secondary steering pump Wiring diagram WD604
MO8701 Cab fan Wiring diagram WD806
MO8702 Fan cyclone filter Wiring diagram WD807
MO8703 Actuator air mixing damper Wiring diagram WD806
MO8707 Actuator heat valve Wiring diagram WD806
MO8711 Pause coolant pump Wiring diagram WD806
Voltage outlet
(socket)
PO3901 Voltage socket 24 V Wiring diagram WD301
PO3902 Voltage socket 12 V Wiring diagram WD326
PO3910 Voltage socket 12 V, rear Wiring diagram WD301
PWM valves
PWM2303 Fuel control valve (FCV) Wiring diagram WD260
PWM2602 Control, pump P3 Wiring diagram WD201
PWM4213 Forward gear Wiring diagram WD403
PWM4214 Reverse gear Wiring diagram WD403
PWM4215 1st gear Wiring diagram WD403
PWM4216 2nd gear Wiring diagram WD403
PWM4217 3rd gear Wiring diagram WD403
PWM4218 4th gear Wiring diagram WD403
PWM6601 Lever steering (CDC), left Wiring diagram WD602
PWM6602 Lever steering (CDC), right Wiring diagram WD602
PWM9133 Output control, hydraulic pump Wiring diagram WD908
Resistors
R02–R05 Load resistor Wiring diagram WD325
R15 Fuse test Wiring diagram WD325
R2701 Hand throttle Wiring diagram WD202
Monitoring
system
RC8401 Back-up camera Wiring diagram WD804
RM8401 Back-up monitor Wiring diagram WD804

Relays
RE01 Hydraulic servo Wiring diagram WD901
RE02 Reversing light, reversing alarm Wiring diagram WD324
RE03 Work lights front Wiring diagram WD331
RE04 Work lights cab, rear Wiring diagram WD334
RE05 Hydraulic servo Wiring diagram WD901
RE07 Work lights cab front Wiring diagram WD331
RE08 Boom Suspension System, engagement Wiring diagram WD903
RE09 Windshield wiper rear Wiring diagram WD801
RE10 Brake lights Wiring diagram WD501
RE11 Work lights roof Wiring diagram WD334
RE12 30-feed controlled by HMICU, hold voltage Wiring diagram WD302
RE13
RE13 Voltage feed ECM, GPMECU1, GPMECU2 Wiring diagram WD302
RE14 Voltage feed CCM, magnet clutch AC Wiring diagram WD302
compressor, pause coolant pump
RE15 Windshield wiper front Wiring diagram WD801
RE16 15A supply Wiring diagram WD304
RE17 15B feed Wiring diagram WD304
RE18 15EA supply Wiring diagram WD304
RE2301 Electrically heated fuel filter Wiring diagram WD202
RE2501 Preheating Wiring diagram WD264
RE2502 Voltage feed, engine Wiring diagram WD303
RE3102 Main relay 2 Wiring diagram WD304
RE3504 Interior lights Wiring diagram WD333
RE3507 Work lights Wiring diagram WD337
RE3524 Time relay, entry light Wiring diagram WD337
RE3610 Fan cyclone filter Wiring diagram WD807
RE3705 Electrically controlled battery disconnect Wiring diagram WD301
switch
RE5502 Parking brake Wiring diagram WD501
RE6401 Secondary steering Wiring diagram WD604
RE8712 Pause coolant pump Wiring diagram WD806
RE9112 Hydraulic servo, adjustable flow, 3rd function Wiring diagram WD905
RF3601 Flasher relay (position RF1 on circuit board) Wiring diagram WD325
Signals
SA3602 Horn left Wiring diagram WD324
SA3603 Horn right Wiring diagram WD324
SA3604 Reversing alarm Wiring diagram WD324
SA3901 Loudspeaker left Wiring diagram WD326
SA3902 Loudspeaker right Wiring diagram WD326
SA9901 Siren, fire supression system Wiring diagram WD915

Sensor
FX1005 SE2302, Water in fuel sensor Wiring diagram WD202
HE2301 Electric heat fuel/water bowl Wiring diagram WD263
FX1007 SE2507 Inlet manifold temperature sensor Wiring diagram WD262
SE2508 Inlet manifold pressure sensor
FX1008 SE2501 Inlet air temperature sensor Wiring diagram WD263
SE2502 Air
FX1009 SE9104 Hydraulic oil level Wiring diagram WD903
SE9105 Hydraulic oil temperature
SE2203 Engine oil pressure sensor Wiring diagram WD262
SE2301 Fuel feed pressure sensor Wiring diagram WD262
SE2302 Water in fuel sensor (FX1005) Wiring diagram WD263
SE2303 Fuel level Wiring diagram WD201
SE2309 Fuel rail pressure sensor Wiring diagram WD262
SE2501 Inlet air temperature sensor (FX1008) Wiring diagram WD263
SE2502 Air cleaner pressure sensor (FX1008) Wiring diagram WD263
SE2507 Inlet manifold temperature sensor (FX1007) Wiring diagram WD262
SE2508 Inlet manifold pressure sensor (FX1007) Wiring diagram WD262
SE2511 Exhaust gas pressure sensor before Wiring diagram WD262
turbocharger
SE2512 Charge air cooler outlet temperature sensor
SE2513 NOx sensor before SCR Wiring diagram WD264
SE2515 EGR differential pressure sensor Wiring diagram WD268
SE2516 EGR temperature sensor Wiring diagram WD268
SE2519 DPF Differential pressure sensor Wiring diagram WD266
SE2521 Exhaust gas temperature sensor before DPF Wiring diagram WD266
SE2522 Exhaust gas temperature sensor after DPF Wiring diagram WD266
SE2533 NOx sensor after SCR Wiring diagram WD264
SE2536 AdBlue®/DEF temperature sensor (FX1079) Wiring diagram WD265
SE2537 AdBlue®/DEF level sensor (FX1079) Wiring diagram WD265
SE2541 AdBlue®/DEF quality sensor (FX1079) Wiring diagram WD265
SE2543 Exhaust gas temperature sensor before SCR Wiring diagram WD266
catalyst
SE2544 Exhaust gas pressure sensor before SCR Wiring diagram WD266
catalyst
SE2603 Coolant level sensor Wiring diagram WD263
SE2604 Cooling fan speed Wiring diagram WD201
SE2606 Coolant temperature sensor Wiring diagram WD262
SE2701 Crankshaft speed sensor Wiring diagram WD261
SE2702 Throttle pedal position Wiring diagram WD202
SE2703 Camshaft speed sensor Wiring diagram WD261
SE2704 Engine rpm, transmission Wiring diagram WD201
SE3601 Washer fluid level Wiring diagram WD801
SE4202 Transmission oil temperature Wiring diagram WD404
SE4213 Turbine rpm Wiring diagram WD405
SE4219 Transmission oil pressure Wiring diagram WD404
SE4227 Arm rest lever steering (CDC) Wiring diagram WD601
SE4307 Output speed transmission Wiring diagram WD405
SE4609 Feedback of engaged differential lock Wiring diagram WD404
SE5201 Available brake pressure Wiring diagram WD501
SE5203 Output brake pressure Wiring diagram WD501
SE5222 Axle oil temperature, front axle Wiring diagram WD405
SE5223 Axle oil temperature, rear axle Wiring diagram WD405
SE5501 Pressure sensor parking brake Wiring diagram WD501
SE6404 Differential pressure secondary steering Wiring diagram WD604
SE6407 Secondary steering pressure Wiring diagram WD604
SE6411 Angle sensor frame joint Wiring diagram WD602
SE6601 Control lever (CDC) Wiring diagram WD601
SE8301 Position monitor, door Wiring diagram WD333
SE8502 Position monitor loading operator's seat Wiring diagram WD802
SE8702 Evaporator, temperature Wiring diagram WD805
SE8705 Ambient air temperature sensor Wiring diagram WD802
SE8706 Temperature, cab Wiring diagram WD805
SE8708 Temperature, air channel Wiring diagram WD805
SE8709 Pressure, refrigerant Wiring diagram WD805
SE9104 Level, hydraulic oil tank (FX1009) Wiring diagram WD903
SE9105 Temperature, hydraulic oil tank (FX1009) Wiring diagram WD903
SE9119 LS-pressure Wiring diagram WD904
SE9156 Inductive sensor, automatic tilt Wiring diagram WD901
SE9157 Inductive sensor, automatic lift Wiring diagram WD901
SE9901 Monitoring of lubrication pressure Wiring diagram WD913
Voltage
converter
SO3902 Voltage converter, 20A Wiring diagram WD326
Switches
FX1001 SW3503, interior lighting, cab (front) Wiring diagram WD333
SW3507, interior lighting, cab (front)
FX1002 SW3508, interior lighting, cab (right) Wiring diagram WD333
SW3509, interior lighting, cab (right)
FX1029 Windshield wiper and washer front Wiring diagram WD801
SW3602, windshield wiper and windshield
washer front
SW3608, windshield washer front
SW2506 Regeneration Wiring diagram WD201
SW3102 Emergency stop Wiring diagram WD304
SW3301 Ignition switch Wiring diagram WD304
SW3501 Switch headlights Wiring diagram WD330
SW3502 High and low beam, headlight flasher Wiring diagram WD330
SW3503 Interior lighting, cab (front) (FX1001) Wiring diagram WD333
SW3504 Work lights front Wiring diagram WD331
SW3505 Work lights roof Wiring diagram WD334
SW3507 Interior lighting, cab (front) (FX1001) Wiring diagram WD333
SW3508 Interior lighting, cab (right) (FX1002) Wiring diagram WD333
SW3509 Interior lighting, cab (right) (FX1002) Wiring diagram WD333
SW3525 Entry light Wiring diagram WD337
SW3526 Extended lights around machine Wiring diagram WD337
SW3601 Electrically heated rear-view mirrors Wiring diagram WD804
SW3602 Windshield wiper and washer front (FX1029) Wiring diagram WD801
SW3604 Horn Wiring diagram WD324
SW3605 Direction indicators Wiring diagram WD333
SW3606 Hazard flashers Wiring diagram WD333
SW3607 Rotating beacon Wiring diagram WD324
SW3608 Windshield washer front (FX1029) Wiring diagram WD801
SW3612 Windshield wiper and washer rear Wiring diagram WD801
SW3614 Electrically controlled rear-view mirrors Wiring diagram WD804
SW3620 Hood, operation Wiring diagram WD807
SW3630 Electrical doorlock rotor switch Wiring diagram WD831
SW3701 Battery disconnect switch Wiring diagram WD304
SW3801 Keypad Wiring diagram WD322
SW4205 Directional gear Forward/Reverse, steering Wiring diagram WD401
column
SW4206 Gear lever steering column Wiring diagram WD401
SW4207 Activation Forward/Reverse lever carrier Wiring diagram WD402
SW4208 Forward/reverse lever carrier Wiring diagram WD402
SW4209 Kick-down lever carrier Wiring diagram WD402
SW4210 Engine brake lever carrier Wiring diagram WD402
SW4211 Fully automatic gearshifting (FAPS) Wiring diagram WD405
SW4216 Activation of lever steering (CDC) Wiring diagram WD601
SW4217 Forward/Reverse, Comfort Drive Control Wiring diagram WD601
(CDC)
SW4219 Lock-up Wiring diagram WD406
SW4220 Kick-down CDC Wiring diagram WD601
SW4221 Single lever control, forward−neutral−reverse Wiring diagram WD402
SW4222 Single lever control, kick-down Wiring diagram WD402
SW4602 Differential lock Wiring diagram WD404
SW5501 Parking brake Wiring diagram WD501
SW8701 Controls climate control system Wiring diagram WD805
SW9140 Single lever control, electric lever lock Wiring diagram WD902
SW9141 Hydraulic servo Wiring diagram WD901
SW9142 Hydraulic servo Wiring diagram WD901
SW9143 Attachment lock Wiring diagram WD904
SW9144 Floating position Wiring diagram WD911
SW9146 Emergency stop, 3rd hydraulic function Wiring diagram WD908
SW9147 Hold function, 3rd hydraulic function Wiring diagram WD908
SW9148 Boom Suspension System, activation/ Wiring diagram WD903
function selection
SW9149 Single-acting lift function Wiring diagram WD903
SW9174 Electric lever lock Wiring diagram WD902
SW9175 Hydraulic servo, adjustable flow, 3rd function Wiring diagram WD905
Service socket
VP TechTool communication socket Wiring diagram WD322
Control units
ACM Aftertreatment Control Module Wiring diagram WD264
ECM Engine Control Module Wiring diagram WD302
CCM Climate Control Module Wiring diagram WD302

HMICU Human Machine Interface Control Unit Wiring diagram WD201
GPMECU1 General Purpose Machine Electronic Control Wiring diagram WD201
Unit 1 Wiring diagram WD302
WECU Telematics ECU Wiring diagram WD321
CU3605 Electrical doorlock control unit Wiring diagram WD831
CU6601 Control unit monitoring CDC Wiring diagram WD302
CU9901 Central lubrication unit Wiring diagram WD913
CU9902 Control unit, fire supression system Wiring diagram WD915
CU9903 Alarm panel, fire supression system Wiring diagram WD915
Monitoring
system
RC8401 Back-up camera Wiring diagram WD804
RM8401 Display window Wiring diagram WD804
Connectors, position
Connectors Position Wiring diagram
15A Electrical distribution box, circuit board Wiring diagram WD304
15B Electrical distribution box, circuit board Wiring diagram WD304
15EA Electrical distribution box Wiring diagram WD304
30A Electrical distribution box, circuit board Wiring diagram WD301
30C Electrical distribution box, circuit board Wiring diagram WD301
30K Electrical distribution box, circuit board Wiring diagram WD301

31C1 Electrical distribution box, battery, cab wall Wiring diagram WD301
31C2 Electrical distribution box Wiring diagram WD202
31E1 Engine, alternator – engine block Wiring diagram WD301
31F1 Front frame Wiring diagram WD371
31K Electrical distribution box, circuit board Wiring diagram WD302

31R1 Rear frame – battery Wiring diagram WD301
31R2 Rear frame – engine block Wiring diagram WD275

AA Cab Wiring diagram WD802
BA Electrical distribution box Wiring diagram WD302
BC Cab Wiring diagram WD806
CA Cab Wiring diagram WD324

CC Cab (roof), 12 V DC Wiring diagram WD324
CF Electrical distribution box, circuit board Wiring diagram WD804
CG Front frame Wiring diagram WD804
CK Cab Wiring diagram WD333
CM Cab Wiring diagram WD337
CN Cab Wiring diagram WD337
CP Cab Wiring diagram WD831
DA Cab, hazard flashers Wiring diagram WD302

DB Electrical distribution box Wiring diagram WD302
DC Electrical distribution box Wiring diagram WD302
DD Electrical distribution box Wiring diagram WD301
DE Electrical distribution box Wiring diagram WD302
DF Electrical distribution box Wiring diagram WD302
DG Electrical distribution box Wiring diagram WD304
DH Electrical distribution box Wiring diagram WD304
ED Engine Wiring diagram WD260
EE Engine Wiring diagram WD262
EK Engine Wiring diagram WD263
FA Cab wall, electrical distribution box Wiring diagram WD324
FD Front frame Wiring diagram WD903
FE Front frame Wiring diagram WD324

FF Front frame Wiring diagram WD331
FM Cab Wiring diagram WD324
FU Front frame Wiring diagram WD404
GA Cab Wiring diagram WD324

HE3 Cab Wiring diagram WD802
KG Cab Wiring diagram WD915

LB Electrical distribution box Wiring diagram WD302
LD Cab, control levers Wiring diagram WD902
LE Cab, control levers Wiring diagram WD902
LF Electrical distribution box Wiring diagram WD324

LJ Cab, control levers Wiring diagram WD902
LK Cab, control levers Wiring diagram WD402
MC Cab, underside Wiring diagram WD913
ME Front frame Wiring diagram WD804
MF Cab Wiring diagram WD804
MG Cab Wiring diagram WD908
MK Rear frame Wiring diagram WD301

MK1 Cab Wiring diagram WD301
ML Under cab, adjustable flow 3rd function Wiring diagram WD905
MM Electrical distribution box, circuit board Wiring diagram WD325
MN Electrical distribution box, circuit board Wiring diagram WD325
MO Cab Wiring diagram WD337
OCA Cab, seat Wiring diagram WD802
P Electrical distribution box, circuit board Wiring diagram WD306
P2 Electrical distribution box, circuit board Wiring diagram WD302
PA Electrical distribution box, cab wall Wiring diagram WD301
PB Electrical distribution box, cab wall Wiring diagram WD301
RA Engine, rear frame Wiring diagram WD201

RE Rear frame Wiring diagram WD330
RM Engine Wiring diagram WD263

RP Rear frame Wiring diagram WD201
RW Rear frame Wiring diagram WD375

RY Rear frame Wiring diagram WD201
RZ Rear frame Wiring diagram WD324
SS Under cab Wiring diagram WD604
ST CDC Wiring diagram WD360

SU CDC Wiring diagram WD601
SV Under cab Wiring diagram WD602
T1 Cab Wiring diagram WD831
TA Engine, rear frame Wiring diagram WD201

UA Engine, rear frame Wiring diagram WD201
UB CDC Wiring diagram WD602
VP Electrical distribution box, Tech Tool socket (OBD) Wiring diagram WD322
WA Cab Wiring diagram WD330

Figure 1
Connectors, position in electrical distribution box and on circuit board
Figure 2
Connectors, position in cab
Figure 3
Connectors, position under cab
Figure 4
Connectors, position in front frame
Figure 5
Connectors, position in rear frame
Control valve, description
The control valve is a spool valve with closed centre. This means that no oil passes through the valve in neutral position. There are
two spools for lift/lower and tilt in/out, respectively, in the control valve.
The valve consists of a section where the lift/lower function's spool and the tilt function's spool are integrated.
Shock valves, load holding valves, as well as sequence valves for each function are located in the control valve.
The lift/lower function and tilt function are connected in parallel, which means that these functions can be run at the same time.
The valve is provided with shock valves on the lift and tilt function. The shock valves cannot be adjusted and are replaced as a
complete unit.
The valve is also equipped with a back-up valve for return oil which ensures good anti-cavitation function (afterfilling).
Figure 1
Control valve
Figure 2
Control valve
1. Tilt spool
2. Sequence valve for (3)
3. Tilt out (-), load holding valve/return tilt in
5. Tilt in (+), load holding valve/return tilt out
6. Shuttle valve, LS tilt/lift
7. Pressure back-up valve
8. Tilt out (-), shock/anti-cavitation valve
9. Tilt in (+), shock/anti-cavitation valve
11. Lift (+), load-holding valve/return lower
13. Lower (-), load-holding valve/return lift
14. Float position spool
15. Non-return valve (tilt in/lower)
16. Anti-cavitation valve, lower
17. Shock valve, lift
18. Restriction
19. Lift spool
20. Float position piston
21. Checking point, servo pressure, tilt in (plugged)
22. Checking point, LS-pressure, tilt (plugged)
23. Checking point, LS-pressure, lift (plugged)
24. Checking point, servo pressure, lift (plugged)
25. Checking point, servo pressure, lower (plugged)
B1 Output pressure, tilt cylinder's minus side

A1 Output pressure, tilt cylinder's plus side
P Input pressure from pump
LS LSW-signal to central block
D Drain point
T Return to tank
PSS Servo pressure, tilt out
PS Servo pressure, lower
PSL Servo pressure, tilt in
PL Servo pressure, lift
Figure 3
Tilt section, neutral (principle illustration)
Red Pressure oil
Green Atmospheric pressure or lower pressure
Violet Trapped oil
Orange Standby pressure
Control valve, included components (principle illustration, tilt section)
1. Spool acted on by servo pressure and centred in neutral position by a double-acting spring (10).
The LS-channel (8) is a drilled hole through the centre of the spool.
2. Load holding valve, left, prevents the bucket from tilting out when, e.g., lifting. When the oil returns to tank, the load holding
valve is controlled by the sequence valve (3), which is acted on by the servo pressure that controls the spool (1).
Load holding valve, right, prevents the bucket from tilting in when, e.g., the bucket's front end is on the ground and the
boom is lowered slightly. At tilt in, when the oil returns to tank, the load holding valve is controlled by the sequence valve (4),
which is acted on by the servo pressure that controls the spool (1).
3. Sequence valve that drains the load holding valve's (2) spring side to tank when the load holding valve is to open for return
oil when tilting out.
4. Sequence valve that drains the load holding valve's (2) spring side to tank when the load holding valve is to open for return
oil when tilting in.
5. Shock valve with anti-cavitation function, not adjustable (plus side).
6. Shock valve with anti-cavitation function, not adjustable (minus side).
7. Pressure back-up valve for return oil.
8. LS-channel, a drilled hole in the centre of the spool (1). In neutral position the channel is connected to tank.
9. Shuttle valve that selects the highest LS-signal from LS-tilt or LS-lift.
10. Double-acting spring that holds the spool (1) in neutral position.
Figure 4
Tilt section, tilt in
Red Pressure oil

Blue Return oil
Tilt section, tilt in

Servo pressure acts on the right side of the spool (1), and on the sequence valve (4). When the sequence valve (4) is moved
upwards, the oil is drained on the spring side of the right load holding valve (2) to tank.
The oil from the hydraulic pump opens the left load holding valve (2) and continues to the tilt cylinder's plus side.
Just before that, pump pressure is delivered to the LS-port tilt in.
The shuttle valve (9) closes the function with lowest load when lift and tilt are used at the same time. This prevents pressure loss
through the function with the lowest load.
The oil from the tilt cylinder's minus side opens the right load holding valve and is led to the back-up valve (7) via the spool (1).
When back-up valve opens, the oil is led to tank.
Figure 5
Tilt section, shock
Red Pressure oil

Blue Return oil
Tilt section, shock

In this example, shock pressure is reached on the tilt cylinder's plus side in case, e.g., a big rock falls on the bucket's front end.
The shock pressure opens the left shock valve (5).
The oil is led to the back-up valve (7) which ensures that cavitation is avoided by making sure that the pressure in the control valve
does not become too low.
The anti-cavitation function in the right shock valve (5) opens and leads the oil to the tilt cylinder's minus side.
The surplus oil from the tilt cylinder's plus side (piston rod volume) is led to tank.
Figure 6
Lift section, lower
Red Pressure oil

Orange Servo pressure
Blue Return oil
Lift section, lower

Servo pressure acts on the left side of the spool (1) and on the sequence valve (3) as well as on the float position spool (9).
The float position spool (9) is not moved until the servo pressure is higher than approx. 2 MPa (20 bar) (290 psi).
The oil from the hydraulic pumps opens the right load holding valve (2) and is led on to the lift cylinder's minus side.
At the same time oil is delivered through the LS-channel (12) to the LS-port lift section, lower and then continues to the shuttle valve
(11) which is moved to the left. Then the oil continues to the pump's flow compensator.
Oil from the lift cylinder's plus side opens the left load holding valve (2) and is led via the spool (1) to the back-up valve (7) and
thereafter to tank.
Figure 7
Lift section, lower/tilt in
Red Pressure oil

Blue Return oil
Pink Partial pressure
Lift section, lower/tilt in

To get the hydraulic pump to build up pressure so that it is possible to tilt in the bucket and lower at the same time, the servo
pressure is led from the tilt in section past the non-return valve (8), to the spring side on the right load holding valve (2).
Thus the load holding valve (2) is kept closed and the pump can built up pressure to the tilt function. Oil from the cylinders' plus side
is led via the spool to the back-up valve (7). Surplus oil from the plus side opens the anti-cavitation valve (6) and afterfills the minus
sides.
Figure 8
Lift section, float position

Blue Return oil
Lift section, float position

Servo pressure acts on the left side of the spool (1), the sequence valve (3), and on the float position spool (9).
When the lowering lever passes the sensing position, the servo pressure increases above approx. 2 MPa (20 bar) (290 psi) and
forces down the float position spool (9). Now the servo pressure can be led to the sequence valve (4). When this takes place, the oil
on the top of the float position spool is connected to tank.
The spring side of the load holding valve (12) is drained to tank. When the spring sides of both load holding valves are drained to
tank, they can open for oil flow in either direction. The spool (1), which now is in float position, allows the oil to flow freely between
both sides of the cylinder.
Coolant with anti-freeze and corrosion protection, recommendation
Coolant
The cooling system is filled with Volvo Coolant VCS. Always use the same coolant that the system was previously filled with.
NOTE!
To avoid damage to the engine, different coolants must NOT be mixed. Nor may pure water be used alone.
When using concentrated coolant and pure water the mixture must contain 40–60% concentrated coolant and 40–60% pure water.
The content of coolant must not be less than 40% of the total mixture, see table below
Anti-freeze protection down to Mixture of concentrated coolant

–25°C 40%
–35°C 50%
–46°C 60%
If there is any doubt whether or not the water is absolutely pure then ready mixed coolant must be used.
Pure water for the cooling system must also fulfil the following requirements
Description Value
Total quantity of fixed particles < 340 ppm
Total hardness < 9.5° dH
Chloride < 40 ppm
Sulphate < 100 ppm
pH–value 5.5 – 9
Silicon < 20 mg SiO₂/litre
Iron < 0.10 mg FE/litre
Manganese < 0.05 mg Mn/litre
Electrical conductive capacity < 500 µS/cm
Organic content, COD–Mn <15 mg/litre
NOTE!
To avoid damage to the engine, different ready mixed coolants must not be mixed.
Cooling fan motor, description
Figure 1

2. SE2604, speed sensor, cooling fan
Cooling fan, component location
Figure 1

2. Hydraulic oil cooler
3. Cooling Fan
4. Hydraulic Fan Motor
6. Central valve
7. Valve block, Reversible cooling fan [1]
For description of components, see
 Cooling fan motor, description

 Reversible cooling fan, description
Cooling fan, description
The machine is equipped with an electrically-controlled hydraulic fan. The fan's function, together with the engine's radiator,
intercooler (charge-air cooler), hydraulic oil cooler, transmission oil cooler, and the air conditioner system's [1] condenser, is to cool
the machine's various systems. The cooling fan can also work as an auxiliary brake by increasing the engine's load. The fan can also
run in the opposite direction, when a reversible cooling fan [2] is installed, to blow out dirt from the cooling module.
Other systems that can affect the cooling fan are:
 Auxiliary brake (engine braking), description.

 Cooling system, description.
 Braking system, description.
 Hydraulic transmission, description.
The machine can also be equipped with various optional equipment that affects the cooling fan:
 Climate control system, description.

 Reversible cooling fan, description.
 Hydraulic attachment locking, description.
 Exhaust Aftertreatment System, description.
Figure 1
Cooling fan system

Green Return oil
1. Central valve
FX1009 Hydraulic oil tank temperature (SE9105) and level (SE9104)

PWM2602 Control, pump P3 (cooling)
SE2604 Cooling fan speed
P3 Hydraulic oil pump
The hydraulic oil pump supplies the cooling fan's hydraulic motor with hydraulic oil. The displacement of pump P3 is controlled by the
control unit GPMECU1 via the PWM2602, depending on the cooling need, which is received from different systems. GPMECU1
receives feedback from the fan’s rpm sensor SE2604 on whether or not the signal deployed to the valve for the cooling fan control
has resulted in the correct cooling fan speed.
The system that requests the greatest cooling need controls the speed of the cooling fan. Note that when the brake system requests
brake pressure charging, then brake pressure charging is always given priority. This fan/brake priority is selected by the brake
pressure charging valve MA5503.
When there is no cooling need, the fan remains at a so-called base speed.
Hydraulic oil heating function
This function controls the heating of the hydraulic oil which also affects the cooling fan. When the hydraulic oil temperature is low,
≤15°C (59 °F), brake pressure charging is requested in order to warm the hydraulic oil. This is done by forcing the hydraulic oil
through a restriction, leading to a rise in temperature. This causes the fan speed to decrease.
Figure 2
Signal diagram for the cooling fan system
1 High temperature, exhaust system, regeneration in progress

2 Auxiliary brake, fan speed requested, internal function, see Auxiliary brake (engine braking), description
CCM Climate control module
ECM Engine control module
HMICU Human-machine interface control unit
SE8709 Refrigerant pressure
SE2512 Charge air cooler, outlet temperature
SE2701 Engine speed (crankshaft speed)
SE2606 Coolant temperature
SE2604 Fan speed
SE5201 Brake accumulator pressure
SW9143 Attachment locking
SE4202 Transmission, oil temperature
SE8705 Ambient temperature
FX1009 Hydraulic oil temperature (SE9105)
MA5503 Fan/brake priority selection
PWM2602 Pump P3 pressure control
Summary
Cooling is shared with the brake system.
The cooling fan speed is mainly controlled by:
 The cooling need requested by the systems.

 The flow from the hydraulic oil pump P3, controlled by PWM2602.
Parameters
Relevant parameters for the cooling fan system’s functionality.

P1JKP Cooling fan mode
Additional information
 Temperature limits for cooling fan speed, specifications.

 Cooling fan rpm, specifications.
 Hydraulic diagram, complete.
 Cooling fan, component location.
The risk of clogging the radiator is higher under certain operating conditions. To prevent the radiator from clogging, the machine may
be equipped with a reversible cooling fan, see Reversible cooling fan, description[3].
Function check
 Hydraulic pump P3, checking function.
Diagnostics
Cooling system, component location
Figure 1
1. Expansion tank
2. AdBlue®/DEF dosing injector, MA2519
3. Cylinder liner
4. EGR cooler
5. Transmission oil cooler
6. Radiator
7. Coolant level sensor, SE2603
Figure 2
1. Thermostat housing
2. Coolant temperature sensor, SE2606
3. Thermostat
4. Coolant pump
5. AdBlue®/DEF tank
6. Coolant valve, MA2517
7. AdBlue®/DEF pump unit, FX1074
8. Lubrication oil cooler with oil filter housing
Cooling system, description
Introduction
The cooling system is a pressurized closed system. It uses a belt driven pump to circulate the coolant throughout the system. The
coolant transfers heat from parts and oil that need cooling, both inside the engine as well as outside. The coolant is cooled in the
radiator by an air flow generated by a cooling fan. A thermostat controls the coolant path.
When the engine is cold, the coolant bypasses the radiator to conserve heat instead of removing it.
An expansion tank is used to handle expansion of the coolant. There is a pressure relief valve integrated in the cap.
For information about other systems that affect or are affected by the cooling system, see:
 Lubrication system, description

 Inlet and exhaust system, description
 Exhaust Aftertreatment System, description
 Exhaust Gas Recirculation (EGR), description
Function diagram
Figure 1
Cooling system
ECM = Engine control module
Blue = Cold coolant
Red = Warm coolant

Narrow red = Air breather lines
Dashed red and blue = optional paths depending on if the coolant is warm enough to have opened the thermostat
Black dashed = Wiring
A. To cab heating [1]

B. From cab heating ⁽¹⁾
1. Cylinder block 9. Coolant valve

2. Cylinders 10. AdBlue®/DEF pump
3. EGR cooler and actuator 11. AdBlue®/DEF dosing injector
4. Thermostat housing 12. Lubrication oil cooler with oil filter housing
5. Coolant temperature sensor, SE2606 13. Coolant pump
6. Expansion tank 14. Transmission oil cooler [2]
7. Coolant level sensor, SE2603 15. Radiator
The coolant pump delivers the coolant via the lubrication oil cooler to the engine, around the cylinder liners and through the
thermostat housing. The thermostat controls the coolant flow out to the radiator (see red line with dashed outline in figure) or in
bypass flow (see blue line with dashed outline in figure) into the engine again, depending on the coolant temperature.
The coolant pump also forces some coolant to the EGR cooler, via internal channels inside the cylinder block and on to external
pipes. The EGR coolant flow is also routed through the EGR actuator. After cooling the exhaust in the EGR cooler, the coolant is
routed back to the engine via external pipes to the thermostat housing.
The coolant pump forces the coolant to the SCR system components via the lubrication oil cooler housing. The AdBlue®/DEF dosing
injector is cooled by a constant flow of coolant. The AdBlue®/DEF tank and AdBlue®/DEF pump are defrosted by the coolant at low
ambient temperatures. This is regulated by the coolant valve and controlled by the Aftertreatment control module (ACM). After the
SCR system components, the coolant is led to the thermostat housing.
The coolant is cooled in the radiator and is then transported back into the engine cooling system via the transmission oil cooler (if
equipped with transmission oil cooler).
On machines equipped with cab heater, the coolant is also transported via external pipes and hoses to the cab heater. The cab
heater takes its coolant from the warm side of the engine and the return leading to the pump's suction side.
Coolant pump
The coolant pump is of impeller type and is belt driven. The rear of the pump is bolted to the cylinder block, lubrication oil cooler and
oil filter housing, and has channels for coolant distribution.
Thermostat
The coolant circulation thermostat is of the piston type and has a temperature sensitive wax body which controls opening and
closing. The thermostat begins to open when the coolant temperature reaches a level which indicates that the engine is warm and
the coolant needs to transport heat away from the engine. The thermostat is located inside the thermostat housing which contains
channels for coolant distribution. The thermostat housing is bolted to the cylinder head.
Radiator
The coolant flows through the radiator and is cooled by an air flow generated by the cooling fan.
Expansion tank
Figure 2
Expansion tank, principle
A. Cold coolant
B. Warm coolant
1. Filling cap
2. Pressure cap
The expansion tank is used to handle the expansion of the coolant. There is a pressure relief valve integrated in its cap. When the
coolant pressure increases the coolant is pushed through the internal channel in the expansion tank over to the expansion chamber.
When the coolant decreases in temperature a vacuum is created that sucks back the coolant to the expansion tank.
Coolant shall always be filled through the filling cap.
Summary
The coolant is circulated into the lubrication oil cooler by the coolant pump. From the lubrication oil cooler, the coolant is distributed to
components that need cooling or heating.
The thermostat is a valve that controls the coolant flow. It bypasses the radiator to preserve heat when the engine is cold. When the
coolant temperature has increased to a set temperature, the thermostat opens and forces the coolant to the radiator for cooling.
Parameters
 There are no parameters for this function.
Complementary information
 Tech Tool, operations

 Cooling system, component location
Function check
 Tech Tool operation 28407-3 Sensor values, monitoring

 Carbon dioxide in coolant system, checking
Diagnostics
Detailed information regarding appropriate warnings and error codes for the components can be found under the Diagnostics tab in
PROSIS.
[1]Only valid for applications equipped with cab heating
[2]Only valid for applications equipped with transmission oil cooler

Crankcase ventilation, description
Since some of the combustion pressure enters the crankcase after passing by the pistons and piston rings (blow-by), the crankcase
must be ventilated.
The purpose of the crankcase ventilation is to balance the pressure in the crankcase in order to avoid damage to engine components
and to prevent oil mist formation and oil leakage into the ambient air.
The crankcase ventilation consists of a housing containing a filter, with connections to the oil sump and ventilation piping.
Figure 1
Crankcase ventilation housing
Air containing oil particles comes from the crankcase via the cylinder head into the crankcase ventilator. The air (blue arrows) passes
through the filter, while oil particles (red arrows) are caught and led back to the oil sump via a return pipe.
 Engine, description
 Component location
Diagnostic tools, description
Software installed on a laptop PC is used to be able to set parameters and read function data, e.g., error indications registered in the
pump's control unit.
Connect the PC as shown.
The tools required to connected the PC to the pump's control unit are available as a service kit, 17201553 Intermediate plate, where
the following tools are included:
Figure 1
1. Laptop PC with software

2. 88830187 Connecting cable
3. 88830185 Cable, between interface and connecting cable.
4. 88830186 Cable, between interface and PC
5. 88830184 Interface
For any questions about the software, contact VCE Software Support.
Differential lock, description
The differential lock consists of two dog-clutches. One dog-clutch rotates with the half shaft and is guided by the piston towards the
other dog-clutch. The other dog-clutch is installed on the differential housing. When the dog-clutches are engaged with each other (in
mesh) the half shafts, and thus the road wheels as well, are forced to rotate at the same speed.
When engaging the differential lock, the piston is pressurized with servo oil pressure by solenoid valve SW4602 and solenoid valve
MA4603. The push rod is forced to the right and transfers the force from the servo oil pressure. The shift fork ensures that the two
dog-clutches engage. This means that there is equal drive on both wheels.
When the dog-clutches are engaged with each other (meshed), the circuit is closed with SE4609 and the symbol for differential lock
is shown in the display. When SW4602 is deactivated, the oil pressure will be drained. The return spring presses up the piston to pull
apart the dog-clutches. As long as the wheels want to rotate at different speeds the dog-clutch will be engaged (in mesh). The
indicator light follows the dog-clutch via SE4609.
Figure 1
1. Sensor, SE4609
2. Piston
3. Push rod
4. Shift fork
5. Differential housing
6. Half shaft
7. Dog-clutch
8. Dog-clutch
Front axle, component description
Front and rear axles, tightening torque
Software
The differential lock is engaged with the foot switch, SW4602, which activates the solenoid valve, MA4603. When the switch closes
the circuit to the solenoid valve the light on the instrument panel (I-ECU) turns on.
When the differential lock is engaged, the mechanical monitor sends a signal to the V-ECU to acknowledge that the differential lock is
engaged.
Figure 2
Function check
Differential lock, function check
Parameters
-
Diagnostics
Detailed information about relevant warnings and error codes below is available under the diagnostics tab.
Component Description
SE4609 SE4608, description and measuring
SW4602 -
Dosage valves, description
General
The metering valves are adapted so that each grease point receives the correct amount of lubricant.
The metering valves are marked with stamped numbers, for identification of correct lubrication amount, see specifications.
The metering valves are grouped in distribution blocks, available with varying number of connections. Connections not used are
plugged.
The metering valves should never be dismantled since this may introduce impurities, which causes malfunction. Metering valves
cannot be overhauled, instead they must be replaced if they are defective.
The metering valve consists of two chambers, one for each channel.
During the lubrication cycle when lubricant is pressed in from one channel to the chamber, a piston in the metering valve is affected
which presses in the lubricant in the other chamber out to the grease point.
During the lubrication cycle, the piston in the metering valve is pressed back and forth when the pressure in channels A and B shifts.
The function of the metering valve is described by a division into four subsequent phases.
Figure 1
Distribution block with metering valves
1. Metering valve
2. Part number
3. Manufacturing date
4. Metering valve, numbering
5. Lubrication pressure sensor
Different phases of the metering valves
Phase 1
The metering valve is not yet filled with lubricant.
Figure 2
Phase 1
Phase 2
From the main line's channel A, pressure retaining phase, lubricant is pumped into the metering valve (pressure retaining phase in
cycle A).
The piston 3, is pressed to the right until it has passed channel 1.
The lubricant passes via the channel 1, fills the chamber 2, the piston 4 is pressed to the right.
After a certain time, channel A is depressurized. This does not affect the metering valve.
The stroke of the piston 4, determines the amount of lubricant.
Figure 3
Phase 2
Phase 3
From the main line's channel B, lubricant is pumped into the metering valve's channel 6 (pump phase in cycle B).
The piston 3, is pressed to the left past the channel 8. Lubricant fills the chamber 7, the piston 4, is pressed back. The lubricant in the
chamber 2, on the other side of the piston 4, is pressed on via channel 1 to channel 9, the non-return valve 10 opens, the lubricant is
pressed on to the secondary line 5, and out to the grease point.
After a certain time, channel B is depressurized. This does not affect the metering valve.
Figure 4
Phase 3
Phase 4
In this phase, the function sequence is the same as in phase 2. Now the chamber 7, is filled with lubricant.
The piston 4, is pressed to the right, the chamber 2, is filled with lubricant. The lubricant in the chamber 7, is pressed on via channel
8, to channel 9, the non-return valve 10 opens, the lubricant is pressed on to the secondary line 5, and out into the grease point.
As long as the lubrication system is functional, phases 3 and 4 will alternate with each other.
Figure 5
Phase 4
See also animation: Metering unit
Drive axles, description
The drive axle reduces the speed (rpm) from the propeller shaft in the final drive (differential carrier assembly) and hub reduction to
wheel speed. The final drive has a differential with differential side gears, enabling the wheels to rotate at different speeds.
The drive axles have floating drive shafts (half shafts) and planetary gear hub reductions with built-in, oil-cooled disc brakes. The
axles have a common oil space for the hub reductions and the final drive (differential carrier assembly).
The front axle is bolted to the frame and therefore it cannot oscillate. It may also have a hydraulically controlled differential lock which
is operated with SW4602. The dog-clutch locks the differential and the road wheels will rotate at the same speed. For more
information, see: Differential lock, description.
The rear axle is mounted with an axle suspension which enables it to oscillate. The rear drive axle may be provided with an
automatic differential brake of the type "Limited Slip". For more information, see:
- Rear axle mounting, component description
- Automatic differential brake - Limited Slip, description
Final drive (differential carrier assembly)
The propeller shafts turn the pinion, which in turn causes the crown wheel, installed on the differential housing, to rotate. Since the
pinion has fewer gear teeth than the crown wheel, a reduction of the rotational speed (rpm) is obtained. When the differential housing
rotates, the differential spider also turns.
A differential side gear is located on each of the four arms on the differential spider. These four side gears are in mesh with the half
shafts' differential gears. When the differential spider turns the half shafts also turn.
When operating straight forward or backward, the differential side gears will not rotate. When turning left or right, the differential side
gears will rotate and allow the half shafts to rotate at different speeds.
Figure 1
Final drive, front axle with differential lock
1. Crown wheel 5. Differential side gear on half shaft

2. Pinion 6. Differential spider
3. Drive flange 7. Differential housing
4. Differential pinion 8. Half shaft
Hub reduction
The half shafts transmits the power to the sun gear. The sun gear drives the planet gears, which in turn are in mesh with the ring
gear. The ring gear is one with the hub reduction's housing. When the planet gears rotate in the ring gear, they pull along the planet
carrier, which in its turn drives the hub on which the road wheel is installed. The planet gear further reduces the speed (rpm) between
the half shaft and hub.
Figure 2
Hub reduction, front and rear axle
1. Planet carrier 8. Thrust plate

2. Hub seal 9. Brake disc
3. Wheel hub 10. Automatic clearance adjusters
4. Wear indicator 11. Brake piston
5. Sun gear 12. Attaching bolts, hub carrier — axle housing
6. Planet gear 13. Air nipple, brakes
7. Ring gear 14. Sun gear shaft
Software
Axle oil temperature
Sensor SE5222 on the front axle and sensor SE5223 on the rear axle monitor the oil temperature and inform the operator in case of
too high temperature. In case of too high axle oil temperature, an alarm is triggered at two levels for each axle.
- Drivetrain, component location
- Front and rear axles, specifications
- Front axle, component description
- Rear axle, component description
- Tech Tool, operations
- Braking system, description
Function check
- 46003-3 Sensor values, front and rear axle, check
Parameters
-
Diagnostics
Go back to Index Page
Driver seat, component description

There are four different seat types for the machines in the H-generation.
This describes ISRI 6000 / 348.
ISRI 6000 / 345 and ISRI 6000 / 575 have similar builds and designs.
Figure 1
Pos. Part Pos. Part
1 Backrest 2 Seat
3 Seatbelt 4 Bellows
5 Spring 6 Spring, 2 pcs.
7 Shock absorber 8 Spring, 2 pcs.
9 Controls 10 Spring, 2 pcs.
Go back to Index Page
Driver seat, component description

Operator's seat ISRI 6500KM / 348, li
Figure 1
Pos. Part Pos. Part
1 Backrest 2 Seat
3 Seatbelt 4 Bellows
5 Spring 6 Spring, 2 pcs.
7 Air damper 8 Shock absorber
9 Compressor, 24V 10 Relay, 20A
Drivetrain, component location
Figure 1
1. Front axle
2. Front propeller shaft
3. Parking brake
4. Hydraulic transmission
5. Rear propeller shaft
6. Rear axle
7. Engine
Component positions
Hydraulic transmission: Transmission, component position
Oil cooler: Oil cooler, component location
Component descriptions
Front axle: Front axle, component description
Rear axle: Rear axle, component description
Propeller shaft: Propeller shaft, component description
ECM, I/O list
output is not used.

EA1:1 — — —
EA1:2 — — —
EA1:3 — — —
EA1:4 — — —
EA1:5 — — —
EA1:6 — — —
EA1:7 MO2503 Air intake throttle Wiring diagram WD262
SE2515 EGR differential pressure sensor
SE2516 EGR temperature sensor
EA1:8 — — —
EA1:9 — — —
EA1:10 — — —
EA1:11 FX1007 Inlet manifold temperature sensor Wiring diagram WD262
MO2503 Air intake throttle
EA1:12 PWM2303 Fuel control valve (FCV) Wiring diagram WD260
EA1:13 — — —
EA1:14 — — —
EA1:15 FX1008 Inlet air temperature sensor Wiring diagram WD263
EA1:16 PWM2303 Fuel control valve (FCV) Wiring diagram WD260
EA1:17 — — —
EA1:18 — — —
EA1:19 SE2309 Fuel rail pressure sensor Wiring diagram WD262
EA1:20 — — —
EA1:21 SE2515 EGR differential pressure sensor Wiring diagram WD268
EA1:23 — — —
EA1:24 — — —
EA1:25 — — —
EA1:26 — — —
EA1:27 — — —
EA1:28 — — —
EA1:29 FX1008 Inlet air temperature sensor Wiring diagram WD263
EA1:30 — — —
EA1:31 — — —
EA1:32 — — —
EA1:33 — — —
EA1:34 — — —
EA1:35 — — —
EA1:36 MA2306 Fuel injector 6 Wiring diagram WD260
EA1:37 SE2701 Crankshaft speed sensor Wiring diagram WD261
EA1:39 — — —
EA1:41 — — —
EA1:42 — — —
EA1:43 — — —
EA1:45 SE2703 Camshaft speed sensor Wiring diagram WD261
EA1:46 SE2703 Camshaft speed sensor Wiring diagram WD261
EA1:49 — — —
EA1:50 — — —
EA1:51 — — —
EA1.52 MA2302 Fuel injector 2 Wiring diagram WD260
EA1:53 — — —
EA1:54 — — —
EA1:55 — — —
SE2703 Camshaft speed sensor
EA1:58 — — —
MA2302 Fuel injector 2
EA1:61 — — —
EA1:62 — — —
EB1:1 MO2503 Air inlet throttle Wiring diagram WD268

EB1:2 — — —
EB1:3 — — —
EB1:4 — — —
EB1:6 — — —
EB1:7 HE2501 Preheater element Wiring diagram WD264
EB1:8 FX1005 Electric heat fuel/water bowl Wiring diagram WD263
EB1:9 — — —
EB1:10 FX1005 Electric heat fuel/water bowl Wiring diagram WD263
SE2603 Coolant level sensor
EB1:11 SE2203 Engine oil pressure sensor Wiring diagram WD262
EB1:12 SE2511 Exhaust gas pressure sensor before turbocharger Wiring diagram WD262
EB1:13 — — —
EB1:14 — — —
EB1:15 — — —
EB1:16 SE2301 Fuel feed pressure sensor Wiring diagram WD262
EB1:17 SE2511 Exhaust gas pressure sensor before turbocharger Wiring diagram WD262
SE2301 Fuel feed pressure sensor
FX1007 Inlet manifold temperature sensor
EB1:18 SE2512 Charge air cooler outlet temperature sensor Wiring diagram WD263
FX1008 Inlet air temperature sensor
EB1:19 — — —
EB1:20 — — —
EB1:21 CAN L Backbone 2(L) Wiring diagram WD321
EB1:22 CAN H Backbone 2(H) Wiring diagram WD321
EB1:23 SE2603 Coolant level sensor Wiring diagram WD263
EB1:25 RE2501 Preheating Wiring diagram WD264
EB1:26 — — —
EB1:27 SE2606 Coolant temperature sensor Wiring diagram WD262
EB1:28 — — —
EB1:29 MO3301 Starter motor Wiring diagram WD306
EB1:30 — — —
EB1:31 FX1008 Inlet air temperature sensor Wiring diagram WD263
EB1:32 SE2512 Charge air cooler outlet temperature sensor Wiring diagram WD263
EB1:33 — — —
EB1:34 — — —
EB1:35 FX1079 Engine subnet CAN (L) Wiring diagram WD265
MO2505
EB1:36 FX1079 Engine subnet CAN (H) Wiring diagram WD265
MO2505
EB1:37 — — —
EB1:38 — — —
EB1:39 — — —
EB1:40 — — —
EB1:41 — — —
EB1:42 — — —
EB1:43 — — —
EB1:44 — — —
EB1:45 — — —
EB1:46 — — —
EB1:47 — — —
EB1:48 SE2516 EGR temperature sensor Wiring diagram WD268
EB1:49 — — —
EB1:50 — — —
EB1:51 CAN H Backbone 1(H) Wiring diagram WD320
EB1:52 — — —
EB1:53 — — —
EB1:54 — — —
EB1:55 CAN L Backbone 1(L) Wiring diagram WD320
EB1:56 — — —
EB1:57 ECM Voltage feed (supply) 24 V Wiring diagram WD264
EB1:58 ECM Ground Wiring diagram WD264
EB1:60 ECM Voltage feed (supply) 24 V Wiring diagram WD264
EB1:62 — — —
ECO - accelerator pedal
The 'Eco Power' pedal has a function focusing on the engine's fuel consumption. The pedal has a physically noticeable resistance at
approx. 75% of the total angle movement. Using this function the operator can choose to focus on the machine's performance or a
machine with good fuel economy.
Figure 1
A: Cut-off point between economy and power mode
0–75% (green arrow): Economy mode
76–100% (red arrow): Power mode
Economy mode: focus on fuel efficiency, lower rimpull and reduced speed in highest gear.
Power mode: focus on maximum performance, rimpull and high speed in every gear.
The operator uses the 'Eco Power' pedal just like a standard accelerator pedal but a distinct resistance can be noted at the cut-off
point between economy and power. To overcome this resistance the operator has to press down the pedal with more force.
Normal operation
The pedal has the same functionality regardless of if forward gear or reverse gear is selected.
If the system is unable to determine which mode is active, the standard is power mode. This is to ensure that a malfunction in the
system does not limit machine use.
The accelerator pedal's position sensor, SE2702, communicates with the Human machine interface control unit (HMICU) which, in
combination with other signals, controls the engine's speed (rpm) via the Engine control module (ECM).
Diagnostics
PROSIS.
Electric door opener, description
This equipment enables wireless locking/unlocking and wireless door opening. Note that standard opening using the cab door's
handles is not affected by using this system.
The main components of this equipment are a key with wireless remote (pre-paired with receiver), door lock motor, door opener
motor, rotor switch, and a control unit with receiver.
Figure 1
Door lock mechanism with key.
General function
A signal from the wireless key is received by the electronic control unit, CU3605, and then the electronic control unit activates the
corresponding motor function.
The control unit is assembled together with the lock motor and the door opener motor, inside the cab door. The lock motor, MO3613,
locks or unlocks the cab door via a linkage, limiting any movement from the door handle’s push-button. A movement of the lock
motor, MO3612, is transmitted by wire to the door lock mechanism, where the rotor switch is located.
The rotor switch, SW3630, is a safety function to ensure that the door can neither be unintentionally locked with the wireless key if
the door is open, nor be locked when the mechanical door lock's handle inside the cab is used.
Figure 2
Main parts of the electric door opener.
1. Door opener motor, MO3612

2. Lock motor, MO3613
3. Control unit, CU3605
4. Rotor switch, SW3630
Power supply
The electric door opener is powered by the machine’s current feed and its battery disconnector needs to be turned on.
Key functions
Any combinations of keys being pressed other than those described below will be ignored.
Figure 3
1. Eject key —One click will eject the door key.

2. Lock button —One click will lock the door.
3. Unlock button —One click will unlock the door.
4. Open button —A fast double-click will unlock and open the door.
Lock function
To lock the cab door with the wireless key, the cab door needs to be fully closed followed by a click on the lock button.
It is not possible to lock the door with the wireless key if the door is not fully closed. This is so since the control unit CU3605 will not
receive any signal from the switch SW3630.
It is also possible to lock the door manually with the key.
Unlock function
When the door is locked, a click on the unlock button will unlock it. It is always possible to unlock the door, regardless of if the door is
fully closed or not.
It is also possible to unlock the door manually with the key.
Open door function
A fast double-click on the open button will unlock the cab door as well as open the door. Regardless of if the cab door is open or
closed, or if the cab door is locked or not, the door will be opened.
It is also possible to open the door manually by using the door handle after the door has been unlocked.
Safety feature
Available safety features for the electric door opener are stated below:
 If the cab door is not fully closed, then it is not possible to lock the door with the wireless key.
 A locked cab door that is opened with the door handle on the inside will be unlocked automatically.
 An open cab door that has been locked with the mechanical key will be unlocked automatically when the door is closed.
 There is a built-in motor protection feature to prevent the door opener motor from overheating. This feature will be activated if
too many attempts to open the door have been made within too short a time period, which disables the electric door opener
function for 30 seconds. After 30 seconds the system will return to normal operation.

 Wiring diagram WD831 Update G
Function check
-
Diagnostics
Component Action
CU3605 See CU3605, description and measuring
MO3612 See MO3612, description and measuring
MO3613 See MO3613, description and measuring
SW3630 See SW3630, description and measuring
Symptoms
FGI 8
Symptom type Door problems
Symptom Electric door opener does not work
Electrical symbols and designations
Designation Symbol Explanation
ACM Control unit
CCM
ECM
GPMECU1
GPMECU2
GPMECU3
HMICU
WECU
AL Alternator with charging regulator
Alternator with charging regulator
BA Battery
C Capacitor
CR Radio
Communication radio (two-way radio)
CU Electronic unit
DI Diode
FC Fuse
FH
FU
FX Component with several included functions
HE Heating element
Heating coil seat heating
IM Instrument, i.e. hour meter
LA Light, fixed light

Light, flashing light
LC Light-emitting diode
MA Solenoid valve or PWM-valve for control of oil
MO Electric motor
Starter motor
PO Voltage socket 12 V / 24V
R Resistor
Rheostat
RC Back-up camera
RE Relay
RF Flasher relay
SA Audible signal
Audible signal
Speaker
SE Frequency sensor
Inductive sensor
Level sensor
Temperature sensor
Pressure sensor
Pressure monitor
Mechanical monitor
Level monitor
Angle sensor
SO Voltage converter
SW Single terminal switch with manual on and off
Single terminal switch with manual on and automatic off
Double terminal switch with manual on and off with lock-out
Ignition switch
Electric lever lock
Ground connection
Ground connection engine block
Twisted cable
Shielded cable
Electrical system, description
Electrical system components
The main electrical system consists of:
 Battery switch
 Distribution box with fuses
 Alternator
 Preheating coil
 Electrically controlled battery disconnector
 Batteries
The batteries are connected in series and provide a 24 V electrical system. They are located in a battery box on the right side of the
cab.
The battery main switch is located by the steps to the cab and is connected to the batteries' positive side.
Voltage feed of the machine takes place via a fuse box located on the left side of the machine, under the cab.
From the fuse box the preheating coil voltage is fed and the charge from the alternator is received.
Fuse FU74 and FU75 are located next to the battery main switch.
FU74 supplies the voltage converter 12 V and installed equipment for electrically controlled battery disconnector.
Figure 1
Electrical system, main components
1. Battery switch
2. Distribution box with fuses
3. Alternator
4. Preheating coil
5. Electrically controlled battery disconnector
6. Batteries
NOTE!
Voltage feed via fuse FU74 is not cut off by the battery disconnector.
The voltage converter feeds the radio, and the 12V electric power outlet.
Relays and fuses are mainly located on the circuit board in the electrical distribution box on the rear wall in the cab.
Figure 2
Rear wall in cab
1. Voltage converter
2. Circuit board
NOTE!
Do not replace a relay with a quench diode for a relay with a resistor
Components are marked according to which function group they belong. The first two digits indicate function group and the other
digits are running numbers, e.g., SE2203.
For components with several functions, e.g., FX1006 and contains two sensor functions SE2202 and SE2205, the component is only
marked with FX1006.
NOTE!
For working on the electrical system, follow the instructions in section Electrical system, work instructions.
Parameters
 Software parameters, description
1. Components list
2. Chassis connection
3. Connectors, position
4. Electronic control system, description
Relevant Tech Tool operations
 30901-3 Power supply control unit (ECU), check
Function check
1. Batteries: Battery condition, check

2. Alternator: AL3201, description and measuring
Diagnostic
Detailed information about relevant warnings and error codes are available under the diagnostic tab in Prosis.
Electrical system, work instructions
Batteries
1. Fully charged and otherwise satisfactory batteries must always be used when working on the electrical system.
2. Test the batteries with an acid tester (does not apply to maintenance-free batteries). The battery disconnector shall be off,
see also Battery condition, check.
3. When installing a battery, make sure that the battery is connected with the correct polarity.
4. When changing batteries connected in series, make sure they are of equal capacity, for example, 2 batteries of 105 Ah. The
batteries should have the same age (same quality), since the charging current required to reach a certain voltage varies with
the battery's age.
5. If booster battery is required when starting, the following instructions must be followed at all times; Safety when working with
batteries and Starting with booster batteries.
Charging
1. Before performing any tests of the alternator or regulator, the batteries must be checked regarding insulation, loose fit, and
corrosion. Check the alternator belts.
2. "Safe" connections shall be used to prevent sparks and voltage transients. A disconnected cable may result in destruction of
both alternator and regulator.
3. Never disconnect the alternator leads while the engine is running. This could damage both the alternator and regulator.
4. If the current alternator output socket should be connected to the chassis, damage may occur to the alternator and regulator.
Components
When removing or installing components in the electrical system, turn off the voltage supply with the battery disconnector.
Welding
For electric welding on the machine or on attachments on machine:
 voltage feed turned off with battery disconnect switch

 all connectors in the cab's rear wall shall be unplugged to avoid damaging the machine's electronics.
NOTE!
 Ground the welding unit as close as possible to the welding point.

 Welding on the cab is not permitted, it affects the cab's approval for FOPS and ROPS .
Figure 1
Connectors on the rear of the cab wall
Electronic control system, description
General
Figure 1
Position of control units
1. Engine Control Module (ECM)

2. Aftertreatment Control Module (ACM)
4. General Purpose Machine Electronic Control Unit 2 (GPMECU2). (Only when CDC is installed).
6. Human Machine Interface Control Unit (HMICU)
7. Climate Control Module (CCM)
8. Telematics ECU (WECU)
9. Instrument cluster (IC)
Figure 2
Figure 3
Control units on cab wall
Control units
Control units included in the system are the Engine Control Module (ECM), Aftertreatment Control Module (ACM), General Purpose
Machine Electronic Control Unit 1 (GPMECU1), General Purpose Machine Electronic Control Unit 2 (GPMECU2), General Purpose
Machine Electronic Control Unit 3 (GPMECU3), Climate Control Module (CCM), Human Machine Interface Control Unit (HMICU) and
Telematics ECU (WECU).
Engine Control Module (ECM)

The ECM controls the engine and together with the ACM controls the need of regenerations.
Figure 4
Engine Control Module (ECM)
Aftertreatment Control Module (ACM)
The ACM controls the exhaust aftertreatment system (EATS) and calculates, together with the ECM, when regeneration is needed.
For detailed description of the exhaust aftertreatment system (EATS), see Exhaust Aftertreatment System, description.
Figure 5
Aftertreatment Control Module (ACM)
General Purpose Machine Electronic Control Unit 1 (GPMECU1)
The GPMECU1 controls the most of the machines electronical functions with exceptions of transmission and hydraulics.
The GPMECU2 controls the electric servo for the hydraulics and the hydraulic functions. (GPMECU2 is used when CDC option is
installed.)
The GPMECU3 controls the transmission and transmission gear shift strategies.
Figure 6
General Purpose Machine Electronic Control Unit (GPMECU)
Climate Control Module (CCM)
The CCM controls the climate control system.
For detailed description of the climate control system, see Climate control system, description.
Figure 7
Human Machine Interface Control Unit (HMICU)
The HMICU presents information from all control units to the operator on the display unit, including warning and control lights. The
HMICU is the control unit that sends the information which is then shown on the display unit.
Figure 8
Telematics ECU (WECU)
The WECU is connected to the machine's electronic system, which gives access to remote readouts from the control units. For
detailed description of the CareTrack system, see CareTrack W-ECU, description.
Figure 9
CareTrack unit (WECU)
1. WECU
2. Satellite modem
Communication and Diagnostics
Figure 10
1. Display unit
2. Keypad
3. Diagnostic connector
Controller Area Network (CAN)

The different control units communicate with each other via CAN link. The backbone or main communication channel will consist of
two links, thereby referred to as Backbone 1 (BB1) and Backbone 2 (BB2). The new CAN bus replacing SAE J1708/J1587 uses the
ISO 14229 standard. The nodes in the system monitors its communication links. If a fault is detected in the communication link
supervision the node informs the operator about the fault.
Subnet
The use of subnets will facilitate the communication between nodes that have a frequent data exchange between them.
Local Interconnect Network (LIN)
LIN communication is appropriate for use in the interaction between the operator and the machine, such as communication with
switches and keypad.
Figure 11
Keypad
Diagnostic Link (DL)
Access for both diagnostics, software download and programming of parameters will be performed via the diagnostic link. From an
external client the diagnostic link is accessed from an On Board Diagnostic II (OBDII) female connector on the diagnostic link.
Diagnostics
The different control units stores information if a malfunction should occur or if any part of the system reacts abnormally. Intermittent
malfunctions are stored in the control units and can then be traced at a later time. The service tool Tech Tool communicates with the
machine’s different ECUs via the diagnostic link, if the diagnostic link is cut off no communication with the machine can be performed.
For service personnel, the communication unit for the service tool Tech Tool can be connected to an OBDII socket located by the
electrical distribution box behind the operator's seat. The service tool is used to download software, programming of parameters and
to readout diagnostic trouble codes.
Diagnostic Trouble Code (DTC)
The DTCs can be viewed in the machine’s display or with the service tool Tech Tool. The complete DTC has a seven character
display value which can be divided into three parts:
 System Category
 Consecutive Number
 Failure Type Byte (FTB)
Both the consecutive number and the FTB are hexadecimal.
System Category: Consecutive number: Failure Type Byte:

DTC Display value: C1 054 11
All DTCs will belong to a specific system category. The different system categories are:
 Body (B)
 Chassis (C)
 Power train (P)
 Network (U)
The letter is followed by a number 0-3.

The FTB defines the DTC Failure Category and Failure Subtype of a base DTC. It represents the type of fault in the circuit or system
(e.g. sensor open circuit, sensor shorted to ground, algorithm-based failure, etc.). It replaces the previous Failure Mode Identifier
(FMI) defined in SAE J1587.
A FTB value of 00 indicates that no subtype information is contained in the FTB. This means that a standard DTC is already defined
for the component/system and that DTC description already comprehends the failure type information, e.g. emissions-related DTC
P0127 Intake Air Temperature Too High.
Standard DTCs and all FTBs are defined in SS-ISO 15031-6.
Machine software
To determine which software that is programmed into the control units, the part number of the software can be read in the information
panel or with the service tool Tech Tool. Updating of the machine's software is handled through releases of new editions. The
releases are defined as Year:edition, for example, R2006:5. Updating of software for control units takes place through Tech Tool by
downloading of new software from Volvo central systems.
Software parameters
In the software there are different types of parameters, they are used to activate functions and give the possibility to change settings
for the functions. There are two types of parameters that can be programmed, machine parameters and customer parameters. The
programming is done with Tech Tool.
Machine Parameter:
 Parameters are set during production but are also visible and changeable on the aftermarket.
 All changes at the aftermarket will be logged and sent back to the Volvo central systems.
Customer Parameter:
 The parameters are visible and changeable at the aftermarket by a mechanic.

 The changes are not logged or sent back to the Volvo central systems.
 Software parameters, description
Diagnostics
Engine, description
The engine is a straight six cylinder, four stroke, turbocharged diesel engines with direct injection and charge air cooler. The engine
meet US Tier 4 final and California Tier 4 final emission requirements and EU Stage IV emission requirements.
The engine uses a common rail fuel system controlled by the engine control module (ECM). Engines with ACT (advanced
combustion technology) feature split injection and turbocharger with mechanical wastegate. The exhaust aftertreatment system
(EATS) is equipped with a diesel oxidation catalyst (DOC), a diesel particulate filter (DPF) and an SCR system to reduce emissions.
Cooled exhaust gas recirculation (EGR) also reduces emissions.
For more information, see:
 Crankcase ventilation, description

 Lubrication system, description
 Fuel system, description
 Cooling system, description
The cylinders are numbered in sequence, starting at the flywheel. Ignition order: 1-5-3-6-2-4. The engine rotational direction is
counter-clockwise, seen from the flywheel side.
Engine identification
Figure 1
Identification plates
1. Engine serial number
The engine serial number is stamped on the side of the cylinder block. The identification plates on the side of the cylinder block and
on the valve cover contain model designation, serial number, manufacturing country, recommended fuels and so on. They also
include the emission related supplementary information. The engine model designation and serial number must be indicated when
ordering spare parts.
Rating plates on mufflers
Figure 2
1. Rating plates of DPF and SCR catalyst
The serial numbers of the exhaust aftertreatment system components are stamped on the rating plates.
Engine protection
There are several proactive functions, and different applications have different functions activated. Various protective actions such as
warning lights, engine derate and forced idle may be taken when the below functions reach dangerous levels that may damage the
engine.
Engine derate
The engine power is limited. Engine derate is active until the parameter has reached a safe level or until key-OFF. Engine derate can
be triggered by:
 High inlet manifold air temperature

 High oil temperature
 Low coolant level
 High EGR temperature
 High soot load
 Crystallization in AdBlue®/DEF mixing tube
 High exhaust temperature
 High ECM temperature
 High DPF temperature
 High charge air temperature (calculated)
 High altitude (ensures that high compressor charge air temperature is never reached)
 Low coolant temperature
 Crank or cam sensor failure
 Fuel system error
If regeneration is denied or delayed for too long the soot load in the DPF will be too high and the engine will be derated in form of
engine torque reduction to 50% at 1300 rpm and above.
Forced idle
The engine can be forced to idle speed by the engine protection function. Forced idle is active until conditions triggering the problem
are back within normal working range or key-OFF. Forced idle can be triggered by:
 Low oil pressure

 High coolant temperature
For limits and actions, see the relevant error code description.
Emission compliance
In order to reduce the NOx content in the exhaust, the engine is equipped with a SCR system. AdBlue®/DEF is added to the exhaust
and a reaction in a SCR-catalyst reduces the NOx. The SCR system is monitored by the software, and a SCR system that does not
work will result in a non-working engine by way of an engine derate.
The engine will be derated if:
 The AdBlue®/DEF tank level is too low

 AdBlue®/DEF is of poor quality (e.g., highly diluted)
 Malfunction of the SCR system (e.g., disconnected sensors, clogged AdBlue®/DEF hose, etc.)
 The defrosting time to get the SCR system working is too long
In case of repeated malfunction of the system the time to derate will become shorter.
As a minimum, the components that can trigger the protective system are:
 Blocked EGR valve

 Blocked AdBlue®/DEF hose or AdBlue®/DEF dosing injector
 Disconnected AdBlue®/DEF level sensor
 Disconnected AdBlue®/DEF pump
 Disconnected SCR system wiring
 Disconnected NOx sensor
 Disconnected AdBlue®/DEF quality sensor
 Disconnected AdBlue®/DEF temperature sensor
 Disconnect exhaust temperature sensor
Levels of NOx before and after the SCR are measured continuously to determine if the system works as expected. If the NOx
reduction is too low, and the ACM detects a problem in the system, it will react with a warning and then engine derate.
The AdBlue®/DEF quality sensor makes sure that, if e.g., water or fuel is filled in the tank instead of AdBlue®/DEF, it will be detected
and the system will react with an engine derate.
The SCR system is able to dose AdBlue®/DEF within 70 minutes of operation from a cold start. Otherwise, an error code will be
generated and the engine will be derated.
There are two levels of engine derate that are activated after a certain period of time depending on what kind of an error it is and if it
has been repeated or not:
1. Derate level 1: Engine torque is reduced to 75%

2. Derate level 2 (US market): Forced engine idle ("Full derate")
Derate level 2 (Europe and Asia market): Engine torque is reduced to 50% and maximum engine speed to 60%
For safety reasons the derate of the engine is done in smooth transitions, both when activating and deactivating the derate.
Restored operation (Emission compliance)
If the engine is restarted (key OFF-key ON) with an active engine derate, it can achieve full engine power for 10 minutes twice for
reduction level 1. This can be used if a dangerous situation occurs and the machine must be moved. This will not prolong the
activation time of an engine derate.
During restored operation, full engine speed and torque is available for 10 minutes. After that the engine will return to its previous
reduction level within one minute. If the engine is shut down during this state and the time for restored operation has not ran out, it
will be stored in the system.
Parameters
 There are no parameters for this function
 Engine, specifications
Function check
 Tech Tool operation 17030-3 Parameter, programming
Diagnostics
PROSIS.
Exhaust Aftertreatment System, component location
Figure 1
Mufflers
1. Exhaust gas temperature sensor before DOC, SE2521

2. DPF differential pressure sensor, SE2519
3. Exhaust gas pressure sensor before SCR, SE2544
5. NOx sensor after SCR, SE2533
6. Exhaust gas temperature sensor before DPF, SE2522
7. NOx sensor before SCR, SE2513
8. Exhaust gas temperature sensor after DPF, SE2543
Figure 2
Exhaust aftertreatment system
1. Turbocharger
2. Inlet throttle, MO2503
4. Air cleaner
6. AdBlue®/DEF tank armature quality, temperature, and level sensor, FX1079 (SE2541, SE2536, SE2537)
7. Screen filter
8. Control unit for tank armature
9. Coolant valve, MA2517
10. AdBlue®/DEF pump unit
Exhaust Aftertreatment System, description
Introduction
The engine features an exhaust aftertreatment system (EATS) in the form of two mufflers. The first one contains a diesel oxidation
catalyst (DOC) and a diesel particulate filter (DPF) to reduce emissions of particulate matter (PM). The second one contains a
selective catalytic reduction catalyst (SCR) to reduce nitrogen oxide (NOx) emissions.
The SCR uses diesel exhaust fluid, called AdBlue® or diesel exhaust fluid (DEF), to reduce the NOx emissions. An AdBlue®/DEF
injection system is used to add this fluid to the exhaust.
There are other systems that affect or are affected by the exhaust aftertreatment system. For more information, see:
 Fuel system, description

Function diagram
Figure 1
Exhaust after treatment system
Purple = AdBlue®/DEF
Red = Exhaust
Yellow = Coolant
1. Diesel oxidation catalyst (DOC) 6. AdBlue®/DEF tank

2. SCR catalyst 7. Coolant valve
3. Diesel particulate filter (DPF) 8. AdBlue®/DEF pump unit
4. AdBlue®/DEF dosing injector 9. Turbocharger
5. Diesel engine
The DPF filters out particulate matters (PM) from the engine exhaust. The trapped PM is burned off during regeneration.
In order to reduce NOx emissions, a reaction is started in the SCR catalyst. AdBlue®/DEF is mixed with the exhausts in order to start
the reaction. The last part of the SCR catalyst has a different coating which will remove any remaining ammonia from this reaction.
In order to ensure reduction of emissions, the aftertreatment system is monitored by the diagnostic system in the aftertreatment
control module (ACM). If the system cannot meet the emission requirements, the machine may not be used to perform productive
work in a normal way. This takes place in the form of derate, which entails reducing both engine torque and rpm. For more
information, see Engine, description.
Regeneration is constantly performed passively during normal operation. If the temperatures needed for regeneration are not met
during normal operation (for example, due to low load cycles), there is a function in the engine management system that uses the
inlet throttle to increase the exhaust temperature. A parked regeneration involves the use of the inlet throttle and additionally injected
fuel in the exhaust using a late post-injection performed by the engine fuel injectors. This allows the DOC to oxidize the fuel, which
increases the temperature in the aftertreatment system.
AdBlue®/DEF injection system
Figure 2
AdBlue®/DEF injection system
ACM = Aftertreatment control module
CAN = Contoller area network
Red = Exhaust
Yellow = Coolant

1. Exhaust gas temperature sensor before DOC, SE2521 14. AdBlue®/DEF quality, temperature and level sensor, FX1079
(SE2541, SE2536, SE2537)
2. Exhaust gas temperature sensor before DPF, SE2522 15. AdBlue®/DEF tank, suction line screen filter
3. Mufflers and mixing tube 16. AdBlue®/DEF pump unit, screen filter on inlet
4. DPF differential pressure sensor, SE2519 17. Non-return valve
5. NOx sensor before SCR, SE2513 18. Return flow screen filter
6. Exhaust gas temperature sensor after DPF, SE2543 19. Coolant valve, MA2517
7. NOx sensor after SCR, SE2533 20. Reversal valve
8. Exhaust gas pressure sensor before SCR, SE2544 21. AdBlue®/DEF pump unit, FX1074
9. AdBlue®/DEF dosing injector, MA2519 22. AdBlue®/DEF pump
10. Screen filter 23. AdBlue®/DEF pump unit, full flow filter
11. Diesel engine 24. AdBlue®/DEF pump unit, temperature and pressure sensor
12. Tank fill point screen filter 25. Turbocharger
The AdBlue®/DEF injection system pumps AdBlue®/DEF from the tank to the AdBlue®/DEF dosing injector, which injects
pressurized AdBlue®/DEF into the exhausts in the mixing tube. The pressure between the pump and the AdBlue®/DEF dosing
injector is kept constant at 0.9 MPa (130.5 psi).
AdBlue®/DEF tank
Figure 3
AdBlue®/DEF tank with tank fitting
Yellow = Coolant
1. Control unit
2. Breather filter
3. Breather hose
4. AdBlue®/DEF tank armature including quality, level and temperature sensor, FX1079 (SE2541, SE2536, SE2537)
5. AdBlue®/DEF tank, suction line screen filter
6. Splash guard (optional equipment)
7. AdBlue®/DEF tank fill point, screen filter
AdBlue®/DEF fluid is stored in the AdBlue®/DEF tank. The tank is equipped with a tank armature including a quality, level, and
temperature sensor. A splash guard is installed around the connection for the tank armature in order to protect sensitive components.
Inside the tank armature there is also a breather hose for venting the tank. The breather hose is connected to a breather filter.
The quality sensor is used to determine that the right quality and concentration of AdBlue®/DEF fluid is used in the tank. It detects
the presence of other fluids in the tank instead of AdBlue®/DEF, for example, water or fuel. The signals from the sensors are sent to
the ECM and ACM via the CAN-network.
Filters are used at the AdBlue®/DEF fill point and the AdBlue®/DEF suction pipe inlet to filter out impurities. Coolant pipes are routed
down into the tank for defrosting the AdBlue®/DEF at low temperatures.
AdBlue®/DEF pump unit
Figure 4
AdBlue®/DEF pump unit
Yellow = Coolant
A. Coolant inlet
B. Coolant outlet
C. AdBlue®/DEF inlet
D. AdBlue®/DEF return flow
E. AdBlue®/DEF outlet
1. Connector, FX1074
2. AdBlue®/DEF full flow filter
3. Screen filter
4. Combined restriction/non-return valve
5. Screen filter
6. Reversal valve
7. Electrical pump
8. AdBlue®/DEF pump unit, temperature and pressure sensor
The AdBlue®/DEF pump unit includes an electrical pump, a reversal valve, two screen filters, a full flow filter, a combined
temperature and pressure sensor and a combined restriction/non-return valve. The pump is controlled by the ACM. The pump runs at
a set speed.
AdBlue®/DEF draining
The reversal valve integrated in the pump unit reverses the flow of AdBlue®/DEF at key-off in order to drain the AdBlue®/DEF hoses.
The combined restriction/non-return valve ensures that the pump does not draw AdBlue®/DEF from the tank when the hoses are
being drained.
AdBlue®/DEF dosing injector
Figure 5
AdBlue®/DEF dosing injector
Purple = Adblue®/DEF
Yellow = Coolant
AdBlue®/DEF, supplied by the AdBlue®/DEF pump, is injected into the exhaust flow before the SCR catalyst by the dosing injector.
The injected AdBlue®/DEF vaporizes due to the heat from the exhausts. The vaporized AdBlue®/DEF starts a reaction in the SCR
catalyst. The reaction reduces the NOx content of the exhaust. The required amount of AdBlue®/DEF is calculated by the ACM using
the temperature and pressure sensors installed in the AdBlue®/DEF pump unit and the NOx sensors.
In the AdBlue®/DEF dosing injector there is a nozzle in the form of a dosing valve as well as a screen filter. The dosing valve is
controlled electrically by the ACM. The dosing injector is sensitive to high temperatures and is constantly cooled by the engine
coolant.
Defrosting/cooling of AdBlue®/DEF components
Figure 6
Defrosting/cooling of AdBlue®/DEF components
Yellow = Coolant
Orange flash = Electrical heating
1. AdBlue®/DEF dosing injector

2. Coolant pump
3. AdBlue®/DEF pump unit
4. Coolant valve
6. AdBlue®/DEF tank armature
Since AdBlue®/DEF freezes at –11 °C (12 °F), the AdBlue®/DEF-system has a defrosting function. The engine cooling system helps
to defrost the system by circulating coolant via the AdBlue®/DEF tank and the AdBlue®/DEF pump. The AdBlue®/DEF hoses are
heated electrically. The defrosting system is activated when needed in cold conditions, and the AdBlue®/DEF dosing will start within
70 minutes. The temperature sensors that individually activate the defrosting function are the ambient temperature sensor, the
AdBlue®/DEF tank temperature sensor and the AdBlue®/DEF pump temperature sensor. When there is no need for defrosting, the
coolant valve is closed and hose heating is turned off so that the AdBlue®/DEF does not get too warm.
In order to avoid overheating of the AdBlue®/DEF dosing injector, the engine coolant is also circulated to this component in a
separate circuit. This is done constantly.
Coolant valve
Figure 7
Coolant valve
The coolant for the AdBlue®/DEF tank and AdBlue®/DEF pump unit is controlled by a flow directional coolant valve. The coolant
valve is an electromagnetic solenoid valve controlled by the ACM.
AdBlue®/DEF hoses
Figure 8
AdBlue®/DEF hose
The AdBlue®/DEF hoses are heated electrically to prevent AdBlue®/DEF from freezing in the hoses.
The heated hoses have a 2 pin electrical connector that is used for hose heating. The hose is a spiral wound with resistance wire.
The current for the hoses is supplied via the ACM.
The hose end with the electrical connector is always installed toward the AdBlue®/DEF pump unit.
Mufflers
DPF muffler
Figure 9
Mufflers and mixing tube
Red = Exhaust
1. DPF muffler
2. SCR muffler
3. Exhaust gas temperature sensor before DPF, SE2522
4. AdBlue®/DEF mixing tube
5. AdBlue®/DEF dosing injector
6. Exhaust outlet
7. Exhaust gas temperature sensor before DOC, SE2521
8. Exhaust gas inlet
9. DPF differential pressure sensor, SE2519
10. Exhaust gas pressure sensor before SCR, SE2544
11. NOx sensor before SCR, SE2513
12. Exhaust gas temperature sensor after DPF, SE2543
13. NOx sensor after SCR, SE2533
The DPF muffler consists of three main sections which are secured together with V-clamps; the diesel oxidation catalyst (DOC)
section with integrated inlet, the diesel particulate filter (DPF) section, and the outlet section. The muffler features two temperature
sensors, one before the DOC, one before the DPF, and a differential pressure sensor across both the DOC and DPF.
When the exhaust enters the DPF, it passes through a porous ceramic substrate which traps and removes the Particulate Matter
(PM) from the exhaust and allows the filtered exhaust to exit the DPF.
Since the DPF is continuously loaded with PM, there is a need for a regeneration to remove them. Some of the PM is burned to ash
during regeneration. Ash gradually accumulates in the DPF. The ash comes primarily from the engine oil and engine wear. Ash is not
burned off during regeneration and therefore the DPF must be cleaned at regular intervals.
The DOC is used to reduce emissions of HC and CO. A desired outcome of the HC-reduction is that it increases the temperature of
the exhausts. During passive regeneration, the DOC is used to convert NO into NO₂. The NO-conversion will reduce the temperature
required to run the regeneration since the PM oxidizes with NO₂ at a lower temperature.
AdBlue®/DEF mixing tube
A tube transports the exhaust between the two mufflers. In the tube, there is an integrated AdBlue®/DEF dosing injector, a mixer, a
temperature sensor, a pressure sensor and a NOx sensor.
The mixer is a rigid impeller welded inside the mixing tube. When the AdBlue®/DEF droplets hit the mixer, they are atomized and
deflected in the direction of the exhaust flow. This facilitates mixing of AdBlue®/DEF with the exhaust, which in turn ensures high NOx
reduction.
SCR muffler
The second muffler consists of a selective catalytic reduction catalyst (SCR) in a single casing with inlet and outlet.
The SCR catalyst reduces NOx with AdBlue®/DEF that is injected into the exhaust in the mixing tube. In order to achieve good NOx
reduction, a catalyst temperature of more than 250 °C (482 °F) is essential.
There are two sensors for measuring the NOx reduction, one before and one after the SCR catalyst. The readout is controlled by the
ACM. The NOx sensors have to be warm to be able to give any values. Therefore the control units will delay their function until the
sensors are warm.
The NOx sensors are turned off automatically if the SCR gets too cold, for example, when idling. This is done to protect the sensors
from condensation that may destroy the sensors.
The last section of the SCR catalyst has a different coating. The purpose is to remove any remaining ammonia from the SCR system.
The DPF, the DOC and the SCR are all coated with active catalytic substances. These coatings are prone to sulphur poisoning. That
is the reason why ultra-low sulphur fuels have to be used or the catalysts will lose their function. If the catalysts lose their function it is
no longer possible to run a regeneration or reduce NOx emissions, and eventually the machine will not be able to operate.
Emission compliance
A NOx control system monitors that the SCR system works correctly. The most important factor that this system monitors is the
quality of the AdBlue®/DEF. A malfunction in the system will trigger the NOx emission monitoring and engine will be derated after a
certain time. Before any derate takes place, a warning and a message about the active problem is always shown to the operator. By
solving the problem, the system is fixed. If the problem is not resolved, the next level of derate will be activated after a certain time.
For more information, see: Engine, description.
Regeneration strategies
The purpose of a regeneration is to increase the temperature in the aftertreatment system so that any trapped substance is
combusted to allow the system to regain its full capacity. Regeneration is run at three levels:
 passive regeneration
 parked regeneration
 service regeneration (parked regeneration performed via Tech Tool)
PM regeneration in the DPF can take place at both low temperatures (NO₂ based reaction) and at high temperatures (O₂ based
reaction). To remove crystals from the AdBlue®/DEF mixing tube, the temperature needs to be high. This requires a parked
regeneration.
During a parked regeneration, the exhaust temperature in the DPF increases to approximately 600 °C (1,112 °F). A passive
regeneration takes place at approximately 250–350 °C (482–662 °F).
If the PM load becomes too high, the engine will be derated to protect the engine. Before any derate of the engine, a warning and a
message is always shown to the operator. For more information, see: Engine, description.
Passive regeneration
A passive regeneration is what takes place during normal operation. When the engine is running, the heated exhaust heats the
exhaust aftertreatment system. A passive regeneration does not involve any operator interaction. A passive regeneration takes place
continuously and does not have any start or stop. However, regeneration effectiveness is increased by the temperature of the
exhaust. Effective passive regeneration requires a temperature of at least 250 °C (482 °F).
If the machine operating conditions do not permit a successful passive regeneration, there may be a need to restrict (throttle) the
engine. One example would be if the engine has been idling a lot or has been running with very low loads. Restricting (throttling)
makes the engine work harder, thus increasing the temperature of the exhaust. The ACM calculates when and if this is needed and
the ECM will engage the inlet throttle. Restricting (throttling) is done in two stages. If the first stage is not enough to run passive
regeneration the second stage will be used.
Figure 10
Inlet throttle
Blue = inlet air
1. Throttle disc
No information is shown to the operator on the instrument panel until there is a need for a service regeneration.
Parked regeneration
If the passive regeneration is not sufficient to reduce the PM and crystals, or if too much time has passed since the last parked
regeneration, a parked regeneration is requested.
A parked regeneration must be performed every 500 hours in order to ensure complete removal of PM and crystals. This will be
performed at the engine oil change interval (before changing the engine oil) in the machine service program.
NOTE!
If the regeneration is not performed within 625 hours since the last regeneration, a service regeneration with Tech Tool will be
required. Between 450 and 625 hours it is possible to start a service regeneration from the machine display.
Parked regeneration requires operator interaction to park the machine, apply the parking brake, or lock out lever, and to start the
regeneration manually. No work can be performed with the machine during parked regeneration. The engine speed will be changed
to a predefined value and cannot be affected by the operator. The reason for this is that the engine speed and load levels must
remain constant. This is done to ensure a more uniform temperature distribution, exhaust flow and oxygen concentration in the DPF
due to higher thermal stress during a regeneration with higher PM loads.
To increase the heat of the exhaust, restricting (throttling) and also adding vaporized fuel to increase the HC reaction in the DOC is
used. The extra fuel is injected into the exhaust by late post-injection performed by the engine fuel injectors.
It is not recommended to interrupt or cancel an ongoing parked regeneration other than in emergency situations. For example, if the
parking brake is released, the regeneration will be interrupted immediately without warning and will have to be restarted to be run
successfully.
If the regeneration is not performed as requested for some reason, eventually the engine protection function, in the form of derates,
is activated.
Summary
The exhaust aftertreatment system (EATS) reduces PM and NOx emissions in the exhausts. A DPF is used to trap the PM and a SCR
is used to reduce NOx. AdBlue®/DEF is injected into the exhaust to facilitate the reaction in the SCR catalyst.
Since the DPF is continuously loaded with PM it has to be regenerated. Passive regeneration is performed constantly. Parked
regeneration has to be started by the operator after the parking brake, or lock out lever, has been applied.
During parked regeneration, the exhaust temperature is increased. An inlet throttle is used to increase the temperature. During
parked regeneration, fuel is also injected into the exhaust by late post injection to react with the DOC in order to increase the
temperature. This will burn off PM and crystals. Ash is not burned off during regeneration, and the DPF must therefore be cleaned at
set intervals.
Parameters
There are no parameters for this function.
 Engine, description
 Exhaust Aftertreatment System, component location
 Inlet and exhaust system, specification
Function check
 Tech Tool operation 25456-3 Exhaust aftertreatment diagnostics

 Tech Tool operation 25474-3 Exhaust aftertreatment system, reset
 Tech Tool operation 25847-3 SCR system drain, test
 Tech Tool operation 25849-3 SCR system, test
 Tech Tool operation 25920-3 Exhaust aftertreatment system service regeneration
 Tech Tool operation 25964-3 SCR system, diagnostics
 Tech Tool operation 25965-3 SCR system, dosing, test
 Tech Tool operation 25966-3 SCR system, heating, test
Diagnostics
PROSIS.
Exhaust gas recirculation (EGR), component location
Figure 1
EGR system
1. Charge air cooler

2. Charge air cooler outlet temperature sensor, SE2512
3. Exhaust gas pressure sensor before turbocharger, SE2511
4. Inlet manifold temperature and pressure sensor, FX1007 (SE2507, SE2508)
5. Mixing chamber
6. Venturi tube
7. EGR temperature sensor, SE2516
8. EGR differential pressure sensor, SE2515
9. EGR control valve and actuator
10. Turbocharger
11. EGR cooler
12. Non-return valves
Exhaust Gas Recirculation (EGR), description
Introduction
The engine features a cooled external Exhaust gas recirculation (EGR), and its main purpose is to lower the combustion temperature
to reduce the nitrogen oxide (NOx) content in the exhaust. In addition to reducing the NOx content, the engine is also equipped with
an exhaust aftertreatment system in the form of a Selective Catalytic Reduction (SCR) system.
For information about systems that affect the EGR system, see:

Function diagram
Figure 1
EGR system
CAN = Contoller area network

Blue = Inlet air
Brown = Engine oil
Red = Exhaust
Yellow = Coolant
A = to Exhaust aftertreatment system
1. Inlet throttle 10. Mixing chamber

2. EGR temperature sensor, SE2516 11. Preheater, HE2501
3. EGR differential pressure sensor, SE2515 12. Air cleaner
4. EGR venturi tube 13. Ambient air temperature sensor, SE8705
5. Diesel engine 14. Inlet air temperature and air cleaner pressure sensor,
FX1008 (SE2501, SE2502)
6. EGR cooler 15. Inlet manifold temperature and pressure sensor, FX1007
(SE2507, SE2508)
7. EGR control valve and actuator 16. Turbocharger with wastegate
8. Charge air cooler 17. Exhaust gas pressure sensor before turbocharger, SE2511
9. Charge air cooler outlet temperature sensor, SE2512
The amount of exhaust recirculated from the engine exhaust manifold is controlled by the Engine control module (ECM), by way of
the EGR control valve with the EGR actuator. The EGR gas continues to the inlet manifold via the EGR cooler, the control valve, the
venturi tube and the mixing chamber. The mass flow of the cooled EGR is determined in the venturi tube using a differential pressure
sensor and a temperature sensor. The sensors provide a feedback signal to the ECM for closed loop control of the EGR valve
position.
The cooled EGR gas flows to the inlet side of the engine via the mixing chamber, where it mixes with inlet air that has been cooled
through the charge air cooler. From the mixing chamber, the combined EGR gas and inlet air flow continues into the inlet manifold.
The temperature reduction of the inlet air and EGR gas is done to keep the temperature low for NOx reduction.
For EGR exhaust to flow, a pressure difference is required across the inlet and exhaust manifold. The pressure in the engine inlet
manifold is reduced by means of an inlet throttle valve so that it is lower than the back pressure in the exhaust manifold.
The NOx sensor, located on the DPF muffler outlet, provides feedback on the EGR system efficiency and control. The NOx sensor is
used for calibrating EGR control with regards to factors that affect EGR flow, for example varying ambient conditions such as high
altitude and gradually filled inlet and DPF filters. The NOx sensor makes reference measurements at certain fixed engine load points
and adapts the EGR control algorithms correspondingly.
EGR control valve and actuator
Figure 2
EGR control valve and actuator
Red = Exhaust
Yellow = Coolant
1. Lever
2. EGR actuator
3. Valve
4. Control valve housing
5. Actuator connector
The engine uses an EGR control valve to regulate the amount of recirculated exhaust. It is a two channel butterfly type of valve,
operated by an electronically controlled actuator. The EGR control valve is located inside the valve housing. The valve housing is
cooled with coolant from the engine coolant system. The exhaust and the coolant are first led through the EGR cooler, then through
the valve housing, and back again to the cooler.
The design of the exhaust manifold couples the front cylinders in a single manifold that leads to one channel of the EGR control
valve, and the rear cylinders in another single manifold leading to the other channel. Then the two channels are kept separate all the
way through the cooler and past the non-return valves, where the two channels meet.
The actuator provides the following functions:
 Position control
 Feedback of position
 Internal diagnostic functions
The rotational movement of the actuator is transferred to the EGR control valve lever by way of a linkage.
EGR cooler
Figure 3
EGR cooler and non-return valves
Red = Exhaust
Yellow = Coolant
Green = Cut away view in image
A = Exhaust inlet
B = Exhaust passing through the EGR control valve housing
C = Exhaust outlet
1. Non-return valves
2. Non-return valve housing
3. EGR cooler
The EGR cooler design leads the exhaust through its shell to be precooled by air. Then it passes the control valve and back into the
centre of the EGR cooler where it is cooled by coolant. The coolant, taken from the engine cooling system, flows in the shell as well
on the inside of the cooler.
The EGR gas flows through the cooler in two separate channels, originating from the front or rear cylinders as described earlier in the
section on the EGR control valve.
The non-return valves are in form of reed valves, designed like a flap. The valves let the EGR gases pass one way and not the other,
facilitating effective use of the EGR driving pulses. There are eight reed valves located at the EGR cooler exhaust outlet.
Venturi tube
Figure 4
Venturi tube
Red = Exhaust
Green = Cut away view in image
1. EGR temperature sensor, SE2516

2. EGR differential pressure sensor, SE2515
3. Venturi tube
The venturi tube assembly consists of a venturi tube with varying inner diameter, a differential pressure sensor, SE2515, and a
temperature sensor, SE2516. There is one pressure outlet from the large diameter and one pressure outlet from the small diameter.
These two outlets lead to the differential pressure sensor. The ECM receives information about the measured pressure difference
and, by also monitoring the EGR temperature, the EGR mass flow rate can be calculated.
The ECM collects information from the sensors and controls the EGR valve and turbocharger nozzle to obtain optimal EGR flow.
To be able to control the EGR valve, the ECM needs feedback from many sensors on the engine, not only those in the EGR system.
For example, it needs information on the exhaust back pressure, engine coolant temperature, ambient temperature, engine speed
and from many sensors included in the aftertreatment system.
Summary
Some exhaust is recirculated by leading the gas via the EGR cooler. The cooled exhaust is mixed with inlet air and led to the inlet
manifold. This is done to reduce the NOx levels in the exhaust. The ECM collects information from the sensors and controls the EGR
valve and inlet throttle to create the correct EGR flow.
Parameters

 Exhaust gas recirculation (EGR), component location
Function check

 Tech Tool operation 29332-3 Exhaust gas circulation, function test
Diagnostics
PROSIS.
Filling lubricant
Figure 1
Filler connection
Lubricant must be topped up before the level falls below the minimum marking on the reservoir.
NOTE!
Let the level drop completely to the bottom every other time grease is filled so that old grease is not at the top of the reservoir.
on the pump unit there is a filler connection (grease nipple) to which a hand pump or an industrial pump is connected when filling.
NOTE!
If and industrial pump is used, the filter between connection and pump must be cleaned regularly. A partly blocked filter can easily
burst, with a consequent great risk of small particles entering the lubrication system. This may in turn lead to a breakdown in the
lubrication system.
for information on type of grease, see lubricant recommendations on page Automatic central lubrication.
Proceed as follows:
1. Remove the protective cap. Carefully clean the filler connection and the connection on the filler hose.
2. fill the filler hose completely full with grease before beginning to fill. this will prevent air from entering the system.
3. Connect the connection on the filler connection.
4. Fill with lubricant to the maximum level on the reservoir.*) If it is difficult to pump in the grease, either the filter behind the filler
connection is blocked or there may be dirt in the filler nipple itself. Clean the filter, if required replace the nipple and try again.
5. Reinstall the protective cap.
6. keep the grease pump in a dust-free place, so that it will not be exposed to dirt.
*) If the reservoir is filled above the maximum level, the surplus lubricant will be drained through the ventilation hole on the left side of
the reservoir. Any air under the plate in the reservoir is also drained through the ventilation hole.
Fire suppression system, component description
Figure 1
1. Parking brake SW5501

2. Parking brake MA5501
3. Control unit CU9902
4. Control panel CU9903
5. Siren SA9901 and Strobe light LA9901
6. Battery
7. Manual release (activation) button
8. Activation cartridge
9. Propellant gas cartridge
10. Extinguishing agent container
11. Sprinkler circuit
12. Detector circuit
13. Gas generator cable (squib cable) MA9903
14. Terminating resistor
Figure 2
1. Emergency stop SW3102

Emergency stop SW3102

Pressing in SW3102 cuts off the signal current to RE3101 Electrically controlled battery disconnector. The machine stops and the fire
suppression system goes to automatic mode.
Control panel CU9903
Figure 3
1. Plastic cover
2. Manual release (activation)
3. Fire alarm
4. Fault actuator
5. Fault detector
6. Manual
7. On
8. Test/Reset
1. The safety seal is broken if the plastic cover is raised
2. Hold in the button for 1 second to activate the sprinkler system when fire is indicated. The engine is not stopped. Can be
used when the machine has to be moved at the same time as the system is activated.
3. The light-emitting diode is red when fire is detected, and the siren and strobe light are activated at the same time. To activate
the sprinkler system with the manual activation button, see below.
4. The light-emitting diode is yellow when there is a malfunction of the activation function.
5. The light-emitting diode is yellow when there is a malfunction of the detector circuit.
6. The light-emitting diode is yellow when the system is in manual mode, that is, the parking brake is released.
7. The light-emitting diode is green when the machine is parked and when the system is in automatic mode. The system is
supplied with electric power. Even when the battery disconnector is off, the system is supplied with electric power.
Control unit CU9902

The control unit handles all functionality in the system. The system works in automatic mode even without the control panel being
connected.
Figure 4
1. Gas generator cable (squib cable)
Input signals:
 Detector circuit
 Signal from Parking brake (MA5501) ON/OFF
 Control panel CU9903
Output signals:
 Gas generator cable (squib cable) MA9903

 Siren SA9901 and Strobe light LA9901
 Control panel CU9903
When the control unit indicates fire via the detector circuit, the control unit waits for 0.5 second and then checks that the signal still
remains before the system indicates fire, or in automatic mode activates the system.
There is an internal control system in the control unit that restarts the central unit in case any problems should occur. This restart is
indicated by flashing light-emitting diodes on the control panel, as for the manual test procedure.
Detector circuit
The detector circuit consists of two insulated twisted cables with a terminating resistor. When the cable is exposed to heat, approx.
160–180 °C, the insulation melts and the two wires come into contact with each other. The central unit detects that the resistance in
the circuit has been reduced when the wires come into contact with each other, and that the terminating resistor no longer is part of
the circuit.
Gas generator MA9903
When the system is activated via the control unit (CU9902), an electric signal is sent to the gas generator. In the gas generator, a
powder charge is ignited and the gas acts on the pneumatic activation device which is installed on the propellant gas cartridge. The
striker pin in the activation device punctures the propellant gas cartridge 's diaphragm, and enables the gas to expand out to the
underside of the extinguishing agent container's piston.
When the gas generator is activated, both cables are contacted in the central unit.
Siren and strobe light SA9901/LA9901
Figure 5
Siren and strobe light
Siren/strobe light activated
 when fire is detected

 when the sprinkler system is activated using the control panel
 when the test button on the control panel is pressed in.
Siren/strobe light remain activated until the test button on the control panel is pressed in. If fire indication remains, the siren/strobe
light start again.
Gas generator MA9903
When the system is activated via the control unit (CU9902), an electric signal is sent to the gas generator. In the gas generator, a
powder charge is ignited and the gas acts on the pneumatic activation device which is installed on the propellant gas cartridge. The
striker pin in the activation device punctures the propellant gas cartridge 's diaphragm, and enables the gas to expand out to the
underside of the extinguishing agent container's piston.
Manual release (activation) button
Figure 6
2. Tampering seal
3. Manual release (activation) button
The manual release (activation) button can be used in all modes to activate the sprinkler system, even when the machine is not
operated and if the machine's electric power supply is turned off.
Propellant gas cartridge with pneumatic actuator
The pneumatic actuator is installed on the top of the propellant gas cartridge. The gas generator and the hose from the manual
actuator are both connected to the pneumatic actuator. When the system is activated, the gas pressure from one of the connections
acts on the striker pin, which punctures the propellant gas cartridge's diaphragm and the gas pressure spreads to the underside of
the extinguishing agent container's piston.
Extinguishing agent container
Figure 7

2. Propellant hose
The extinguishing agent container is a light metal container with internal piston. The propellant is led in the bottom of the container
via a hose connection to the propellant gas cartridge. In the top of the extinguishing agent container there is a burst disc that
prevents the extinguishing agent from leaking out in the sprinkler circuit before activation. The burst disc ruptures and opens the
sprinkler circuit at 20 bar pressure in the container.
In the extinguishing agent container's piston, there is a valve that opens when the piston has reached its upper position for the
purpose of emptying the sprinkler circuit of extinguishing agent.
Sprinkler circuit with nozzle
The nozzles on the sprinkler circuit are positioned 7 on the left side, 7 on the right side, and 1 under the cab.
Supplementary information:
See also:
Fire suppression system, functional description
Fire suppression system, specification
Fire suppression system, component location.
The Fire Suppression System is an automatic fire suppression system with freeze-protected extinguishing agent. In case of fire, the
fire suppression system dampens the fire.
The system includes the functions Electrically controlled battery disconnector (83528) and Engine Shutdown (83528).
The system can work in two modes: automatic mode (parking brake applied) and manual mode (parking brake released).
The system's detector circuit consists of two insulating electrically conductive cables that melt together and give a closed electric
circuit. Detection of fire takes place at a temperature of approx. 160 °C — 180 °C.
When the control unit detects fire, the control unit activates the gas generator MA9903 which punctures the diaphragm on the
propellant gas cartridge
The pressure from the propellant gas cartridge blows apart the outlet plate which is installed in the extinguishing agent container. The
piston in the extinguishing agent container is pushed upwards and releases the extinguishing agent out in the sprinkler circuit to the
sprinkler nozzles.
The fire suppression system can be activated manually by the operator using the manual activation button located under the steps,
or using the red button on the control panel in the cab. This can always be done, even if the engine is off and the battery
disconnector is off.
The electrically controlled battery disconnector RE3101, with SW3102 located in the cab, reduces the risk of electric short-circuiting
caused by fire. This means a higher safety level and reduced repair costs.
The emergency stop function turns off the machine in the same way as for key shut-off with SW3301.
Figure 1
1. Parking brake SW5501

2. Parking brake MA5501
5. Siren SA9901 and Strobe light LA9901
6. Battery
7. Manual activation button
13. Gas generator cable (squib cable) MA9903
Activation of fire suppression system

If the battery in the machine is discharged and without voltage, then the fire suppression system's voltage is safeguarded by a back-
up battery, which is indicated by flashing of the control panel's green light ”On”.
Figure 2
Control panel
1. Control panel, green light “On”
If the 9 volt battery's voltage in the control unit is too low, then this is indicated by all lights on the control panel flashing in a
wandering sequence. Then the 9 volt battery should be replaced immediately. Run a battery test by pressing the red indicator button
which is located at the top in the middle of the circuit board.
Figure 3
Control system
1. Battery type GP CR-9V Lithium 800 mAh

2. Indicator button
The red button at the top in the middle of the circuit board is used for a quicker check of the 9 volt battery's condition in the control
unit. Normally the control unit checks the 9 volt battery's condition automatically every 10-15 minutes. When the red indicator button
on the circuit board is activated, the check is run more often, every 10th second. If the battery's condition is normal, the green light is
activated on the control panel. In case of defective battery condition, all lights on the control panel are activated in a wandering
sequence.
Figure 4
1. Indicator button
Machine at work – parking brake not applied

If fire is detected, the operator is alerted by the control panel's red light Fire alarm, the strobe light flashes, and the siren sounds until
the system is reset or the battery is discharged. There is no automatic activation of the system.
The operator activates the system by pressing:
Button "Manual activation" on control panel CU9902 in cab:
1. The fire suppression system is activated.

2. Engine on
3. Parking brake released
5. It is possible for the operator to move the machine to a safer location.
Button, Emergency stop SW3102:
1. Engine stops.
2. The parking brake is applied.
3. Electric power supply is cut off.
Idle, parking brake applied:

If fire is detected, the fire suppression system is activated automatically. The control panel's red light Fire alarm is activated, the
strobe light flashes, and the siren sounds until the system is reset or the battery is discharged.
Fully automatic (the engine protection function stops the engine)

2. The engine is turned off after a few minutes (engine shutdown).
External activation
Regardless of if fire has been detected or not, the system can always be activated with the manual activation button.
The operator activates the system using the manual activation button under the steps.
1. The activation cartridge punctures the diaphragm in the propellant gas cartridge, which in turn activates the extinguishing
agent container.
2. The outlet plate in the container is blown apart by the pressure and opens the flow of extinguishing agent to the sprinkler
circuit with nozzles.
Machine parked, not operated, and battery disconnector off:

If fire is detected, the fire suppression system is activated automatically. The control panel's red light Fire alarm is activated, the
strobe light flashes, and the siren sounds until the system is reset or the battery is discharged.
Checking the system

When the system is working and is being used, the green operating light is lit on the control panel.
To check how the system has been activated, check the indicator light inside the control unit. In case of manual activation with the
button on the control panel, the red indicator light in the control unit is on with a fixed light.
In case of automatic activation of the system after detected fire, the red indicator light in the control unit flashes.
To reset the memory after manual or automatic activation, connect the tool to the control unit. Press the grey button.
Figure 5
Control unit
1.
The propellant gas cartridge triggers the extinguishing agent container, which is activated.
Supplementary information:
See also
Fire suppression system, component location
Wiring diagram WD915.
Foot brake valve, description
The foot brake valve is of the proportional type, which means that the output brake pressure is proportionate to the angle of the brake
pedal. The valve has two circuits, one for the front axle brakes and one for the rear axle brakes. The maximum output brake pressure
is limited. This reduced brake pressure can be adjusted on the underside of the valve by increasing or reducing the stroke of the
brake pedal.
Figure 1
1. Pressure check connection

2. Seal
3. Adjusting screw for max. output brake pressure
4. Piston
5. Adjusting screw for pedal free travel
6. Plug
Frame joint, description
Figure 1
Upper frame joint bearing
Figure 2
Lower frame joint bearing
Frame, description
The front frame is constructed as an open box section.
It carries the loader unit and is the mounting for the front axle.
The rear axle is composed of two frame members. Each frame member consists of one box section.
The rear frame carries the cab, engine and transmission.
The counterweight and the rear axle are attached to the rear frame.
The engine and transmission are rubber-mounted in the frame.
Important attaching surfaces between the frame and components are machined for exact positioning of components and strong
joints.
The frame joint is dimensioned to handle high stress loads.
The upper bearing arrangement consists of a spherical link bearing and the lower bearing arrangement consists of two tapered roller
bearings.
Figure 1
Frame parts
Figure 2
Frame joint bearings
Figure 3
Frame supporting points (principle diagram)
Front axle, component description
For information on the drive axles' functions, see: Drive axles, description.
Figure 1
1. Sensor axle oil temperature, SE5222 8. Filler point and level axle
2. Axle oil cooling, outlet 9. Breather nipple, axle
3. Differential lock, SE4609 10. Wear indicator, brake disc (2 pcs.)
4. Differential lock, operation 11. Bleed nipple, brakes (2 pcs.)
5. ID-plate 12. Brake pressure, connection (2 pcs.)
6. Axle oil cooling, inlet (2 pcs.) 13. Drain point, oil, hub reduction (2 pcs.)
7. Drain point, oil axle
Fuel system, component location
Figure 1
Fuel system
1. Pressure relief valve, PRV 11. Fuel feed pump

2. Rail pressure sensor, SE2309 12. Fuel feed pressure sensor, SE2301
3. Hand pump 13. High pressure pump
4. Prefilter 14. Fuel control valve, FCV
5. Fuel injector no. 1 MA2301 15. Main filter
6. Fuel injector no. 2 MA2302 16. Water trap
7. Fuel injector no. 3 MA2303 17. Water-in-fuel sensor, FX1005
8. Fuel injector no. 4 MA2304 18. Fuel tank
9. Fuel injector no. 5 MA2305 19. Fuel level sensor, SE2303
10. Fuel injector no. 6 MA2306
Fuel system, description
Introduction
Engine D6J has a fuel system known as the Common Rail system.
Fuel injection using Common Rail enables injection pressure and ignition timing to be varied across a wide range. This is possible
since the functions for pressure build-up and fuel injection have been separated from each other.
There are other systems that affect and are affected by the fuel system. For more information, see:
Function diagram
Figure 1
Fuel system
Light green = Suction and return lines, low or no pressure
Dark green = Feed pressure
Red = High pressure
1. Pressure relief valve (PRV) 11. Water-in-fuel sensor, SE2302 [T1]

2. Fuel rail 12. Hand pump
3. Fuel injector no. 1 MA2301 13. Fuel tank
4. Fuel injector no. 2 MA2302 14. Prefilter with water separator
5. Fuel injector no. 3 MA2303 15. Fuel feed pump
6. Fuel injector no. 4 MA2304 16. Main filter
7. Fuel injector no. 5 MA2305 17. Fuel feed pressure sensor, SE2301
8. Fuel injector no. 6 MA2306 18. High pressure pump 1
9. Rail pressure sensor, SE2309 19. Fuel control valve (FCV), PWM2303
10. Fuel level sensor, SE2303 20. High pressure pump 2
[T1]If equipped with electric heat fuel/water separator: FX1005 (SE2302, HE2301)
Low pressure circuit

The low pressure circuit consists of a fuel tank, a hand pump (located in the prefilter housing), a prefilter with water trap, a fuel feed
pump, a main fuel filter and a fuel control valve (FCV). The purpose of the low pressure system is to store and feed filtered fuel to the
high pressure pumps.
The fuel feed pump draws fuel from the tank through the prefilter with water trap and into the fuel feed pump inlet. Then the fuel is
forced from the pump through the main filter to the FCV which is located between the high pressure pumps. The FCV is a pulse width
modulated (PWM) controlled solenoid valve which controls the fuel volume to the high pressure pumps. The FCV makes sure that
the high pressure pumps are filled so that the pressure indicated for the fuel rail is maintained.
High pressure circuit
The high pressure circuit consists of two high pressure pumps driven by the engine camshaft, a Common Rail (fuel rail), high
pressure pipes, a high pressure sensor (for fuel in fuel rail) and six electronically controlled fuel injectors.
During machine operation, high pressure from the fuel rail is available to the fuel injectors. The high pressure pumps create the
desired injection pressure which is stored in the fuel rail.
The engine control module (ECM) controls the fuel injectors injection timing and volume. If the pressure in the fuel rail at any time
exceeds abnormally high levels (over pressure), the pressure relief valve (PRV) will open and limit the pressure in the rail to a safe
level. At that time, the engine continues to run, but with reduced performance. This is called Limp-Home mode.
Fuel feed pump
Figure 2
Fuel feed pump
The engine has a belt driven pump to feed fuel to the high pressure pumps. The fuel quantity is dependent on the engine speed. The
pump has a built-in overflow valve to maintain pressure in the fuel system. There is a bypass valve in the pump to facilitate bleeding
of the fuel system.
Fuel Control Valve (FCV)
Figure 3
Fuel Control Valve (FCV)
A. To high pressure pumps

B. Inlet from fuel filter
C. Return to tank
D. Return to suction side of feed pump
1. Fuel feed pressure sensor, SE2301

2. MProp, PWM2303
The purpose of the fuel control valve (FCV) is to provide correct fuel amount in relation to engine load and speed. The FCV includes
a magnetic proportional solenoid valve (MProp), an overflow valve, and a non-return valve. The overflow valve opens and reduces
the pressure out from the MProp to the correct pressure if the fuel feed pump supplies too high pressure. The excess fuel is drained
to the fuel tank.
When the MProp is closed there is always a slight leakage. The leakage is drawn back to the fuel feed pump via a suction drain so it
is not to raise the pressure in the return flow to the fuel tank. This overflow valve is equipped with a non-return valve so that the fuel
feed pump does not bypass the MProp.
When bleeding the fuel system, the MProp is closed and, since the pressure is not high enough to open the overflow valve, a
narrowed bleeding drain by-passes the overflow valve and returns the air/fuel mixture to the fuel tank.
High pressure pumps
Figure 4
High pressure pumps
1. Fuel Control Valve (FCV)

2. Fuel to high pressure pump
3. Fuel to fuel rail
4. Roller tappet
5. Camshaft cam
The fuel system has two high pressure pumps that are driven by the camshaft via roller tappets. The high pressure pumps pressurize
the fuel rail. The high pressure pumps low pressure side and high pressure sides are hydraulically separate. Three camshaft cams
give six pump strokes per camshaft revolution (three strokes per pump).
Fuel rail
Figure 5
Fuel rail
1. Fuel rail
2. Pressure relief valve (PRV)
3. Rail pressure sensor, SE2309
The fuel rail acts as a high pressure accumulator. The stored volume is designed to work as a damper for any pressure variations.
Pressure variations can occur due to the pulsating feed of the fuel pump to the high pressure pump or temporary high fuel use during
injection through the injectors. The fuel rail is dimensioned to supply full fuel volume without any noticeable pressure-drop. The fuel
rail is equipped with a pressure sensor and a pressure relief valve (PRV).
The PRV is a mechanical safety device and protects the system against excessive pressure caused by any problems or
malfunctions. If the PRV is open, the rail pressure is reduced to a safe level (depending on engine speed and load). The engine
continues to run, but with reduced performance (Limp-Home). During normal operating conditions, the PRV does not open.
The high pressure pipes from the rail are designed so that all of them have the same length to avoid pulsations in the system.
If a malfunction is detected, the engine control module (ECM) can force the PRV to open by increasing the rail pressure. The rail
pressure sensor measures the pressure in the rail and delivers data to the ECM, which compares the actual pressure with a
reference value, which is dependent on engine speed and injection volume. The PRV limits the system pressure to prevent damage
to the system.
Fuel injectors
Figure 6
Fuel injector
1. Fuel injector holder

2. Fuel injector
3. Fuel pipe with filter
Injection timing and the fuel amount to be injected are determined by the ECM, which sends signals to the electro-magnetically
controlled fuel valve in the injector valve housing. The duration of the injection time determines the amount of fuel that is injected into
the cylinder. The 'Common Rail' system enables more than one injection during the piston working phase, thus giving flexible control
of the combustion process. The injection pressure is determined by the pressure in the rail and varies all the time.
In order to support the exhaust aftertreatment system (EATS), the injectors also perform a late post-injection. This injection takes
place after the main injection to increase the fuel content of the exhaust. The extra fuel in the exhaust reacts with the coating in the
diesel oxidation catalyst (DOC), thus increasing the temperature of the exhaust to enable running of an EATS regeneration. For more
information, see: Exhaust Aftertreatment System, description.
Summary
Fuel is fed to the high pressure pumps by the fuel feed pump. High pressure fuel is led into the fuel rail. From the fuel rail, the six fuel
injectors are connected via high pressure fuel pipes. The fuel injectors are controlled by the ECM to deliver the correct amount of fuel
for each injection phase.
Parameters
 P1JOC (Number of PRV activations)

 P1JOD (Total PRV activation time)
 (P1G3O) Trimcode CRIN 3.3 injector cylinder 1
 (P1G3P) Trimcode CRIN 3.3 injector cylinder 2
 (P1G3Q) Trimcode CRIN 3.3 injector cylinder 3
 (P1G3R) Trimcode CRIN 3.3 injector cylinder 4
 (P1G3S) Trimcode CRIN 3.3 injector cylinder 5
 (P1G3T) Trimcode CRIN 3.3 injector cylinder 6

 Fuel system, component location
 Fuel system, specifications
Function check
 Tech Tool operation, 23016-3 Cylinder balancing, test

 Tech Tool operation, 23712-3 - Injectors shut off, manual
 Tech Tool operation, 23777-3 - Fuel system, check
 Tech Tool operation, 23713-3 - Injection system, check
 Feed pump, checking feed pressure
Diagnostics
PROSIS.
GPMECU1, I/O list
output is not used.

A1 HE8501 Seat heating Wiring diagram WD802
A2 FX1029/SW3608 Windshield wiper Wiring diagram WD801

MO3601 Windshield washer front
A3 CU9901 Central lubrication unit Wiring diagram WD913
A4 — — —
A5 RE15 Windshield wiper front Wiring diagram WD801
A6 FX1029/SW3602 Windshield washer Wiring diagram WD801
A7 RE09 Windshield wiper rear Wiring diagram WD801
A8 FX1029/SW3602 Windshield washer Wiring diagram WD801
A9 CU6601 Control unit monitoring CDC Wiring diagram WD602
A10 — — —
A11 — — —
A12 SW3612 Windshield wiper and washer rear Wiring diagram WD801
A13 MA2601 Cooling fan, braking Wiring diagram WD201
A14 — — —
A15 CANH Backbone2 (BB2) Wiring diagram WD321
A16 CANL Backbone2 (BB2) Wiring diagram WD321
A17 SW3612 Windshield wiper and washer rear Wiring diagram WD801
MO3603 Windshield washer rear
A18 — — —
A21 — — —
A22 — — —
A23 — — —
A24 MA2602 Cooling fan, rotational direction (reversible fan) Wiring diagram WD201
A25 SW9148 Boom Suspension System, activation/ function Wiring diagram WD903
selection
A26 SW9148 Boom Suspension System, activation/ function Wiring diagram WD903
selection
A27 SE6404 Differential secondary steering pressure Wiring diagram WD604
A28 RE6401 Secondary steering Wiring diagram WD604
A29 — — —
A30 — — —
A31 — — —
A32 — — —
A33 PWM2602 Control, pump P3 Wiring diagram WD201
A34 PWM2602 Control, pump P3 Wiring diagram WD201
A35 PWM9133 Output control, hydraulic pump Wiring diagram WD908

A36 PWM9133 Output control, hydraulic pump Wiring diagram WD908
A37 MA5503 Brake pressure charging Wiring diagram WD501
A38 MA5503 Brake pressure charging Wiring diagram WD501
A39 CU9901 Central lubrication unit Wiring diagram WD913

A40 MA9106 Attachment lock, close Wiring diagram WD904
A41 — — —
A42 SE8502 Position monitor loading operator's seat Wiring diagram WD802
A43 — — —
A44 RE08 Boom Suspension System, engagement Wiring diagram WD903
A45 FU51 Voltage feed Wiring diagram WD305
A46 SW3528 Guide lights Wiring diagram WD335
A47 — — —
A48 GPMECU1 Instrument and switch light Wiring diagram WD335
A49 — — —
A50 — — —
A51 — — —
A52 — — —
A53 SE2604 Cooling fan speed Wiring diagram WD201
A54 — — —
A55 — — —
A56 — — —
A57 GPMECU1 Ground Wiring diagram WD302
A58 SE2604 Cooling fan speed Wiring diagram WD201
A59 — — —
A60 — — —
A61 — — —
RE13
B1 — — —
B2 — — —
B3 — — —
B4 FU25 Voltage feed Wiring diagram WD302
RE13
B5 — — —
B6 — — —
B7 — — —
B8 SE9119 LS-pressure Wiring diagram WD904
B9 — — —
B10 — — —
B11 — — —
B12 — — —
B13 — — —
B14 — — —
B15 — — —
B16 — — —
B17 — — —
B18 SW9143 Attachment lock Wiring diagram WD904
MA9127 Attachment lock, open
B19 — — —
B20 — — —
B21 CU6601 Control unit monitoring CDC Wiring diagram WD602
B25 — — —
B26 — — —
B27 — — —
B28 — — —
B29 — — —
B30 — — —
B31 — — —
B32 SE5201 Available brake pressure Wiring diagram WD501
B33 — — —
B34 — — —
B35 — — —
B36 — — —
B37 — — —
B38 — — —
B39 SE6407 Secondary steering pressure Wiring diagram WD604
B40 — — —
B41 — — —
B42 — — —
B43 — — —
B44 — — —
B45 — — —
B46 — — —
B47 — — —
B48 — — —
B49 — — —
B50 — — —
B51 — — —
B52 — — —
B53 — — —
B54 — — —
B55 SE6407 Secondary steering pressure Wiring diagram WD350
B56 SE5501 Pressure sensor parking brake Wiring diagram WD350
SE5203 Output brake pressure Wiring diagram WD501
B57 GPMECU1 Ground Wiring diagram WD302
B58 SE5201 Available brake pressure Wiring diagram WD352
SE6407 Secondary steering pressure Wiring diagram WD501
SE9119 LS-pressure Wiring diagram WD604
B60 — — —
B61 — — —
RE13
GPMECU2, I/O list
output is not used.

A1 SE4227 Arm rest lever steering (CDC) Wiring diagram WD601
A2 SW4216 Activation of lever steering (CDC) Wiring diagram WD601
A3 — — —
A4 — — —
A5 — — —
A6 — — —
A7 — — —
A8 — — —
A9 — — —
A10 — — —
A11 — — —
A12 — — —
A13 — — —
A14 — — —
A17 — — —
A18 — — —
A19 — — —
A20 — — —
A22 — — —
A23 — — —
A24 — — —
A25 — — —
A26 — — —
A27 — — —
A28 — — —
A29 — — —
A30 — — —
A31 — — —
A32 — — —
A33 — — —
A34 — — —
PWM6602 Lever steering (CDC), right
A37 — — —
A38 — — —
A39 — — —
A40 — — —
A41 — — —
A42 — — —
A43 — — —
A44 — — —
A45 — — —
A46 — — —
A47 — — —
A48 — — —
A49 — — —
A50 — — —
A51 — — —
A52 — — —
A53 — — —
A54 — — —
PWM6601 Lever steering (CDC), left
A58 — — —
A59 — — —
A60 — — —
A61 — — —
RE13
B1 — — —
B2 — — —
B3 — — —
B4 FU51 Ignition-dependent voltage feed to ECU:s and Wiring diagram WD305
B5 SE6601 Control lever (CDC) Wiring diagram WD601
B6 — — —
B7 — — —
B8 — — —
B9 — — —
B10 — — —
B11 — — —
B12 — — —
B13 — — —
B14 — — —
B15 — — —
B16 — — —
B17 — — —
B18 — — —
B19 — — —
B20 — — —
B21 — — —
B22 — — —
B23 — — —
B24 — — —
B25 — — —
B26 — — —
B27 — — —
B28 — — —
B29 — — —
B30 — — —
B31 — — —
B32 — — —
B33 — — —
B34 — — —
B35 — — —
B36 — — —
B37 — — —
B38 — — —
B39 — — —
B41 — — —
B42 — — —
B43 SE6411 Angle sensor frame joint Wiring diagram WD602
B44 — —
B45 — — —
B46 — — —
B47 — — —
B48 SE6411 Angle sensor frame joint Wiring diagram WD602
B49 — — —
B50 — — —
B51 — — —
B52 — — —
B53 — — —
B54 — — —
B55 GPMECU2 5 V power feed Wiring diagram WD350
CU6601 Control unit monitoring CDC
SE6411 Angle sensor frame joint
B61 — — —
RE13
GPMECU3, I/O list
output is not used.

A1 SE4609 Feedback of engaged differential lock Wiring diagram WD404
A2 SW4211 Fully automatic gearshifting (FAPS) Wiring diagram WD405
A3 SW4602 Differential lock Wiring diagram WD404
A4 RE5502 Parking brake Wiring diagram WD501
SW5501
A5 RE02 Working lights, rear Wiring diagram WD324
RM8401 Back-up monitor Wiring diagram WD804
A6 SW4219 Lock-up Wiring diagram WD406
A7 — — —
A8 — — —
A9 — — —
A10 — — —
A11 — — —
A12 SW5501 Parking brake Wiring diagram WD501
A13 — — —
A14 — — —
A17 SW5501 Parking brake Wiring diagram WD501

A18 — — —
A21 RE13 Voltage feed Wiring diagram WD302
FU24
A22 — — —
A23 — — —
A24 — — —
A25 SW4207 Activation Forward/Reverse lever carrier Wiring diagram WD402
A26 SW4208 Forward/reverse lever carrier Wiring diagram WD402
A27 SW4208 Forward/reverse lever carrier Wiring diagram WD402
SW4221 Single lever control, forward−neutral−reverse
A28 — — —
A29 SW4221 Single lever control, forward−neutral−reverse Wiring diagram WD402
A30 RE10 Brake lights Wiring diagram WD501
A31 — — —
A32 — — —
A33 — — —
A34 — — —
A35 — — —
A36 — — —
A37 — — —
A38 — — —
A39 — — —
A40 — — —
A41 SE4213 Turbine rpm Wiring diagram WD405
A42 — — —
A43 — — —
A44 — — —
A45 MA5501 Parking brake Wiring diagram WD501
SW5501 Parking brake
CU9902 Control unit, fire supression system
A46 — — —
A47 — — —
A48 — — —
A49 SW4222 Single lever control, kick-down Wiring diagram WD402
A50 SE4307 Output speed transmission Wiring diagram WD405
A51 — — —
A52 — — —
A53 SE2704 Engine rpm, transmission Wiring diagram WD201
A54 — — —
A55 — — —
A56 — — —
A58 SE2704 Ground. Engine and transmission sensors Wiring diagram WD351
SE4213
SE4307
A59 — — —
A60 — — —
A61 — — —
A62 RE13 Voltage feed Wiring diagram WD302
FU24
B1 — — —
B2 – – –
B3 – – –
B4 FU51 Ignition-dependent voltage feed to ECU:s and Wiring diagram WD305
B5 SE5223 Axle oil temperature, rear axle Wiring diagram WD405
B6 SE5222 Axle oil temperature, front axle Wiring diagram WD405
B7 — — —
B8 SW4206 Gear lever steering column Wiring diagram WD401
B9 SW4217 Forward/Reverse, Comfort Drive Control (CDC) Wiring diagram WD601
B10 — — —
B11 — — —
B12 — — —
B13 SW4217 Forward/Reverse, Comfort Drive Control (CDC) Wiring diagram WD601
B14 SW4210 Engine brake lever carrier Wiring diagram WD402
B15 — — —
B16 SW4602 Differential lock Wiring diagram WD404
MA4603 Differential lock Wiring diagram WD404
B17 — — —
B18 SW4220 Kick-down CDC Wiring diagram WD601
B19 SE4202 Transmission oil temperature Wiring diagram WD404
B20 — — —
B21 SE5203 Output brake pressure Wiring diagram WD501
B22 — — —
B23 SE4219 Transmission oil pressure Wiring diagram WD404
B24 SE5501 Pressure sensor parking brake Wiring diagram WD501
B25 PWM4213 Forward gear Wiring diagram WD403
B26 PWM4213 Forward gear Wiring diagram WD403
B27 — — —
B28 SW4205 Directional gear Forward/Reverse, steering Wiring diagram WD401
column
B29 PWM4214 Reverse gear Wiring diagram WD403
B30 PWM4214 Reverse gear Wiring diagram WD403
B31 — — —
column
B33 PWM4215 1st gear Wiring diagram WD403
B34 PWM4215 1st gear Wiring diagram WD403
B37 PWM4216 2nd gear Wiring diagram WD403
B38 PWM4216 2nd gear Wiring diagram WD403

column
B40 — — —
B41 PWM4217 3rd gear Wiring diagram WD403
B42 PWM4217 3rd gear Wiring diagram WD403
B43 — — —
B44 — — —
B45 PWM4218 4th gear Wiring diagram WD403
B46 PWM4218 4th gear Wiring diagram WD403
B47 — — —
B48 — — —
B49 — — —
B50 — — —
B51 — — —
B52 — — —
B53 — — —
B54 — — —
B55 — — —
SE5501 Pressure sensor parking brake
B58 SE5501 Ground. Brake and transmission sensors Wiring diagram WD351
SE5222 Axle oil temperature, front axle Wiring diagram WD405
SE5223 Axle oil temperature, rear axle Wiring diagram WD501
SE4219 Transmission oil pressure Wiring diagram WD405
SE4202 Transmission oil temperature Wiring diagram WD404
B60 SE4219 Transmission oil pressure Wiring diagram WD350
B61 — — —
B62 RE13 Voltage feed Wiring diagram WD302
FU24
HMICU, I/O list
output is not used.

1 RE3504 Interior lights Wiring diagram WD333
FX1001 Interior lighting, cab (front) Wiring diagram WD805
EEC Control unit
2 SW3525 Step lighting Wiring diagram WD337
3 RE3705 Electrically controlled battery disconnect switch Wiring diagram WD301
4 SW3701 Battery disconnect switch Wiring diagram WD304
5 FU24 Voltage feed HMICU Wiring diagram WD302
RE13
GPMECU3 Vehicle control unit
6 RE12 30-feed controlled by HMICU, hold voltage RE13 Wiring diagram WD302
FU51 Voltage feed, HMICU. Wiring diagram WD305
7 — — —
8 SW3801 Keypad Wiring diagram WD322
9 SW3504 Work lights front Wiring diagram WD331
RE07
10 — — —
11 — — —
12 — — —
13 SW3301 Ignition switch Wiring diagram WD304
MO3301 Starter motor Wiring diagram WD306
14 — — —
15 CANH Backbone2 (BB2) Wiring diagram WD321
16 CANL Backbone2 (BB2) Wiring diagram WD321
17 SW2506 Regeneration Wiring diagram WD201
21 SW2506 Regeneration Wiring diagram WD201
23 VP Tech Tool test connector Wiring diagram WD322
24 — — —
25 SW3502 High and low beam, headlight flasher Wiring diagram WD330
FX1072
FX1073
26 — — —
27 IC Instrument Cluster Wiring diagram WD322
29 — — —
30 SE2702 Throttle pedal position Wiring diagram WD202
33 SE3601 Washer fluid level Wiring diagram WD801
35 — — —
36 — — —
37 AL3201 Alternator Wiring diagram WD306
38 R2701 Hand throttle Wiring diagram WD202
40 — — —
41 SE9104 Level, hydraulic oil tank (FX1009) Wiring diagram WD903
42 SE9105 Temperature, hydraulic oil tank (FX1009) Wiring diagram WD903
43 RE3524 Time relay, step lighting Wiring diagram WD337
44 — — —
45 SW3301 Ignition switch Wiring diagram WD304
FU20 Voltage feed ignition
46 SE8705 Ambient air temperature sensor Wiring diagram WD802
R2701 Hand throttle
49 — — —
50 SE2303 Fuel level Wiring diagram WD201
52 FX1009 Hydraulic oil tank Wiring diagram WD350
53 — — —
54 — — —
57 HMICU Ground Wiring diagram WD302
R2701 Hand throttle
59 FX1009 Hydraulic oil tank Wiring diagram WD201
SE2303 Fuel level Wiring diagram WD352
SE8705 Ambient air temperature sensor Wiring diagram WD802
60 FU51 Voltage feed, HMICU. Wiring diagram WD305
61 SW3607 Rotating beacon Wiring diagram WD324
LA3601
62 FU02 Voltage feed, HMICU, IC Wiring diagram WD302
Hood opening
The engine hood is opened with an electric motor located on the left side of the hood.
The hood motor MO3611 is operated with switch SW3620 located by the steps to the cab beside the battery disconnector.
Voltage feed is via fuse FU75 located inside of switch SW3620.
There are no failure diagnostics for the hood motor.
Figure 1
Hood opening
Secondary opening
Secondary opening of the engine hood takes place by turning with an Allen key size 6 mm on the hood motor's shaft. First remove
the protective plate and the plug (6 mm Allen) that covers the hood motor's shaft. Then turn with a ratchet handle or drill until the
hood is open.
Figure 2
1. Remove cover to access hood motor.

Figure 3
2. Hood motor shaft.

Hydraulic attachment locking, description
The hydraulic attachment bracket is optional equipment, where attachments are locked into place using a hydraulic cylinder
(attachment lock).
The attachment lock is opened and closed with switch SW9143 located in the cab. Feedback on current attachment lock status, as
well as any malfunctions in the electrical circuit, is shown on the operator’s display.
Other systems that can affect the attachment lock functionality are:

General function
MA9106 and MA9127 handle closing and opening, respectively, of the attachment lock with pressurized hydraulic oil from the brake
circuit, see figure Directional valve for attachment lock and differential lock.
For more detailed information, see Hydraulic diagram, complete and Wiring diagram WD904.
Figure 1
Directional valve for attachment lock and differential lock.
1. MA9106, Attachment lock, closing solenoid

2. MA9127, Attachment lock, opening solenoid
3. Differential lock solenoid
In neutral position (unaffected) the attachment lock valve maintains a limited hydraulic pressure to the lock cylinder, lock position, due
to a restricted channel in its control spool, see figure Overview for hydraulic attachment lock. In addition, only solenoid MA9106 for
closing the attachment lock is controlled by GPMECU1. MA9127 is controlled directly with switch SW9143.
Figure 2
Overview for hydraulic attachment lock
1. Solenoid valves for differential lock and attachment lock

2. Hydraulic cylinder, attachment lock
3. Accumulator valve, brake
4. Central valve (with MA5503)
When the engine is started and the switch SW9143 for the attachment bracket is in position "close", the machine’s electronic control
requests increased hydraulic pressure for a short time and energizes MA9106 for 120 seconds. If the position of SW9143 changes
from "close" to "open" within 120 seconds, the locking sequence will be cancelled and the attachment lock will open since MA9127 is
energized.
Electronic control
Tech Tool parameter P1JKS must be enabled to allow hydraulic attachment lock functionality.
A conceptual function diagram of how the machine’s electrical system interacts and exchanges information with other parts of the
machine is seen in the figure below.
Figure 3
Conceptual signal diagram for attachment lock functionality.
1 Operator request:
– Open or close attachment lock
2 Operator feedback:
– Attachment lock opened or locked
– Alarms (error)
3 Operator confirmation:
– Check attachment lock
4 Machine's electronic system
5 Attachment lock:
– Open
6 Attachment lock:
– Close
7 Engine:
– Engine running
– Charge-air temperature
Opening the attachment lock

When the catch on switch SW9143 is released and pressed, MA9127 is supplied with voltage and a signal is sent to the HMICU. The
HMICU sends a signal to GPMECU1 for brake pressure charging, thus providing increased hydraulic pressure for ten seconds.
If the charge-air temperature is higher than 90°C (194°F), no brake pressure charging takes place until the temperature has dropped
to below 90°C (194°F), see figure below. For any incorrect signal from the charge-air temperature sensor SE2512, see Inlet and
exhaust system, description, the attachment functionality sets the temperature signal to below 90°C (194°F).
Figure 4
Signal diagram for opening the attachment lock.
1 Display:
Symbol – Red central warning
2 Display:
Message – Attachment lock open
SW9143 In position open
MA9127 Opening solenoid
MA5503 Brake pressure, charging for 10 seconds
FX1007 Charge-air temperature, 90°C (197°F)
PWM2602 Pump P3, pressure control
The directional valve’s spool is moved and opens the connection between port P2 and port B2 so that hydraulic oil is led out to the
cylinder's rod end, (-) side. The oil from the cylinder's piston end, (+) side, is drained via port A2 and port T to the hydraulic oil tank,
see Figure 2. When the voltage to MA9127 is cut off, the valve spool returns its to neutral position and no hydraulic oil can pass
through the valve.
When the attachment lock is opened, a red warning is shown on the operator’s display with message "Attachment lock open".
Closing the attachment lock
When switch SW9143 is moved to position "close", a signal is sent to GPMECU1 via the HMICU. Subsequently, GPMECU1
energizes closing solenoid MA9106. When MA9106 is energized, GPMECU1 requests brake pressure charging, providing an
increased hydraulic pressure for ten seconds. If the charge-air temperature is higher than 90°C (194°F), no brake pressure charging
takes place until the temperature has dropped to below 90°C (194°F), see figure below.
Figure 5
Signal diagram for closing the attachment lock.
1 Display:
Symbol – Yellow central warning
2 Display:
Message – Check attachment lock and confirm
SW9143 In position close
MA9106 Closing solenoid (energized for 30 seconds)
MA5503 Brake pressure, charging for 10 seconds
FX1007 Charge-air temperature, 90°C (197°F)
PWM2602 Pump P3, pressure control
The directional valve's spool is moved and pressurized hydraulic oil is led to the cylinder's piston end, (+) sides, and oil is drained to
tank on the cylinder’s piston rod-end, (-) side.
When a request for closing the attachment lock reaches the HMICU, a yellow warning is shown with message "Check attachment
lock and confirm". When locking has been confirmed it shall be acknowledged with the ESC-key on the keypad.
When the voltage to MA9106 is cut off, the valve spool returns to its neutral position and no hydraulic oil can pass through the valve.
For more information, see Cooling fan, description, Braking system, description and Safety when working on hydraulic systems.
Parameters
Relevant parameters for attachment lock functionality.

P1JKS Attachment Bracket Installed

Function check
 Tech Tool op. 92402–3 Attachment lock, test
Diagnostics
Component
MA9106 See MA9106, description and measuring
MA9127 See MA9127, description and measuring
Hydraulic components, cleanliness when handling
WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries
NOTICE
It is very important to keep the hydraulic system free from any impurities, as these can cause abnormal wear and may lead
to expensive downtime. Greatest possible cleanliness should be maintained during all handling of hydraulic components
and hydraulic oil.
NOTE!
A vacuum pump should be used for work on the hydraulic system in order to avoid oil spills.
Hydraulic oil tank, description
Figure 1
Hydraulic tank
1. Filter housing
2. Filter insert
3. Level glass
4. SE9101, sensor, hydraulic oil level
SE9102, sensor, hydraulic oil temperature
The hydraulic oil tank is common to the whole hydraulic system. The tank is provided with a return oil filter with magnetic rod. Air is
vented through a breather filter. In the hydraulic oil tank there is a sensor (FX1009) that monitors the hydraulic oil level and the
hydraulic oil temperature.
Hydraulic pump flow regulation, description
The machine's hydraulic oil pumps have variable displacement and are controlled electrically.
Flow control of hydraulic pump P2
The flow control of pump P2 is electrically controlled with PWM9133, where the purpose is to limit the hydraulic oil flow to avoid
sudden engine stops.
P2, standby pressure

The pump begins to rotate and deliver a flow immediately when the engine is started. The pump's displacement is maximal at start
due to the spring force acting on the yoke. As the oil flow increases, the oil pressure builds up and affects the flow compensator’s
spool, which then counteracts the spring force.
As the yoke’s spring force is overcome, the flow compensator’s spool changes its position so that a connection opens to the pump's
displacement piston. The displacement piston moves to the right and acts on the pump's yoke, which reduces the oil flow but obtains
and maintains the system’s standby pressure, see figure below.
Figure 1
P2, standby pressure

Green Without pressure (tank)
1 Flow compensator
2 Pressure compensator
3 Displacement piston
P2, working pressure

When any hydraulic function is used, the LS-pressure acts proportionally on the spring side of the flow compensator and tries to
counteract the oil pressure from the pump on the opposite side. Before correct pressure has been reached, the displacement piston
that affects the yoke is drained and the pump displacement increases since pump P2 supplies a higher oil flow. When correct LS-
pressure is obtained, pump pressure will affect the right side of the displacement piston. Subsequently the pump displacement and
the oil flow decrease at the same time as the pressure is maintained.
Figure 2
P2, working pressure

Pink LS–pressure
1 Flow compensator
P2, maximum pressure

When a hydraulic function reaches its end-position, system pressure will increase and counteract the pressure compensator spool’s
spring. As the spring force is counteracted, its spool moves to the right where a channel opens, which allows pump pressure to act
on the displacement piston, limiting the pump’s maximum pressure. The oil displacement of pump P2 decreases while maintaining
maximum system pressure as long as the lever is held in the same position.
Figure 3
P2, maximum pressure.
Green Without pressure (tank)

Pink LS–pressure
1 Flow compensator
P2, power-controlled flow limitation

GPMECU1 supplies current to PWM9133 when the engine speed is low and the engine load is high in order to reduce the hydraulic
pressure provided by pump P2. When energized the PWM-controlled spool moves to the left, ensuring that the displacement piston
lowers the pump’s displacement and subsequently removes the hydraulic load from the engine.
Figure 4
P2 controlled by energized PWM9133

Green Pressureless
Pink LS–pressure
1 Flow compensator
The flow limitation function’s correlation with the machine signals is shown in the signal diagram in the figure below.
Figure 5
Signal diagram for flow limitation control of P2 (PWM9133)
1 Current gear
2 Engine running
3 Barometric pressure
HMICU Human Machine Interface Control Unit
ECM Engine Control Module
SE9119 Pressure, load-sensing
SE2702 Accelerator pedal
SE2701 Engine speed (rpm)
FX1007 Charge-air temperature
PWM9133 Electrically controlled hydraulic pump P2
If any input error is detected for the electric flow control of pump P2, then the flow limitation function is disabled.
P2, flow limitation – On
The flow limitation is activated as the LS-pressure is higher than 10 MPa (100 bar, 1,450 psi) and the engine speed is lower than
1,300 rpm. When the limitation has been enabled it will remain activated for as long as the LS-pressure is higher than 4 MPa (40 bar,
580 psi), see figure below.
Depending on the input values, see figure above, the flow limitation can vary as long as the conditions noted below are fulfilled, see
figure below.
Figure 6
Conditions for initializing and maintaining flow limitation.

2 LS-pressure > 10 MPa (100 bar, 1,450 psi)
3 Engine speed < 1,300 rpm
4 Flow limitation, START
5 LS-pressure > 4 MPa (40 bar, 570 psi)
6 Engine speed < 1,300 rpm
7 Flow limitation, ON
P2, flow limitation – Off

Pump flow limitation will be deactivated when the LS-pressure drops below 4 MPa (40 bar, 570 psi) or when the engine speed is
higher than 1,300 rpm, see figure below.
Figure 7
Conditions for deactivating flow limitation

2 LS-pressure < 4 MPa (40 bar, 570 psi) or engine speed > 1,300 rpm
3 Flow limitation, OFF
Flow control of hydraulic pump P3

Pump displacement for pump P3 is controlled electrically with PWM2602, via GPMECU1, together with its compensator spool, see
figure below.
Figure 8
Hydraulic diagram for P3 flow control.
1 PWM2602 and max. pressure limiting valve

3 Compensator spool
Under normal conditions the output current is controlled by GPMECU1, where minimum pump displacement is obtained at a 500 mA
current to PWM2602. Any higher current level will not decrease pump displacement any more and vice versa, subsequently no
current output from GPMECU1 will set maximum pump displacement.
The purpose of maximum displacement, where no current is supplied to PWM2602, is to make sure that sufficient oil flow is delivered
to the brakes and to the fan function in case of electrical failure, see Braking system, description and Cooling fan, description.
The regulation control for pump P3 is described in the following four steps according to the hydraulic diagram in the figure above,
with a hydraulic motor connected.
P3, maximum displacement
The PWM-valve has no or low current and is completely closed to tank. This means that the compensator's spool is acted on by the
same pressure on both end surfaces and moves to the right due to the spring force. Subsequently, the left side of the displacement
piston drains, which means that the angle of the pump's yoke increases.
P3, controlled state
To control the pump's oil flow, the PWM-valve is supplied with current to drain some of the flow to tank. Due to the restriction R2 and
the PWM-valve draining to tank, the pressure is reduced on the compensator spool's spring side and the spool moves to the left. The
displacement piston is affected on its left side by oil entering via the compensator's spool and on the right side by the pressure from
the pump circuit. The angle of the pump's yoke is balanced so that the intended flow is reached by increasing and decreasing the
current to PWM2602. The PWM-valve needs a minimum specified standby pressure to be able to affect the compensator spool.
Note that if the standby pressure is set too low, there may be problems with starting this regulation control function.
P3, minimum displacement
To obtain minimum displacement, PWM2602 is supplied with max current from GPMECU1.
All oil that passes via R2 is drained to tank and the compensator's spool moves to the left. The displacement piston's left end surface
is affected by the same pressure as there is in the pump circuit and on the displacement piston's right end surface. Since the spool’s
left cross-sectional area is larger than its right side, it will move to the right, and thus the pump’s displacement decreases.
The purpose of restriction R1 is to decrease pressure that is too high so that the compensator's spool maintains continuous control of
the pump’s displacement piston.
P3, maximum pressure
PWM-valve PWM2602 has a built-in pressure limiting function.
Maximum pump pressure is controlled via the PWM-valve's spring force and the compensator spool’s set spring tension. The pump
circuit's pressure acts on the spring via the pilot line and, when maximum pressure has been obtained, the PWM-valve drains to tank.
The compensator spool moves to the left, which means that the displacement piston is affected and angles down the pump's yoke,
thus maintaining maximum pressure in the circuit.
Parameters
Relevant parameters for hydraulic pump flow control's function

- -
 Hydraulic pump (P2), specifications

 Hydraulic pump (P3), specifications
Function check
 -
Diagnostics
Hydraulic pumps, description
Pump 2
Figure 1
Pump 2
1. Flow compensator
2. Max. pressure regulator
Figure 2
Pump P2 control
1. Flow regulator
2. Max. pressure regulator
3. Displacement piston
Pump 2 is an axial piston pump with variable displacement. Pump 2 supplies oil to the steering system, working hydraulics, and the
servo system. Secondarily P2 also supplies oil to the brake system.
Pump 3
Figure 3
Compensator housing
1. Flow compensator slide

2. Restriction
3. Adjustment, standby pressure
4. Adjustment, max. pressure
5. PWM-slide
Figure 4
Pump 3 control
1. Flow regulator
2. PWM-valve
Pump 3 is an axial piston pump with variable displacement and PWM-controlled pressure control. Pump 3 supplies oil to the fan and
brake charging.
Hydraulic transmission calibration, description
The main purpose of transmission calibration is to secure good gearshifting comfort and to eliminate unwanted slipping of the
clutches, which could damage the clutch discs. The calibration adapts the ECU to the hardware in the transmission. Therefore it is
necessary to perform a calibration in the following cases:
 Replaced transmission
 Replaced components in or on the transmission that control the clutches
 Dismantling and reassembling of clutches, even without replacement of any parts
 Replacement of GPMECU3
 Replacement or repair of transmission cable harness
A calibration should always be performed in case of unsatisfactory gearshifting quality. All transmission-related error codes must be
solved before calibration.
Components
Electrical components that are involved in calibration of the transmission.
Figure 1
Components
ID Function ID Function
ECM Engine control module GPMECU3 General Purpose Machine
Electronic Control Unit 3
SE2701 Engine speed (crankshaft) PWM4213 Clutch F solenoid valve
SE4202 Transmission oil temperature PWM4214 Clutch R solenoid valve
SE4213 Converter turbine speed PWM4215 Clutch 1 solenoid valve
SE5203 Output brake pressure PWM4216 Clutch 2 solenoid valve
SE5501 Parking brake pressure PWM4217 Clutch 3 solenoid valve
SW4205 Directional gear selector PWM4218 Clutch 4 solenoid valve
SW4206 Gear lever steering column
Software
Clutch calibration
The transmission calibration is based on the interaction between machine software functionality and a user interface displayed by
Tech Tool. The calibration task is to measure the fill time and the spring load pressure for each clutch.
Fill time is the time that it takes to pressurize the backside of the clutch piston and move it to the point where the friction discs come
into contact with the steel discs. Spring load pressure is the pressure needed to compress the clutch return springs to the point
where the clutch starts to generate a predefined torque.
To be able to find the values for fill time and spring load pressure for each clutch, the clutch is engaged repeatedly until the best
settings are found. The settings are found by controlling the clutch's PWM-valve with differently shaped current curves until the
desired curve for the turbine speed is reached. To achieve the turbine speed reaction, another clutch (F or 2) is fully engaged during
the clutch calibration.
Figure 2
Clutch F/1
1. Springs
2. Friction discs
3. Steel discs
4. Piston
Calibration errors
During the calibration procedure the machine’s software function monitors the components presented in the figure “components”. It
monitors component malfunctions, function errors/problems, and deviations of the preconditions for running the calibration. Errors
related to function or precondition are not presented or stored in the HMICU. They are only presented in Tech Tool. These
malfunctions are listed with recommended action in: Error codes when calibrating.
Replacement values
If a malfunction should occur with regards to the fill time or spring load pressure for a clutch, then the corresponding clutch
parameters will be programmed with replacement values. These values will be the min. or max. calibration value in combination with
the previously calibrated value. That is, min. or max. fill time in combination with the previously calibrated spring load pressure. This
strategy will result in the best possible gearshifting comfort until the malfunction is corrected. For min. and max. calibration values
(replacement values), see: Transmission, specifications.
Adaptive parameter reset
When the calibration is finished, a reset of the adaptive parameter is done. This reset causes the machine software to restart the
calculation of the overlap time between speed gears that always occurs during a gearshift.
-
Function check
Transmission, function check
Parameters
Relevant parameters for transmission calibration are P1JO0 and P1JOQ — P1JOZ for more information see: Software parameters,
description.
Diagnostics
Hydraulic transmission, description
The transmission is driven by the engine. The transmission transmits the torque via the torque converter and clutch shafts as well as
output shafts to the front and rear propeller shafts. The gears are in constant mesh in the transmission. The disc packs on the clutch
shafts are applied with oil pressure for the different gears. The transmission has a closed oil system.
Transmission oil flow
Figure 1
Transmission oil flow
Red Main pressure

Blue Torque converter pressure
Yellow Lubrication pressure
Green Return oil
1. Engine 9. PWM-valve, 2nd 17. Sump with suction strainer

2. Main pressure valve 10. PWM-valve, Forward 18. SE4219 Main pressure sensor
3. Torque converter pressure valve 11. PWM-valve, Reverse 19. Rear axle
4. Lubrication oil valve 12. PWM-valve, 4th 20. SE4213 Turbine speed sensor
5. Torque converter 13. Safety valve, filter 21. PWM-valve, 3rd
6. Oil cooler 14. Pump 22. Front axle
7. SE2704 Engine speed sensor 15. Oil filter 23. PWM-valve, 1st
8. SE4307 Output speed sensor 16. SE4202 Temperature sensor
Transmission oil pump

Before the oil reaches the gear selector valve, the pump forces it through the filter.
Oil filter
The oil filter is provided with a bypass function which will ensure oil to the transmission even if the filter is clogged. When the
differential pressure across the filter reaches a trigger level the machine detects and reports “clogged filter”.
Gear selector valve
The gear selector valve for the transmission contains the PWM-valves responsible for the actual gearshifting operation, and the main
pressure valve.
For more information, see: Transmission, component position
PWM-valve
The current applied to the solenoid of the PWM-valve determines the pressure applied to the corresponding clutch. The higher the
current, the higher the pressure to the clutch.
Figure 2
PWM-valve
A. Main pressure
B. Output pressure to clutch
C. Tank return
Heat exchanger
The transmission has a heat exchanger for cooling or warming its oil. In the heat exchanger the oil and the coolant are pumped in
opposite directions to increase heat exchange performance.
The coolant passes the transmission's heat exchanger after it has been cooled in the radiator and then returns to the engine by way
of the pump’s suction side.
Figure 3
Heat exchanger
1. Heat exchanger
Clutch shafts
When a gear has been selected, GPMECU3 sends out a PWM-signal to the selected gear solenoid and the oil flow is sent out to the
relevant clutch. When the clutch pressure overcomes the spring force, the friction discs and steel discs are pressed together. The
clutch will lock the drum and the gear with the shaft
When any of these components for gear selection is affected, removed, or replaced, then a transmission calibration needs to be
performed in order to secure high-quality gearshifting.
For more information, see: Hydraulic transmission calibration, description
Figure 4
Clutch shaft
1. Lubrication channel
2. Cavity
3. Piston
4. Hub
5. Gear
6. Drum
7. Steel plate
8. Friction disc
9. Spring
10. Roller bearing
At deactivation, the PWM-signal is cut off and the clutch pressure is drained through the solenoid valve passing via the gear selector
valve and back to the sump.
Lubrication
From the main pressure valve some of the oil is led to the torque converter, continuing to the heat exchanger and finally to the clutch
shafts for lubrication.
There is a lubrication oil pressure valve to safeguard the lubrication oil pressure, in case of too high pressure the surplus is led to
tank.
Figure 5
Lubrication
1. Lubrication oil valve

2. Heat exchanger
Torque converter
The torque converter is a hydraulic clutch consisting of a pump rotor connected to the engine's flywheel, a turbine rotor connected to
the input shaft in the transmission, and a stator.
The pump rotor rotates with the engine's rpm and pumps the oil to the turbine rotor, which wants to rotate with the pump rotor. The
stator’s job is to redirect the fluid returning from the turbine rotor before it strikes the pump rotor again, giving the impeller an added
boost or torque. This will dramatically increase the efficiency of the torque converter and multiply the torque generated by the engine.
Figure 6
Torque converter
1. Incoming power from engine

2. Stator
3. Pump rotor
4. Turbine rotor
5. Transmission input shaft
Software
APS
The gearshifting mode selector, APS (Automatic Power Shift), controls gearshifting based on the current engine speed, output speed,
selection of directional gear, speed gear, kick-down, and engine braking. The APS selects a suitable gear and when shifting should
take place in order to protect the transmission. With the mode selector the operator can select different gearshifting programs to
adapt to the corresponding operating style.
The mode selection of the APS is made on the display
1. Access the transmission section using the keypad
2. Using the navigation arrows, look for the APS settings and press Enter
3. The APS mode select will be shown.
MODE SELECT
○ Light
○ Medium
○ Heavy
● Auto
○ Service
The following applies to each APS-mode:
Light The machine shifts automatically at low engine speed and at low travel speed.
Medium The machine shifts automatically at higher engine speed than in position (mode) Light.
Heavy The machine shifts automatically at higher engine speed and travel speed than in position (mode) Medium.
Auto The machine shifts automatically and selects gearshifting program in order to achieve best comfort and economy.
Service The gears are shifted manually
For more information, see: Automatic shifting (APS).

FAPS
The machine has a function called Fully Automatic PowerShift, FAPS. This function is activated or deactivated with switch SW4211
located on the cab pillar’s panel.
Figure 7
SW4211
When FAPS is activated:
 There is automatic shifting 1-4.

 Transmission can skip gears for fast speed change.
 Shifting to 1st gear does not take place when brakes are applied.
When FAPS is deactivated:
 There is automatic shifting 2-4.

 Cannot skip gears during fast downshifting, always 4-3-2-1.
 Downshift to 1st is automatic (protective downshift) in case of high engine rpm and only in forward. Manual downshifting is
also possible using the kick-down buttons.
 Protective downshift to 1st gear takes place to protect the transmission. Protective downshift to 1st does not take place when
braking the machine.
For the effects on the Boom Suspension System (BSS), see:Boom Suspension System, description
Engine braking/downshifting
Protective function.
Engine brake is activated with SW4210. When activating the engine brake, downshifting takes place one step at a time, but not to 1st
gear. If SW4210 is held in, upshifting can be prevented until the button is let up or the protective function intervenes and performs an
upshift. During engine braking and the engine speed increases above 1,300 rpm, the cooling fan speed increases to max. rpm and
the hydraulic pump brakes the transmission (Auxiliary brake).
Figure 8
Lever carrier, electric servo
1. SW4210, Engine brake
In order to avoid higher rpm than recommended, the transmission has overspeed protection which results in automatic upshifting to
the next gear when the corresponding machine speed is exceeded. Warning for overspeeding transmission is shown on the display.
 The machine will also perform a protective upshifting when the engine speed exceeds approx. 2,600 rpm.
Controlling slipping of clutches in transmission

The transmission has the following sensors for control of slipping:
1. SE4213 – Frequency sensor, turbine speed

2. SE4307 —Frequency sensor, transmission/output speed/travel speed
Information from these sensors enables control unit GPMECU3 to register if there is a clutch slipping in the transmission.
In case of slipping, GPMECU3 will increase the current to the PWM-valve, so the clutch pressure is increased in order to stop
slipping. If slipping remains, the operator will be informed by a warning text on the information display unit, and if slipping lasts longer
than 0.5 second, the transmission protection will reduce the engine speed significantly.
Transmission disengagement
The function is activated on the machine display.
1. Access the transmission section using the keypad.
2. Using the navigation arrows to look for the transmission disengagement and press Enter.
3. The disengagement mode select will be shown on display
MODE SELECT
● Off
○1
○2
○3
○4
Transmission disengagement means that, when the brakes are applied and the function is activated, the transmission is shifted to
neutral gear.
This takes place when all the following conditions are met:
1. Selected output brake pressure is exceeded

2. Forward 1st–3rd or Reverse 1st–3rd gear is activated
3. Speed is lower than set value
Speed is preset to 3 km/h but it can be changed with Tech Tool, parameter P1KBR. There are four levels for output brake pressure
that can be selected. These four pressure levels can also be changed with Tech Tool parameters P1KBE — P1KBH. For more
details, see: Software parameters, description.
Speed limitation
There are three factors that can limit the speed of the machine:
1. Legal speed limit

2. Design speed limit
3. CDC speed limit
The lowest of the limits above will govern the speed limitation. The legal speed limit is set by the value of parameter P1KLM, and the
CDC speed limit by parameter P1KLN. The CDC speed limit is only considered if the function is installed and activated.
Transmission oil pressure
For protection, the transmission has three alarm levels. For more details, see: Hydraulic transmission, specifications.
Transmission oil temperature
The transmission also considers two temperature alarm levels. If the transmission oil temperature increases above the highest alarm
level, the transmission protection will reduce the engine speed significantly. For more details, see: Hydraulic transmission,
specifications.
Gears selectors, priority
Priority among the gear selectors means that if a gear selector with a higher priority than the active gear selector is activated, the
gear selector with the lower priority is deactivated (1 is highest).
1. Gear selector, steering column

2. Gear selector, CDC
3. Gear selector, lever carrier
Software parameters, description
Drivetrain, component location
Transmission, component position
Transmission, specifications
Hydraulic transmission calibration, description
Hydraulic diagram transmission
Function check
Hydraulic transmission, checking oil pressure
Parameters
Code Description
P1KLM Selection of maximum speed to fulfil legal requirements.
P1KLN Selection of maximum speed when CDC is installed and activated.
P1KBE The brake pressure at which the transmission disengagement is activated if the first transmission disengagement
setting is used.
P1KBF The brake pressure at which the transmission disengagement is activated if the second transmission disengagement
setting is used.
P1KBG The brake pressure at which the transmission disengagement is activated if the third transmission disengagement
setting is used.
P1KBH The brake pressure at which the transmission disengagement is activated if the fourth transmission disengagement
setting is used.
P1KBR Speed limit up to which it is possible to use the transmission disengagement function.
Summary
Power transmission takes place using the internal torque converter and a number of clutches and shafts inside the transmission. The
gear selector valve, together with the control unit, are responsible for the correct electrohydraulic combinations in order to fulfil each
gear selection.
The transmission has a heat exchanger that is connected to the main engine cooling circuit to warm or cool the transmission oil.
The transmission considers some protective functions like overspeed protection, transmission disengagement, engine brake
downshifting, and control of clutch slipping. With regards to alarms, the transmission has 2 alarm levels for temperature and 3 alarm
levels for pressure.
Diagnostics
Information display, general
Figure 1
Instrument panel
1 Keypad
2 Display unit
Figure 2
Information panel with display unit
Figure 3
Keypad
The information panel provides the operator with information, messages, warnings, and alarms. With the keypad, the operator can
select group/function from which to read information. The keypad is also used to make settings and enter number values.
The information panel and keypad are located on the instrument panel. The information panel is connected to the HMICU (Human
Machine Interface Control Unit).
When the machine is started, the latest figure is shown from the time that the machine was turned off. The information can be
adapted to the operator by selecting language and display format for units, time, and date.
Information organization
The information in the information panel is built up in a number of groups/functions:
 Initial display
 Operating information
 Engine
 Transmission
 Hydraulics
 Axles/Brakes
 Electrical system
 Vehicle information
 Vehicle messages
 Service
 Setup
For detailed information, see description of each group in Operator’s Manual.

Changing display screen
Move between groups/functions with the function keys on the keypad. When changing group/function, you always arrive at the top
figure in each function group. Return to the figure for “operating information” takes place with the ESC-key or automatically when
machine speed is over 20 km/h (12 mph).
Keypad
The following can be performed with the keypad:
Figure 4
Keypad
 Select group
 Scroll within group
 Activate/deactivate functions
 Reset and acknowledge
 Setup (settings)
The keys' function are also described in the following table.

Certain keys also correspond to a digit which is shown on the key's lower right corner. The number values are used, e.g., when
setting date and entering PIN-code for theft protection.
The key SELECT is used to, for example make selections, acknowledge, and to get detailed information about any
malfunctions.
The key is used to return or cancel.
1 2 Hydraulic system 3
Return Engine Transmission
Scroll up Axles 4 Electrical system 5 Vehicle information 6

SETUP
Scroll down Vehicle messages 7 Service 8 Setup (settings) 9
SELECT
Confirm Cycle information 0
Service mode
The information panel has a function called Service mode. With active Service mode it is possible to access additional or alternative
information, for example numerical values instead of bars and part numbers for software. Service mode also has additional functions,
for example simultaneous acknowledgement of all alarms.
The following conditions must be fulfilled to activate Service mode:
 Parking brake applied

 Service key pressed in for more than 3 seconds
 Approved message “Enter Service mode” with SELECT-key within 10 seconds.
When Service mode is active the symbol is shown in the lower field in the operating display. To leave Service mode, press in the
Service-key for at least 3 seconds.
The functions for Service mode are described further under each group.
Warnings and alarms
Warnings and alarms from the machine are obtained through a combination of central warning, buzzer, and messages in the
information panel. For further information about central warning, see Operator’s Manual.
Messages about alarms in the information panel are either instructional or informative. In case of serious malfunction, both
instructional and informative messages are obtained as follows:
 First the instructional message is obtained, for example Stop vehicle or Turn Off Engine.
 After the instruction has been performed, the informative message is obtained, for example Low oil level engine.
WARNING
Do not ignore the alarm and continue to operate the machine! Safely shut down the machine. Inspect and repair the fault.
Failure to comply could result in injury!
For further information about alarms, see Operator’s Manual.
Information display, service mode
Service (Service mode)

Next service
Central lubrication
Test
Next service
Resid. time 125 h
Interval 250 h
Confirm service No
Central lubrication
Interval Normal
Test
Brake test Off
Brake test log Off
Sound test Off
Pr. test fan pump Off
Under the menu Service (Service mode) in the information panel, there are the following information and tests.
To activate Service mode, press and hold service symbol key for four seconds.
Select menu with arrow key, press SELECT.
Conditions for activating Service mode, see Information display, general.
To return to previous figure, press [ESC].
Next service
Resid. time: Time to next service.
Interval: Shows next type of service interval (125, 250, 500, 1000, 2000 hours)
Confirm: Press SELECT to confirm performed service.
No will switch to Yes for a few seconds and then reverts to showing No.
Service is now confirmed.
NOTE!
Alarm for service is generated 8 hours before the end of the interval. Service can only be acknowledged during these 8 hours.
If the 8 hour interval passes without acknowledgement of service, the alarm for service is removed.
Central lubrication
Interval: Shows selected interval (Light / Normal / Heavy).
To change setting, press SELECT. Make selection with the arrow keys and press SELECT to confirm the selection.
Test
Make test selection with the arrow keys.
Information
XX km/h
Accelerate over 20 km/h
close:
Information
XX km/h
Brake to standstill
close:
Brake test
Retardation x m/s²
Pressure xx bar
Accelerate to start new test
close:
Information
Brake test failed
Brake test log

1: xx bar xx m/s²
2: xx bar xx m/s²
3: xx bar xx m/s²
close:
Brake test: Press SELECT.
1. Accelerate over 20 km/h

2. Brake to standstill
3. Read off the test result: Retardation and Pressure.
If the brake test failed, "Brake test failed" is shown for 3 seconds. (Retardation > 8 m/s²)
To perform new test: Accelerate to start new test
To return to previous figure, press ESC.
Brake test log: Press SELECT.
Memory of retardation for the last 3 brake applications.
Memory of output brake pressure for the last 3 brake applications.
Sound test: Press SELECT. Off changes to On and obtains a cooling fan speed that is 70% max. engine rpm.
To cancel the test, press SELECT.
Pr. test fan pump

Engine rpm rpm
Fan rpm rpm
close:
I/O-List
HMIECU
GPMECU1
GPMECU2
GPMECU3
I/O-List
Pr. test fan pump: Press SELECT and the figure changes to the figure with rpm.
To perform pressure test, see Hydraulic pump P3, checking function.
I/O-List
Select control unit and press SELECT.
 HMICU = Human Machine Interface Control Unit

 GPMECU1 = General Purpose Machine Electronic Control Unit 1
For more information contact your local product support.

Inlet and exhaust system, component location
Figure 1
1. Charge air cooler 8. Engine control module, ECM

2. Charge air cooler, outlet temperature sensor, SE2512 9. Inlet throttle
3. Inlet air temperature and air cleaner pressure sensor, FX1008 10. Preheater, HE2501
(SE2501, SE2502)
4. Air cleaner 11. Turbocharger
5. Exhaust gas pressure sensor before turbocharger, SE2511 12. Exhaust manifold
6. Inlet manifold temperature and pressure sensor, FX1007 13. Inlet manifold
(SE2507, SE2508)
7. Aftertreatment control module, ACM
Inlet and exhaust system, description
Introduction
The engine takes in clean air through the inlet system. When the fuel and the inlet air combust inside the engine, the exhaust is led
out from the engine through the exhaust system.
Included in the inlet and exhaust systems, there are subsystems such as the exhaust aftertreatment system (EATS), exhaust gas
recirculation system (EGR) and crankcase ventilation. For information on the subsystems, see:

Function diagram
Figure 1
Inlet and exhaust system
Blue = Inlet air

Red = Exhausts
Yellow = Coolant
Brown = Engine oil
A = to Exhaust aftertreatment system
1. Inlet throttle 10. Mixing chamber

2. EGR temperature sensor, SE2516 11. Preheater, HE2501
3. EGR differential pressure sensor, SE2515 12. Air cleaner
4. EGR venturi tube 13. Ambient air temperature sensor, SE8705
5. Diesel engine 14. Inlet air temperature and air cleaner pressure sensor,
FX1008 (SE2501, SE2502)
6. EGR cooler 15. Inlet manifold temperature and pressure sensor, FX1007
(SE2507, SE2508)
7. EGR control valve and actuator 16. Turbocharger with wastegate
8. Charge air cooler 17. Exhaust gas pressure sensor before turbocharger, SE2511
9. Charge air cooler, outlet temperature sensor, SE2512
The inlet air is drawn in by the turbocharger through the air cleaner. Then the charge air is led to the charge air cooler, where it is
cooled. The air then passes the inlet throttle and meets the recirculated exhaust (EGR) in the mixing chamber. For information on the
EGR system, see Exhaust Gas Recirculation (EGR), description.
From the mixing chamber, the mixture of EGR and inlet air is led via the preheating coil into the inlet manifold and on to the cylinders.
After combustion, the exhaust is led to the exhaust manifold. Some of the exhaust is recirculated (EGR) and mixed with inlet air in
the mixing chamber, and the rest of the exhaust is led through the turbocharger and then cleaned in the exhaust aftertreatment
system. For information on the exhaust aftertreatment system, see Exhaust Aftertreatment System, description.
Air cleaner
Figure 2
Air cleaner
It is important that the air drawn into the engine is free from impurities. The air filter insert consists of a folded filter paper which is
protected by a mesh.
Turbocharger
Figure 3
Turbocharger with wastegate valve
Blue = air
Red = exhausts
1. Turbine housing
2. Wastegate valve
3. Compressor rotor housing
The function of the turbocharger is to compress air and press it into the engine cylinders.
The turbocharger is driven by the exhaust that passes through the turbine housing on its way out into the exhaust system. The
exhaust flow causes the turbine rotor in the turbine housing to rotate.
The compressor rotor is mounted on the same shaft as the turbine rotor. The compressor rotor is located in a housing which is
connected between the air cleaner and the charge air cooler. When the compressor rotor turns, air is drawn from the air cleaner. The
air is compressed and forced into the engine cylinders via the charge air cooler.
The turbocharger has force feed lubrication from the engine oil system. For more information, see Lubrication system, description.
Turbocharging increases the temperature of the air so that the compressed air is cooled before entering the inlet manifold.
Wastegate
The turbocharger is equipped with a wastegate valve, in the form of a pneumatic actuator connected via a rod to a valve unit
mounted inside the turbine housing. The wastegate valve is controlled by the charge air pressure. It lets a small amount of the
exhaust to by-pass the turbine wheel at high engine speeds (high charge air pressure). This allows the turbo to limit its maximum
charge air output.
Charge air cooler
The charge air cooler is an air to air cooler and reduces the temperature of the air after it has passed the turbocharger. This reduces
the volume of the air so that more air (oxygen) can be pressed into the cylinders.
Inlet throttle
Figure 4
Inlet throttle
1. Throttle disc
The inlet throttle is a simple flap valve controlled by the ECM.

The inlet throttle is used during moving and parked regeneration to make the engine work harder, which creates more heat in the
exhausts. This enables regeneration of the aftertreatment system. For more information, see Exhaust Aftertreatment System,
description.
The inlet throttle is also used for driving the EGR flow. It reduces the pressure in the inlet manifold so that it is lower than the back
pressure in the exhaust manifold, thus creating a pressure difference. For more information, see Exhaust Gas Recirculation (EGR),
description.
Mixing chamber
Cooled recirculated exhaust (EGR) meets the inlet air from the charge air cooler in the mixing chamber. For more information, see
Exhaust Gas Recirculation (EGR), description.
From here the mixture flows through the inlet manifold into the engine combustion chambers. The most important function of the
mixing chamber is to facilitate equal EGR distribution to each cylinder.
Preheater[1]
Figure 5
Preheater
The purpose of the preheating coil is to heat the air in the inlet manifold before the engine is started. This heated air eases engine
start and reduces white smoke in cold starts. The preheater is heated electrically and consists of two, or more, heater coils through
which the air flows.
The heater is engaged when the operator has turned the start key to position 1 and if the engine coolant temperature and the
ambient temperature is below a set limit. Preheating ends when the engine starts. Extra preheating, so called postheating, begins
after engine start if the temperature requires it.
The preheating and postheating times are controlled by the ECM and are dependent on the coolant temperature. For more
information on when heating is activated, see Inlet and exhaust system, specification.
Inlet and exhaust manifold
Each cylinder has a separate inlet channel and a separate exhaust channel on the same side of the cylinder head.
The inlet manifold is mounted from above, supplying air and EGR gas vertically into each cylinder. Gaskets are used to prevent
leakage between each cylinder and the inlet manifold.
The exhaust manifold is mounted under the inlet manifold, receiving exhaust horizontally. The exhaust manifold covers the cylinder
exhaust outlets. Gaskets are used to prevent exhaust leakage between the cylinder head and the exhaust manifold. The
turbocharger and the EGR cooler are connected to the exhaust manifold.
Summary
The inlet air is drawn in by the turbocharger through the air cleaner. Then the charge air is cooled in the charge air cooler before it is
forced through the inlet throttle.
Some of the exhaust is recirculated back into the engine, through the EGR system.
The inlet air is mixed with the EGR gas in the mixing chamber. The preheater is used when the inlet air needs to be heated.
The exhaust leaves the exhaust manifold and then drives the turbocharger. The exhaust is then led to the exhaust aftertreatment
system to reduce particulate matters and NOx.
Parameters

 Inlet and exhaust system, component location
 Inlet and exhaust system, specification
Function check

 Tech Tool operation 25001-3 Preheater, test
Diagnostics
PROSIS.
[1]Not available for all applications

Intermittent wiper and washer
Use Tech Tool test 36385-3 Windscreen wiper and washer, test to test the functions.
Interval wiper front windshield
Interval wiper is engaged by turning the control SW3602 to interval position. Wiper MO3602 performs a sweep (wiping movement)
after which it rests for 7 seconds before performing another sweep. The sequence is repeated until he control is turned to position 0.
The wiper MO3602 is controlled via relay RE15.
Setting time interval
The time interval (5—60 seconds) can be set using SW3602 as follows:
First turn the control to interval position and let the wipers operate for awhile, then turn the control to position 0 and wait for the time
that is desired as the new time interval, turn the control back to interval position.
When the engine is turned off by turning start key to position 0 the time interval reverts to the basic setting of 7 seconds.
Figure 1
SW3602
NOTE!
Time between sweeps may not be shorter than 5 seconds or longer than 25 seconds.
If attempts are made to set the time between sweeps to less than 5 seconds, the time interval will be 5 seconds.
If attempts are made to set the time between sweeps to longer than 60 seconds, no time setting will take place and instead the
previous time interval will apply.
Washing front windshield
Button SW3608 pressed in (rocker switch) = Windshield washer with wiping until the button is let out. Wiping continues 5 seconds
after finished washing.
Washer pump MO3601 is not controlled by the software, it is controlled directly by the button for windshield washer.
Figure 2
SW3608
Interval wiping rear window when operating forward
Control SW3602 is turned to continuous position or interval and switch SW3612 in position On. The wiper performs a sweep after
which it rests for 7 seconds before the wiper performs a new sweep. The sequence is repeated until control SW3602 is turned to
position 0.
The wiper MO3604 is controlled via relay RE09.
Figure 3
SW3602
Continuous wiping rear window when reversing
Control SW3602 in position continuous or interval and switch SW3612 in position On. The rear wiper is activated continuously when
reversing.
Figure 4
SW3612
Washing rear window
Switch SW3612 pressed in (rocker switch) = Rear window washing with wiping until the button is let out. Wiping continues 5 seconds
after finished washing.
Washer pump MO3603 is not controlled by the software, it is controlled directly by the button for windshield washer.
Washer fluid level
The washer fluid reservoir is located in a metal box on the right side of the cab.
Level sensor SE3601 in the washer fluid reservoir generates an alarm when low level is sensed for more than 20 seconds.
Information — Low washer fluid level.
Key feed
Key feed is used as a condition in software functions to define when voltage feed considered to be On and Off, respectively.
Input signals Conditions for output functions Output functions
 System voltage  Voltage < 8 V  Key feed Off
 Voltage > 12 V  Key feed On

Leak detector 951 1207, new model
Figure 1
Leak detector 951 1207
1. Start/Stop
2. Sensitivity High/Low
3. Reset
4. Alarm
5. LED–indicator 1, lit when the leak detector is on
6. LED–indicator 2–6 for visual leak size
7. Sensor
8. Flexible probe
9. End of probe
10. Filter
11. Outlet for charger
12. Battery
WARNING
Explosion risk when using leak detector in explosive environments.
Leak detector 951 1207 shall be used to check sealing of the AC unit. The leak detector indicates refrigerant leakage with audible
signal and visual signal, the audible signal can be disconnected.
The instrument is designed around a microcomputer, and a sensor part. The sensor current is affected by the content of refrigerant
gas in the surrounding air.
Battery
The LED–indicator closest to the buttons is always lit when the leak detector is on.
 The battery is fully charged when the LED–indicator is activated with a green light.
 The battery should be recharged after use when the LED–indicator is orange.
 The battery should be recharged immediately when the LED–indicator is red.
Charging of battery
NOTE!
To avoid damaging the battery, it should only be charged in temperatures between 10 °C – 40 °C (50 °F – 104 °F).
Connect the charger on the back of the leak detector and plug in to a wall outlet.
 Fast flashing orange = battery is being charged.

 Slow flashing green = battery fully charged.
 Slow flashing red = battery cannot be charged.
The leak detector can be connected to the charger when it is not in use. When the battery is fully charged, the charger will only
provide the battery with a trickle-charge.
Sensor
The sensor needs to be replaced every once in awhile. The first LED–indicator will flash when it is time to replace it. If the sensor is
missing or is completely defective LED–indicator 2 – 6 will flash red quickly.
Sensor, changing
 Carefully turn the flexible probe counter-clockwise at the connection on the leak detector, to expose the sensor.
 Remove the sensor by carefully gripping under the flange to pull the sensor straight out.
 Install the new sensor so that the pins fit in the contact. Carefully press in the sensor in the contact until the orange seal is
half as big as its original size.
 Screw the flexible probe into place clockwise.
NOTE!
Never use the leak detector without the flexible probe.
Probe
The end of the flexible probe can be removed for cleaning and filter change.
 Loosen the end of the probe to check if the filter is discoloured or dirty. Change if needed.
 The end of the probe can be cleaned with a mild cleaning agent. Let it dry completely before it is reinstalled.
Button functions
1. Start/Stop = Button 1 Always start the leak detector in fresh air.

2. Setting sensitivity = Button 2The leak detector has two modes for sensitivity High/Low. When the unit is started it is set to
high sensitivity. To change sensitivity, press in button 2. Then the LED–indicator will be activated with orange light starting
from the upper light to go to the lowest. To change from low to high, the orange signal will run from the lowest to the
uppermost light. An audible signal will also be activated to confirm the selection.
In the high sensitivity mode, the unit will beep quickly approx. 2 times every other second in fresh air.
In the low sensitivity mode, the unit will beep approx. 1 time every other second in fresh air.
3. Reset function = Button 3. This button can also be used during leak detection. By pressing in button 3 the sensor will
search for a higher concentration of refrigerant than the previous value. In this way, the leakage area can be pinpointed. To
set a more sensitive mode, press in button 3 in fresh air. Every time that the reset button is pressed in the LED–indicator will
flash, to confirm the activation.
NOTE!
When checking for major leaks it is better to set the leak detector to low sensitivity.
4. Audible alarm = Knapp 4Activate/deactivate button 4 for audible alarm and visual alarm, or only visual alarm.
WARNING
Explosion risk when using leak detector in explosive environments.
Leak detection
1. Press in button 1 to start the unit.

2. The LED–indicator will flash from below and upward during the time that it warms up (approx. 20 seconds).
3. Select sensitivity with button 2. Start leak detection.
4. If a leak is detected, the unit will emit an audible signal and a light signal. The signals will increase in intensity the higher the
refrigerant concentration.
 Green = minor leak

 Orange = medium leak
 Red = major leak
Leak detection tips

When the engine is off the air conditioning system should be charged with refrigerant that gives a value of at least 340 kPa (50 PSI)
on the pressure gauge. At temperatures below 15 °C (59 °F), it is difficult to detect leaks if the system does not have that pressure.
Keep the end of the sensor and probe clean. Clean with a dry rag. Do not use cleaning agents on the sensor as it may react to it.
Check the entire AC system visually and look for signs of refrigerant leaks, e.g., damage and rust on pipes, defective hoses and
components.
Follow the system in one direction to not miss areas with potential leaks. Do not move the leak detector too fast.
The refrigerant gas may be heavier than the air and may collect under the leakage area itself. That is why leak detection should also
be performed under possible leakage areas.
In spaces where there have been major refrigerant leaks, it is possible to reset the leak detector in fresh air to prevent it from reacting
to the surrounding air which contains refrigerant.
Avoid leak detection in a windy environment. Try to provide wind protection for the area to be checked.
Keep in mind that a leak is an even flow of refrigerant, that is why the leak detector will emit a repeated signal at the leak itself every
time that the leak detector closes in on it. Not repeated signal is often a sign that you are close to the leak.
When the leak has been found, it can be verified by:
1. Blowing clean with compressed air at the suspected leakage.

2. Moving the leak detector to fresh air and then resetting it. Then hold it as close as possible to the suspected leak and move it
slowly around the area to verify the leak.
Lever control, hydraulic servo, description
Multi-lever control, hydraulic servo, basic
Figure 1
Multi-lever control, hydraulic servo, basic
1. Lift, lower
2. Tilt
3. 3rd hydraulic function [1]
4. Kick-down, SW4209
5. Horn, SW3627
6. Engine braking and downshifting, SW4210
7. Forward / Neutral / Reverse, SW4208
8. Lever lock
9. Activation of Forward / Neutral / Reverse, SW4207
Multi-lever control, hydraulic servo, complete

Figure 2
Multi-lever control, hydraulic servo, complete
1. Lift, lower
2. Tilt
4. 4th hydraulic function [3]
6. Horn, SW3627
9. Lever lock, SW9174
Single-lever control, hydraulic servo

Figure 3
Single-lever control, hydraulic servo
1. Lift, lower, and tilt

5. Horn, SW3604
6. Lever lock, SW9140
Lifting cylinder, description
Figure 1
1. Lock–ring
2. Piston
3. Support ring
4. Piston seal
5. O-ring
6. Cylinder tube
7. Piston rod
8. Back-up ring
9. Piston rod seal
10. Scraper ring
11. Bushing
Lighting, description
Headlights
Headlights are operated with switch SW3501 located on the pillar panel.
 Switch upper part pressed in = Headlights on.

 Switch in middle position = Parking and instrument lights on.
 Switch lower part pressed in = Headlights off.
Figure 1
High and low beam, switch
Main and dipped beams are controlled with SW3502, the right-hand stalk switch on the steering column
 Away from steering wheel = High beams.

 Neutral position = Low beams.
 Towards steering wheel = Headlight flash.
Control light on the front instrument panel indicates that high beams are on.
Work lights front
Work lights front are operated with switch SW3504 located on the pillar panel.
 Switch upper part pressed in = Work lights front, cab, and attachment on.
 Switch in middle position = Work lights cab on.
 Switch lower part pressed in = Work lights off.
Control light on the front instrument panel indicates that work lights are on.
Figure 2
Switches, lighting
Work lights roof
Work lights rear are operated with switch SW3505 located on the pillar panel.
 Switch upper part pressed in = Work lights cab and radiator casing on when reverse gear is engaged.
 Switch in middle position = Work lights cab and radiator casing on.
 Switch lower part pressed in = Work lights off.
Work lights rear, continuous/gear-dependent (optional equipment)
With this function it is only possible to select continuous or gear-dependent engagement of rear work lights. Selection of function is
done with switch SW3505 located on the pillar panel.
 Switch upper part pressed in = Work lights cab and radiator casing on when reverse gear is engaged.
 Switch in middle position = Continuous work lights cab and radiator casing on.
 Switch lower part pressed in = Continuous work lights cab and radiator casing on.
Guide lights in switches and lighting in climate control system's panel
Light intensity for guide lights in switches and lighting in climate control system's panel are controlled with rheostat R3501.
 Rheostat's upper part pressed in = light intensity increases.

 Rheostat's lower part pressed in = light intensity decreases.

Rotating beacon
Rotating beacon LA3601 is controlled with switch SW3624 located on the pillar panel.
Control light on the front instrument panel indicates that rotating beacon is on.
Lubricating system, description
The lubrication oil system is a force-feed circulation system, fed by an oil pump, with oil cooler and oil filter arranged in a full flow
circuit. The oil pump is driven by the crankshaft.
For information about other systems that are affected by the lubrication system, see:

Figure 1
Lubrication system
1 Turbocharger 11 Oil cooler by-pass valve

2 Lubrication oil to turbocharger bearings 12 Oil cooler
3 Roller tappets for high pressure fuel pumps with rocker arm 13 Oil sump
pulse lubrication
4 Rocker arm, lubrication of valve mechanism 14 Connecting rod bearing (big end bearing)
5 Return line to oil sump 15 Crankshaft main bearing
6 Piston cooling injection nozzle 16 Oil filter
7 Camshaft bearing 17 Engine oil temperature and level sensor, FX1006 [1]
8 Engine oil pressure sensor, SE2203 18 Pressure control valve
9 Main oil gallery 19 Oil pump
10 Oil filter by-pass valve
The oil pump draws oil from the sump through the strainer, and then forces the oil through the oil cooler where it is cooled before
continuing to the full flow filter. When the oil has a high viscosity, for example, during cold-starts, the by-pass valve opens to allow the
oil to pass through a channel, by-passing the oil cooler. From the full flow filter the oil is forced through the main gallery and from
there it is distributed to the camshaft and crankshaft bearings, as well as to the valve mechanism. Oil is also led from the main gallery
to the piston cooling nozzles and turbocharger bearing housing.
The oil flow is controlled by the following valves:
 Oil cooler by-pass valve, opens when the oil has a high viscosity, for example, during cold-starts, for quicker warm-up of the
oil.
 Oil filter by-pass valve, ensures engine lubrication in case the oil filter gets clogged.
 Pressure control valve, controls the pressure in the lubrication system.
The engine is also equipped with a piston cooling system that sprays oil on the underside of the pistons to maintain a stable
operating temperature.
Engine oil cooler and oil filter housing
The oil filter and oil cooler are installed together. The oil cooler is located on the oil filter housing.
The oil cooler is a parallel flow heat exchanger.
Engine oil pump
Figure 2
1. Pump housing
2. Crankshaft driven
The oil pump is a rotary pump integrated with the front cover. The rotor is seated on and driven by the crankshaft. The pump is of the
internal gear type with constant displacement.
Piston cooling system
Piston cooling channels, one for each cylinder, lead engine oil to the pistons. The piston cooling has no regulation, i.e., piston cooling
is performed continuously.
Parameters
 There are no parameters for this function
 Lubrication system, component locations
Function check
Diagnostics
PROSIS.
[1]Not valid for all applications

Lubrication points, central lubrication
Position of units
Figure 1
Pipe connections and hose connections
Figure 2
Grease points
Grease points
Pos. no. Designation Pos. no. Designation

1 Steering cylinder, left, rear bearing 14 TP-linkage, bearing point I
2 Steering cylinder, right, rear bearing 15 Bearing point J
3 Frame joint, upper bearing 16 Bearing point C, left side
4 TP-linkage, bearing point G 17 Hydraulic attachment lock, right side
5 TP-linkage, bearing point H 18 Bearing point P, right side
6 Steering cylinder, left, front bearing 19 Hydraulic attachment lock, left side
7 Frame joint, lower bearing 20 Bearing point E
8 Bearing point A, left side 21 Bearing point O, right side
9 Steering cylinder, right, front bearing 22 Bearing point P left side
10 TP-linkage, bearing point F 23 Bearing point C, right side
11 TP-linkage, bearing point D 24 Bearing point O left side
12 TP-linkage, bearing point B 25 Support bearing
13 Bearing point A right
Figure 3
TP-linkage, bearing points
Lubrication system, component locations
Figure 1
Lubrication system
1. Piston cooling injection nozzle
2. Turbocharger
3. Crankcase ventilation
4. Pressure control valve
5. Oil cooler by-pass valve
6. Oil cooler
7. Oil pump
8. Oil filter by-pass valve
9. Oil filter
10. Engine oil pressure sensor, SE220

Parameter settings
To adjust the parameter settings for central lubrication, access to the diagnostics tool is required, see Diagnostic tools, description.
The parameter settings must be checked when replacing the pump unit or when retrofitting the central lubrication system.
Enter the parameter values according to that which is stated in the tables and load in the ECU for central lubrication.
Parameter settings according to "Timer parameter group"
1. Set the function parameters for times, temperatures, etc., according to the table below.
Heavy duty 20 [min.]

Medium duty 30 [min.]
Light duty 45 [min.]
Active duty mode Medium
Maximum pump time 15 [min.]
Vent multiply factor 1.0 x
Number of attempts 10 x
Pump motor current limit Auto [A]
Temp. high indication level 70 [°C]
Temp. low indication level —20 [°C]
Fast automatic cycles 10 x
Parameter settings according to "Timer activation options"
1. Set the activation parameters according to the table below.
Interval timer operated by. External command (pin 3)

Command input (pin 3) connected to Power
When command input activated Stop interval timer
Enable double coil valve OFF
Enable PS without resistor OFF
Disable lamp output OFF
Enable fast multiply test OFF
Enable pump relay output OFF
Disable duty mode selector OFF
Enable low level pump stop ON
Select extra I/O function Not used
2. Send the settings to the central lubrication's electronic unit.

NOTE!
If the wrong settings are selected, both the function and monitoring may fail.
Parking brake, component location
Figure 1
1. Parking brake
2. Central block
3. Pump 2
4. Pump 3
5. Parking brake valve
6. Accumulator block
7. Hydraulic tank
1. Parking brake, function description

2. Central valve, description
3. Hydraulic pumps, description
4. Brake accumulator, description
5. Hydraulic oil tank, description
Parking brake, function description
The parking brake is a spring-loaded disc brake that is applied when there is no hydraulic pressure to overcome the spring force.
Figure 1
Parking brake
1. Adjustment screw
2. Piston and magnetic assembly
3. Spring disc
4. Piston
The parking brake construction includes an adjustment screw that facilitates the setting of the right clearance between the brake disc
and the inner brake pad.
For more information, see: Parking brake, replacing brake pads
When there is no oil entering the connection port the disc springs push the piston into the lining and carrier assembly which
squeezes the brake disc. (parking brake applied)
Figure 2
Hydraulic connection to the parking brake
1. Brake disc
2. Connection port
3. Hydraulic hose
4. Brake pads
In order to release the parking brake, pressurized hydraulic oil is led to the connection port to overcome the spring discs forces and
move the piston away from the brake disc.
Every time the pressurized oil is withdrawn the parking brake returns to its normally applied position.
The pressure needed to release the parking brake is ensured by the accumulator block also used by the brake system, see Brake
accumulator, description.
For more information, see
Figure 3
Parking brake

Green Return oil
1. Brake accumulator block

2. Parking brake valve
3. Parking brake
4. Central valve
MA5501 Parking brake valve

RE5502 Parking brake relay
SE4307 Output speed sensor transmission
SE2701 Engine rpm
SE5501 Parking brake pressure sensor
SW5501 Parking brake switch
A1–A3 Accumulators
Conditions regarding parking brake status

When the engine is off and the parking brake is depressurized, a number of springs apply the parking brake, see Parking brake,
component description.
When the engine is started, the brake system is pressurized and there is pressure available to release the parking brake. The
pressure is locked in the parking brake valve, which means that the valve ensures that the parking brake is still applied. If there is no
pressure present in the parking brake, SE5501 sends a signal to GPMECU3, which in turn activates the control light for the parking
brake.
Relay hold circuit
When switch SW5501 is in the applied position, the current from the control unit GPMECU3 passes through the switch via terminals
1–2. The current continues to relay RE5502, terminal 86, and the relay is activated. When the relay is activated, the current passes
from the control unit via relay’s terminals 30–87 and back to the relay which becomes self-holding.
Figure 4
Switch in the applied position when the machine is started

Green Return oil
58A Voltage feed, instrument lighting
31C1 Ground connection
15EA Ignition dependent voltage
However if the engine is started and SW5501 is in the released position, the feed from GPMECU3 will not reach the terminal 86 and
RE5502 will not be activated. This means that to enable release of the parking brake, SW5501 must first be moved to the applied
position, then to the released position.
Figure 5
Switch in the released position when the machine is started

Green Return oil
Parking brake release request

Once SW5501 is moved to the released position, the current from GPMECU3 passes via RE5502, continues through SW5501,
terminals 2–3 and to MA5501. The oil from the brake accumulator block can pass through the parking brake valve and the parking
brake is pressurized. The hydraulic oil pressure then overcomes the spring force and the parking brake is released. SE5501 is also
pressurized and sends a signal to GPMECU3, resulting in the control light for the parking brake being turned off.
Figure 6
Parking brake release requested

Green Return hydraulic oil
Parking brake return to applied status

When SW5501 changes to the applied position or the engine is turned off, the electric current to MA5501 is cut. The oil from the
hydraulic pumps cannot pass through the parking brake valve to the parking brake, without any pressure present; the spring force is
applied to the parking brake once again.
SE5501 becomes depressurized and sends a signal to GPMECU3, resulting in the control light for the parking brake being turned on
(if the ignition is on).
NOTE!
The current that keeps RE5502 held, continues to do so until the ignition key is turned off. The parking brake is not applied if there is
an unexpected engine stop.
Parking brake and neutral request
If the parking brake is activated below 5 km/h, neutral gear is engaged. Directional gear F or R will not be activated even if the
operator tries to activate it.
However, the neutral activation is not requested when the APS (Automatic Shifting System) is in Service mode, and gear F3 is
selected in order to allow the parking brake function test.
If the machine is moving at 5 km/h or faster, the neutral gear request is not activated when the parking brake is applied. In this case
the parking brake is used as a supplementary brake and, in addition, engine braking is used to reinforce this action.
NOTE!
The parking brake must be released before forward or reverse gears can be applied.
Parameters
-
 Parking brake, specifications
 Parking brake, component location
Function check
 Parking brake, function checking

 Tech tool, 55102-3 Parking brake system test
Diagnostics
Pause heater, description
Cab heat timer
Cab Heat Timer (CHT) is a function that heats the cab when the machine is off.
Depending on actual cab and ambient temperature, heat can be added to the cab if the ambient temperature is lower than 17 °C.
The CHT-function is activated by pressing in the button for Cab Heat Timer/cab ventilation for 60 seconds before the machine is
turned off, or 15 seconds after the machine has been turned off with the key. If the CHT-function is activated more than 60 seconds
before the machine is turned off, CHT is deactivated automatically.
Green light is on when the function is active.
When CHT has been activated to warm the cab, an electric coolant pump starts and circulates the engine's coolant.
The heat control valve is set to open position and the air recirculation damper is set to max. recirculation of the cab air and the fan is
controlled at speeds up to half of max. speed.
When the CHT-system is active, the fan and coolant pump are controlled automatically in relation to the ambient and actual cab
temperature. After the switch has been activated it may take some time for control to take place.
CHT strives for 20 °C set temperature regardless of the temperature control's position.
CHT-warming can only be active for 1 hour.
If the engine's coolant no longer can give off heat to the cab and added air temperature is lower than 25 °C, then CHT is turned off.
Cab heat timer ventilation
When the ambient temperature is higher than 17 °C the cab can be ventilated to prevent it from becoming too warm. ECC cannot
cool when the machine is off.
When CHT has been activated to ventilate the cab, the heat control valve closes, the recirculation damper is set to max. inlet of
ambient air, and the cab fan is controlled at speeds up to max. half speed.
CHT-ventilation can only be active for 2 hours.
CHT is deactivated with the button or by starting the engine.
Figure 1
Control panel
1. Button for cab heat timer/cab ventilation

Preheating, description
There is an electric pre-heater on the engine's induction manifold. The heater is engaged when the operator has turned the start key
to position 1 and if the engine's coolant temperature is too low. If the engine is started, the preheating ends. Extra preheating, post-
heating, starts after engine start if the temperature requires it. Preheating and post-heating time is controlled by the engine's control
system. The advantage is easier start as well as less white smoke in the exhausts.
The symbol for preheating is lit on the information panel when the preheating coil is engaged.
Figure 1
1. Preheating coil
Software
The function activates preheating and informs the operator if there is a system malfunction.
Engagement times for preheating and post-heating are controlled automatically by the ECM and are dependent on the coolant
temperature.
Engagement time (s)
Atmospheric pressure (kPa) Coolant temperature, SE2606 (° -20 –15 -10 ≥0

C):
70 0 0 0 0
75 10 10 10 0
90 30 30 15 0
Preheating is not engaged if coolant temperature is ≥ 0 °C (32 °F)

There is no preheating during the start-up phase. When the engine has started, the ECM will engage the preheating coil for post-
heating. Preheating can be interrupted by starting the engine or by turning off the ignition.
See also Wiring diagram WD264, Wiring diagram WD303, and Wiring diagram 301.

Preheating (before start)
 Ignition, SW3301  The ECM engages the
 Coolant  Ignition SW3301 in position 1 preheating coil HE2501 via
temperature,  When the symbol for preheating has gone off, the preheating relay RE2501
SE2606 engine is started by turning the ignition SW3301 to  Symbol for preheating is lit
 Atmospheric starting position. on the information panel.
pressure (internally  Post-heating engaged after engine start by
in ECM) ECM as needed.
 Monitoring, RE2501  System malfunction, open circuit or short circuit  Amber central warning
See Diagnostics  Check — Preheating failure
Pressure monitor, description
Figure 1
Differential-pressure monitor
1. Steering
2. Poppet
3. Piston
4. Spring
5. Nut
6. Sensor SE6404
The pressure monitor senses the differential pressure between the LS-pressure and the steering pressure.
Pressure monitor, description
The pressure monitor, located in one of the distribution blocks, indicates when system pressure has been reached in the channel that
is being pressurized for the moment.
There is a high pressure monitor in the pump unit to protect the system from overpressures.
The pressure monitor includes a resistor between the pins in the connector, which allows monitoring of the cable harness to the
pressure monitor.
The pressure monitor cannot be adjusted, therefore the pressure monitor may have different part numbers since different positions in
the system mean that the pressure level must be different.
Figure 1
1. Pressure chamber
2. Piston
3. Spring
4. Connector
Propeller shaft, component description
Figure 1
1. Front propeller shaft

2. Support bearing
3. Lubrication hoses
4. Intermediate propeller shaft
Propeller shafts shall be installed with all spiders and propeller shaft forks pointing in the same direction.
The support bearing's height shall be adjusted with shims so that the propeller shaft ends up in a straight line.
Pump unit, description
The pump motor drives a radial piston pump. Drive takes place via a gear that drives a shaft with an off-center washer, the same
shaft drives a stir paddle in the bottom of the reservoir. The off-center washer acts on three pistons in the radial piston pump. The
pistons pump lubricant from the reservoir through the shift valve to the connection out to the main line's channel (A or B), on to the
metering valves, and from there to the grease points. The shift valve's position is determined by in which channel (A or B) the
pressure is to be built up. After each cycle (A or B), there is a change of channel. The pressure is built up alternately in both
channels.
While the pressure builds up in one channel, the shift valve opens the passage to the reservoir for the other channel, and thus
depressurization of that channel takes place. See also Shift valve, description.
The pump pressure is limited by an overflow valve that leads the lubricant back to reservoir when the max. pressure has been
exceeded.
The pressure retaining phase is interrupted when the desired pressure is reached at the lubrication pressure sensor.
On the pump housing, there is an opening for an air breather and run-off of excess lubricant from the reservoir. When the reservoir is
filled with lubricant, the air above the follower plate will be pressed out. This air is led down through a channel in the follower plate's
guide pin and leaves the pump unit through the breather opening.
The lubricant reservoir has markings (lines) for highest and lowest level for the follower plate, thus showing the max. and min.
lubricant level.
If the reservoir is overfilled with lubricant, the drain channel in the follower plate's guide pin opens and excess lubricant drains
through the pump unit's breather opening.
When the lubricant reaches a pre-determined min. level in the reservoir, this is indicated by a level switch.
For start of one or several test cycles, the pump is provided with a test button.
The test button is also used to reset the control unit in case of error codes.
See also, System test.
Figure 1
Pump unit
1 Follower plate 11 Control unit, CU9901
2 Agent tank 12 Test button (/reset button)
3 Stir paddle 13 Filler connection
4 Off-center washer 14 Overflow (relief) valve
5 Pump piston, (3 pcs.) 15 Breather valve
6 Shift valve 16 Electrical connection
7 Connection main line, channel A 17 Level switch
8 Connection main line, channel B 18 Guide pin, follower plate
9 Gear 19 Breather channel, with connection to breather valve (15)
10 Pump motor, MO13
Rear axle, component description
For information on the drive axles' functions, see: Drive axles, description.
Figure 1
1. Drain point, oil, final drive 7. Bleed nipple, brakes (2 pcs.)

(differential carrier assembly)
2. Filler point and level 8. Brake pressure, connection (2 pcs.)
3. Breather nipple, axle 9. Hub reduction
4. Axle mounting 10. Drain point, oil, hub reduction
5. Sensor, axle oil temperature SE5223 11. Final drive (Differential carrier assembly)
6. Wear indicator, brake disc (2 pcs.) 12. ID-plate
Reversible cooling fan, description
To prevent the radiator from clogging, the machine may be equipped with a reversible cooling fan. Using the machine's software and
with the valve for the reversible fan it is possible to change the rotational direction of the fan. This is accomplished by shifting the
pressure and return side of the fan motor.
Other systems that can affect the reversible cooling fan are:

 Auxiliary brake (engine braking), description
The machine can also be equipped with various optional equipment that affects the reversible cooling fan:
 Climate control system, description

Figure 1
Hydraulic diagram for the reversible cooling fan system
Brown = hydraulic oil
Green = return oil
Grey = electrical
1. Central valve
2. Valve block reversible cooling fan
5. Hydraulic oil pump P3
MA5503 Brake pressure charging valve

MA2601 Fan delay
MA2602 Cooling fan, rotational direction (reversible fan)
PWM2602 Control cooling fan pump P3
General function
Reversal of the fan goes through a sequence of four different states to control the hydraulic oil flow to the fan. When reversal of the
fan is requested, by the operator or by the system after the timing interval has expired, the function goes through the following
phases:
1. Pre-reversing phase
When all starting conditions are fulfilled, reversing is allowed, the control unit, GPMECU1, increases the current to the valve
PWM2602 "Control cooling fan". The solenoid valve MA2601 "Fan delay" is activated. This phase lasts until the cooling fan's
rpm has dropped to 100 rpm or approx. 13 seconds have passed.
2. Reversing phase
After the fan speed has been slowed down to an adequate speed, the fan's direction of rotation is reversed when the
solenoid valve MA2602 is activated and the solenoid valve MA2601 is deactivated. The fan is kept reversed until the set time
for the selected mode has elapsed. During the reversing phase, the pump flow enters via port P and is conveyed to port B.
The return flow goes from port A to port Pd.
3. Post-reversing phase
When reversing is completed, the fan is once again decelerated to a near stand-still. The control unit, GPMECU1, increases
the current to the valve PWM2602. The solenoid valve MA2601 is activated. The delay phase lasts until the cooling fan's rpm
has dropped to 100 rpm or approx. 13 seconds have passed.
4. Normal phase
After the reversing fan speed has been slowed down to an adequate speed, normal operation is resumed when the solenoid
valves MA2602, and the solenoid valves MA2601 are deactivated. The pump flow enters via port P and is conveyed to port A.
The return flow goes from port B to port Pd. The fan rotates in the normal direction and the fan's rpm depends on the
machine's current cooling need and engine rpm. For more information about the cooling fan, see Cooling fan, description.
The reversible cooling fan and the different phases: Reversible cooling fan, principle (Animation)
Depending on setting of the reversible cooling fan, the fan can either be reversed manually by the operator or at a pre-determined
time interval.
In case of an engine warning for high charge-air temperature (the temperature value depends on which engine is used) or if the
auxiliary brake requests the cooling fan during the delay phase, the delay phase is cancelled and returns to normal phase. When
these no longer request the cooling fan, the delay phase starts again.
The reversal phase is cancelled if the AC requests more than 50% cooling fan, or if a pressure test of the cooling fan pump or a
sound test is requested during the reversal phase.
If the engine rpm has been below 1000 rpm for 10 secs the cooling fan reduces the reversal speed to 400 rpm. If the engine speed
≥1000 rpm during the reversing phase then the reversible fan speed shall be set to the maximum allowed cooling fan speed in the
current cooling fan mode.
For further information regarding the cooling fan rpm, see Cooling fan rpm, specifications.
Reversible fan starting conditions
The reversible fan shall only be activated if all of the following conditions are fulfilled:
 engine running
 pressure test of cooling fan pump not requested
 fan noise test not requested
 hydraulic oil temperature above 20 °C (68 °F)
 charge air temperature below a limit
 no fan speed requested for auxiliary braking
 hardware for stopping the fan is not malfunctioning.
To check that these conditions are fulfilled, the reversible cooling fan function get inputs from the various other systems. The input
and output signals shown in the figure below.
Figure 2
Signal diagram for the reversible cooling fan system
1 Auxiliary brake, fan speed requested, internal function, see Auxiliary brake (engine braking), description
CCM Climate control module
HMI Human-machine interface
– Reversal mode by operator
– Manual reversal activated by operator
– Pump pressure test by operator
SE2703 Engine speed (camshaft speed)
SE2512 Charge air cooler, outlet temperature
SE8709 Refrigerant pressure
MA2601 Malfunctioning deceleration, actuator alarm
PWM 2602 Pump P3 pressure control
SE2604 Fan speed
MA2601 Fan direction request
MA2602 Fan deceleration request
FX1009 Hydraulic oil temperature (SE9105)
Summary
 If a system requests increased cooling fan rpm, the fan will not be reversed.
Parameters

P1KCD Reversible cooling fan installed
P1KI6 Reversible fan mode
P1KCH Reversible fan manual reversal time
P1KCJ Reversible fan short reversal time
P1KCK Reversible fan short interval time
P1KCI Reversible fan long reversal time
P1KCE Reversible fan long interval time
Additional information

 Cooling fan rpm, specifications
Function check
 Hydraulic pump P3, checking function

 Tech Tool, 26385-3 Reversible cooling fan, test
Diagnostics
Detailed information about relevant warnings and error codes is available under the diagnostics tab.
Secondary steering, component location
Figure 1
1. Pressure monitor
2. Secondary steering pump

 Secondary steering, description
Secondary steering, description
The secondary steering equipment is used to steer the machine even if the ordinary steering pump P2 does not deliver enough flow
to reach steering pressure, for example, in case the engine stops. This pump is only intended to run for a short time, to be able to
steer the machine to safety.
Figure 1
Secondary steering

Blue Increased return pressure
Green Return, oil without pressure
1. Central valve
3. Steering valve
4. Left steering cylinder
5. Right steering cylinder
6. Pump secondary steering
7. Pressure monitor
8. Connecting valve, LS-pressure
SE4307 Sensor, output speed transmission

SE6404 Sensor, differential pressure
SE6407 Sensor, secondary steering test
RE6401 Relay, secondary steering
MO6402 Motor, secondary steering
Engagement of secondary steering

For secondary steering to engage, machine speed must exceed 3 km/h (2 mph) for at least 5 seconds, at the same time as the
machine's control unit GPMECU1 via SE6404 registers an incorrect steering pressure for more than 0.5 seconds.
During normal operating conditions, pump P2 supplies the required oil flow to the steering valve. First when the steering wheel is
turned, and the steering valve's position changes, is an oil pressure generated through the LS-channel, which gives feedback to
pump P2 about increased oil need, and the pump displacement increases.
The mechanical differential pressure sensor SE6404 monitors P2-pressure and LS-pressure. The pressure that is generated by the
oil flow from P2 normally overcomes the spring force in the sensor and the back-pressure from LS, and the circuit in the sensor
remains open.
If the pressure from pump P2 drops so much that the difference between the P2-pressure and LS-pressure is less than 7 bar, the
mechanical circuit closes in sensor SE6404. Then the differential pressure sensor SE6404 sends a signal to the machine's control
unit GPMECU1, which sends a signal to RE6401 and activates MO6402 that drives the secondary steering pump.
The secondary steering pump delivers a constant oil flow to the steering valve so that the machine can be steered, however, with
limited pressure and flow, see Secondary steering pump, specifications. If no steering is requested, the pressure in the pump is
limited by its built-in maximum pressure limiter, which opens to the machine's hydraulic tank.
When secondary steering is activated, steering is only possible with the steering wheel. In case the engine stops and CDC (Comfort
Drive Control, optional equipment) is activated, then CDC also stops working despite its symbol being shown as active in the
operator’s display, see Comfort Drive Control (CDC), description. This is so since the oil flow from the secondary steering pump is
prioritized to the steering valve directly via a built-in non-return valve. The secondary steering function continues to be activated until
the travel speed is below 3 km/h (3 mph) for more than 2 seconds, then the secondary steering function will be deactivated.
Automatic test
An automatic function test of the secondary steering pump starts every time that the engine is started and the engine speed exceeds
600 rpm. The test continues until SE6407 sends a signal indicating that the required steering pressure has been reached, which
usually takes place within one second. A error message will appear in the operator’s display if correct steering pressure level has not
been reached within 5 seconds.
Parameters
Relevant parameters for secondary steering function.

P1IUR Secondary steering installed

 Secondary steering, component location
Function check
 Tech Tool 64721-3 Secondary steering, test
Diagnostics
Service
For the machine to operate safely and at the lowest possible cost, it must receive thorough and complete maintenance. Intervals for
maintenance and lubrication refer to normal operating and environmental conditions. Maintenance work is described in the
Operator's Manual and the manual "Service and maintenance" as well as the Service Programme.
Service Programme
The checking boxes in the Service Programme show what type of service should be done for intervals from every 10 hours up to and
incl. 4000 hours. The service intervals from and incl. 4500 hours only contain the additional service points that are to be done at each
interval.
The additional service points that are to be done at the first 100 hours and 1000 hours are presented in the same way.
Time Guide
The Time Guide for service intervals for every 10 hours up to and incl. 4000 hours shows time for the total service. Intervals from and
incl. 4500 hours only show time for the additional service points.
Example, 4500 hour interval:
Do all maintenance according to the standard interval every 500 hours and also do the extra interval 4500 hours.
Follow the same example at the first 100 and first 1000 hours.
Servo system, description
The hydraulic servo system controls the working hydraulic system and is supplied with oil from hydraulic pump P2. Affected main
components for the hydraulic servo system are hydraulic pump P2, central valve, servo valve, main control valve, and boom lowering
valve.
General function
As soon as the engine starts, oil from pump P2 will be directed to the central valve’s port P and its priority spool. The priority spool
maintains a standby pressure for steering function, where all surplus oil is directed to working hydraulics, to the servo system, and to
charging the accumulator for the boom lowering function.
If the steering is used, the priority spool in the central valve will direct oil from pump P2 to the steering function. Since pump P2’s
maximum oil feed capacity is more than is needed for maximum steering, the servo circuit will still be maintained by minimum servo
pressure.
Even though the working hydraulics and steering can reach high oil pressures, an adjustable pressure limiting valve in the central
valve ensures that the servo circuit's oil pressure does not exceed maximum servo pressure Servo system, specifications, see figure
below.
Figure 1
Oil from pump P2 supplying servo circuit

Green Return oil
1. Central valve
2. Servo valve
4. Boom lowering valve
5. Pressure limiting valve, servo circuit
SW9141 Switch, automatic tilt-in

SW9144 Switch, float mode
MA9141 Hold solenoid, bucket positioner
MA9142 Hold solenoid, boom kick-out
From the central valve’s port PR, servo pressure oil is directed to the boom lowering valve where the accumulator for the boom
lowering function is charged via a non-return valve Hydraulic diagram, complete. The purpose of the accumulator is to provide
sufficient servo pressure for affecting the directional spool in the main control valve, so that the boom can be lowered safely with the
engine off.
Control of working hydraulics
The servo valve’s basic function resembles that of a pressure limiting valve. In neutral position the valve spool is closed, which shuts
out the servo pressure, while the servo connection to the spool in the main control valve is drained to tank. When the output servo
pressure reaches a value corresponding to the lever deflection, and thereby the servo valve spool’s spring force, the valve closes.
This results in a controlled oil pressure, which acts on the main control valve’s spool.
With enabled SW9141 for automatic tilt, the servo lever is held in tilt-in position by hold solenoid MA9141 until the pre-set position
from inductive sensor SE9156 is reached. The pre-set position can be adjusted by changing the position of the inductive sensor on
its bracket.
With enabled SW9142 for automatic lift, the servo lever is held in lift position by hold solenoid MA9142 until the pre-set position from
inductive sensor SE9157 is reached. The pre-set position can be adjusted by changing the position of the inductive sensor on its
bracket.
With enabled SW9144 for float mode, the servo lever is held in lowering position by hold solenoid MA9143 until SW9144 is disabled.
Figure 2
Servo valve, diagram for automatic lift with enabled solenoid awaiting signal from inductive sensor.

MA9141 Hold solenoid, automatic tilt
MA9142 Hold solenoid, automatic lift
SW9141 Switch, automatic tilt
SW9144 Switch, float mode
SE9156 Inductive sensor, automatic tilt
SE9157 Inductive sensor, automatic lift
See Working hydraulic system, description for more information about automatic hydraulic functions.
Servo pressure can be prevented from being directed to the hydraulic control valves if the lever lock is engaged. This lock prevents
movement of the servo control levers.
Figure 3
Activated lever lock disables the movement of the servo levers.
1. Lever lock
Note! If 4th hydraulic function is installed, the servo lever lock is enabled with SW9174 which activates MA9112, preventing servo
pressure oil from being directed to the servo levers or single lever [1]
Figure 4
Activated lever lock disables servo pressure feed to the servo valve.
1. Lever lock
To obtain emergency boom lowering function, the ignition key must be in position "I" when the engine is off and the servo circuit
accumulator must be charged.
Parameters
Relevant parameters for servo system function.

- -

Function check
 Servo pressure, checking and adjusting

 Accumulator removed, checking
Diagnostics
Component Information
MA9141 See MA9141, description and measuring.
SE9156 See SE9156, description and measuring.
SE9157 See SE9157, description and measuring.
[1](Optional equipment)
Servo valve, description
Figure 1
Servo valve
1. Thrust pin
2. Valve spool
3. Spring
4. Connection to control valve
The servo valve has a closed centre and has one section for each hydraulic function. One function for lifting and tilting respectively.
The servo valve is equipped with detent solenoids (electro magnets) for the floating position, bucket positioner and boom kick-out.
If the machine is equipped with 3rd or 3rd/4th functions, the servo valve will consist of three or four sections.
Shift valve, description
The shift valve opens and closes the pump's connection with the main lines' channels during the lubrication cycle.
The shift valve's valve slide is acted on by a spring and a solenoid.
In resting position the valve slide is acted on by the spring, in affected position the solenoid is activated and overcomes the spring
force, and thus displaces the valve slide.
In resting position channel P has a connection with the main line's channel A, at the same time lubricant is drained back from the
main line's channel B to the reservoir through channel Rb.
In affected position channel P has a connection with the main line's channel B, at the same time lubricant is drained back from the
main line's channel A to the reservoir through channel Ra.
Figure 1
Shift valve in resting position
A Main line channel A

B Main line channel B
P Channel from pump
Ra Return channel to reservoir
Rb Return channel to reservoir
Software parameters, description
New Incorrectly set parameters may cause malfunction symptoms. Check the parameter values so that these are reasonable by
comparing them to the correct values and limits. Use Tech Tool to check the parameters.
There are two types of parameters that can be programmed, machine parameters (MP) and customer parameters (CP).
Machine parameters are of the accessory type or legal requirements, and does not requires on-line connection to the Volvo data
base VDA (Vehicle Data Administration) to enable programming. The machine parameters are reported to VDA when an on-line
connection is present.
Customer parameters does not require on-line connection, they can be programmed directly.
The “Default set” values are factory settings for a machine without options. The values are valid for machine models L60H, L70H,
L90H, L110H, L120H, L150H, L180H, L220H and L250H unless stated in “Additional explanation”
NOTE!
Default set parameters in the description can be different according to the options installed on the machine and to the changes made
during machines lifetime.
Engine control module(ECM)
DOID[T1] Titles in Tech Tool / Type Default set Set range

Description in Tech Tool Additional explanation
P1AM4 Injector Cylinder 1, Calibration / MP – –
The connector on the unit injector displays the 9 character Valid for L150H–L250H
trim code (T/C). New code must be programmed after
replacing the unit injector. Used for unit injector with trim
code.
code.
code.
code.
code.
code.
P1E3I Engine Idle, Minimum Allowed Speed / MP 650 0–1000
Minimum allowed engine speed at idle. Valid for L60H–L90H
Min value=0 r/min
Max value=1000 r/min
P1F9W Engine Idle, Target Speed / CP 700 0–2000
Target engine speed at idle. Valid for L60H–L90H
Min value=0 r/min
P1G3K EECU Identification / CP – –
Engine manufacturer specific information Valid for L60H–L90H
(DEUTZ_ECU_ID)
P1G3L Engine Specific Data / CP – –
Engine manufacturer specific information (engine number) Valid for L60H–L90H
(DEUTZ_DATA).
P1G3O Trimcode CRIN3.3 Injector Cylinder 1 / CP – –
The new trim code must be programmed after replacing Valid for L60H–L90H
the unit injector. The trim code (T/C) is shown on the
injector label and consists of up to 10 characters.
P1G3P Trimcode CRIN3.3 Injector Cylinder 2 / CP – –
P1G3Q Trimcode CRIN3.3 Injector Cylinder 3 / CP – –
P1G3R Trimcode CRIN3.3 Injector Cylinder 4 / CP – –
P1G3S Trimcode CRIN3.3 Injector Cylinder 5 / CP – –
P1G3T Trimcode CRIN3.3 Injector Cylinder 6 / CP – –
P1HT6 Maximum Idle ESPD at Warm Up ON / CP See list below 600–2800
Maximum allowed idle ESPD when warm up functionality L60H-L90H=1100 r/min
is enabled. ESPD - Engine Speed L150H-L250H=2800 r/min
Min value=600 r/min
P1I18 Customer Shutdown for Coolant Temperature / CP 0 –
Customer shutdown status. Valid for L60H–L90H
0=No action
1=Forced idle
2=Shut off engine
P1I19 Customer Shutdown for Oil Pressure / CP 0 –
Customer shutdown status. Valid for L60H–L90H
0=No action
1=Forced idle
2=Shut off engine
[T1] DOID = Diagnostic Object Identity
DOID Titles in Tech Tool / Type Default set Set range

P1I20 Hand Throttle Installed / MP 0 –
Activation of the function when hand throttle is installed on 0=Not installed
the machine. An error code will be set if the parameter is 1=Installed
activated without the hardware.
P1JKQ Axle Oil Cooling Installed / MP 0 –
Activation of the function when axle oil cooling is installed 0=Not installed
on the machine. 1=Installed
P1K6N Central Lubrication Installed / CP 0 –
Activation of the function when the hardware is installed on 0=Not installed
the machine. 1=Installed
P1K6L Automatic Engine Shut Off Installed / MP 0 –
Activation of the function automatic engine shut off.The 0=Not installed
function automatically shuts off the engine after being idle 1=Installed
for a certain time.
P1K6M Automatic Engine Shut Off, Idle Time / CP 4 2–50
Setting of time in minutes until automatic engine shut off. Min value=2 min
The function automatically shuts off the engine after being Max value=50 min
idle for the selected time.
P1K9X Regeneration Type / MP 2 –
Parameter to set the type of regeneration of the exhaust 1=Optional, regeneration is only activated manually,
aftertreatment system. machine parked.
2=Standard, regeneration starts automatically during
operation.
P1KBD Engine Oil Change Interval / CP 0 –
Selection of engine oil change interval. This function 0=125 h
informs the driver when 8 hours remain to next oil change. 1=250 h
2=500 h
P1KBI Transmission Declutch Installed / MP 0 –
Activation of the function when transmssion declutch is 0=Not installed
installed on the machine. 1=Installed
P1KCD Reversible Fan Mode / CP 3 –
Defines which type of mode to use for reversing the cooling 0=Manual
fan. 1=Long
2=Short
3=Off
P1KI6 Reversible Cooling Fan Installed / MP 0 –
Activation of the function when reversible cooling fan is 0=Not installed
installed on the machine. An error code will be set if the 1=Installed
parameter is activated without the hardware.
P1KLM Legal Machine Speed Limit / MP 0 20–40
Selection of maximum machine speed to fulfill the legal 0=No limit
requirements. When Off is selected the machine speed can 1=20 km/h
not be higher than the technical requirements. For more 2=30 km/h
information see other service information. 3=40 km/h
P1KLN CDC speed limit / MP 0 –
Selection of maximum machine speed when CDC (Comfort 0=No limit
Drive Control) is installed and activated. 1=20 km/h
2=30 km/h
P1LDP Washer Fluid Alarm Installed / MP 0 –
The function informs the operator when the washer fluid 0=Not installed
level is low. 1=Installed
P1LKN Turbo Hot Shut Down Notification / MP 3 –
Configure the presentation conditions for showing the 0=No notification.
"Turbo Hot Shut Down Notification"-picture. 1=60 second engine idle timer until OK to shut down.
2=120 second engine idle timer until OK to shut down.
3=Engine load monitoring
P1LKO Postlubrication System Installed / MP 0 –
Indicates whether the machine is equipped with a 0=Not installed
postlubrication system. 1=Installed
P1LKP Idle Control Installed / MP 0 –
The function prevent the engine speed from dropping too 0=Not installed
low too fast to avoid engine stall at high power outlet at low 1=Installed with hydraulic servo lever
engine speed. 2 = Installed with electric servo lever
P1LKQ Warm Up Idle Speed / MP 700 0–700
Warm up idle speed is defined as the idle speed that is Min value=0 rpm
used to let the machine warm up when Idle control function Max value=700 rpm
is installed.
P1LSS Entry Light Timer / CP 180 0–300
The time in seconds that the entry light stays lit after Min value=0 s
activation. Max value=300 s
P1LSV Anti-Theft Time Delay / MP 15 3–180
The time the ignition is allowed to be off before the anti- Min value=3 min
theft is reactivated and a new operator authorization is Max value=180 min
required.
P1LSW Anti-Theft System Activation / MP 0 –
Activation of the anti-theft functionality in the machine. 0=Not activated
1=Activated
P1LSX Anti-Theft Protection PIN Code / CP 1234 0–9999
Operators 4 digit PIN code, used to be able to start the Min value=0
machine if the Anti-theft system is activated. Max value=9999
P1LWK Distance Driven Installed / MP 0 –
Activates the function Distance driven in Operational Data 0=Not installed
menu on the drivers display. 1=Installed
Caretrack control unit (WECU)

P1K59 Satellite Modem Activation / MP 1 –
Informs the Telematics ECU if the Satellite Modem is 0=Satellite Modem function deactivated
activated or deactivated. The Satellite Modem function 1=Satellite Modem function activated
requires additional hardware to be installed.
P1K6A GSM Modem Activation / MP 1 –
Informs the Telematics ECU if the GSM Modem is activated 0=GSM Modem function deactivated
or deactivated. 1=GSM Modem function activated
P1K6I Country Code Used in GSM SMS Number / MP 1 –
Used to add the Country code in the beginning of the GSM 0=Country code not used in GSM SMS numbers
SMS numbers for telematics communication. 1=Country code used in GSM SMS numbers

P1KQI Air conditioning installed / MP 0 –
Activation of the Air Condition function when the hardware 0=Not installed
is installed on the machine. 0 = Not installed 1 = Installed 1=Installed
P1KQL Cab Pause Heating Installed / MP 0 –
Activation of the cab pause heating function when the 0=Not installed
hardware (Pause heating pump) is installed on the 1=Installed
machine.
P1KQT Air Condition cycling level / MP 0 –
Activation of the AC Cycling Level function when the 0=Not installed
hardware is installed on the machine. 1=Type 1 (Off = 3, On = 7)
The values for the different types defines at which 2=Type 2 (Off = 2, On = 5)
temperature, in degrees Celsius, the AC shuts off and on 3=Type 3 (Off = 4, On = 8)
to prevent ice formation on the Air Conditioning 4=Type 4 (Off = 1, On = 6)
evaporator.
P1KQU Cab Fan Speed Limitation With Open Door Installed / 0 –
MP
Activation of the Cab Fan Speed Limitation with open door 0=Not installed
function. 1=Installed
P1KQW Climate Control System Heating Element Installed / 0 –
MP
Activation of the Climate Control System Heating function 0=Not installed
when the hardware is installed on the machine. 1=Installed
P1KQX Cab Pause Heating, Start Temperature / MP 20 20–26
Selection of cab temperature when pause heater starts. Min value=20 degrees Celsius
Max value=26 degrees Celsius

P1I5Y Parking Brake Not Applied Alert, Installed / MP 0 –
Activation of the parking brake not applied alert function 0=Not installed
P1IUR Secondary Steering Installed / MP 0 –
Activation of the secondary steering function when 0=Not installed
secondary steering hardware is installed on the machine. 1=Installed with automatic test
P1JKP Cooling Fan Mode / MP 0 –
Selection of cooling fan modes for different markets/needs. 0=Not applicable
1=Mode A (Low Noise)
2=Mode B (Standard Cooling)
P1JKQ Axle Oil Cooling Installed / MP 0 –
Activation of the function when axle oil cooling is installed 0=Not installed
on the machine. 1=Installed
P1JKS Attachment Bracket Installed / MP 0 –
Activation of the function when attachment bracket is 0=Not installed
P1JMC CDC Installed / MP 0 –
Activation of the CDC (Comfort Drive Control) function 0=Not installed
P1K10 Boom Suspension Disconnection, Reverse, FAPS On / 0 0–20
CP
Boom suspension, speed dependent disconnection. Min value=0 km/h
Setting of speed for disengaging of boom suspension Max value=20 km/h
when gear selector is in reverse position and automatic
downshift to first gear (FAPS) is activated.
P1K11 Boom Suspension Disconnection, Forward, FAPS Off / 5 5–20
CP
when gear selector is in forward position and automatic
downshift to first gear (FAPS) is deactivated.
P1K12 Boom Suspension Engagement, Reverse, FAPS Off / 6 2–20
CP
Boom suspension, speed dependent engagement. Setting Min value=2 km/h
of speed for engagement of boom suspension when gear Max value=20 km/h
selector is in reverse position and automatic downshift to
first gear (FAPS) is deactivated.
P1K1Y Boom Suspension Installed / MP 0 –
Activation of the function when BSS Boom suspension, is 0=Not installed
P1K1Z Boom Suspension Disconnection, Forward, FAPS On / 8 8–20
CP
when gear selector is in forward position and automatic
downshift to first gear (FAPS) is activated.
P1K6N Central Lubrication Installed / MP 0 –
The parameter activates the display and error code 0=Not installed
function when central lubrication is installed on the 1=Installed
machine. For more information about the parameter For L180H HL default = 1
consult other service information. An error code will be set
if the parameter is activated without the hardware.
P1KBV Hydraulic Oil Heater Installed / MP 0 –
Activation of the function Hydraulic Oil Heater. 0=Not installed
1=Installed
P1KCD Reversible Cooling Fan Installed / MP 0 –
Activation of the function when reversible cooling fan is 0=Not installed
P1KCE Reversible Fan Long Interval Time / CP 30 5–180
Time in minutes between reversing of the cooling fan. This Min value=5 min
setting is used by the system if reversible fan is activated Max value=180 min
and "Long" is selected in the drivers display. The selected
time must be longer than the Short interval.
P1KCH Reversible Fan Manual Reversal Time / CP 180 60–180 s
Time in seconds when the cooling fan reversion is ongoing Min value=60 s
if the setting "Manual" is selected in the drivers display. Max value=180 s
P1KCI Reversible Fan Long Reversal Time / CP 30 20–180
Time in seconds when the cooling fan reversion is ongoing Min value=5 min
if "Long" is selected in the drivers display. The selected Max value=180 min
time must be longer than the Short reversal time.
P1KCJ Reversible Fan Short Reversal Time / CP 20 20–180
Time in seconds when the cooling fan reversion is ongoing Min value=20 s
if the setting "Short" is selected in the drivers display. The Max value=180 s
selected time must be shorter than the Long reversal time.
P1KCK Reversible Fan Short Interval Time / CP 15 5–180
Time in seconds between reversing of the cooling fan. The Min value=5 s
selected time must be shorter than the Long Interval. This Max value=180 s
setting is used by the system if reversible fan is activated
and "Short" is selected in the drivers display.
P1KHI Hydraulic Flow Control Power Offset / MP 0 0–100
Used to move the curve in the flow range by modify the Min value=0%
offset of the function. Increased value result in more Max value=100%
hydraulic flow, but larger risk that engine stalls at high
altitude.
P1KHJ Hydraulic Flow Control Engine Speed Offset / MP 0 0–200
Used to move the curve in the flow range by modify the Min value=0 rpm
offset of the function. Increased value result in more Max value=200 rpm
hydraulic flow, but larger risk that engine stalls at high
altitude.
P1KI6 Reversible Fan Mode / CP 3 –
Defines which type of mode to use for reversing the 0=Manual
cooling fan. 1=Long
2=Short
3=Off
P1LIR LS Pressure Sensor, Installed / MP 0 –
Parameter defines if LS Pressure (load sensing pressure) 0=Not installed
sensor is installed. 1=Installed
P1LSX Anti-Theft Protection PIN Code / CP 0 0–9999
Operators 4 digit PIN code, used to be able to start the 0 – 9999
machine if the Anti-theft system is activated.

P1J70 Boom Lower End Position / MP -500 -3142 to 3142
The calibrated lower end position value of the boom. The Min value=-3142 mRad
calibrated value is a calculated correction factor for the Max value=3142 mRad
lower end position.
P1J71 Boom Upper End Position / MP 2000 -3142 to 3142
The calibrated upper end position value of the boom. Min value=-3142 mRad
Max value=3142 mRad
P1J7W Tilt Out, Position 3, End Position Calibration Value / 0 -3142 to 3142
MP
The calibrated tilt value for the 3rd position. Min value=-3142 mRad
Max value=3142 mRad
P1J7X Tilt In, Position 2, End Position Calibration Value / MP 0 -3142 to 3142
The calibrated tilt value for the 1st position. Min value=-3142 mRad
Max value=3142 mRad
P1J7Y Tilt Out, Position 1, End Position Calibration Value / 0 -6283 to 6283
MP
The calibrated tilt value for the 1st position. Min value=-6283 mRad
Max value=6283 mRad
P1J7Z Tilt In, Position 4, End Position Calibration Value / MP 0 -3142 to 3142
The calibrated tilt value for the 4th position. Min value=-3142 mRad
Max value=3142 mRad
P1J90 Tilt Out, Start Current Calibration Value / MP 250 0–3000
The calibrated start current value for the function. Min value=0 mA
Max value=3000 mA
P1J91 Tilt Out, End Current Calibration Value / MP 675 0–3000
The calibrated end current value for the function. Min value=0 mA
Max value=3000 mA
P1J92 Tilt In, Start Current Calibration Value / MP 250 0–3000
Max value=3000 mA
P1J93 Tilt In, End Current Calibration Value / MP 0 0–3000
Max value=3000 mA
P1J9R Boom Function and Lever Type Installed / MP 0 –
The parameter defines which type of lever that are 0=Not installed
installed with the boom. 1=Boom function is installed with standard lever
2=Boom function is installed with single lever
P1J9S Tilt Function and Lever Type Installed / MP 0 –
The parameter defines which type of lever that are 0=Not installed
installed with the tilt. 1=Tilt function is installed with standard Lever
2=Tilt function is installed with single lever
P1J9T Boom Function Filter Type Installed / MP 0 –
The low pass filter provides smother movements of the 0=Not installed
function. The band stop filter prevents self-oscillating lever 1=Low pass filter installed
movements. 2=Low pass filter and bandstop filter installed
P1J9U Tilt Function Filter Type Installed / MP 0 –
P1J9W Boom Down, Start Current Calibration Value / MP 250 0–3000
Max value=3000 mA
P1J9X Boom Down, End Current Calibration Value / MP 590 0–3000
Max value=3000 mA
P1J9Y Boom Up, Start Current Calibration Value / MP 250 0–3000
Max value=3000 mA
P1J9Z Boom Up, End Current Calibration Value / MP 675 0–3000
Max value=3000 mA
P1KBJ 4:th Function Installed / MP 0 –
Activation of the 4:th function when electric servo lever 0=Not installed
control hardware is installed on the machine. 1=Type 1, 4:th function is installed with standard lever
2=Type 2, 4:th function is installed with single lever
P1KH0 CDC Right End Angle Calibrated Value / MP -1500 -6283 to 6283
An angle value of the calibrated right end position for the Min value = -6283 mrad
CDC (Comfort Drive Control). Max value = 6283 mrad
P1KH4 3:rd Function End Current Negative Valve / MP 630 0–3000
Max value=3000 mA
P1KHK 4:th Function Filter Type Installed / MP See list below –
L110H–L120H, L350F=1
L150H–L250H=2
P1KHL 4:th Function Start Current Negative Valve / MP 270 0–3000
Max value=3000 mA
P1KHM 4:th Function End Current Negative Valve / MP 630 0–3000
Max value=3000 mA
P1KHN 4:th Function Start Current Positive Valve / MP 270 0–3000
Max value=3000 mA
P1KHO 4:th Function End Current Positive Valve / MP 630 0–3000
Max value=3000 mA
P1KHP 3:rd Function End Current Positive Valve / MP 630 0–3000
Max value=3000 mA
P1KHQ 3:rd Function Start Current Positive Valve / MP 270 0–3000
Max value=3000 mA
P1KHR 3:rd Function Start Current Negative Valve / MP 270 0–3000
Max value=3000 mA
P1KHS 3:rd Function Filter Type Installed / MP 0 –
P1KHV 3:rd Function Installed / MP 0 –
Activation of the 3rd function when electric servo lever 0=Not installed
control hardware is installed on the machine. 1=Type 1, 3rd function is installed with standard lever
2=Type 2, 3rd function is installed with single lever
P1KHY CDC End Position Retardation Installed / CP 0 –
Activation of the function CDC (Comfort Drive Control) end 0=Not installed
position retardation. 1=Installed
P1KHZ CDC Left End Angle Calibrated Value / MP 1500 -6283 to 6283
An angle value of the calibrated left end position for the Min value=-6283 mRad
CDC (Comfort Drive Control). Max value=6283 mRad
P1KJ3 CDC Left, Start Current Calibration Value / MP 255 0–3000
Max value=3000 mA
P1KJ4 CDC Left, End Current Calibration Value / MP 655 0–3000
Max value=3000 mA
P1KJ5 CDC Right, Start Current Calibration Value / MP 255 0–3000
Max value=3000 mA
P1KJ6 CDC Right , End Current Calibration Value / MP 655 0–3000
Max value=3000 mA
P1KJN Boom Function End Position Retardation Type / CP 0 –
Type of retardation that is installed. 0=No retardation
1=Type 1 retardation upper end position
2=Type 2 retardation lower and upper end position
3=Type 3 retardation lower end position

P1I22 Tyre Size / CP See list below 1000–9999
The circumference of the tyres used on the machine. Range: 1000 – 9999 mm
L60H–L90H=4681 mm
L110H–L120H=5121 mm
L150H–L180H=5561 mm
L220H–L250H=5875 mm
L350F=6440 mm
P1JMH Transmission Protective Downshift / MP 0 –
Transmission Protective Downshift 0=Not installed
1=Installed
P1JO0 Spring Pressure Clutch 1 / MP See list below 0–1000
The calibrated spring pressure for the clutch. Min value=0 kPa
Max value=1000 kPa
L60H–L90H=287 kPa
L110H–L180H=250 kPa
L220H–L250H=268 kPa
P1JOP Fill Time Clutch 4 / MP See list below 0–500
The calibrated nominal fill time for the clutch. Min value=0 ms
Max value=500 ms
L60H–L90H=160 ms
L110H–L180H=170 ms
L220H–L250H=200 ms
P1JOQ Fill Time Clutch 3 / MP See list below 0–500
Max value=500 ms
L60H–L90H=160 ms
L110H–L180H=170 ms
L220H–L250H=200 ms
P1JOR Fill Time Clutch 2 / MP See list below 0–500
Max value=500 ms
L60H–L90H=150 ms
L110H–L180H=120 ms
L220H–L250H=170 ms
P1JOS Fill Time Clutch 1 / MP See list below 0–500
Max value=500 ms
L60H–L90H=170 ms
L110H–L180H=120 ms
L220H–L250H=180 ms
P1JOT Fill Time Clutch R / MP See list below 0–500
Max value=500 ms
L60H–L90H=180 ms
L110H–L180H=150 ms
L220H–L250H=200 ms
P1JOU Fill Time Clutch F / MP See list below 0–500
Max value=500 ms
L60H–L90H=180 ms
L110H–L180H=150 ms
L220H–L250H=200 ms
P1JOV Spring Pressure Clutch R / MP See list below 0–1000
Max value=1000 kPa
L60H–L90H=336 kPa
L110H–L180H=300 kPa
L220H–L250H=264 kPa
P1JOW Spring Pressure Clutch F / MP See list below 0–1000
Max value=1000 kPa
L60H–L90H=336 kPa
L110H–L180H=300 kPa
L220H–L250H=264 kPa
P1JOX Spring Pressure Clutch 4 / MP See list below 0–1000
Max value=1000 kPa
L60H–L90H=338 kPa
L110H=197 kPa
L120H=150 kPa
L150H=197 kPa
L180H=240 kPa
L220H–L250H=321 kPa
P1JOY Spring Pressure Clutch 3 / MP See list below 0–1000
Max value=1000 kPa
L60H–L90H=338 kPa
L110H=200 kPa
L120H=210 kPa
L150H=200 kPa
L180H=250 kPa
L220H–L250H=339 kPa
P1JOZ Spring Pressure Clutch 2 / MP See list below 0–1000
Max value=1000 kPa
L60H–L90H=302 kPa
L110H–L180H=350 kPa
L220H–L250H=268 kPa
P1JY2 Lever Console Type Installed / MP 0* –
Describes which type of lever console the machine is 0=Not installed
equipped with. 1=Lever console
2=Single lever console
For L180H default = 1
P1K6P Engine Speed Limiter On. Time Hour / CP 0 –
Hour when the engine speed limiter should be activated. Min value=0
Example: Parameter value is 18. Parameter Engine Speed Max value=23
Limiter On Time Minutes is set to 15. Then engine speed
limiter will be activated at 18:15.
P1K6Q Engine Speed Limiter On. Time Minutes / CP 0 –
Minute when the engine speed limiter should be activated. Min value=0
Example: Parameter value is 15. Parameter Engine Speed Max value=59
Limiter On Time Hour is set to 18. Then engine speed
limiter will be activated at 18:15.
P1K6R Engine Speed Limiter Off. Time Hour / CP 0 –
Hour when the engine speed limiter should be Min value=0
deactivated. Example: Parameter value is 6. Parameter Max value=23
Engine Speed Limiter Off Time Minutes is set to 15. Then
engine speed limiter will be deactivated at 06:15.
P1K6S Engine Speed Limiter Off. Time Minutes / CP 0 –
Minute when the engine speed limiter should be Min value=0
deactivated. Example: Parameter value is 15. Parameter Max value=59
Engine Speed Limiter Off Time Hour is set to 6. Then
engine speed limiter will be deactivated at 06:15.
P1K6T Maximum Time Controlled Engine Speed / CP 1800 1800–5000
Maximum engine speed when engine speed limiter is Min value=1800 rpm
activated. Max value=5000 rpm
P1K6O Time Controlled Engine Speed Limiter Activation / MP 0 –
Activation of the function time controlled engine speed 0=Not activated
limiter. 1=Activated
P1KBI Transmission Declutch Installed / MP 0 –
Activation of the function when transmission declutch is 0=Not installed
installed on the machine. 1=Installed
P1KBE Transmission Declutch Pressure Level 1 / MP See list below 0–10000
The brake pressure at which the transmission declutch is Min value=0 kPa
activated if the first transmission declutch setting is used. Max value=10000 kPa
L60H–L180H=800 kPa
L220H–L250H=1600 kPa
L350F=800 kPa
P1KBF Transmission Declutch Pressure Level 2 / MP See list below 0–10000
activated if the second transmission declutch setting is Max value=10000 kPa
used. L60H–L180H=1400 kPa
L220H–L250H=2200 kPa
L350F=1400 kPa
P1KBG Transmission Declutch Pressure Level 3 / MP 3000 0–10000
activated if the third transmission declutch setting is used. Max value=10000 kPa
P1KBH Transmission Declutch Pressure Level 4 / MP 3500 0–10000
activated if the fourth transmission declutch setting is Max value=10000 kPa
used.
P1KBR Transmission Declutch Speed Limit / MP 3 0–50
Speed limit up to which it is possible to use the Min value=0 km/h
transmission declutch function. Max value=50 km/h
Software, parameter settings and read-outs
Parameter settings and read-outs for the connected control unit are shown under four different tabs. "Main", "Parameters", "Errors"
and "Diagnosis ". Click on the name of the tab in question to show the tab.
NOTE!
The tabs "Parameters", "Errors" and "Diagnosis" are only shown if communication has been established between the computer and
the control unit.
Tab "Main" (F9)
The tab "Main" shows the most important details for the pump unit, the control unit and its hardware.
Figure 1
General information
Last user ID Shows the identification number for the user who last connected the computer or diagnostic
unit to the control unit. The number is updated when the connection between the computer
and control unit is cut off.
Access date of last user Shows time and date when computer or diagnostic unit last was connected to the control
unit. Time and date are updated when the connection between the computer and control unit
is cut off.
Last parameter load ID Shows the identification number for the user who last changed a setting for this control unit.
The number is updated when the connection between the computer and control unit is cut off
if any setting has been changed.
Date last parameter load Shows time and date when settings last were changed for this control unit. Time and date are
updated when the connection between the computer and control unit is cut off if any setting
has been changed.
Current user ID Shows the current user's identification number. This number will be stored in the control unit.
Authorization level Shows the authority level that has been set for the used software. Normally, the authority
level is set to 100. This setting cannot be changed.
Date/Time
Current date Shows current date.
Current time Shows current time.
Dealer
Shows dealer's name
Registration date Shows date software was registered
Product information
Part number Shows part number of the connected control unit.
Serial number Shows serial number of the connected control unit.
Timer version Shows timer version of the connected control unit.
History
Total pumping time Shows the total number of hours that the pump has been activated.
Total operating time Shows the total number of hours that the control unit has been activated.
Total grease cycles Shows the total number of lubrication cycles that the system has performed since it was
installed.
total eeprom writes Shows number of times that settings/parameters have been changed and saved when
ignition key has been turned to position 0.
Variables
Remaining cycle time Shows time that remains of the lubrication cycle in progress. This time can be changed by
double-clicking on the current value and changing it to the desired value. Press "Enter" on
the keypad to approve the indicated value. It's advantageous to use this, for example, to start
the pump phase immediately.
Phase Shows in which phase of the lubrication cycle that the system is for the moment.
Last pumping time Shows duration of the last pump phase (in seconds).
Tab "Parameters" F10

The tab "Parameters" shows the parameter settings that control the lubrication cycles. The tab can be used to view the parameters
and to change them.
There are two ways to change parameter settings:
1. Click on the small arrow button to the right of the value to increase or decrease the current parameter setting.
2. Double-click on the value and enter a new value with the number keys on the keypad.
If you want to save all parameter changes, click on "Save", select Save from the File menu or press the keys Ctrl+S. Now, the Save
window opens and you may select where the changed parameter settings should be saved and what the file name should be.
To reset parameter settings, press the button "Restore".
To download parameter settings to the control unit, select Load Parameters from the File menu or press the keys Ctrl+L. The window
Open opens and you can select a file with parameter settings to be downloaded. When you've selected file and clicked on "Open" the
program wants you to confirm the download.
Figure 2
Timer Parameters Group A

Heavy duty cycle Lubrication cycle's duration according to setting for demanding conditions.
Normal duty cycle Lubrication cycle's duration according to setting for normal conditions.
Low duty cycle Lubrication cycle's duration according to setting for light conditions.
Maximum pump time Maximum duration of pump phase.
Venting multiply factor The factor (shown value divided by 10) with which the pump phase's actual duration should
be multiplied to be able to calculate the duration of the pressure reduction phase. Example: A
value of 15 gives a multiplication factor of 1.5.
Cycle mode select Shows which lubrication cycle has been selected. If this parameter is set to "Button
disabled", it is not possible to change the selected lubrication cycle with the button on the
instrument panel. If this parameter is set to "Button disabled", the lubrication cycle is always
"lubrication cycle".
Number of attempts Shows the number of consecutive lubrication cycles allowed without required lubrication
pressure being reached. When this value is exceeded, no further attempts will be made and
the control light will be activated with a fixed glow.
Display duty count Shows how many times the control light will repeat the signal for selected lubrication cycle
each time the ignition key is turned from position 0.
Command signal inverted In applicable cases where the function is installed, it decides when the pump should be
activated.
No= The control unit is activated when there is a "comm.signal", that is, when pin 3
in the electrical connection is supplied with current.
Yes= The control unit is activated when there is no "comm.signal", that is, when pin 3
in the electrical connection is not supplied with current.
Tab "Errors” (F11)

The tab "Errors" shows the number of errors and what type of malfunction that has occurred in the system.
Error categories
Since installation Number of times error has occurred since pump unit was installed.
Since last correction Number of times error has occurred since the last correct lubrication cycle. The numbers
increase each time the error occurs, but is reset if the error didn't occur in the subsequent
lubrication cycle.
Max. nr. in succession Number of times error has occurred in consecutive lubrication cycles. The values are
updated only if a new session's number of repeated errors exceeds the number of errors in
an earlier session.
Figure 3
Errors
No pressure change line A The lubrication pressure sensor was not activated during lubrication cycle A.
No pressure change line B The lubrication pressure sensor was not activated during lubrication cycle B.
System on pressure before grease The lubrication pressure sensor was still activated when the next lubrication cycle started.
cycle The pressure never dropped during the previous pressure reduction phase.
Overcurrent pump circuit The electric current to the pump motor has been too high, for example, due to short-circuiting
in the motor.
Open load pump circuit The electric current to the pump motor has been too low, for example, due to open circuit in
the cable.
Overcurrent lamp circuit The electric current to the control light has been too strong.
Open load lamp circuit The electric current to the control light has been too weak.
Overcurrent valve circuit The electric current to the shift valve has been too strong.
Open load valve circuit The electric current to the shift valve has been too weak.
Low level detection Low level in lubricant reservoir has been registered.
Empty reservoir Low level in lubricant reservoir has been registered at the same time as maximum pump time
has been reached (since there wasn't enough lubricant).
Tabn “Diagnosis” (F12)

The tab "Diagnosis 2" shows the status of the control unit's input and output signals using an information field.
If the information field is green, it means that an input or output signal has been activated. A grey information field means that the
signal has been deactivated.
Figure 4
Input/Output
Pump on The pump motor is engaged.
Valve on The shift valve is affected.
Lamp on The control light is on.
Pressure The lubrication pressure sensor is closed.
Command Signal inverted The control unit is activated when there is a control signal.
OL pump No current in the pump circuit. The pump's circuit is open. This indication is valid only when
the pump normally isn't active.
OL valve No current in the shift valve's circuit. The shift valve's circuit is open. This indication is valid
only when the shift valve normally isn't activated.
OL lamp No current in the control light's circuit. The control light's circuit is open. This indication is valid
only when the control light normally isn't activated.
Low level The level monitor is closed.
Test The test button on the pump unit is pressed in.
OC pump Short-circuiting in pump motor's circuit.
OC valve Short-circuiting in shift valve's circuit.
OC lamp Short-circuiting in control light's circuit.
Command Signal There is a control signal, that is, the control unit is active.
(Spare) Not used.
Under the tab "Diagnosis", it's possible to by-pass the control unit and affect the output signals manually.
Normally, the pump is in Automatic mode.
By selecting Manual mode, the output signals are put under manual control. Three buttons are then visible under the information
fields. By clicking on these buttons, it's possible to manually activate or deactivate the pump motor, the shift valve and the control
light.
NOTE!
The system returns to Automatic mode when the start key is turned to position 0 and back to 1 again.
By selecting Single cycle mode, a single lubrication test cycle is initiated. A test cycle cannot be initiated during on-going pump
phase.
NOTE!
By selecting Multiple cycle mode, a continuous lubrication test cycle is initiated. A test cycle cannot be initiated during on-going pump
phase. During a continuous lubrication test cycle, the system skips the lubrication phases and pauses.
NOTE!
Checking test button
The test button on the pump unit can be checked with the tab "Diagnosis". Press in the test button for 3 seconds or 7 seconds to
perform single-cycle or multiple-cycle test. Check that pressing of the button is indicated in the tab "Diagnosis".
Steering cylinder, description
Figure 1
Steering cylinder
1. Lock-pin
2. Piston
3. Support ring
4. Piston seal
5. O-ring
6. Cylinder tube
7. Piston rod
8. Back-up ring
9. Piston rod seal
10. Scraper ring
11. Bearing
12. Lock-ring
Steering system, component location
Figure 1
1. Central valve
3. Steering cylinder
4. Steering valve
5. Steering column
6. Pump 2
8. Pump 3
9. Pressure monitor
10. CDC valve
 Steering valve, description

Steering system, description
The machine is provided with a hydraulic load-sensing (LS) articulated frame steering. Its main components are hydraulic pump P2
with variable displacement, a steering valve, anti–cavitation valve and two steering cylinders see Steering system, component
location.
The steering valve is of the closed centre type which is connected to a LS outlet which directs oil to the LSS port on the central valve
as soon as the machine is steered see Steering system, checking and adjusting working pressure.
The central valve is equipped with a pressure limiting valve, which is limiting max steering pressure to the steering system, and
affecting the steering priority spool.
The machine can also be equipped with optional equipment such as Comfort Drive Control (CDC) and secondary steering for safety.
For information about other related hydraulic systems, see:

 Secondary steering, description
 Hydraulic pump flow regulation, description
Neutral position
P2 delivers oil to the central valve’s priority spool via inlet port P. Since the steering valve is closed in its neutral position, no LS
pressure is generated. Oil pressure is build up in the central valve’s PS line, and internal oil is channelled to the steering function,
which creates a standby steering pressure, see figure below.
Figure 1
Oil flow for steering pump P2 in neutral steering position.
Green Return oil pressure

Violet Trapped oil
Red Maximum working pressure
1. Steering valve
2. Accumulator
4. Steering cylinder (left)
5. Steering cylinder (right)
7. Central valve´s priority spool
8. Central valve
9. Pressure limiting valve for max. steering pressure
10. Restriction
Due to lack of LS pressure when the steering is not used, the standby pressure will overcome the priority spool’s spring force. Hence,
the priority spool will direct surplus oil from pump P2 to the working hydraulics, servo- and brake system via the central valve’s outlet
port PW, PR and PB.
The steering standby pressure from central valve’s port PS is directed to the steering valve on its inlet port P.
Steering right
The steering valve is kept in neutral position by a coil spring which is used as a return spring. The steering valve enables
engagement of the steering in two possible stages. For a slow steering wheel movement, an oil channel opens to the metering unit,
which in turn directs oil to the steering cylinders, resulting in high steering precision. For a faster steering wheel movement, another
channel opens in the steering valve, by-passing the metering unit allowing oil to be directed to the anti-cavitation valve and steering
cylinders, resulting in higher steering speed.
As the steering wheel is turned clockwise, the LS line from the steering valve’s LS port becomes active to the central valve. The LS
signal affects the central valve’s priority spool via the LSS port, prioritising the steering function above the working hydraulics, as well
as increasing pump P2 oil displacement via the central valve’s LSP port.
The amount of oil passing through to the steering valve to outlet port R to the left steering cylinder’s piston end (+) side and right
steering cylinder’s rod end (-) side via the anti-cavitation valve, is proportional to the number of revolutions of the steering wheel.
Charging of the accumulators located on the anti-cavitation valve provides a smooth pressure build up.
Oil on the non-pressurized cylinder sides will flow from the left steering cylinder’s rod end (-) side to the right steering cylinder’s
piston end (+) side. This oil distribution is backed up by an accumulator connected to the anti-cavitation valve, where the purpose of
the distribution is to minimize any surplus oil to be directed to tank via the steering valve.
Figure 2
Oil flow from steering pump P2 directed to the steering cylinders when steering right (light conditions).
Green Return oil without pressure

Pink LS signal
1. Steering valve
2. Accumulator
8. Central valve
10. Restriction
Figure 3
Oil flow from steering pump P2 directed to the steering cylinders when steering right (heavy conditions).
Green Return oil without pressure

Pink LS signal
1. Steering valve
2. Accumulator
8. Central valve
10. Restriction
When steering to the left, the sequence of events is opposite to the description above.
If any of the cylinders are forced in any direction by external forces, increased oil channel pressure is generated. This pressure must
be released in a safe way to protect hydraulic components.
The increased pressure affects the shock valves in the steering valve, which open up and release pressure to the tank. Due to the
increased oil channel pressure, a partial vacuum is also generated, which will be topped up by the now low pressure oil via its anti-
cavitation valve.
Optional steering equipment
The machine can be equipped with lever steering, CDC-system (Comfort Drive Control) see Comfort Drive Control (CDC),
description.
Secondary steering is optional equipment which enables an emergency steering capability to steer the machine into safety if ordinary
steering fails see Secondary steering, description.
Parameters
 Steering system, component location

 Steering, specifications
Function check
 Steering system, function check
Diagnostics
Steering valve, description
Figure 1
Steering valve
System voltage
The function monitors the system voltage and informs the operator when the system voltage is too high or too low.
 Engine On/Off  Voltage level > 31 V  Amber central warning

 System voltage  Check
High system voltage
 Engine On  Amber central warning

 Voltage level < 19 V  Check
Low system voltage
The following Tech Tool operations are available for function group 2. Operations used when changing or working on components are
mandatory.
Operation Application
21006-3 Cylinder compression, test Perform a cylinder compression test via Tech Tool.
23712-3 Injectors shut off, manual Used to shut off one or more injectors via Tech Tool
23713-3 Injection system, check Perform all electrical diagnosis that is active during normal operation, but
with the engine switched off.
23768–3 Pressure relief valve, reset Reset the pressure relief valve (PRV) opening counters.
23777-3 Fuel system, check Check the following components in the fuel system:
 Fuel control valve (FCV)

 Pressure relief valve (PRV)
 High pressure fuel pumps
or read out fuel pressures vs. engine speed.

25001-3, Preheater, test Activate the preheater element and check that it is heated.
25474-3 Exhaust aftertreatment system, reset Reset values for the exhaust aftertreatment system.
25847-3 SCR system drain Check the draining function of the selective catalytic reduction (SCR)
system of AdBlue®/DEF.
25920-3 Exhaust aftertreatment system, service Used to regenerate the exhaust aftertreatment system.
regeneration
25964-3 SCR system, diagnostics Check if a newly repaired, serviced or replaced selective catalytic
reduction (SCR) system is functioning. The test checks that the SCR
system is capable of deliver Adblue®/DEF and build up pressure.
25965-3 SCR system, dosing Check that a newly installed, repaired or replaced selective catalytic
reduction (SCR) system works correctly by dosing a predefined amount of
AdBlue®/DEF into a container.
25966-3 SCR system, heating Check the heating functions of the selective catalytic reduction (SCR)
system
26385-3 Reversible cooling fan, test Check the function of the reversible cooling fan’s hydraulic valves:
 MA2601, drains hydraulic oil to tank

 MA2602, change of the fan’s rotational direction
27102-3 Accelerator pedal, test Check the function of the accelerator pedal and hand throttle.
28407-3 Sensor values, monitoring Check that the sensors connected to the ECM and ACM gives realistic
values.
29332-3 Exhaust gas circulation, function test Perform a test of the EGR actuator and the EGR valve.
The following TechTool operations are available for function group 4.
Calibrate
42101-3 Transmission, calibration The purpose of this operation is to calibrate the transmission to
ensure good gearshifting quality, by finding the best settings for
each clutch.
The operation shall be run if:
— The transmission has been replaced
— The transmission has been dismantled and assembled without
any replacement of parts
— The GPMECU3 has been replaced
— Any component in the transmission has been replaced
Test
40012-3 Gear selector position sensor, test Check the function of the gear selecting controls.
40025-3 Solenoid valves, test Check the function of the gearshifting solenoid valves.
40901-3 Sensor, transmission, test Check that the sensors give reasonable values.
42106-3 Clutch 1, solenoid valve, test Check and set the current to the gearshifting solenoid valve
42111-3 Clutch Forward, Solenoid valve, test Check and set the current to the gearshifting solenoid valve
42112-3 Clutch Reverse, Solenoid valve, test Check and set the current to the gearshifting solenoid valve
46003-3 Sensor values, front and rear axle, check Check the function of the temperature sensors in the axles
The following Tech Tool, operations are available for function group 5. Operations used when changing or working on components
are mandatory.
52003-3 Sensor braking system, check The purpose of the test is to check the function of the sensors in the brake
system.
52005-3 Brake pressure charging, test The purpose of the test is to check the function of the included electrical
components for brake pressure charging.
55102-3 Parking brake system test The purpose of the test is to check the function of the included electrical
connections and electrical components for the parking brake.
The following Tech Tool operations are available for function group 6. Operations used when changing or working on components are
mandatory.
64101-3 Lever steering, current values, adjust This operation enables individual adjustments between Min. and Max. values for
start and end currents.
64186-3 Lever steering, calibration complete The operation is used to calibrate the CDC steering's function.
The operation should be run when any of the following components has been
changed:
Proportional valve, main slides in valves, springs for valve slides, valve housing,
complete valve housing. Or in case of incorrect lever response.
64187-3 End position lever steering right/left, The operation is used to calibrate end-positions for the hydraulic steering system.
calibration The operation should be run when any of the following components has been
changed or adjusted: Angle sensor for steering.
64595-3 Electric servo lever steering, testThe purpose of the test is to check the function of components and connections
used in the lever controls.
64721-3 Secondary steering, test The purpose of the test is to check the function of the secondary steering system.
64528-3 Angle Sensor Value, Lever Steering The purpose of the test is to check that the angle sensor SE6401 registers angle
CDC, Check change when the machine changes position.
The following Tech Tool operations are available for function group 8.
Operation Applikation
87361-3 Sensor values, Climate Control The following Tech Tool operations are available for function group 8
System, check
87378-3 CCM Input and Output signals status Check the function of components controlled by the CCM.
The following TechTool operations are available for function group 9. Operations used when changing or working on components are
mandatory
91310-3 Hydraulic pump P3, hydraulic The purpose of the operation is to control hydraulic pump P3, to enable
pressure, adjust adjustment of standby pressure or max. pressure.
91311-3 LS (load sensing) pressure, sensor The operation reads off the LS-pressure (load-sensing pressure), the sensor
value, check signal's voltage, and current supply.
92402-3 Attachment lock, test The purpose of the test is to check the function of the switch and solenoid valve
for attachment lock.
Tightening torque:
Outer hex nut, distribution bolt 44 ±4 Nm (32.5 ±2 lbf ft)

Threaded cover 94 ±14 Nm (70 ±10 lbf ft)
Lock nut, attaching bolt 271 Nm (200 lbf ft)
Air bleeder screw 25 ±3 Nm (18 ±2 lbf ft)
Tilt cylinder, description
Figure 1
1. Lock–ring
2. Piston
3. Support ring
4. Piston seal
5. O-ring
6. Cylinder tube
7. Piston rod
8. Back-up ring
9. Piston rod seal
10. Scraper ring
11. Bushing
TP-Linkage's bearing points
Figure 1
Designations for TP-Linkage's bearing points
Transmission, component position
For information on the hydraulic transmission's functions, see: Hydraulic transmission, description.
Figure 1
1. Lifting eye
2. Power take-off hydraulics
3. Lifting eye
4. Parking brake
5. Magnetic plug
6. SE4307 Output speed (rpm)
7. SE4213 Turbine speed (rpm)
8. Oil filter
9. Lubrication oil valve with pump
10. SE4219 Main pressure
11. SE2704 Engine speed
12. Gear selector valve
13. ID-plate
Gear selector valve

Figure 2
1. Pressure check connection, reverse

2. Pressure check connection, 4th gear
3. Pressure check connection, forward
4. Pressure check connection, 2nd gear
5. Pressure check connection, 1st gear
6. Pressure check connection, 3rd gear
7. PWM4215, 1st gear
8. PWM4217, 3rd gear
9. PWM4216, 2nd gear
10. PWM4213, forward
11. PWM4214, reverse
12. PWM4218, 4th gear
Lubrication oil valve with pump
Figure 3
1. Pressure check connection, lubrication oil pressure

2. Pressure check connection, torque converter pressure
3. Pressure check connection, main pressure
4. SE4202 Temperature
5. SE4219 Main pressure
6. Connection, suction pipe
7. Filter connection
8. Pump
Viscous cab suspension, description
The cab suspension consists of four vibration-shock dampers.
The function of the vibration dampers is to isolate the cab from the frame noise and the vibrations in the machine, as well as dampen
the shocks that are generated during work with the machine.
Like in a traditional cab suspension design, the vibration dampers are made up of a rubber body that absorbs the cab's own weight
as well as insulates from frame noise and vibrations. In addition, there is a vertical-action shock absorber unit consisting of a
damping piston, that works in a chamber filled with high-viscosity fluid. This unit provides improved damping of shocks.
Figure 1
Vibration damper
1. Vibration damper
The ROPS-parts (ROPS= Roll Over Protection System) consist of a heavy-duty bolt (ROPS-bolt) with permanently installed washer
(ROPS-washer). These are installed on the same plate as the can mounting. In case of an accident where the machine rolls over the
ROPS-parts prevent detachment of the cab from the machine.
The viscous cab suspension is a comfort detail (similar to shock absorbers) and may have to be replaced during the machine's life.
The service life of the cab suspension depends on the application.
Figure 2
1. Vibration damper
2. Bolt for vibration damper
3. ROPS-bolt
W-ECU, I/O list
output is not used.

1 — — —
2 — — —
3 FU74 RE3705, voltage feed. Wiring diagram WD301
4 — — —
5 — — —
6 — — —
7 — — —
8 — — —
9 — — —
10 CANH Communication, BB2 Wiring diagram WD321
11 — — —
12 — — —
13 FU74 RE3705, voltage feed. Wiring diagram WD326
14 WECU Ground, 31C1 Wiring diagram WD326
15 — — —
16 CANL Communication, BB2 Wiring diagram WD321
17 — — —
18 Ground Ground, 31C1 Wiring diagram WD326
Windows, general, gluing
General instructions for gluing window panes
Place the window pane on the intended work surface for gluing. Use lifting tools.
Glue on the screen print side of the glass.
Apply primer on the surfaces to be glued.
Check the window pane to find any damage.
Check the 'Best before' date of the glue.
NOTE!
Old glue may cause problems.
There are two types of glue joint lines: type A, type B.
Choice of glue joint line is determined by the work instructions.
Pressure and speed shall be adapted so that the relevant glue joint line looks like type A, type B.
Figure 1
Type A
1. Cab frame
2. Glass
3. Glue
4. Glue, quantity and shape (milimetre)
Figure 2
Type B
1. Cab frame
2. Glue
3. Glass
4. Glue, quantity and shape (milimetre)
The window pane shall be installed within 10 minutes when the parts are at room temperature.
Windows, general
Windows
There are 8 window panes in the cab; the windscreen comprises one large pane connected to two smaller panes on either side
below the windscreen.
Windows, replacing
Use clean tools and protective gloves when replacing windows since residue and grease can affect the adhesive capacity. The
adhesive curing process, which is contingent on temperature and humidity, is indicated in this section with a curing time based on a
temperature of approximately 23° C (73° F) and normal humidity. A longer curing time is required during other weather conditions
with freezing temperatures and low humidity.
NOTE!
The panes should not come in contact with metal or welded joints. Use rubber spacers and follow the instructions and steps for
replacing window panes.
SikaAktivator
SikaAktivator is a specially-developed cleaning agent and adhesive fluid used for contact surface pre-treatment before polyurethane
adhesive application. Drying time: 10 minutes (min.), 2 hours (max.).
SikaPrimer-206 G+P
SikaPrimer-206 G+P is a black, moisture-inhibiting, low viscosity primer specially developed for use on contact surfaces before
polyurethane adhesive application. SikaPrimer-206 G+P is used on window panes without a composite moulding (the black
impregnation around the window pane edges) in order to protect the adhesive from UV radiation or when the contact surface is newly
surface coated. In both cases, the surface must be cleaned with SikaAktivator before priming. Drying time for SikaPrimer-206 G+P is
10 minutes.
NOTE!
Never use SikaPrimer-206 G+P on residue from old adhesive.
SikaTack-Drive
SikaTack-Drive is a fast-drying, cold-application polyurethane adhesive. SikaTack-Drive cures using the humidity in the air. Reduced
humidity, which occurs at lower temperatures, causes drying time to become longer. Under these conditions, let the machine idle with
the cab heating fan switched on. In order to raise the level of moisture in the air, a bucket of water can be placed in the cab. In
varying weather conditions, apply a bead of adhesive to a bit of cardboard to check curing time.
Sikaflex 521FC
Sikaflex 521FC is a one-part adhesive and sealing compound which cures on exposure to atmospheric moisture to form a permanent
elastomer. To ensure the best treatment properties, the cartridges should maintain room temperature. Apply Sikaflex in a V-shaped
bead and remove masking tape within 15 minutes.
Working hydraulic system, component location
Figure 1
1. Lift cylinder
2. Tilt cylinder
3. Servo valve
4. Hydraulic pump 2
6. Hydraulic pump 3
7. Central valve
8. Load lowering block
 Servo valve, description

 Cooling fan motor, description
 3rd/4th hydraulic function, valve, description [1] 
Working hydraulic system, description
The working hydraulic system's task is, e.g., to control the machine’s lift, lower, and tilt functions.
The machine’s primary components for the working hydraulic system include the hydraulic oil tank, hydraulic oil cooler, oil pump with
variable displacement, central valve, main control valve, and cylinders for the lift and tilt functions. The working hydraulic system’s
function areas are:
 Lift and lower function

 Tilt function
 Float mode function
 Automatic tilt-in and automatic lift.
Other systems that can affect the working hydraulic system are

The machine can also be equipped with various optional equipment that affect the working hydraulic system.
 Boom Suspension System, description

General function
Hydraulic oil pump P2 supplies the working hydraulics with oil to the servo system and to the steering system.
When any servo lever is activated, for tilt or lift, servo pressure oil increases on the spools in the main control valve, see also Control
valve, description. The spools' movement is proportional to the given servo pressure, where their stroke is determined by the servo
pressure counteracting the spools’ springs. The function of the spools’ springs is to center the spools in neutral position when no
servo pressure is applied.
As the servo pressure oil is directed to the main control valve’s spool, a channel is opened to the LS-channel via a shuttle valve. The
pressure is propagated to the pump's pressure and flow compensator (regulator); the heavier the load, the higher the LS-pressure,
thus increased oil pump displacement is obtained. The affected spool in the main control valve will direct high-pressure oil to cylinder
(s) to obtain the desired hydraulic function.
Since the spools for the servo valve are of the closed center type, no oil can cause any unwanted hydraulic function without
movement of the servo lever.
The ignition key must be in position "I" and the lever lock must be disabled for lowering the boom when the engine is off.
See figure below for an overview of the working hydraulic system’s hydraulic components in neutral, unaffected position.
Figure 1
Diagram of main hydraulic components for working hydraulics in neutral, unaffected position.
Green Return oil

Yellow Standby pressure
Purple Trapped oil
1 Central valve
3 Servo valve
Lift and lower function

The servo pressure moves the spool in the main control valve, which opens a connection between the pump and the lift cylinders via
the load-holding valves. Pressurized oil from the pump opens one of the load-holding valves and is routed to the lift cylinders’ piston
rod end, (-) side, or piston end, (+) side, depending on if it is a lower or lift action.
The LS-signal is led back to the pump’s flow compensator via the shuttle valve, affecting pump P2's oil displacement. Return oil from
the lift cylinders opens the second load-holding valve and is routed to tank via the back-up valve, see figure below.
Figure 2
Activated lift function
Green Return oil

1 Central valve
3 Servo valve
Tilt function
The servo pressure moves the spool in the main control valve, which opens a connection between the pump and the lift cylinders via
the load-holding valves. Pressurized oil from the pump opens one of the load-holding valves and is routed to the tilt cylinder’s piston
rod end, (-) side, or piston end, (+) side, depending on if it is a tilt-out or tilt-in action.
The LS-signal is led back to the pump's flow compensator via the shuttle valve, affecting pump P2's oil displacement. Return oil from
the lift cylinders opens the second load-holding valve and is routed to tank via the back-up valve, see figure below.
Figure 3
Simultaneous tilt-in and boom lowering

1 Central valve
3 Servo valve
4 Non-return valve
5 Restriction
6 Sequence valve
7 Float mode spool
8 Load lowering block
In order to achieve tilt-in at the same time as the boom lowers, servo pressure oil is directed from the tilt-in section’s non-return valve
(4) to the oil channel on the lift cylinders' piston end, (-) side. This applied oil pressure ensures sufficient oil circuit pressure via the
restricted oil channel (5) and also affects the pilot spool for boom lowering. The purpose of affecting the boom lowering's pilot spool is
to apply pressure on its load-holding valve, while the LS-signal from the tilt-in function will be higher and the hydraulic oil pump will
subsequently provide increased oil flow. If the load-holding valve was not pressed down, oil would pass directly to the lift cylinder's
piston rod end, (-) side, for the boom lowering function. Note that the applied servo pressure is not high enough to counteract the
spool's spring (7).
One of the non-return valves opens and directs the LS-signal back to the hydraulic pumps’ regulators. The return oil from the tilt
cylinder opens the other load-holding valve and is routed to the back-up valve. When the back-up valve opens, oil is directed to tank.
Float mode function
The float mode function allows the boom to follow along any uneven or rough spots in the road by using only its dead weight and only
passive use of the working hydraulics. This feature allows the operator to fine grade, clean hard surfaces, and back-drag loose
materials without use of bucket-down pressure.
The function is enabled with switch SW9144, which activates the hold solenoid MA9143 so that the boom control lever can be locked
in maximum lowering position. Oil is drained to tank from the spring side of the load-holding valves, allowing oil to flow freely between
the lift cylinders’ piston end (+) and piston rod end (-) sides. The back-up valve in the main control valve ensures that cavitation is
prevented during rapid height changes of the boom.
The increased servo pressure counteract the spring force on the spool (7), allowing oil to move the spool (6), which in turn blocks any
oil pressure from affecting the load-holding valve for lowering the boom.
Automatic tilt-in and automatic lift
When activated, the automatic tilt-in function allows the bucket to be tilted in automatically to a predefined position. The function is
activated with switch SW9141 for tilt, the servo lever is held in tilt-in position by hold solenoid MA9141 until the pre-set position from
bracket.
With enabled SW9142 for automatic lift, the servo lever is held in lift position by old solenoid MA9142 until the pre-set position from
bracket.
If bucket angle is larger than the set angle for automatic tilt-in, then the function will not be available.
Figure 4
Hydraulic diagram and wiring diagram for automatic lift with enabled solenoid awaiting signal from inductive sensors

MA9141 Hold solenoid, automatic tilt-in
MA9142 Hold solenoid, automatic lift
Hydraulic servo system

The hydraulic servo system controls the main working hydraulics as well as additional and optional hydraulic equipment, 3rd, or
3rd/4th hydraulic function, description.
For more information about the servo system, see Servo system, description.
If any of the cylinders are forced in any direction by external forces, an increased pressure is generated. This pressure must be
released in a safe way to protect the hydraulic components. The increased pressure affects the shock valves in the main control
valve, which open up and release the pressure to tank. Due to the increased oil pressure, a partial vacuum is also generated in the
cylinder, which will be topped up by the low-pressure oil via the anti-cavitation valve. The back-up valve, located in the main control
valve, obtains a back-up oil pressure before directing any surplus oil to tank to ensure after-filling capabilities.
Optional hydraulic function
The machine can be equipped with additional hydraulic functions, see 3rd, or 3rd/4th hydraulic function, description.
The Boom Suspension System (BSS) is optional equipment that uses accumulators together with the lift/lower function to enable
vertical suspension of the boom. For more information, see Boom Suspension System, description.
Parameters
Relevant parameters for working hydraulic system's function.

P1KBV Hydraulic Oil Heater Installed

 Hydraulic pump flow regulation, description
 Boom Suspension System, description
Function check
 Tilt, functional check

 Lift/lower function, checking
Diagnostics
Explanations to hydraulic diagram
Symbols
Symbol Explanation
Line
Servo line / Pilot line

Line junction
Crossing lines not connecting
Outlet, plugged
Quick-action coupling (e.g. checking point)
Restriction
Restriction, insignificantly viscosity-dependent
Adjustable restriction
Reservoirs and accumulators

Atmospheric (open) reservoir
Accumulator
Filter
Filter, strainer
Filter with magnetic element
Heat exchanger
Cooler without representation of lines for the coolant
Control devices
Manual control by push button
Manual control by lever
Manual control by pedal
Mechanical control by spring, neutral position spring, return spring
Electromagnetic control (one winding)
Hydraulic pressure control
Hydraulic pressure control, two pressure levels
Control via hydraulic pressure drop
Pneumatic control
Control via pneumatic pressure drop
Sources of energy
Combustion engine
Electric motor
Pumps
Hydraulic pump with fixed displacement and one direction of flow
Hydraulic pump with variable displacement and one direction of flow

Hydraulic pump with variable displacement and two directions of flow
Hydraulic pump with variable displacement, pressure controlled
Hydraulic pump with variable displacement, pressure controlled with

pressure-compensated control
Motors
Hydraulic motor with fixed displacement and one direction of flow
Hydraulic motor with fixed displacement and two directions of flow
Cylinders
Single-acting cylinder with return stroke by spring
Double-acting cylinder with single piston rod

(The piston end is called plus side and the piston rod end is called minus
side)
Valves
Non-return valve which requires very low opening pressure
Non-return valve which requires a certain opening pressure
Shuttle valve
Pressure-limiting valve
Pressure-limiting valve with adjustable opening pressure
Pressure-reducing valve
Pressure-reducing valve with adjustable closing pressure
Pressure-reducing valve, pressure controlled
Three-position valve, lever-controlled and spring-centred
Lines parallel with the long sides of the valve symbol show that the valve
can take up any position between its end positions (stepless movement)
Shut-off valve / Breather valve
Application
The symbols in a diagram show connections, flow paths and function of the components in the system, but does not show the design
of the components.
NOTE!
In a hydraulic diagram the valve symbols are always drawn in neutral position.
Valve symbols
The basic element of a valve symbol is a square box. One box is shown for each position that the moving part of a valve (spool or
similar) can take up.
Figure 1
Valve symbol
If the valve does not have fixed positions, but can be operated steplessly, this is shown with parallel lines along the valve symbol.
Figure 2
Valve symbol, steplessly controlled valve
Internal flow paths and flow directions are drawn in the boxes. Line connections to the valve are drawn to the box that shows the
valve position when other components are actuated according to the diagram.
Figure 3
Closed valve
Figure 4
Open valve
Interpretation of valve symbols
In a three-position valve the spool can be placed in three positions, which in the symbol are represented by one box for each
position. The box that represents the intended position is drawn between the line connections, which means that the appropriate
connecting paths in the valve are shown in the diagram.
The position in the diagram
Figure 5
Neutral position
1. Inlet
2. Outlet
The spool is centred in neutral position by the springs. The inlet is connected to the outlet through the spool.
Imagined position for piston movement outwards
Figure 6
The piston rod is pressed out
1. Inlet
2. Outlet
The spool is actuated with the lever so that the plus side of the cylinder is connected to the inlet at the same time as the minus side is
connected to the tank.
Imagined position for piston movement inwards
Figure 7
The piston rod is pressed in
1. Inlet
2. Outlet
The spool is actuated with the lever so that the minus side of the cylinder is connected to the inlet at the same time as the plus side is
connected to the tank.
Hydraulic diagram transmission
Figure 1
A PWM4213, Forward gear D PWM4214 Reverse gear

B PWM4215, 1st gear E PWM4218, 4th gear
C PWM4216, 2nd gear F PWM4217, 3rd gear
F Clutch, Forward gear R Clutch, reverse gear

1 Clutch, 1st gear 10 Pressure control valve
2 Clutch, 2nd gear 11 Pressure check connection, lubrication oil pressure
3 Clutch, 3rd gear 12 Gear selector unit
4 Clutch, 4th gear 13 Torque converter pressure valve
5 Pump with bypass valve 14 Pressure check connection, torque converter pressure
6 Filter 15 Main pressure valve
7 Torque converter 16 SE4202 Transmission oil temperature
8 Transmission oil cooler 17 SE4214 Transmission oil pressure
9 Lubrication oil valve 18 Pressure check connection, main pressure
Hydraulic diagram, basic machine
2 Hydraulic oil cooler
6 Central valve
7 Foot brake valve
8 Differential lock- and attachment lock valves
10 Fan motor
11 Hydraulic oil filter
12 Hydraulic oil pumps, P2 and P3
13 Load lowering valve
14 Servo valve
15 Accumulator block, brake
17 Parking brake valve
18 Steering valve
23 Connecting block, LS-pressure for steering
36 Rear axle
37 Front axle
38 Steering cylinder, left
39 Steering cylinder, right
Figure 1
Hydraulic diagram
Hydraulic diagram, complete
2 Hydraulic oil cooler
3 Pump, secondary steering
4 Connecting block, differential pressure sensor, secondary steering
5 Comfort Drive Control (CDC) valve
6 Central valve
7 Foot brake valve
8 Differential lock- and attachment lock valves
9 Boom Suspension System (BSS)
10 Fan motor
11 Hydraulic oil filter
12 Hydraulic oil pumps, P2 and P3
13 Load lowering valve
14 Servo valve
15 Accumulator block, brake
17 Parking brake valve
18 Steering valve
19 Control valve, 3rd/4th hydraulic function
21 Reversible fan valve
23 Connecting block, LS-pressure for steering
26 Solenoid valve for servo pressure
36 Rear axle
37 Front axle
38 Steering cylinder, left
39 Steering cylinder, right
Figure 1
Hydraulic diagram
Table of contents, wiring diagrams
Wiring diagram Function
Wiring diagram WD201 Engine cooling, fuel level, reversing cooling fan, and regeneration switch
Wiring diagram WD202 Accelerator pedal, hand throttle and electrically heated fuel filter
Wiring diagram WD260 Injection
Wiring diagram WD261 Sensors connected to ECM. Engine speed.
Wiring diagram WD262 Sensors connected to ECM. Inlet-, oil-, fuel-, rail-, coolant-, and exhaust
sensors.
Wiring diagram WD263 Sensors connected to ECM. Fuel filter, air filter, charge air, and coolant
sensors.
Wiring diagram WD264 Preheating, voltage feed ECM, EGR valve, and NOx sensors
Wiring diagram WD265 Aftertreatment. ACM. AdBlue®/DEF temp, level, quality. NOx sensors.
Wiring diagram WD266 Sensors connected to ACM. DPF pressure, exhaust gas sensors.
Wiring diagram WD268 Engine sensors. Oil pressure, air intake throttle and EGR sensors.
Wiring diagram WD269 Sensors connected to ACM. AdBlue®/DEF temperature, quality, level, and
hose heater.
Wiring diagram WD270 Aftertreatment. ACM. Fuel dosing unit.
Wiring diagram WD301 Voltage feed, grounding points, starter motor, battery disconnector, power
outlet 24 V, and main fuse box
Wiring diagram WD302 Voltage feed control units
Wiring diagram WD303 Voltage feed and fuses outside circuit board
Wiring diagram WD304 Voltage feed control units, emergency stop.
Wiring diagram WD305 Voltage feed control units
Wiring diagram WD306 Starter motor, alternator
Wiring diagram WD320 Communication, control units
Wiring diagram WD321 Communication, control units
Wiring diagram WD322 Keypad and HMICU
Wiring diagram WD324 Voltage socket, audible signals, and back-up alarm
Wiring diagram WD325 Fuse test, unused connections
Wiring diagram WD326 Radio/CD, voltage socket, voltage converter loudspeakers, and WECU,
Telematics ECU.
Wiring diagram WD330 Headlights, front
Wiring diagram WD331 Work lights, front
Wiring diagram WD333 Brake lights, position lights, direction indicators, and hazard flashers.
Wiring diagram WD334 Work light, rear
Wiring diagram WD335 Instrument lighting
Wiring diagram WD337 Entry light, extended light around machine
Wiring diagram WD350 Voltage feed 5 V from HMICU, GPMECU1, GPMECU2, and GPMECU3.
Wiring diagram WD351 GPMECU3, ground connections
Wiring diagram WD352 Ground connections, GPMECU1, GPMECU2, and HMICU
Wiring diagram WD360 Voltage feed, 15EA
Wiring diagram WD361 Voltage feed, 15B
Wiring diagram WD362 Voltage feed, 15A
Wiring diagram WD363 Voltage feed, 30K
Wiring diagram WD371 Ground connections, 31C1, 31F1
Wiring diagram WD372 Ground connections, 31C1
Wiring diagram WD373 Ground connections
Wiring diagram WD401 Gear selector, forward–reverse, steering column.
Wiring diagram WD402 Gearshifting, forward–reverse
Wiring diagram WD403 Gear shifting solenoids
Wiring diagram WD404 Sensor transmission, differential lock
Wiring diagram WD405 Axle oil temperature, sensor transmission, FAPS (Full Auto Power Shift).
Wiring diagram WD406 Lock-up switch (not valid for L60H)
Wiring diagram WD501 Brakes
Wiring diagram WD601 Lever steering, CDC (Comfort Drive Control)
Wiring diagram WD602 Angle sensor, lever steering (CDC)
Wiring diagram WD604 Secondary steering
Wiring diagram WD801 Windshield wiper and windshield washer
Wiring diagram WD802 Operator's seat, position monitor, and ambient temperature
Wiring diagram WD804 Back-up camera, rear-view mirrors
Wiring diagram WD805 Air conditioning
Wiring diagram WD806 Climate control system, pause heater
Wiring diagram WD807 Fan cyclone filter. Fuel heating. Electric door. Electric hood opening.
Wiring diagram WD831 Electric door
Wiring diagram WD901 Working hydraulics, automatic lift and tilt
Wiring diagram WD902 Working hydraulics, automatic lift and tilt
Wiring diagram WD903 BSS (Boom Suspension System), hydraulic oil temperature and level
Wiring diagram WD904 LS-pressure, attachment locking
Wiring diagram WD905 Hydraulic servo, adjustable flow, 3rd function
Wiring diagram WD908 Electrically controlled hydraulic pump, emergency stop and hold function
3rd hydraulic function.
Wiring diagram WD911 Floating position
Wiring diagram WD913 Central lubrication
Wiring diagram WD915 Fire supression system
Wiring diagram - Aftertreatment
Aftertreatment function
Figure 1
Documents related to this function:

Components list
Designation Function Designation Function
ACM Aftertreatment control module (ACM) HMICU Human Machine Interface Control Unit
FU24 Voltage feed ACM MA2517 AdBlue®/DEF coolant valve
FU30 Voltage feed ACM MA2519 AdBlue®/DEF dosing injector
FU33 Regeneration (SW2506) SE2513 NOx sensor before SCR
FU78 NOx sensors SE2519 DPF Differential pressure sensor
FU83 NOx sensors SE2521 Exhaust gas temperature sensor before
DOC
FX1074 AdBlue®/DEF pump unit SE2522 Exhaust gas temperature sensor before DPF
FX1079 SE2536 AdBlue®/DEF temperature sensor SE2533 NOx sensor after SCR
SE2537 AdBlue®/DEF level sensor
HE2511 AdBlue®/DEF hose (supply/return) SE2543 Exhaust gas temperature sensor after DPF
HE2512 AdBlue®/DEF hose (supply/return) SE2544 Exhaust gas pressure sensor before SCR
catalyst
HE2513 AdBlue®/DEF hose (supply/return) SW2506 Regeneration
Component position:
Figure 2
Wiring diagram - Brake
Brake system
Figure 1

Components list

15EA Voltage feed (supply) MA5503 Brake pressure charging
30K Voltage feed (supply) RE10 Brake lights
31K Ground connection RE5502 Parking brake
FU01 Brake lights SE5201 Brake pressure
FU48 Voltage feed (supply) SE5203 Output brake pressure (RBB)
GPMECU1 General Purpose Machine Control Unit 1 SE5501 Pressure sensor applied parking brake
GPMECU3 General Purpose Machine Control Unit 3 SW5501 Parking brake
MA5501 Parking brake
Component position:
Figure 2
Wiring diagram - BSS
BSS function
Figure 1

Components list

DI20 Lock-out diode MA9104 Single-acting lift CT1 (valve block 2)
DI21 Lock-out diode MA9114 Boom Suspension System (BSS) CT1
FU32 Boom Suspension System BSS RE08 Boom Suspension System, engagement
BSS, single acting lift
FU42 Fully automatic downshifting (FAPS) SW9148 Boom Suspension System, activation and
Gear selector lever carrier function selection
CDC armrest down position
Boom Suspension System, activation and
function selection
GPMECU1 General Purpose Machine Electronic Control SW9149 Single-acting lift function
Unit
MA9103 Boom Suspension System CT4 (BSS)
Component position:
Figure 2
Wiring diagram - CDC
CDC function
Figure 1

Components list

CU6601 Control unit monitoring CDC PWM6602 Lever steering (CDC), right
FU39 Horn SE4227 Arm rest lever steering (CDC)
Kick-down (CDC)
FU42 Fully automatic gearshifting (FAPS) SE6411 Angle sensor frame joint
Gear selector lever carrier
CDC (armrest)
Boom Suspension System, activation / function
selection
GPMECU1 General Purpose Machine Electronic Control SE6601 Control lever (CDC)
Unit 1
GPMECU2 General Purpose Machine Electronic Control SW4216 Activation of lever steering (CDC)
Unit 2
GPMECU3 General Purpose Machine Electronic Control SW4217 Forward/Reverse, Comfort Drive Control (CDC)
Unit 3
PWM6601 Lever steering (CDC), left SW4220 Kick-down CDC
Component position
Figure 2
Wiring diagram - Electrically controlled battery disconnector - Key operated, with
emergency stop
Electrically controlled battery disconnector, function
Figure 1
Links:
Components list

BA3101 Batteries HMICU Human Machine Interface Control Unit
BA3102
DI16 Lock-out diode MO3301 Starter motor
DI3301 Start protection MO3611 Hood motor
DI3701 SW3102, emergency stop RE16 15A supply
DI3703 SW3102, emergency stop RE17 15B supply
DI3705 Diode unit, RE3102 RE18 15EA supply
ECM Engine Control Module RE3102 Main relay 2
FU20 Voltage feed ignition. Electrically controlled RE3705 Electrically controlled battery disconnect
battery disconnector. switch
FU74 Sensing of battery voltage SW3102 Emergency stop electric battery disconnect
Voltage converter
FU75 Hood, operation SW3301 Ignition switch
FU89 Hood, operation SW3620 Hood, operation
Component position:
Figure 2
Wiring diagram - Electrically controlled battery disconnector - Manual, with
emergency stop
Figure 1
Links:
Components list

BA3101 Batteries MO3301 Starter motor
BA3102
DI16 Lock-out diode MO3611 Hood motor
DI3301 Start protection RE16 15A supply
DI3705 Diode unit, RE3102 RE17 15B supply
ECM Engine Control Module RE18 15EA supply
FU20 Voltage feed ignition. Electrically controlled RE3705 Electrically controlled battery disconnect
battery disconnector. switch
FU74 Sensing of battery voltage SW3102 Emergency stop electric battery disconnect
Voltage converter
HMICU Human Machine Interface Control Unit SW3701 Battery disconnect switch
Component position:
Figure 2
Wiring diagram - Electrically controlled battery disconnector - Manual, without
emergency stop
Figure 1
Links:
Components list

BA3101 Batteries MO3301 Starter motor
BA3102
DI16 Lock-out diode MO3611 Hood motor
DI3301 Start protection RE16 15A supply
ECM Engine Control Module RE17 15B supply
FU20 Voltage feed ignition. Electrically controlled RE18 15EA supply
battery disconnector.
FU74 Sensing of battery voltage RE3705 Electrically controlled battery disconnect
Voltage converter switch
HMICU Human Machine Interface Control Unit SW3701 Battery disconnect switch
Component position:
Figure 2
Wiring diagram - Gear
Gear function
Figure 1
1. Machines with single lever (optional equipment).

Components list

FU24 ECM, FU30 voltage feed SW4205 Directional gear Forward/Reverse, steering
column
FU31 Travel direction, gear shifting SW4206 Gear lever steering column
FU42 Fully automatic gearshifting (FAPS) Gear SW4207 Activation Forward/Reverse lever carrier
selector lever carrier CDC (armrest) Boom
Suspension System, activation / function
selection
GPMECU3 General Purpose Machine Electronic Control SW4208 Forward/reverse lever carrier
Unit
PWM4213 Forward gear SW4210 Engine brake lever carrier
PWM4214 Reverse gear SW4211 Fully automatic gearshifting (FAPS)
PWM4215 1st gear SW4217 Forward/Reverse, Comfort Drive Control
(CDC)
PWM4216 2nd gear SW4220 Kick-down CDC
PWM4217 3rd gear SW4221 Single lever control, forward−neutral
−reverse
PWM4218 4th gear SW4222 Single lever control
Component position:
Figure 2
Wiring diagram - Start
Start circuit function
Figure 1

Components list

DI16 Diode, control voltage RE18 RE16 15A supply
DI3301 Diode, starter motor RE17 15B feed
ECM Engine Control Module RE18 15EA supply
FU20 Voltage feed ignition. MO3301 Starter motor
Electrically controlled battery disconnector.
FX1026 Main fuse box SW3301 Ignition switch
HMICU Human Machine Interface Unit
Component position
Figure 2
Engine cooling, fuel level, reversing cooling fan, and regeneration switch
Figure 1
Links:
Components list
Chassis connection
Designation Function
MA2601 Cooling fan, braking
MA2602 Cooling fan, rotation direction (reversible fan)
PWM2602 Control, pump P3
SE2303 Fuel level
SE2604 Cooling fan speed
SE2704 Engine rpm, transmission
SW2506 Regenerate
Component position:
Figure 2
Accelerator pedal, hand throttle, and electrically heated fuel filter
Figure 1
Wiring diagram
Links:
Components list
Chassis connection
FX1005 HE2301, Electric heat fuel (see also Wiring diagram WD263)
R2701 Hand throttle
RE2301 Electically heated fuel filter
SE2702 Throttle pedal position
Component position:
Figure 2
Component position
Injection
Figure 1
Links:
Components list
Chassis connection
MA2301 Injector 1
MA2302 Injector 2
MA2303 Injector 3
MA2304 Injector 4
MA2305 Injector 5
MA2306 Injector 6
PWM2303 Fuel control valve (FCV)
Component position:
Figure 2
Sensors connected to ECM. Engine speed.
Figure 1
Links:
Components list
Chassis connection
SE2701 Crankshaft speed sensor
SE2703 Camshaft speed sensor
Component position:
Figure 2
Sensors connected to ECM. Inlet-, oil-, fuel-, rail-, coolant-, and exhaust sensors.
Figure 1
Links:
Components list
Chassis connection
FX1007 SE2507, Inlet manifold temperature sensor
SE2508, Inlet manifold pressure sensor
SE2203 Engine oil pressure sensor
SE2301 Fuel feed pressure sensor
SE2309 Fuel rail pressure sensor
SE2511 Exhaust gas pressure sensor before turbocharger
SE2606 Coolant temperature sensor
Component position:
Figure 2
Sensors connected to ECM. Fuel filter, air filter, charge air, and coolant sensors.
Figure 1
Wiring diagram
Links:
Components list
Chassis connection
FX1005 SE2302, Water in fuel sensor
HE2301, Electric heat fuel (see also WD202)
FX1008 SE2501, Inlet air temperature sensor
SE2502, Air cleaner pressure sensor
SE2512 Charge air cooler outlet temperature sensor
SE2603 Coolant level sensor
Component position:
Figure 2
Preheating, voltage feed ECM, EGR valve, and NOx sensors
Figure 1
Links:
Components list
Chassis connection
ACM Aftertreatment Control Module
FU2501 Preheater
HE2501 Preheater element
MO2505 EGR valve
RE2501 Preheating
SE2513 NOx sensor before SCR
[T1]
SE2533 NOx sensor after SCR⁽ᵃ⁾
[T1] Cable markings in machine are wrong. See wiring diagram and component position for correct information.
Component position:
Figure 2
Aftertreatment. ACM. AdBlue®/DEF temp, level, quality. NOx sensors.
Figure 1
Links:
Components list
Chassis connection
FX1079 SE2536 AdBlue®/DEF temperature sensor
(See also Wiring diagram WD269)
MO2505 EGR valve
SE2513 NOx sensor before SCR [T1]
SE2533 NOx sensor after SCR⁽ᵃ⁾
[T1] Cable markings in machine are wrong. See wiring diagram and component position for correct information.
Component position:
Figure 2
Sensors connected to ACM. DPF pressure, exhaust gas sensors.
Figure 1
Links:
Components list
Chassis connection
SE2519 DPF Differential pressure sensor
SE2521 Exhaust gas temperature sensor before DOC
SE2522 Exhaust gas temperature sensor before DPF
SE2543 Exhaust gas temperature sensor after DPF
SE2544 Exhaust gas pressure sensor before SCR catalyst
Component position:
Figure 2
Engine sensors. Oil pressure, air intake throttle and EGR sensors.
Figure 1
Links:
Components list
Chassis connection
MO2503 Air intake throttle
Component position:
Figure 2
Sensors connected to ACM. AdBlue®/DEF temperature, quality, level, and hose heater.
Figure 1
Links:
Components list
Chassis connection
FX1079 SE2536 AdBlue®/DEF temperature sensor
(See also Wiring diagram WD265)
HE2511 AdBlue®/DEF hose (supply/return)
MA2519 AdBlue®/DEF dosing injector
Component position:
Figure 2
Aftertreatment. ACM. Fuel dosing unit.
Figure 1
Links:
Components list
Chassis connection
FX1074 Aftertreatment fuel dosing unit
MA2518 Air purge valve
SE2538 Air temperature sensor
MA2517 AdBlue®/DEF tank heating valve
Component position:
Figure 2
Voltage feed, grounding points, starter motor, battery disconnector, and main fuse box
Figure 1
1. Emergency switch.
2. Battery disconnect switch.
3. Rear frame – battery.
4. Cab feed.
5. Rear frame – starter motor.
6. Engine block – rear frame.
Links:
Components list
Chassis connection
30A Power connection
30K Power connection
31C1 Ground, terminal, 1:st
31E1 Ground, engine 1:st
31R1 Ground, rear frame 1:st
31R2 Ground, rear frame 2:nd
BA3101 Battery 1
BA3102 Battery 2
FU18 Power outlet, 24 VDC
FU74 Alternator, magnetizing.
Voltage converter.
Ignition, key controlled.
WECU.
Fire suppression system.
FU3604 Power outlet, rear
FX1026 Main fuse box
FU70, Secondary steering
FU71, Charging
FU72, Cab
FU73, –
MO3301 Starter motor, see also Wiring diagram WD306
PA Power, Cab
PB Ground, Cab
PO3901 Power outlet, 24 VDC
RE3705 Electrically controlled battery, disconnect switch
Component position:
Figure 2
Voltage feed control units
Figure 1
Links:
Components list
Chassis connection

CCM Climate Control Module FU28 —
CU6601 Control unit monitoring CDC FU29 —
DI01 Lock-out diode FU30 RE2502 voltage feed, ACM
DI24 Lock-out diode FU31 Travel direction, gear shifting, alternator.
DI25 Quench diode GPMECU1 General Purpose Machine Electronic Control
Unit 1
FU02 HMICU, IC (Instrument Cluster) GPMECU2 General Purpose Machine Electronic Control
Unit 2.
FU04 RE14, voltage feed GPMECU3 General Purpose Machine Electronic Control
Unit 3.
FU17 RE13 hold voltage HMICU Human Machine Interface Control Unit.
FU24 ECM voltage feed, FU30, FU31 IC Instrument Cluster
FU25 GPMECU1, voltage feed RE12 30-feed controlled by HMICU, RE13 hold
voltage.
FU26 GPMECU2 voltage feed, CU6601 RE13 CU6601, GPMECU1, GPMECU2,
GPMECU3, HMICU, voltage feed.
FU27 CCM, magnetic clutch, AC compressor, cab RE14 CCM voltage feed, magnet clutch AC
fan, pause coolant pump compressor, pause coolant pump.
Component position:
(See electrical distribution box, circuit board.)
Figure 2
Voltage feed and fuses outside the circuit board
Figure 1
Links:
Components list
Chassis connection
FX1040 Extra fuse holder:
FU77, ACM.
FU78, ECM, FX1041.
FU79, –
FX1041 Extra fuse holder:
FU83, NOx sensors.
FU88, RE2501 preheating, MO2505.
FU89, FU75 (engine hood)
RE2502 Voltage feed, engine
Voltage feed control units, emergency stop
Figure 1
1. Emergency switch (optional equipment).

2. Battery disconnect switch (optional equipment, key operated).
3. Cable between MK:2 and MK:9 removed when Emergency stop is installed.
4. Not installed when key operated battery disconnector is used.
Links:
Components list
Chassis connection

DI16 Lock-out diode RE16 15A supply
DI3301 Start protection RE17 15B supply
DI3701 Battery disconnection relay, 1st RE18 15EA supply
DI3702 Battery disconnection relay, 2nd RE3102 Main relay 2
DI3703 Battery disconnection relay, 1st SW3102 Emergency stop
DI3705 Diode unit, RE3102 SW3301 Ignition switch
FU20 Voltage feed ignition. SW3701 Battery disconnection (not mounted when key
operated battery disconnector is used
according to alt. 2)
Component position:
Figure 2
Voltage feed control units
Figure 1
Links:
Components list
Chassis connection
CCM Climate Control Module
FU51 Ignition-dependent voltage feed.
Tech Tool communication socket (OBD).
RE12.
Starter motor, alternator
Figure 1
Links:
Components list
Chassis connection
AL3201 Alternator
FU36 Ignition-dependent voltage feed
MO3301 Starter motor, see also Wiring diagram WD301
Component position:
Figure 2
Communication, control units
Figure 1
Links:
Components list
Chassis connection
Communication, control units
Figure 1
Links:
Components list
Chassis connection
WECU Telematics ECU
Keypad and HMICU
Figure 1
Links:
Components list
Chassis connection
IC Instrument Cluster
SW3801 Keypad
VP Socket for TechTool (OBD)
Component position:
Figure 2
Voltage socket, audible signals, and back-up alarm
Figure 1
Links:
Components list
Chassis connection
FU09 Voltage feed RE02
LA3601 Rotating Warning Beacon
LA3612 Back-up warning, strobe light
RE02 Reversing light
SA3602 Horn, left
SA3603 Horn, right
SA3604 Reversing alarm
SW3604 Horn
SW3607 Rotating warning beacon
Component position:
Figure 2
Fuse test, unused connections
Figure 1
Links:
Components list
Chassis connection
FU23 Starter relay
FU46 Fuse
FU47 Fuse
LC3701 Fuse tester
RE06 Relay
R02 Resistor
R03 Resistor
R04 Resistor
R05 Resistor
R15 Fuse test
RF3601 Flasher relay (position RF1 on circuit board). See also Wiring diagram WD333.
Radio/CD, voltage socket, voltage converter, loudspeakers. WECU.
Figure 1
1. Basic GPS (AN3903).

2. Satellite (AN3904).
Links:
Components list
Chassis connection
12V DC 12 V power
CR3901 Radio
PO3902 Voltage socket, 12 V
SA3901 Loudspeaker, left
SA3902 Loudspeaker, right
SO3902 Voltage converter, radio
WECU Telematics ECU
Component position:
Figure 2
Headlights front
Figure 1
Links:
Components list
Chassis connection
FU05 Parking light, left front
Left front side light
Parking light, right rear
FU06 Parking light, right front
Right front, side light
Parking light, left rear
Lighting license plate
FU07 Low beam, left
FU08 Low beam, right
FU10 High beam, right
FU11 High beam, left
FU19 SW3501, parking lights, headlights
FX1072 Combination light, left front
LA3502, Low beam
LA3504, High beam
See also Wiring diagram WD333
FX1073 Combination light, right front
LA3503, Low beam
LA3505, High beam
HMICU Instrument control unit
LA3508 Running light, left front
LA3509 Running light, right front
LA3530 Number plate lighting
SW3501 Switch headlights
SW3502 High and low beam, headlight flasher
Component position:
Figure 2
Work lights , front
Figure 1
1. Optional work light, LA3521

2. Optional work light, LA3522
Links:
Components list
Chassis connection
DI06 Lock-out diode
DI07 Lock-out diode
DI08 Lock-out diode
DI09 Lock-out diode
FU03 Work lights cab, front
FU13 Work lights, front
HMICU Instrument control unit
LA3512 Work light, left front
LA3513 Work light, right front
LA3521 Work light, cab, front left
LA3522 Work light, cab, front right
LA3523 Work light cab, left front (optional equipment)
LA3524 Work light cab, right front (optional equipment)
LA3529 Work lights attachment
RE03 Work lights, front
RE07 Work lights cab, front
SW3504 Work lights, front
Component position:
Figure 2
Brake lights, position lights, direction indicators, and hazard flashers
Figure 1
Wiring diagram
1. Parking light, front left.

2. Position light, left.
3. Stop light, left.
4. Parking light, front right.
5. Position light, right.
6. Stop light, right.
Links:
Components list
Chassis connection
FX1001 Interior lighting, cab (front)
Component including LA3501, LA3516, SW3503 and SW3507
FX1002 Interior lighting, (right)
Component including LA3517, LA3518, SW3508 and SW3509
FX1020 Combination light, left rear
LA3510, Tail light
LA3606, Direction indicator
LA5202, Brake light
FX1021 Combination light, right rear
LA3511, Tail light
LA5201, Brake light
FX1072 Combination light, left front
LA3506, Parking light
FX1073 Combination light, right front
LA3507, Parking light
IC Instrument Cluster
RE3504 Interior lights
RF3601 Flasher relay (position RF1 on circuit board)
SE8301 Position monitor, door
SW3605 Direction indicators (FX1029)
SW3606 Hazard flashers
Component position:
Figure 2
Component position
Work light, rear
Figure 1
1. Work lights (replaces LA3526).

2. Work lights, (replaces LA3525).
Links:
Components list
Chassis connection
FU15 Work lights cab, rear
FU16 Work lights roof, front
LA3514 Working light, left, rear
LA3515 Working light, right, rear
LA3525 Work light, cab, rear, left
LA3526 Work light, cab, rear, right
LA3527 Work light cab, left rear (optional equipment)
LA3528 Work light cab, right rear (optional equipment)
RE04 Work lights cab, rear
RE11 Work lights roof
SW3505 Work lights rear
Component position:
Figure 2
Instrument lighting
Figure 1
Links:
Wiring diagram WD201 Wiring diagram WD801
Components list
Chassis connection
Entry light, extended light around machine
Figure 1
Links:
Components list
Chassis connection
LA3548 Entry light / Extended light around machine, 1st
LA3549 Extended light around machine, 2nd
LA3550 Extended light around machine, 3rd
LA3551 Extended light around machine, 4th
RE3507 Working lights, 1st
RE3524 Entry light
SW3525 Entry light
SW3526 Entry light, and extended light around machine
Component position:
Figure 2
Voltage feed 5 V from HMICU, GPMECU1, GPMECU2, and GPMECU3
Figure 1
Links:
Components list
Chassis connection
GPMECU3, ground connections
Figure 1
Links:
Components list
Chassis connection
Ground connections, GPMECU1, GPMECU2, and HMICU
Figure 1
Links:
Components list
Chassis connection
Voltage feed, 15EA
Figure 1
Links:
Components list
Chassis connection
15EA Voltage feed
FU42 Differential lock, indication lamp.
Fully automatic downshifting.
Gear selector lever carrier.
Lever steering, CDC (armrest).
Boom Suspension system, activation/function selection.
FU44 Floating position.
Single-acting lift function.
FU50 Voltage feed, TechTool communication socket.
Attachment locking.
Voltage feed, 15B
Figure 1
Links:
Components list
Chassis connection
FU39 Horn
Kick-down
FU40 FU12, voltage feed, reversing monitor, camera
Voltage feed, 15A
Figure 1
Links:
Components list
Chassis connection
FU32 Boom Suspension System (BSS).
Hold function, 3rd hydraulic function.
3rd hydraulic function together with 4th hydraulic function.
Emergency stop 3rd hydraulic function.
FU33 Electrical lever lock.
Aftertreatment system (ASU) (switch).
Lift/tilt function.
FU34 RE15.
Headlight flasher.
Windshield wiper and windshield washer front.
FU35 Windscreen wiper and washer, rear
FU37 Direction indicators
FU38 Work lights
Fuel heater
For component location, see Components list.

Voltage feed, 30K
Figure 1
Links:
Components list
Chassis connection
FU14 Hazard flashers
FU21 Rotating beacon
Interior lighting
Entry light, and CCM
Extended light around machine
Ground connections, 31C1, 31F1
Figure 1
Links:
Components list
Chassis connection
31C1 Ground terminal, cab, 1st
31F1 Front frame
For connection locations, see Chassis connection.

Ground connections, 31C1
Figure 1
Links:
Components list
Chassis connection
31C1 Ground terminal, cab, first
For connection location, see Chassis connection.

Ground connections
Figure 1
Links:
Components list
Chassis connection
Ground connections
Figure 1
Links:
Components list
Chassis connection
Ground connections
Figure 1
Links:
Components list
Chassis connection
Ground connections
Figure 1
Links:
Components list
Chassis connection
Gear selector, forward/reverse, steering column
Figure 1
Links:
Components list
Chassis connection
SW4205 Directional gear, forward/reverse, steering column
SW4206 Gear lever steering column
Component position:
Figure 2
Gearshifting, forward-reverse
Figure 1
1. SW4222, Single lever control, kick-down. Optional equipment.

Links:
Components list
Chassis connection
SW4207 Activation forward/reverse lever carrier
SW4208 Forward-Reverse lever carrier
SW4209 Kick-down lever carrier
SW4210 Engine braking / downshifting
Component position:
Figure 2
Gear shifting solenoids
Figure 1
Links:
Components list
Chassis connection
PWM4213 Forward gear
PWM4214 Reverse gear
PWM4215 1st gear
PWM4216 2nd gear
PWM4217 3rd gear
PWM4218 4th gear
Component position:
Figure 2
Sensor transmission, differential lock
Figure 1
Links:
Components list
Chassis connection
MA4603 Differential lock
SE4202 Transmission oil, temperature
SE4219 Transmission oil, pressure
SE4609 Feedback of engaged differential lock
SW4602 Differential lock
Component position:
Figure 2
Axle oil temperature, sensor transmission, FAPS (Full Auto Power Shift)
Figure 1
Links:
Components list
Chassis connection
SE4213 Turbine rpm
SE4307 Output speed, transmission
SE5222 Axle oil temperature, front axle
SE5223 Axle oil temperature, rear axle
SW4211 Fully automatic gearshifting (FAPS)
Component position:
Figure 2
Brakes
Figure 1
Links:
Components list
Chassis connection
FU01 Brake lights
FU48 Parking brake
MA5501 Parking brake
RE10 Brake lights
RE5502 Parking brake
SE5201 Available brake pressure
SE5203 Output brake pressure
SE5501 Pressure sensor applied parking brake
SW5501 Parking brake
Component position:
Figure 2
Lever steering, CDC (Comfort Drive Control)
Figure 1
Links:
Components list
Chassis connection
SE4227 Armrest lever steering (CDC)
SE6601 Control lever (CDC)
SW4216 Activating of lever steering (CDC)
SW4217 Forward/Reverse, Comfort Drive Control (CDC)
SW4220 Kick-down CDC
Component position:
Figure 2
Angle sensor, lever steering (CDC)
Figure 1
Links:
Components list
Chassis connection
SE6411 Angle sensor frame joint
Component position:
Figure 2
Secondary steering
Figure 1
Links:
Components list
Chassis connection
MO6402 Secondary steering pump, with temperature protection
RE6401 Secondary steering
SE6404 Differential pressure, secondary steering
SE6407 Secondary steering, pressure
Component position:
Figure 2
Windshield wiper and windshield washer
Figure 1
Links:
Components list
Chassis connection
DI22 Lock-out diode
DI23 Lock-out diode
FX1029 SW3602. Windshield wiper, front and windshield washer, front
SW3608. Windshield washer, front
MO3601 Windshield washer front
MO3602 Windshield wiper, front
MO3603 Windshield washer, rear
MO3604 Windshield wiper, rear
RE09 Windshield wiper, rear
RE15 Windshield wiper, front
SE3601 Washer fluid, level
SW3612 Windshield wiper and washer, rear
Component position:
Figure 2
Operator's seat, position monitor, ambient temperature
Figure 1
Links:
Components list
Chassis connection
HE8501 Seat heating
SE8502 Position monitor loading operator's seat
SE8705 Ambient temperature
Component position:
Figure 2
Back-up camera, rear-view mirrors
Figure 1
Links:
Components list
Chassis connection
FU12 Monitor, back-up camera
FX1036 MO3605, electrically controlled rear-view mirror, left horizontal
MO3606, electrically controlled rear-view mirror, left vertical
HE3602, electric heat left rear-view mirror
FX1037 MO3607, electrically controlled rear-view mirror, right horizontal
MO3608, electrically controlled rear-view mirror, right vertical
HE3604, electric heat right rear-view mirror
RC8401 Back-up camera
RM8401 Display window
SW3601 Electrically heated rear-view mirrors
SW3614 Electrically controlled rear-view mirrors
Component position:
Figure 2
Air conditioning
Figure 1
Links:
Components list
Chassis connection
SE8702 Evaporator, temperature
SE8706 Temperature, cab
SE8708 Temperature, air channel
SE8709 Pressure, refrigerant
SW8701 Controls, climate control system
Component position:
Figure 2
Climate control system, pause heater
Figure 1
Links:
Components list
Chassis connection
MA8701 AC compressor
MO8701 Cab, fan
MO8703 Actuator, air mixing damper
MO8707 Actuator, heat valve
MO8711 Pause coolant pump
RE8712 Pause coolant pump
Component position:
Figure 2
Fan cyclone filter. Fuel heating. Electric door, and electric hood opening.
Figure 1
Links:
Components list
Chassis connection
31C2 Ground terminal, cab 2
FU75 Hood motor.
Battery disconnection switch.
FX1027 Extra fuse box
FU85 Fan cyclone filter (MO8702)
FU86 —
FU87 —
FX1028 Extra fuse box
FU61 Fuel heating
FU64 Electric door
FU65 –
MO3611 Hood motor
MO8702 Fan cyclone filter
RE3610 Extra fuse box, FX1027
SW3620 Hood motor
Component position:
Figure 2
Electric door
Figure 1
Links:
Components list
Chassis connection
CU3605 Electrical doorlock control unit
MO3612 Electrical doorlock opening support motor
MO3613 Electrical doorlock motor
SW3630 Electrical doorlock rotor switch
Component position:
Figure 2
Working hydraulics, automatic lift and tilt
Figure 1
Links
Components list
Chassis connection
DI12 Quench diode
DI13 Quench diode
DI14 Quench diode
DI15 Quench diode
DI17 Quench diode
DI18 Quench diode
DI19 Quench diode
RE01 Bucket positioner
RE05 Boom kick-out (automatic lift)
SE9156 Inductive position sensor bucket positioner (automatic tilt)
SE9157 Inductive position sensor boom kick-out (automatic lift)
SW9141 Bucket positioner
SW9142 Boom kick-out (automatic lift)
Component position
Figure 2
Working hydraulics, automatic lift and tilt
Figure 1
Links:
Components list
Chassis connection
DI10 Quench diode
DI9101 Automatic tilt (MA9141)
DI9103 Automatic lift (MA9142)
DI9104 Automatic float (MA9143)
MA9112 Lever lock−out
MA9113 Lever lock−out, single lever
MA9141 Hold magnet, automatic tilt
MA9142 Hold magnet, automatic lift
MA9143 Hold magnet, float position
MA9144 Hold magnet, 3rd function
SW9140 Single lever control, electric lever lock
SW9144 Float mode
SW9174 Electric lever lock
Component position:
Figure 2
BSS (Boom Suspension System), hydraulic oil temperature and level
Figure 1
Links:
Components list
Chassis connection
DI20 Lock-out diode
DI21 Lock-out diode
FX1009 SE9104. Level hydraulic oil tank
SE9105. Temperature, hydraulic oil tank
MA9103 Boom suspension system CT4 (BSS)
MA9104 Single-acting lift CT1 (valve block 2)
MA9114 Boom Suspension System (BSS) CT1
RE08 Boom Suspension System, engagement
SW9148 Boom Suspension System, activation/function selection
SW9149 Single-acting lift function
Component position:
Figure 2
LS-pressure, attachment locking
Figure 1
Links:
Components list
Chassis connection
MA9106 Attachment lock, close
MA9127 Attachment lock, open
SE9119 LS-pressure
SW9143 Attachment lock
Component position:
Figure 2
Hydraulic servo, adjustable flow, 3rd function
Figure 1
Links:
Components list
Chassis connection
MA9145 3rd function, flow on/off
RE9112 3rd function, flow on/off
SW9175 3rd function, flow on/off
Component position:
Figure 2
Output control pump, emergency stop and hold function 3rd hydraulic function
Figure 1
Links:
Components list
Chassis connection
PWM9133 Electrically controlled hydraulic pump
SW9146 Emergency stop 3rd hydraulic function
SW9147 Hold function, 3rd hydraulic function
Component position:
Figure 2
Floating position
Figure 1
Links:
Components list
Chassis connection
DI10 Lock-out diode
SW9144 Floating position
Component position:
Figure 2
Central lubrication
Figure 1
Links:
Components list
Chassis connection
CU9901 Central lubrication unit
FU43 Central lubrication unit
SE9901 Monitoring lubrication oil pressure
Component position:
Figure 2
Fire supression system
Figure 1
1. Emergency switch.
Links:
Components list
Chassis connection
CU9902 Control unit, fire supression system
CU9903 Alarm panel, fire supression system
LA9901 Beacon, fire supression system
MA9903 Propelling charge solenoid
SA9901 Siren, fire supression system
Component position:
Figure 2
Ref no.: Operation no.: Issuer: Date:
PUB-A GB 321-902 WLO 2014-12-16
Kit no.: Option no.:
VOE17440170
Profile:
L60H Volvo, L70H Volvo, L90H Volvo
Alternator 120 Amp, installing new

Total procedure time (hr): 1.00
Foreword
The Mechanic must always read the instructions in the Service Manual's booklet "Safety and Environment"
booklet before proceeding.
The Installation Instruction sometimes refers to information in the Operator´s and Service Manual.
The equipment must be assembled by an authorized person at an authorized workshop.
The Installation Instruction is based on the use of special tools, E-tools and standard tools generally available.
Regarding bolted joints which are not listed here, see "Volvo standard tightening torques".
Volvo Construction Equipment AB, will accept no responsibility if other tools or work methods than those
described in this publication are used.
Volvo works with continuous improvement of the machine's environmental performance.
Kit list
Part no. Qty. Designation
15196041 1 Alternator
20775463 1 Belt pulley
1. Open the engine hood.
2. Turn off the electric power with the battery disconnector.
3. Remove the intermediate wall.

Figure 1
Part no. Quantity Designation Pos. in Fig. 1

– 1 Intermediate wall A
4. Remove the belt tensioner and remove the belt.
Figure 2

– 1 Belt B
– 1 Belt tensioner C
5. Loosen the electric connections on the alternator.

Figure 3

– 1 Connections D
6. Loosen the bolts for the filter bracket.

Loosen the bolts and remove the alternator.
Figure 4
Figure 5

and 5
– 1 Filter bracket E
– 2 Bolt F
– 2 Bolt J
7. Transfer the nut from the existing alternator to the new alternator.
Figure 6

– 1 Nut G
8. Install the belt pulley and tighten the nut with 90 ±5 Nm.
Figure 7

20775463 1 Belt pulley 2
– 1 Nut I
9. Install the alternator and install the connections.
10. Install the belt.
11. Restore the machine.

PUB-A GB 356-937 WLO 2014-08-27
VOE17210469 84681
Profile:
L60H Volvo, L70H Volvo, L90H Volvo, L110H Volvo, L120H Volvo, L150G Volvo, L150H Volvo, L180G Volvo,
L180H Volvo, L220G Volvo, L220H Volvo, L250G Volvo, L250H Volvo
Attachment worklight, installing new

Foreword
Kit list
946472 1 Flange screw
4881440 1 Strip clamp
11170009 1 Work light
13960143 1 Washer
13971098 1 Flange lock nut
15088078 1 Cable harness
21244697 1 Relay
1. This is a simplified installation instruction.

Turn off the electric power with the battery main switch.
Install the parts as shown in the figure.
Connect the cable harness from the work lights to the existing connector in the front frame.
Part no. Quantity Description Pos. in Fig. 1

11170009 1 Work light 1
946472 1 Flange screw 2
13960143 1 Washer 3
13971098 1 Flange lock nut 4
15088078 1 Cable harness 5
4881440 2 Strip clamp 6
Figure 1
Figure 2
Lamp position
2. Install the relay in the electrical distribution box, in space RE03.

Figure 3

14594545 1 Relay –
PUB-A GB 362-905 WLO 2013-08-13
VOE17202465 85644, 86493
Profile:
L60G Volvo, L60H Volvo, L70G Volvo, L70H Volvo, L90G Volvo, L90H Volvo, L110G Volvo, L110H Volvo,
L120G Volvo, L120H Volvo, L150G Volvo, L150H Volvo, L180G Volvo, L180H Volvo, L220G Volvo, L220H
Volvo, L250G Volvo, L250H Volvo
Back up alarm, installing new

Foreword
Kit list
17222610 1 Reversing alarm 1
13947760 2 Flange bolt 2
13945408 2 Flange nut 3
13960141 2 Washer 4
4973473 2 Spacer sleeve 5
4881440 1 Strip clamp 6
This is a simplified installation instruction.
1. Install the parts as shown in Figure 1
2. Connect the reversing alarm's connector to the existing connector marked SA3604 (RZ).
Figure 1
V1134064
PUB-A GB 356-928 WLO 2013-02-28
VOE17287426 85823
Profile:
Volvo, L250G Volvo, L250H Volvo, L350F Volvo
Cab front work light LED, installing new

Foreword
Kit list
17224577 4 Light holder
946329 2 Flange bolt
13960143 2 Washer
13971095 2 Flange nut
15021902 2 Spacer
1. These are simplified installation instructions.

Turn off the battery disconnect switch.
Install the parts as shown in the figure. Use existing bolts and nuts.
Figure 1

15670554 4 Work light 1
17224577 4 Light holder 2
13960143 2 Washer 4
13971095 2 Flange nut 5
15021902 2 Spacer 6
PUB-A GB 356-933 WLO 2013-03-12
VOE17287439 85827
Profile:
Cab illuminated entrance LED, installing new

Foreword
Kit list
13960143 1 Washer
969161 1 Wire fuse (melt fuse)
4940327 2 Diode
4881440 13 Cable tie
11428156 1 Switch
17222931 1 Switch
17226785 1 Relay
70369702 1 Switch
11204217 18 Plug
1613068 2 Plug
1. Connect Tech Tool Service Toll to the network. Select “Administer software, new”, select Accessory kit
(Conversion kit), and enter number 11720850.
2. Check that all parts are included according to the kit list.
3. Remove the protective cover over the electrical distribution box in the cab.
4. Remove the protective covers over the rear cab pillars.
5. Remove the cover over the instrument panel on the cab pillar.
6.
Figure 1
A. Glove compartment
Remove the glove compartment.
7.
Figure 2
A. Connector
B. Air duct
Remove the air duct (black). Unplug the connector.
8.
Figure 3
A. Air duct
Remove the air duct (grey).
9. Remove the AC-panel, interior rear-view mirrors, lights, and the radio console.
10. Remove the headlining.
11. Remove the rotating beacon from the cab roof. [1]
12.
Figure 4
A. Spacer
Loosen the outer roof and support it with a spacer, for example, a wooden block, approx. 20 cm. See
Fig. 4.
13.
Figure 5
Remove the plastic cover and install the switch.

70369702 1 Switch 13
11428156 1 Switch 14
14.
Figure 6
Connect the cable harness (1) to the switch. Install the rocker. Clamp the cable harness along the cab
floor.
Plug in the connectors. Install the diodes. Install the relay. Connect the cable harness (2) and continue
to clamp it up towards the roof along the rear, right cab pillar. Pull out the cable harness through the
hole in the roof and clamp it along the roof. See Fig. 6.

17226785 1 Relay 8
70369702 1 Switch 13
4940327 2 Diode 12
15.
Figure 7
Install the light holder and work light as shown in Fig. 7. Plug in the connector.

13960143 1 Washer 18
15670553 1 Work light 4
13971095 2 Flange nut 17
4881440 1 Cable tie 15
16.
Figure 8
Remove the spacer and install the outer roof.
17. Install the rotating beacon [2].
18.
Figure 9
A. Air duct
Install the air duct (grey).
19.
Figure 10
A. Connector
B. Air duct
Install the air duct (black). Plug in the connector.
20. Install the headlining (inner cab roof). Use new plugs.
21. Install the AC-panel, radio console, lights, and interior rear-view mirrors.
22. Install the protective covers over the rear cab pillars. Use new plugs.
23. Install the protective cover over the electrical distribution box in the cab.
24. Install the cover over the instrument panel on the cab pillar.
25.
Figure 11
Install the glove compartment.
For L60G-L120G
26.
Figure 12
Figure 13
Install the switch and the flange screws. Install the wire fuse.
Part no. Quantity Designation Pos. in Fig. 12/13

969161 1 Wire fuse (melt fuse) 11
17222931 1 Switch 19
For L150G-L250G
27.
Figure 14
Figure 15

17222931 1 Switch 19
For L350F
28.
Figure 16

17222931 1 Switch 19
Parameters, setting
29. Connect Tech Tool Service Tool to the machine. Run operation 17093–3 program with stored software.
Report to the central system.
PUB-A GB 356-929 WLO 2013-03-12
VOE17287434 85825
Profile:
Cab rear work light LED, installing new

Foreword
Kit list
13960143 12 Washer
21244697 1 Relay

Turn off the battery disconnect switch
Install the parts as shown in Fig. 1 and 2.
Figure 1

15670554 4 Work light 1
13960143 12 Washer 4
13971095 4 Flange nut 5
Figure 2
Electrical distribution box, rear cab wall

21244697 1 Relay 6
PUB-A GB 356-930 WLO 2013-03-12
VOE17287438 85826
Profile:
L120G Volvo, L120H Volvo, L150G Volvo, L150H Volvo, L180G Volvo, L220G Volvo, L250G Volvo, L350F
Volvo
Cab side work light LED, installing new

Foreword
Kit list
13960143 4 Washer
969161 1 Wire fuse (melt fuse)
4940327 2 Diode
11428156 1 Switch
17222931 1 Switch
17226785 1 Relay
70369702 1 Switch
21244697 1 Relay
11204217 18 Plug
1613068 2 Plug
2. Place the machine in service position 1, see Service position in the Service Manual.
3. Remove the protective cover over the electrical distribution box in the cab.
4. Remove the protective covers over the rear cab pillars.
5. Remove the cover over the instrument panel on the cab pillar.
6.
Figure 1
Remove the glove compartment.
7.
Figure 2
A. Connector
B. Air duct
Remove the air duct (black). Unplug the connector.
8.
Figure 3
A. Air duct
Remove the air duct (grey).
9. Remove the AC-panel, interior rear-view mirrors, lights, and the radio console.
10. Remove the headlining.
11. Remove the rotating beacon [1] from the cab roof.
12.
Figure 4
A. Spacer
Loosen the outer roof and support it with a spacer, for example, a wooden block, approx. 20 cm. See
Fig. 4.
13.
Figure 5
Remove the plastic cover and install the switch on the cab pillar.

70369702 1 Switch 13
11428156 1 Switch 14
Figure 6
14. Connect the cable harness to the switch. Install the rocker. Clamp the cable harness along the cab
floor.
Plug in the connectors. Install the diodes. Install the relays. Continue to clamp the cable harness up
towards the roof along the rear, right cab pillar. See Fig. 6.

17226785 1 Relay 8
21244697 1 Relay 10
70369702 1 Switch 13
4940327 2 Diode 12
4881440 8 Cable tie
Figure 7
15. Connect the cable harness (3) to CN. Clamp both cable harnesses along the cab roof and out to both
rear lights.
Clamp the cable harness (3) along the cab roof and on to both front lights. See Fig. 7.

16.
Figure 8
Install both front light holders and work lights as shown in Fig. 8. Plug in the connectors.

13960143 1 Washer 18
15670553 1 Work light 4
17.
Figure 9
Install the rear light holders and work lights as shown in Fig. 9. Plug in the connectors.

13960143 1 Washer 18
15670553 1 Work light 4
13971095 2 Flange nut 17
4881440 1 Cable tie 15
18.
Figure 10
Remove the spacer and install the outer roof.
19. Install the rotating beacon [2].
20.
Figure 11
A. Air duct
Install the air duct (grey).
21.
Figure 12
A. Connector
B. Air duct
Install the air duct (black). Plug in the connector.
22. Install the headlining (inner cab roof). Use new plugs.
23. Install the AC-panel, radio console, lights, and interior rear-view mirrors.
24. Install the protective covers over the rear cab pillars. Use new plugs.
25. Install the protective cover over the electrical distribution box in the cab.
26. Install the cover over the instrument panel on the cab pillar.
27.
Figure 13
Install the glove compartment.
For L60G-L120G
28.
Figure 14
Figure 15

17222931 1 Switch 19
For L150G-L250G
29.
Figure 16
Figure 17

17222931 1 Switch 19
For L350F
30.
Figure 18

17222931 1 Switch 19
G 2015-01-22
Non-Volvo units (machine without Can-Bus integration)
Tech Tool
Order the W-ECU suitable for the appropriate market according to table below.
W-ECU are ordered separately.
V1153304
*** Do not use 11720602 for these applications

** ESW = Embedded Software
*Only in markets where CareTrack is launched with 3G
Tech Tool , ,
W-
date
Software
art
See table for conversion kit number in table on previously page.
Mount antenna with unobstructed view to sky,

with no metal structure covering antenna.
Antenna should also be placed as far away from each
other as practical and away from other radio
communication devices to avoid possible signal interference.
Measure antenna locations on cab roof. Quantity of location

will depend upon quantity of antennas being utilized.
One for the GPS/GSM antenna (oval Area) and one for
the satellite antenna (round area). The recommended hole size
is 15mm. Mount the antenna. Antennas may also be mounted on
mirror brackets, or even inside the cab, close to the vehicle
windscreen. using locally manufactured mounting brackets.
grounded
ground
15198186
17413636
Mount the W-ECU where it is suitable.
0
4
5
17
18
19
On
PUB-C GB 390-902 WLO 2015-01-21
VOE17237322 86483, 86484, 86485, 86486
Profile:
CareTrack, installing new

Tools:
Tech Tool Service Tool
88890300 Interface
88890253 Cable
88890305 Cable
88890306 Cable
NOTE!
Interface cable 88890304 is for WLO-H generation that have OBDII connection.
Interface cable 88890306 is for WLO-G generation that have FCI connection.
Foreword
Installation kit list WLO G-H generation: 17233722
Part no. Quantity Designation

NOTE!
Use the CareTrack ECU (electronic unit)/antenna that is adapted to the market for which the equipment is
intended. See table below.
Tech Tool Preparation
NOTE!
For WLO-G-generation.
1. Start operation “17056-3 – Central systems updating, Change software”.

Run conversion kit (depending on W-ECU hardware) according to table below.
Download the software.
Install the hardware( see installation instruction below)
Program the ECU
Run the operation 39797-3, "Telematics control unit, reset"
Report back to the central system.
NOTE!
For WLO H-generation
1. Run conversion kit (depending on W-ECU hardware) according to table below. For WLO H-
serie with CareTrack W-ECU 3G with GSM,GPS/SAT (pn: 11384320 ) run conversion kit
11720835. For all other CareTrac ECU see table below.
2. Install the hardware( see installation instruction below)
3. Select the operation 17093–3 ”Program with stored software” and follow the instructions to
program the machine.
4. Run the operation 39797-3, "Telematics control unit, reset"
5. Report back to the central system.
Description W-ECU kit Basic Advanced Conversion kit Conversi

Conversion kit ESW** on kit SW
Non ESW**
W-ECU 2G VOE 17202839 (contains 11720511 11720495 11720602
W-ECU: 11381209
Antenna: 17413636)
with Satellite W-ECU: 11381207
Antenna: 17413636 SAT
antenna: 17437414 )
China W-ECU: 11381465
Antenna: 17413636)
Brazil W-ECU 11381560
Antenna: 17413636)
with Satellite W-ECU: 11381460
Brazil Antenna: 17413636 SAT
antenna: 17437414)
W-ECU 3G* W-ECU: 11384310 11720794 11720796 (Other 11720602
Antenna: 17413636 machines)
11720896(ART F(A0xx)
and ART G)***
11720835 (WLO H)***
11720859 (EXC E)***
11720897 (GRD C)***
W-ECU 3G* W-ECU: 11384320 11720793 11720795 (Other 11720602
with Satellite Antenna: 17413636 SAT machines)
antenna: 17437414 11720806(ART F(A0xx)
and ART G)***
11720835 (WLO H)***
1720859 (EXC E)***
1720887 (GRD C)***
*** Do not use 11720602 for these applications

** ESW = Embeded Software
*Only in markets where CareTrack is launched with 3G
NOTE!
After running the conversion kit according to the above table, then one MUST also run
conversion kit no.: 11720602.
2. Turn the battery disconnect switch to the off position.
Antenna
3. Remove the headlining in the cab.
4. Remove the plastic roof from the cab.
Figure 1
Pos 1, the screw on the cab roof.
NOTE!
Follow these instructions if satellite equipment also needs to be installed on the machine.
5. Insert the antenna cable for the GSM/GPS antenna through the hole in the cab roof (pos. 3). Screw in
the antenna (GSM/GPS) in the existing hole on the right side of the roof (pos. 3).
Figure 2

1 Antenna (GSM/GPS) 3
6. Insert the antenna cable for the satellite antenna through the hole in the cab roof (pos. 5). Install the
antenna (satellite) in the existing hole on the right side of the roof (pos. 5).
NOTE!
Remove the color painting on the cab roof to insure good ground connection for the antenna.

1 Antenna kit (satellite) 5
7. Install the plastic roof on the cab and tighten the screws.
8. Secure the antenna (GSM/GPS), with the supplied nut, inside the cab roof.
Tightening torque: 5 Nm (3.7 lb ft)
Figure 3
GSM/GPS-antenna cable with supplied bolt (pos. 5). Tightening torque 5 Nm (3.7 lb ft)
Figure 4
Satellite antenna cable
9. Route and clamp the antenna cable along the cab roof, to the glove compartment by way of the rear
left cab pillar.
There must be at least 55 cm (21.7 in) between the cable and the cab wall in order for the connector
from the antenna to reach the electronic unit (CareTrack ECU).
Figure 5
Figure 6
Electronic unit
10. Pictures below are on the W-ECU 2G CareTrack
Figure 7
CareTrack W-ECU 2G, GSM//GPS, part no: 11381209
Figure 8
CareTrack W-ECU 2G, GSM//GPS + SAT, part no: 11381207
11. Open the glove compartment and remove the two screws (B). Loosen the three screws to the right on
the electrical distribution unit (A). Remove the glove compartment.
Figure 9
12. Install the GSM/GPS electronic unit (pos.1) on the right side of the cab with the flange nuts (pos.2.)
Connect the antenna cable from the GSM/GPS antenna as shown in the photo (pos. 5): blue
connector to blue contact and pink connector to pink contact. Connect the existing connector marked
WECU to the electronic unit (pos. 4.)
Figure 10
W-ECU 3G, GSM/GPS
1. GSM/GPS electronic unit
2. Flange lock nut
4. Existing WECU connector to the ECU

5. Antenna cable, GSM/GPS

For W-ECU 3G, GSM/GPS +SAT
13. Connect the cables from the GPS/GSM antenna and the WECU cable to the ECU.
14. Connect the antenna cable from the satellite antenna to the electronic unit (pos. 3.)
Figure 11
W-ECU 3G, GSM/GPS+SAT Pos. 3, connection for satellite antenna
1. ECU
2. Flange lock nut
3. Antenna cable, satellite
4. Existing connector, WECU to ECU
5. Antenna cable, GSM/GPS

15. Install the headlining and install all protection in the cab.
16. Restoring of the machine

PUB-B GB 387-902 WLO 2012-11-20
VOE17244817 85554
Profile:
Forward view camera, installing new

Foreword
WARNING
Please pay attention to the safety instructions in the Operator's and Service Manuals concerned.
Figure 1
Kit list
Part no. Quantity Description

4785462 2 Clamp
11003048 3 Cover plate
960139 7 Washer
11006457 1 Plug
11411399 1 Clamp
15155712 1 Bracket
952624 1 Clamp
4881440 4 Cable tie
961970 1 Plug 32
17220088 1 Bracket
16817194 1 Camera
17234368 2 Cable
17216337 1 Junction box
15194883 1 Tape
NOTE!
Check that all parts are included before starting any installation work.
1. Turn the battery disconnector on the machine to position “Off” before starting any work.
In the cab
2. Remove the AC-panel, protection for the B-pillar, and the back-piece at the electrical distribution box.
3. Loosen the control panel on the A-pillar and the headlining’s right side.
4. Install the junction box on the B-pillar with double-sided tape.
Figure 2
Kopplingsskåp med anslutningar
Part no. Quantity Description Position. in fig. 2

17216337 1 Junction box 22
15194883 1 Tape 23
5. Unplug the connector between the back-up camera and screen (junction at electrical distribution box).
Cut off the cable ties, re-route the cable from the screen to the junction box at the top on the B-pillar
and plug in the connector marked with “Monitor” (Fig. 2).
Figure 3

17234368 1 Cable 21
961970 1 Plug 32 18
6. Connect the cable for the front camera to C3 on junction box at the top on the B-pillar and route the
cable inside of the headlining, out of the cab (approx.: 70 cm, approx.: 27 in) through Plug 32 on the
right side of the cab roof. (Fig. 3)
Figure 4

17234368 1 Cable 24
7. Re-route the cable, for the back-up camera, from the connector at electrical distribution box to the
junction box at the top on the B-pillar and connect the cable to connection C1 (Fig. 4).
8. Reinstall the control panel on the A-pillar.
9. Reinstall the headlining.
10. Assemble the camera according to fig. 5 och 6.
Figure 5
A. Clamp
C. Bolt
Figure 6
B. Clamp
D. Bolt
E. Camera (20)

16817194 1 Kamera E (20)
11. Install the camera (20) on the camera bracket (19).

Figure 7
F. Washer
G. Nut

11006457 1 Plug 6
12. Install the camera bracket (19) on the fastening bracket (12).
Figure 8

15155712 1 Bracket 12
17220088 1 Bracket 19
11411399 1 Clamp 7
11003048 1 Cover plate 8
960139 2 Washer 10
952624 1 Clamp 13
960139 1 Washer 14
On the cab roof
13. Install the bracket on the light ramp on the front of the cab roof.
Figure 9

4785462 2 Clamp 1
960139 4 Washer 5
14. Connect the cable from the junction box in the ca to the connector by the camera.
15. Clamp the cable with clamps and cable ties, from the camera along the light ramp on the cab roof.
Figure 10

4881440 4 Cable tie 17
16. Perform the following settings in the screen:
 System settings – Camera switch – 3C.

 System settings – Front cam – Enable front cam – 3C.
17. Reinstall the A-pillar.
18. Reinstall the protection on the B-pillar.
19. Reinstall the AC-panel.
20. Install the back-piece by the electrical distribution box.
21. Turn the battery disconnector to position “On”.
22. Adjust the camera so that the desired images is on the screen.
PUB-B GB 356-931 WLO 2014-01-28
VOE17287442 85836
Profile:
Front work light LED, installing new

Foreword
Kit list
946834 2 Clamp
971095 2 Flange nut
16872525 2 Protective plate
11414308 1 Decal
13960143 2 Washer
13960141 4 Washer
21244697 1 Relay
Install the parts as shown in Fig. 1 and 2.
Connect LA3512/LA3513.
Figure 1
Position of work light, LED, overview as well as view C

16872525 2 Protective plate 1
13960141 4 Washer 3
13945408 4 Flange nut 4
15670553 2 Work light 5
13960143 2 Washer 7
971095 2 Flange nut 8
11414308 2 Decal 9
946834 2 Clamp 10
Figure 2
Electrical distribution box, rear cab wall

21244697 1 Relay A
PUB-A GB 356-932 WLO 2013-02-28
VOE17287441 85835
Profile:
Grill work light LED, installing new

Foreword
Kit list
13960143 2 Washer
17246349 2 Bracket
For L60G-L90G
2. Remove the work light, if installed.

Install the bracket with flange bolt, washer, and flange nut. Install the work light. Connect the work light
to the existing cable harness.
Figure 1

13960143 2 Washer 5
13971095 2 Flange nut 4
15670553 2 Work light 1
17246349 2 Bracket 2
For L110G-L250G as well as L350F
3. Remove the work light, if installed.

Install the bracket with flange bolt, washer, and flange nut. Install the work light. Connect the work light
to the existing cable harness.
Figure 2

13960143 2 Washer 5
13971095 2 Flange nut 4
15670553 2 Work light 1
17246349 2 Bracket 2
NOTE!
If the lights do not work, it may be due to the polarity being reversed.
PUB-B GB 272-900 WLO 2014-09-19
VOE17433156 83438, 86000
Profile:
L60F Volvo, L60G Volvo, L60H Volvo, L70F Volvo, L70G Volvo, L70H Volvo, L90F Volvo, L90G Volvo, L90H
Volvo, L110F Volvo, L110G Volvo, L110H Volvo, L120F Volvo, L120G Volvo, L120H Volvo, L150F Volvo,
L150G Volvo, L150H Volvo, L180F Volvo, L180G Volvo, L180H Volvo, L220F Volvo, L220G Volvo, L220H
Hand throttle, instaling new

Foreword
Kit list
11039727 1 Hand throttle, operating control
11039800 1 Steering wheel
Tools

11039727 1 Hand throttle, operating control 1
11039800 1 Steering wheel 2
1. Remove the existing plug on the right cab pillar in the cab. Install the hand control and plug in the
connector to the existing connector in the cab pillar marked R2701.
NOTE!
For G-machines
2. Connect Tech Tool Service Toolto the machine and set the parameter ”FVL” to position “1”.
NOTE!
For H-machines
3. Connect Tech Tool Service ToolTech Tool to the machine and set the parameter “P1I20” to position “1”.
Figure 1
Cab pillar. A = R2701
PUB-A GB 256-901 WLO 2014-12-29
VOE17440387 11298442, 85928
Profile:
Pre-cleaner cyclone type, installing new

Foreword
WARNING
Kit list

13960143 5 Washer
4785462 2 Clamp
4943026 2 Spacer sleeve
11141093 1 Angle
11180657 1 Pre-cleaner cyclone
14016673 3 Clamp
15165037 1 Wide-angle mirror
15199771 1 Mirror arm
16831828 2 Hose clamp
16860768 1 Adapter kit
16860793 1 Bracket
1. Open the engine hood. Turn off the electric power with the battery disconnector.
2. Remove the air inlet by the fender's right side.
Figure 1
A. Air inlet
3. Install the adapter kit and the bracket.
Figure 2
Figure 3
Part no. Quantity Description Pos. in Fig. 2 and 3

16860768 1 Adapter kit 1
16860793 1 Bracket 2
13960143 2 Washer 4
13960143 3 Washer 10
4. Install the angle and hose clamps between the pre-cleaner and air inlet. Install the pre-cleaner.
Figure 4

11141093 1 Angle 6
16831828 2 Hose clamp 7
11180657 1 Pre-cleaner 8
5. Close the engine hood.
Replacing mirror arm
6. Unplug the connector if the machine is equipped with power mirrors and remove the mirror arm from
the machine's right side.
Remove the mirror.
7. Install the existing mirror on the new mirror arm. Install the wide-angle mirror. If the machine is not
equipped with power mirrors, cut off the cable from the mirror arm.
Figure 5

– 1 Mirror C
15199771 1 Mirror arm 2
15165037 1 Wide-angle mirror 4
14016673 2 Clamp 13
8. Install the mirror arm on the machine.

Tightening torque:10±1.5 Nm
Plug in the connector if the machine has power mirrors.
Install the back-piece on the existing mirror.
Adjust the mirror arm and the mirrors.
Figure 6

4785462 2 Clamp 7
14016673 1 Clamp 13

PUB-A GB 256-900 WLO 2014-12-29
VOE17440389 11298442, 85926
Profile:
Pre-cleaner oil bath type, installing new

Foreword
WARNING
Kit list

930468 2 Spacer ring
11117464 4 Washer
13960143 11 Washer
4785462 2 Clamp
14016673 3 Clamp
11445215 1 Clamp
11707307 1 Cover
4880805 1 Air filter
16821628 2 Plate
16861585 1 Bracket
20565673 1 Vacuum switch
Figure 1
A. Air inlet
3. Install the bracket loosely.

Weight: approx. 18 kg (40 lbs)
Install the adapter kit and torque-tighten all bolts.
Figure 2
Figure 3

16861585 1 Bracket 2
16821628 2 Plate 3
13960143 8 Washer 5
13960143 3 Washer 8
930468 2 Spacer ring 9
4. Install the air filter and the clamp. Do not tighten the bolts completely.
Weight: approx. 20 kg (44 lbs)
Figure 4

4880805 1 Air filter 10
11445215 1 Clamp 11
11117464 4 Washer 13
5. Install hose and hose clamp between the air filter and the air inlet.
Torque-tighten the bolts for the clamp.
Install the cover.
Figure 5

11707307 1 Cover 14
15017603 1 Hose 15
16831828 2 Hose clamp 16
6. Remove the lower part of the oil-bath air cleaner and fill it with oil to the marked level.
Figure 6
Volume: approx. 5.5 l (1.5 US gal).

8715877 1 Oil, 5.5 l (12.5 US gal) –
7. Remove the existing vacuum switch located on the air pipe to the turbo. Install the new vacuum
switch. NEW PICTURE!!
Figure 7

20565673 1 Vacuum switch 19
Remove the mirror.
10.
Figure 8

– 1 Mirror C
15199771 1 Mirror arm 2
15165037 1 Mirror, wide-angle 4
14016673 2 Clamp 13
Install the existing mirror on the new mirror arm. Install the wide-angle mirror. If the machine is not
11.
Figure 9

4785462 2 Clamp 7
14016673 1 Clamp 13
Install the mirror arm on the machine.

Tightening torque:10 ±1.5 Nm.

PUB-A GB 256-904 WLO 2014-12-29
VOE17440390 11298442, 85924
Profile:
Pre-cleaner turbo type, installing new

Foreword
WARNING
Kit list

13960143 5 Washer
982444 1 Clamp
4785462 2 Clamp
4943026 2 Spacer sleeve
14016673 3 Clamp
11141093 1 Angle
15109294 1 Pipe
16823048 1 Pre-cleaner turbo II
16860793 1 Bracket
Figure 1
A. Air inlet
3. Install the adapter kit and the bracket.
Figure 2
Figure 3

16860793 1 Bracket 2
13960143 2 Washer 4
13960143 3 Washer 14
4. Install the angle and hose clamps between the pre-cleaner and air inlet. Install pipe, clamp, and pre-
cleaner.
Figure 4

11141093 1 Angle 6
16831828 2 Hose clamp 7
15109294 1 Pipe 8
982444 1 Clamp 9
13971095 1 Flange nut 11
16823048 1 Pre-cleaner 12
Replacing mirror arm
Remove the mirror.
7. Install the existing mirror on the new mirror arm. Install the wide-angle mirror. If the machine is not
Figure 5

– 1 Mirror C
15199771 1 Mirror arm 2
15165037 1 Wide-angle mirror 4
14016673 2 Clamp 13
8. Install the mirror arm on the machine.

Tightening torque: 10±1.5 Nm
Figure 6

4785462 2 Clamp 7
14016673 1 Clamp 13

PUB-A GB 715-905 WLO 2015-01-15
VOE17440395 85047
Profile:
Radiator grill guard, installaing new

Foreword
Kit list
Part number Quantity Description

13940090 2 Washer
951985 1 Spring pin
969405 2 Six-point socket screw
983338 8 Washer
11026547 2 Slide bearing
11400568 1 Pin
11400890 8 Spacer
13960145 2 Washer
16821302 1 Hinge half
15179315 1 Warning decal
16826768 1 Protective grating
16821131 1 Upright
16805372 1 Upright
16812880 1 Cap
1. Remove the protective plugs on the counterweight.
2. Install the uprights on the right and left side of the counterweight.
Figure 1
Part number Quantity Description Pos. in Fig. 1

16805308 1 Upright 1
16805368 1 Upright 2
11400890 8 Spacer 8
983338 8 Washer 10
3. Install the slide bearings on the protective grill and install the protective grill between the uprights on
the counterweight.
Figure 2
16810701 1 Protective grating 3
11026547 2 Slide bearing 4
4. Install the hinge half on the upright.
Figure 3

15129760 1 Hinge half 5
13960145 2 Washer 12
5. Install the pin and the spring pin by the hinge half.
Figure 4

11400568 1 Pin 6
951985 1 Spring pin 7
6. Open the cover for the battery disconnector and install the cap and fasten the warning decal.
Figure 5

16812880 1 Cap 13
13940090 2 Washer 14
969405 2 Six-point socket screw 15
PUB-B GB 393-900 WLO 2014-02-14
VOE17202468 85276
Profile:
Radio, installing new

Foreword
Kit list
941263 1 Leadthrough
949921 2 Spring nut
955779 1 Hex nut
960139 2 Washer
1083597 1 Antenna
11100247 2 Spacer
11164554 1 Radio bracket
11170371 1 Power socket
11201898 2 Loudspeaker
11204217 4 Plastic plug
20565961 1 Antenna bracket
20724975 1 Voltage converter
The radio is ordered separately.
1. Remove the loudspeaker grilles and the right cover where the radio is to be installed.
Figure 1
A. Cover for radio

B. Grille for loudspeaker
2. Take out the loudspeaker cables and connect them to the loudspeakers. Install the loudspeakers and
the loudspeaker grilles.
Figure 2

11201898 2 Loudspeaker 9
3. Install the radio bracket in the headlining.

Install the aerial bracket and the aerial.
Route the aerial cable to the radio bracket.
Figure 3

20565961 1 Antenna bracket 3
1083597 1 Antenna 4
11164554 1 Radio bracket 5
949921 2 Spring nut 6
960139 2 Washer 7
941263 1 Leadthrough 15
4. Take out the connector (CR3901) and the aerial cable.
Figure 4
5. Remove the rear panel.

Remove the panel on the rear, right cab pillar.
Remove the right panel.
Figure 5
A. Right panel
B. Cab pillar
C. Rear panel
6. If the machine is equipped with Comfort Drive Control (CDC), remove the control unit and install the
voltage converter with the two existing nuts.
Remove the control unit for Comfort Drive Control (CDC) and install the voltage converter with the two
existing nuts.
Install the spacers on the studs and install the control unit for Comfort Drive Control (CDC) on the
spacers with the six-point socket screws.
If the machine is not equipped with Comfort Drive Control (CDC):
Install the voltage converter on the studs with the nuts.
Plug in connector SO3901.

Figure 6

– – Control unit for Comfort A
Drive Control (CDC)
11100247 2 Spacer B
969419 2 Six-point socket screw C
20724975 1 Voltage converter 11
7. Install the cable harness' line fuse.

Plug in the cable harness' connector SO3901.
Connect the cable harness' cable end 31 to the machine's grounding point.
Connect the cable harness' cable end 30A to the machine's plus terminal.
Clamp the cable harness.
Figure 7

– – SO3901 A
955779 2 Hex nut 14
– 5 Clamp B
– – 30A C
– – 31 D
8. Loosen the panel for the front right cab pillar and move it aside.
Remove the blind plug and install the power socket.
Plug in connector PO3902.
Reinstall the panel for the front right cab pillar.
Figure 8

11170371 1 Power socket 10
9. Reinstall the right panel, the panel on the cab pillar, and the rear panel, see Fig. 5.
PUB-A GB 393-900 WLO 2013-11-22
VOE17413929 85938, 85939
Profile:
L60H Volvo, L70H Volvo, L90H Volvo, L110H Volvo, L120H Volvo, L150H Volvo, L180H Volvo, L220H Volvo,
L250H Volvo
Radio, installing new

Foreword
Kit list
941267 1 Leadthrough
949921 2 Spring nut
960139 2 Washer
1083597 1 Antenna
11100247 2 Spacer
11164554 1 Radio bracket
11170371 1 Power socket
11201898 2 Loudspeaker
11204217 4 Plastic plug
20565961 1 Antenna bracket
20724975 1 Voltage converter
The radio is ordered separately.

1. Remove the loudspeaker grilles and the cover where the radio is to be installed (left or right side).
Figure 1
A. Cover for radio

B. Grille for loudspeaker
2. Take out the loudspeaker cables and connect them to the loudspeakers. Install the loudspeakers and
the loudspeaker grilles.
Figure 2
Part no. Quantity Designation Fig. in Pos. 2

11201898 2 Loudspeaker 12
3. Install the radio bracket in the ceiling.

Install the antenna bracket and the antenna.
Route the antenna cable to the radio bracket.
Figure 3

11164554 1 Radio bracket 7
949921 2 Spring nut 9
960139 2 Washer 11
20565961 1 Antenna bracket 4
1083597 1 Antenna 5
941267 1 Leadthrough 6
4. Take out the connector (CR3901) and the antenna cable.
Figure 4

Remove the panel on the right, rear cab pillar.
Remove the right panel.
Figure 5
A. Right panel
B. Cab pillar
C. Rear panel
6. If the machine is equipped with Comfort Drive Control (CDC):

Remove the control unit for Comfort Drive Control (CDC) and install the voltage converter with the two
existing nuts. Install the spacers on th studs and install the control unit for Comfort Drive Control
(CDC) on the studs with the six-point socket screws.
If the machine is not equipped with Comfort Drive Control (CDC):
Install the voltage converter on th studs with the nuts.
Plug in connector SO3901.

Figure 6

– – Control unit for Comfort A
Drive Control (CDC)
11100247 2 Spacer B
969419 2 Six-point socket screw C
20724975 1 Voltage converter 3
7. Loosen the panel for the front, right cab pillar and fold it aside.
Remove the blind plug and install the power socket.
Plug in connector PO3902
Reinstall the panel for the front, right cab pillar.
Figure 7
Part no. Quantity Designation Fig. in Pos. 7

11170371 1 Power socket 13
8. Reinstall the right panel, the panel on the cab pillar, and the rear panel, see Fig. 5
PUB-A GB 841-901 WLO 2014-08-27
VOE17430640 11298530
Profile:
L60H Volvo, L70H Volvo, L90H Volvo, L110H Volvo, L120H Volvo, L150H Volvo, L180H Volvo, L220H Volvo
Rear view mirror, installing new

Foreword
Kit list
Part No. Quantity Designation

3963413 2 Lock ring
11412709 1 Nut plate
15088143 1 Rocker
11429260 1 Casing
13960143 4 Washer
15099184 1 Control lever
15149454 1 Attaching plate
16683372 2 Rear-view mirror
17230943 1 Mirror arm (right)
17230944 1 Mirror arm (left)
70377101 1 Switch
1. Turn off the battery main switch.
2. Remove the existing exterior rear-view mirrors.
3. Remove the cover from the rear of the new rear view mirrors and fasten the mirror arms. See pos. A in
Figure 1 for distance.
4. Install the covers on the rear view mirrors. Tightening torque 1±0.2 Nm

16683372 2 Rear-view mirror 3
17230943 1 Mirror arm (right) –
17230944 1 Mirror arm (left) 1
Figure 1
A. Min. 100 mm
5. Install the rear view mirrors.

Tightening torque 10±1.5 Nm.
Figure 2

960143 4 Washer 5
6. Remove the headlining and the protection over the control panel on the right front cab pillar.
7. Clamp down the cable harness along the front of the cab roof.
Figure 3

4881440 6 Strip clamp –
8. Install the connectors from cable harness 15153662 in the holes. Tighten the lock rings securely.
Figure 4

3963413 2 Lock ring 5
9. Route the cable harness along the cab pillar and clamp it to the existing cable harnesses.

4881440 3 Strip clamp
10. Reinstall the headlining.
11. Install the attaching plate on the control panel as shown in Figure 5.
Figure 5

15149454 1 Attaching plate 6
11412709 1 Nut plate 7
12. Remove the cap for the switch.

Install the switch and rocker. Connect the connector marked SW3601 to the switch.
Install the control lever.
Connect cable harness 1553662 to the connector marked SW3614 on the control lever. Connect the
connector from the cable harness to the connector marked ME.

15099184 1 Control lever 9
70377101 1 Switch 12
15088143 1 Rocker 13
SW3601 A
SW3614 B
ME C
Figure 6
13. Install the cover on the right cab pillar.

Tightening torque 4.5±0.7.
Figure 7

11429260 1 Casing 10
14. Install the control panel on the cab pillar.

PUB-A GB 362-900 WLO 2011-02-15
VOE11716833 83074
Profile:
L60F Volvo, L60G Volvo, L60H Volvo, L70F Volvo, L70G Volvo, L70H Volvo, L90F Volvo, L90G Volvo, L90H
Volvo, L110F Volvo, L110G Volvo, L110H Volvo, L120F Volvo, L120G Volvo, L120H Volvo, L150F Volvo,
L150G Volvo, L150H Volvo, L180F Volvo, L180G Volvo, L180H Volvo, L220F Volvo, L220G Volvo, L220H
Rotating beacon, installing new

Foreword
Kit list
Part no. Qty. Designation Pos. in fig. 1
976155 3 6-pt socket screwv 2
11170098 1 Rotating beacon 1
11412552 1 Release mechanism 3
11428013 1 Rocker arm 37
14016673 2 Cable tie 7
70377101 1 Swtich 36
This is a simplified installation instruction.

Figure 1
PUB-A GB 362-907 WLO 2013-11-22
VOE17413928 83355
Profile:
L60H Volvo, L70H Volvo, L90H Volvo, L110G Volvo, L110H Volvo, L120G Volvo, L120H Volvo, L150G Volvo,
L150H Volvo, L180G Volvo, L180H Volvo, L220G Volvo, L220H Volvo, L250G Volvo, L250H Volvo
Warning beacon flashing strobe light, installing new

Foreword
Kit list

11117464 2 Washer
11170087 1 Rotating beacon
11412552 1 Release mechanism
4881440 5 Cable tie
1. Remove the bolts (A) and loosen the roof to access the cable harness.
Take out the cable harness.
Reinstall the bolts.
Figure 1
2. Install the lowering device to the left on the back of the cab.
Use the existing spacers.
Route the cable harness (B) forward through the lowering device.

11412552 1 Release mechanism 2
11117464 2 Washer 4
Figure 2
3. Install the supplied cable terminals on the cable harness. Connect the pink cable to + on the rotating
beacon and connect the black cable to - on the rotating beacon.
Install the rotating beacon on the lowering device with the supplied bolts.
Clamp down the cable harness according to figure.
Figure 3
Figure 4

11170087 1 Rotating beacon 1
4881440 1 Cable tie 7
4. Loosen the control panel. Install the cable harness between pin 2 and 3 on SW3607. Clamp down the
cable harness.
Reinstall the control panel.
Figure 5

4881440 1 Cable tie 7
PUB-B GB 867-908 WLO 2014-09-19
VOE17433157 84473
Profile:
Wind shield guard, installing new

Foreword
Kit list
11444421 2 Plate
11444425 2 Bracket
13965664 8 Square neck screw
17405509 1 Front grill (windshield guard)
15059798 2 Plate
Tools
2 pcs. sling 2 m (79 in)

M8 standard thread
1. Loosen the roof on the cab.

2. Remove the external rear-view mirrors.
3. Install the bracket at the top on the right and left side of the windshield.
Figure 1

11444425 2 Bracket 3
4. Drill three holes on each side in the front cab pillar with diameter 7.4±0.1 mm, see Figure 2. Use the
plate 11444421 as template.
Figure 2
A. 191.9 mm (7.56 in)

B. 839.7 mm (33.06 in)
C. 604.7 mm (23.81 in)
D. 369.7 mm (14.56 in)
5. Thread the holes with M8 standard thread.
6. Install the plate on the front grill (windshield guard).
Figure 3

13965664 8 Square neck screw 5
15059798 2 Plate 7
7. Install a sling as shown in the figure and connect a lifting device. Lift up the front grill (windshield
guard) with the sling and align it over the plates.
Figure 4

17405509 1 Front grill (windshield guard) 10
2 Sling, 2 m E
8. Align the plate on the front grill (windshield guard) with the three drilled holes in the cab pillar. Install
the plate between the cab and the plate on the front grill (windshield guard). Install the bolts loosely.
Figure 5

11444421 2 Plate 4
9. Tighten all bolts that hold the front grill (windshield guard) in place. Tightening torque: 25±3 Nm.
10. Install the rear-view mirrors in the new brackets.

Figure 6
11. Remove the sling.

3rd/4th hydraulic function, shock valve, checking
Op nbr 916-017
Tools:
14360000 Vacuum pump / 24V
88830175 Pump
9993825 Check valve
88830213 Measuring equipment
NOTE!
The operations are valid for all shock valves.
1. Place the machine in service position 1, see Service position.
2. Depressurize the system by moving the servo control levers back and forth 10–15 times with the ignition in position 1.
3. Connect the vacuum pump, see Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump.
Figure 1
Control valve 3rd/4th function, as seen from the right side of the machine
1. Shock valve, 4th function

2. Hose connection
3. Shock valve, 3rd function
Figure 2
Control valve 3rd/4th function, as seen from the left side of the machine
1. Shock valve, 3rd function

2. Hose connection
3. Shock valve, 4th function
4. Loosen the hose connection so that the hise can be moved to the side.
5. Remove the shock valve.
6. Plug the hole with the plug from 9993825 Check valve.
7. Screw down the shock valve in 9993825 Check valve and connect the other tools according to the figure.
NOTE!
Only the lower part of 9993825 Check valve should be used. Therefore screw off the upper part before the shock valve is
screwed down into the tool.
Check the shock valve's working pressure by pumping until the pressure no longer rises. Then the shock valve has opened
and the opening pressure can be read off.
Collect the oil that runs out of the drain hole in a suitable container.
Opening pressure, see 3rd/4th hydraulic function, specifications.
The shock valve is not adjustable.
NOTE!
Figure 3
1. 88830175 Pump
2. 9993825 Check valve
3. Shock valve
4. 88830213 Measuring equipment (not in picture)
8. Install the shock valve.
9. Tighten the hose connection.
10. Remove the vacuum pump.

3rd/4th hydraulic, functional check
Op nbr 916-029
After completed repairs, carry out a function check as described below.
1. Start the machine and operate 3rd or 4th function repeatedly to ensure the function.
2. Check that there are no error messages.

Accumulator removed, checking charging pressure
Op nbr 527-001
Tools:
88830175 Pump
E-2014
See also Safety when working on hydraulic systems.

This operation also includes required tools and times for applicable parts of the following operations:
 Accumulator, removal
 Accumulator, installation
 Accumulator, discarding
1. Remove the accumulator according to Accumulator, removal.
2. Connect E-2014 to the accumulator. Connect the other tools according to the figure.
Figure 1
Checking removed accumulator
1. 88830175 Pump
2. Accumulator
3. E–2014
3. Pump oil into the accumulator.

After a few pump strokes the pressure will increase quickly up to the precharge pressure and then increase slowly.
Precharge pressure: See Brake accumulator, specifications.
The accumulator should be discarded if the precharge pressure is less than that stated in specifications, see Accumulator,
discarding.
4. Install the checked or new accumulator according to Accumulator, installation

Accumulator, boom suspension system, discarding
Op nbr 916-072
1. Remove the protective nut.
Figure 1
Accumulator, Boom Suspension System
1. Protective nut
2. Carefully screw out the Allen head bolt.
Figure 2
Accumulator, Boom Suspension System
3. When gas has stopped escaping, remove the Allen head bolt.
Accumulator, discarding
Op nbr 900-050
WARNING
A discarded accumulator which is not punctured may still contain high pressure and must always be handled with great
care.
1. WARNING
Use safety glasses.
Accumulators that are to be discarded must not constitute a hazard.
This is done by carefully puncturing the accumulator with a Ø3 mm (0.118 in) drill.
Figure 1
Accumulator
A. Drill here with a Ø3 mm (0.118 in) drill
1. Nitrogen gas space

2. Rubber diaphragm
3. Connection for oil
Op nbr 900-050
WARNING
care.
1. WARNING
Use safety glasses.
Figure 1
Accumulator

2. Rubber diaphragm
Op nbr 900-050
WARNING
care.
1. WARNING
Use safety glasses.
Figure 1
Accumulator

2. Rubber diaphragm
Accumulator, installation
Op nbr 527-013
 Brake system, bleeding
1. Install the accumulators.
Figure 1
2. Install the side cover.
3. Bleed the brake system, see Brake system, bleeding.

Accumulator, removal
Figure 1
Op nbr 527-012
Tools:
14290266 Hose
 Service position 1, Service position

 Safety when working on hydraulic systems

Leave the battery disconnector turned on.
2. Turn the start key to position 1.
3. Press and hold in key 8 (service) on the keypad for approx. four seconds. When asked if you want to enter Service mode,
press Select.
Information
Enter service mode?

NO YES
4. Press key 4 (axles) to see the accumulator brake pressure.
5. If needed, remove the side cover on the right side under the cab.
6. Depressurize according to Safety when working on hydraulic systems
7. Remove the accumulators.

Collect the oil in a suitable container.
Accumulators, checking in machine
Op nbr 527-003
Braking capacity, checking
1. Start the machine and charge the brake system.
2. Turn off the machine and turn the start key to position 1.
3. Press and hold in key 8 (service) on the keypad for approx. 4 seconds. When asked if you want to enter Service mode, press
Select.
Information
Enter service mode?

NO YES
4. Press key 4 (axles) on the keypad to see the accumulator pressure.
5. Press carefully on the brake pedal until the acc. brake pressure shown on the display matches the cut-in pressure, see Brake
system, specifications.
6. Check the braking capacity by pressing down the brake pedal all the way and then releasing it again. Repeat this four times.
7. Acc. brake pressure shown on the display may not drop below the value for low-pressure indication, see Brake system,
specifications.
If the pressure drops below the value for low-pressure indication, check the accumulators' precharge pressure, see below.
Accumulator precharge pressure, checking
8. Continue to press down the brake pedal all the way and release it several times.
The accumulator pressure will drop slowly (by approx. 2–5 bar (0.2–0.5 MPa/30–70 psi) per brake application).
9. When the accumulator's precharge pressure is reached, the pressure starts to drop drastically. Note the value at the cut-in/
cut-out point and compare to the precharge pressure in Brake accumulator, specifications.
Figure 1
x = pressure (bar)
y = number of brake applications
NOTE!
If the precharge pressure in the accumulator is lower than the value in the specifications, it must be replaced.
Accumulators, replacing
10. Remove the accumulators, see Accumulator, removal.
11. Check the accumulators while they are removed, see Accumulator removed, checking charging pressure.
12. Install the accumulators again, see Accumulator, installation.
13. Start the engine and wait until the brake system has been charged. Check that the vehicle message for low brake pressure
turns off. Check that there are no error codes.
ACM (After treatment control module), replacing, non-programmed
Op nbr 254-022
Tools:
88890300 Interface
88890305 Cable
88890253 Cable
3. If you have access to a connection to the central system:

Connect Tech Tool and start operation 17092-3 Replace hardware.
If you do not have a connection to the central system:
Connect Tech Tool and start operation 17093-3 Program with stored software.
4. Turn off the voltage with the battery disconnector.
Figure 1
1. ECM
2. ACM
5. Unplug the connector from the ACM and remove the clamp for the cable harness.
6. Change the ACM.
7. Plug in the connector for the ACM and install the clamp for the cable harness.
8. Turn on the voltage with the battery disconnector.
9. Close the engine hood,
10. Finish the Tech Tool operation.
11. Start the machine and check that there are no error messages.
12. Restore the machine to operating condition.

Actuator, replacing
Op nbr 821-010
Removing actuator
1. Remove the fender (mudguard) and the plate.
Figure 1
1. Fender
2. Plate
2. Remove the protective screw from the end of the actuator.
Figure 2
1. Protective screw
3. Install a ratchet handle with an extension, and a 6 mm Allen head socket in the actuator screw.
Raise the hood so much that there is enough room to cut off the cable tie for the actuator's cable harness. Unplug connector
MO3611.
Figure 3
1. Ratchet handle, extension, and 6 mm Allen head

2. Actuator
4. Cut off the cable tie for the actuator's cable harness and unplug connector MO3611.
Figure 4
1. Cable tie
2. Connector MO3611
5. Lower the hood with the ratchet handle so that there is room for a spacer of approx. 500 mm (20 in.) between the hood and
counterweight.
Release the pressure in the actuator by carefully lowering the hood against the spacer.
Figure 5
1. Spacer
6. Loosen the attaching bolt and remove the upper pin for the actuator.
Figure 6
1. Pin
2. Attaching bolt
7. Loosen the attaching bolt and remove the lower pin for the actuator.
Figure 7
1. Attaching bolt
2. Pin
8. Lift out the actuator. Weight approx.: 6 kg (13 lbs)
Installing actuator
9. Take out the new actuator.

Remove the protective screw.
Insert a 6 mm Allen head socket and screw out the actuator to the same screwed-out length as the old one that was
removed.
10. Install the actuator in the upper mounting point, first with the pin and then tighten down with the attaching bolt.
11. Then install the actuator in the lower mounting with the pin and then tighten down with the attaching bolt.
12. Reinstall the protective screw.
13. Plug in connector MO3611 for the actuator and fasten it in place with a cable tie.
14. Lift the hood slightly with the switch and remove the spacer between the hood and the counterweight.
15. Reinstall the plate and the fender (mudguard).
16. Test-run the new actuator by opening and closing the hood completely with the switch.
AdBlue®/DEF dosing injector, replacing
Op nbr 254-120
NOTICE
Risk of machine damage.
AdBlue®/DEF causes corrosion damage.
Do not spill AdBlue®/DEF on to connectors. Contaminated connectors cannot be cleaned and must be replaced
immediately.
NOTICE
Always plug AdBlue®/DEF hoses while they are disconnected to prevent dirt getting into the SCR system and AdBlue®/DEF
spilling on to machine components.
2.
Figure 1
Dosing injector
Figure 2
Removing coolant hose
Mark and disconnect the coolant hoses from the dosing injector.
3.
Figure 3
Removing AdBlue®/DEF hose
Unplug the connector and the AdBlue®/DEF-hose.
4. Remove the attaching bolts and the dosing injector.
5. Install the new dosing injector. Connect the coolant hoses, the AdBlue®/DEF-hose, and plug in the connector.
NOTE!
Make sure that the heat shield is installed correctly.
6. Run Tech Tool operation 25964-3 SCR system, diagnostics.

AdBlue®/DEF mixing tube, replacing
Op nbr 254-126
NOTICE
immediately.
NOTICE
For more information about AdBlue®/DEF, see AdBlue®/DEF information.
2. Remove the dosing injector.

Disconnect the sensor pipes and sensor from the mixing tube. Remove the V-clamp from the mixing tube and remove the
bolts from the mixing tube flange. Remove the mixing tube.
Figure 1
1. Dosing injector
2. Exhaust gas pressure sensor
3. Exhaust gas temperature sensor
4. NOx sensor
3. Clean all contact surfaces.
4. Install the mixing tube. Torque-tighten the attaching bolts and v-clamp according to Inlet and exhaust system, tightening
torques.
NOTE!
Use new gaskets.
5. Install the sensor pipes and sensor. Torque-tighten according to Inlet and exhaust system, tightening torques.
6. Install the dosing injector. Torque-tighten according to Inlet and exhaust system, tightening torques.
NOTE!
Figure 2

AdBlue®/DEF pump unit filter, replacing
Op nbr 173-428
Rubber hose ø7 mm (0.79 in) flexible rubber hose
Bottle approx. 1,000 ml (0.26 US gallon)
Bucket
Distilled water, approx. 3,000 ml (0.34 US gallon)
NOTICE
immediately.
NOTICE
For more information about AdBlue®/DEF, see AdBlue®/DEF.
1. Place a suitable container under the pump unit to collect AdBlue®/DEF.

Remove the cover.
Figure 1
1. Cover
2. Remove the rubber plug.

Figure 2
1. Rubber plug
3. Use the tool (supplied with the new filter) to remove the filter, pulling it straight downwards. Install the new filter.
Install the rubber plug and the cover. Tightening torque, see Inlet and exhaust system, tightening torques
Figure 3
1. Tool for removing filter
4. Clean the area around the AdBlue®/DEF-couplings with water and compressed air to prevent dirt from entering the system.
5. Disconnect the AdBlue®/DEF inlet hose and the two outlet hoses from the pump unit. Plug the hoses or place a plastic bag
around the hose couplings and fasten with cable ties.
Figure 4
1. AdBlue®/DEF outlet
2. AdBlue®/DEF, inlet
6. Fill the bottle with distilled water and install the hose and bottle on the AdBlue®/DEF inlet nipple. Install two hoses on the
outlet nipples (marked outlet and backflow) and place the ends in a bucket.
NOTE!
Use distilled water and make sure that the bottle is free from debris.
7. Start the engine and let it run for two minutes. While the engine is running, squeeze the bottle gently to push water into the
AdBlue®/DEF pump unit.
8. Turn off the engine and leave it off for two minutes.
NOTE!
Loosen the cap on the bottle before turning off the engine to avoid overfilling the bottle with air. When the engine is turned off,
the pump will press air via the inlet nipple.
9. Repeat starting/turning off the engine until the AdBlue®/DEF pump unit begins to draw fluid from the bottle on its own, or a
maximum of three times. When the AdBlue®/DEF pump unit draws fluid on its own, the bottle will start to collapse.
NOTE!
Turn off the engine as soon as the AdBlue®/DEF pump unit starts to draw fluid on its own.
10. Remove the hoses and bottle from the inlet and outlet nipples.
11. Remove the plugs and connect the AdBlue®/DEF-hoses to the pump unit.
AdBlue®/DEF pump unit, filter, replacing
Op nbr 254-124
Rubber hose ø7 mm (0.79 in)
Bottle approx 1000 ml (0.26 US gallon)
Bucket
Destilled water approx. 3000 ml (0.34 US gallon)
NOTICE
immediately.
NOTICE
 Service position
 AdBlue®/DEF pump unit, flushing
1. Place the machine in service position 1, see Service position
2. Place a suitable container under the pump unit to collect AdBlue®/DEF.
Figure 1
1. Cover
3. Remove the cover and the rubber plug.

Figure 2
1. Cover
Figure 3
1. Rubber plug
4. Use the tool (supplied with the new filter) to remove the filter, pulling it straight downwards. Install the new filter.
Install the rubber plug and the cover. Tightening torque, see Inlet and exhaust system, tightening torques
Figure 4
1. Tool for removing filter
5. Flush the system according to AdBlue®/DEF pump unit, flushing

AdBlue®/DEF pump unit, flushing
Op nbr 254-130
Rubber hose ø7 mm (0.79 in)
Bucket
NOTICE
immediately.
NOTICE
1. Place the machine in service position, see Service position.
2. Clean the area around the AdBlue®/DEF couplings with water and pressurized air to prevent dirt to enter the system.
3. Disconnect the AdBlue®/DEF inlet hose and the two outlet hoses from the pump unit. Plug the hoses or place a plastic bag
around the hose couplings and fasten with stripes.
Figure 1
1. AdBlue®/DEF outlet
2. AdBlue®/DEF inlet
4. Fill the bottle with distilled water and attach the hose and bottle to the AdBlue®/DEF inlet nipple. Attach two hoses to the
outlet nipples (marked outlet and backflow) and place the ends in a bucket.
NOTE!
Use distilled water and make sure the bottle is free from debris
5. Start the engine and let it run for two minutes.
While the engine is running, squeeze the bottle gently to push water into the AdBlue®/DEF pump unit.
6. Stop the engine and let it be off for two minutes.

NOTE!
Loosen the cap on the bottle before stopping the engine to avoid overfilling the bottle with air. When stopping the engine the
pump will press air via the inlet nipple.
7. Repeat the start/stop of the engine until the AdBlue®/DEF pump unit begins to draw fluid from the bottle on its own, or three
times as a maximum. When the AdBlue®/DEF pump unit draws fluid on its own, the bottle will start to collapse.
NOTE!
Stop the engine as soon as the AdBlue®/DEF pump unit starts to draw fluid on its own.
8. Remove the hoses and bottle from the inlet and outlet nipples.
9. Remove the plugs and connect the AdBlue®/DEF hoses to the pump unit.

AdBlue®/DEF pump unit, replacing
Op nbr 254-107
Tools:
88890300 Interface
1. Place the machine in service position, see Service positions.
2. Run Tech Tool operation 25847–3 SCR system drain, test, to drain the AdBlue®/DEF.
3. Remove the left plastic cover.
NOTE!
AdBlue/DEF is corrosive. Make sure to cover the electric connectors with plastic bags before opening the AdBlue/DEF couplings.
4.  Remove the fastening bolts for the hose clamp brackets and the pump unit.
 Unplug the connectors from the AdBlue®/DEFpump unit.
 Cover all open connectors with plastic bags and seal them using rubber bands or plastic cable ties.
 Clamp hose pliers on to the coolant hoses.
 Mark the positions and remove the coolant hoses from the AdBlue®/DEFpump unit.
 Mark the positions and remove the AdBlue®/DEF -hoses from the AdBlue®/DEF pump unit.
Figure 1
1. Coolant hose (purple)

2. Coolant hose (yellow)
3. AdBlue®/DEF hoses
4. Fastening bolt, needs to be installed at the pump unit before installation of the pump unit
Figure 2
Removal of AdBlue®/DEF -hose
Figure 3
Removal of coolant hose
5. Remove the AdBlue/DEF pump unit.
6. Install the new AdBlue/DEF pump unit.
7. Connect the AdBlue®/DEF -hoses and the coolant hoses.

Remove the hose pliers.
Install the hose clamp brackets.
8. Install the plastic cover.
9. Run Tech Tool operation 25964-3 SCR system, diagnostics to make sure the pump unit works correctly.

AdBlue®/DEF quality, checking
Op nbr 254-121
Tools:
88890110 Indication paper
88890105 Refractometer
NOTICE
immediately.
NOTICE
2. Remove the cap from the AdBlue®/DEF-tank.
Figure 1
1. Cap
3. Remove the screen filter by pressing the clips.

Figure 2
4. Collect some AdBlue®/DEF through a clean hose.
Figure 3
5. Use 88890110 Indication paper to check if the AdBlue®/DEF contains any oil or diesel.
6. Use 88890105 Refractometer to measure if the concentration of AdBlue®/DEF is correct, high or low.
NOTE!
The level must be exactly on the AdBlue®/DEF line for correct concentration. If no level is shown in the instrument it may
indicate chemical residue, such as pure water or diesel.
NOTE!
The scale cannot be used to determine the exact concentration of AdBlue®/DEF.
7. Install the screen filter.
8. Install the cap.

AdBlue®/DEF tank, breather filter, replacing
Op nbr 173-429
1. Cut the cable ties and remove the breather filter.
Figure 1
1. AdBlue breather filter
2. Install a new breather filter on the hose and install new cable ties.
AdBlue®/DEF tank, replacing
Op nbr 254-112
1. Service information is under development and will be available soon.

AdBlue®/DEF tank, tank armature, replacing
Op nbr 254-103
Tools:
88890300 Interface
NOTICE
immediately.
NOTICE
 Service position 1
 Coolant, changing
1. Place the machine in service position 1, see Service position 1.
2. Drain the engine coolant, see Coolant, changing
3. Remove the plastic covers
4. Remove the lower coolant hose.
5. Disconnect the coolant hoses from the AdBlue®/DEF tank armature. Protect the hose openings from dirt by covering them
with plastic bags or similar.
Disconnect the AdBlue®/DEF tank armature breather hose with from the tank armature.
Unplug the sensor FX1079 and remove the attaching bolts for the control unit.
Figure 1
1. Coolant hoses
2. Breather hose with splash guard
3. AdBlue®/DEF hoses
Figure 2
1. Control unit with FX1079
6. Disconnect the AdBlue®/DEF hoses and immediately plug the hoses in order to avoid dirt and air from entering the system.
Figure 3
Removal of AdBlue®/DEF hose
Figure 4
Removal of coolant hose
7. Remove the attaching bolts for the radiator on both sides and remove the attaching bolts for the two radiator supports.
Carefully move the radiator backwards to make room for lifting the tank armature. Put some wooden blocks between the
radiator and the intermediate wall structure to fix the radiator position.
Figure 5
Radiator attaching bolts
8. Mark the position of the tank armature.

Loosen the clamp and lift the rubber boot by the tank armature. Lift the tank armature and turn and tilt the tank armature to
get it out of the tank.
Figure 6
Figure 7
1. Control unit
2. AdBlue®/DEF tank armature, rubber gaiter and clamp
9. Place the control unit under the hydraulic oil hoses in order to get the routing correct.
Install the new tank armature, according to previous markings. Lube the rubber boot with some soapy water for easier
installation. Tighten the clamp.
10. Install the attaching bolts for the radiator and the radiator supports.
Tightening torque, radiator attaching bolts: 230 Nm (170 lb ft)
11. Connect the hoses to the AdBlue®/DEF tank armature.
12. Install the control unit. Plug in the connector to the sensor FX1079.
13. Install the lower radiator hose and fill coolant, see Coolant, changing.
14. Run Tech Tool operation 25964-3 SCR system, diagnostics to make sure that the pump unit works.
15. If the SCR system has been exposed to air, crystals may have been created and the pump unit will eventually not work. If so,
flush the pump unit according to AdBlue®/DEF pump unit, flushing.
AdBlue®/DEF, draining
Op nbr 254-114
Tools:
88830361 Pump
NOTICE
immediately.
NOTICE
For more information on AdBlue®/DEF, see AdBlue®/DEF information.
2. Remove AdBlue®/DEF-cap.
Figure 1
1. Cap
3. Remove the filter.

Figure 2
4. Drain the tank by pumping out AdBlue®/DEF with 88830361 Pump.
Figure 3
1. 88830361 Pump
5. Remove the pump.
6. Install the filter.
7. Fill the tank with new AdBlue®/DEF and install the cap.
8. Delete any associated error codes with Tech Tool Service Tool.

Air conditioning, checking performance
Op nbr 87403
Total procedure time (hr): NaN
NOTE!
Components such as recirculation filter, evaporator, and condenser must be clean.
1. Measure the ambient temperature as well as the air's relative humidity. Perform the measurement in the shade.
2. Close windows and the door.
3. Set the engine speed to approx. 1,800 rpm
1. Activate the switch for air conditioning

2. Set the fan speed to max.
3. Set the temperature value to min.
4. Set the recirculation damper to "Auto"
Figure 1
4. The air conditioning's temperature value is checked by measuring the temperature of the incoming air at the back wall's right
air vent.
5. The temperature should, at some time within a period of approx. 8 minutes, drop to or slightly below the temperature values
indicated in the specifications.
6. If the stated temperatures are not reached in the performance test, see: Troubleshooting, air conditioning unit (AC)
Air conditioning temperature values for performance test

Temperature values at different ambient temperatures in relation to the air's relative humidity. .
Ambient temperature °C Ambient temperature°F
25 30 35 40 77 86 95 104
Air, relative humidity Air conditioning, temperature values
10% 7 7 7 7 44 44 44 44
20% 7 7 7 7 44 44 44 44
30% 7 7 7 7 44 44 44 44
40 % 7 7 7 8 44 44 44 46
50% 7 7 8 11 44 44 46 52
60 % 7 8 10 14 44 46 50 57
70% 7 10 13 17 44 50 55 63
80% 7 11 15 20 44 52 59 68
90% 7 12 18 23 44 54 64 73
Air mix door actuator, replacing
Op nbr 873-011
2. Open the cover for the AC-system (air conditioning).
Figure 1
1. Cover
3. Turn the plastic fasteners, remove the filter and the filter casing.
Figure 2
1. Plastic fastener
2. Filter
3. Filter casing
4. Remove the filter holder and unplug the connector MO8703 for the air mixing damper's motor. Place the filter holder on a soft
surface so that the air mixing damper is not damaged.
Figure 3
1. Filter holder
2. Connector MO8703
5. Disconnect the motor for the air mixing damper.
Figure 4
1. Bolts for air mixing damper
6. Pull out the motor from the damper shaft.
Figure 5
7. Install a new motor for the air mixing damper.
8. Plug in connector MO8703 for the air mixing damper's motor. Install the filter holder and the retaining strap for the cover with
one of the bolts for the filter holder.
Figure 6
1. Filter holder
2. Connector MO8703
3. Retaining strap
9. Test-run the machine and check the function of the cover for the damper motor.
Figure 7
1. Cover
10. Reinstall the filter and filter casing. Turn back the plastic fasteners.
Figure 8
1. Plastic fastener
2. Filter
3. Filter casing
11. Close the cover for the AC-system and check that the drain hoses are not trapped.
Figure 9
1. Cover
12. Restore the machine and test-run it.

Attachment locking, functional check
Op nbr 924-036
After completed repairs, carry out a function check as described below.
1. Start the machine.
NOTE!
If the charge-air temperature is above 120 °C the attachment lock will not work.
2. Operate the attachment lock several times.
Figure 1
Attachment lock
3. Check on the instrument panel that there are no error messages.
4. If an error code appears, troubleshoot according to information in the diagnostics section.
5. Check visually that the pins move in and out to be sure of correct function.
6. If the pins do not move in or out, check the mechanical parts of MA9127 and MA9106.
7. If the pins do not move in or out, check the brake pressure according to Brake system, check and adjusting pressure in
circuit. If the brake pressure is not incorrect, the hose to the attachment lock may be trapped, pinched, or clogged.
Automatic central lubrication filter, replacing
Op nbr 173-513
1. Remove the grease nipple.

Remove the elbow nipple with the strainer.
Figure 1
1. Grease nipple
2. Elbow nipple
2. Remove the spring.

Secure the nipple in a vice and remove the spring with a pair of pliers.
Figure 2
3. Install the new strainer and spring on the elbow nipple.

Install the elbow nipple with the strainer.
Install the grease nipple.
Automatic lubrication pump unit, reconditioning
Op nbr 993-025
Dismantling
1. Remove the round cover and fastening bolt, and lift off the cover.
Check that the O-ring that seals the cover against the grease reservoir is not damaged.
Remove the grease reservoir.
Figure 1
Pump unit
1. Grease reservoir
2. Cover
2. Use a suitable tool in the hole on the guide. Spin off the guide.
Figure 2
1. Guide
2. Tool
3. Remove the bolts that hold the bridge.
Figure 3
1. Bolt, 4 pcs.
2. Bridge
4. Remove the mixer.
Figure 4
1. Mixer
5. Remove the bolts and then the strainer

Figure 5
1. Bolts, 2 pcs.
2. Strainer
6. Remove the hose connections.
Figure 6
1. Hose connections
7. Check that the three O-rings on each hose connection are not damaged.
Figure 7
1. O-rings, 3 pcs.
8. Remove the grease nipple and the grease nipple connection.
Figure 8
1. Grease nipple
2. Connection
9. Stand the pump unit upside-down on two suitable blocks so that the level sensor is in the clear.
Remove the bolts for the pump cover.
Remove the pump cover and rubber seal.
Figure 9
1. Pump cover
2. Bolt, 4 pcs.
10. Mark up all connectors accurately and remove them from the circuit board.
Figure 10
11. Remove the circuit board by pressing together the locks for the plastic tabs.
Figure 11
1. Plastic tabs, 6 pcs.

2. Circuit board
12. Remove the bolts that hold the pump unit.

Remove the pump unit.
Figure 12
1. Bolt, 4 pcs.
2. Pump unit
13. Remove the microswitch for the test function.

Figure 13
1. Microswitch
14. Carefully remove the connector for the level sensor.
Figure 14
1. Connector
15. Turn the connector 45° counter-clockwise and remove it. Remove the lock ring and the cable harness.
Figure 15
1. Connector
16. Remove the level sensor with a long socket 24 mm
Figure 16
17. Remove the lock ring from the shift valve and carefully tap it off the valve housing.
Check so that the O-ring between the solenoid and the valve housing is not damaged.
Figure 17
1. Lock ring
2. Valve housing
3. Solenoid
18. Remove the lock ring that holds the solenoid against the shift valve and remove it.
Figure 18
1. Lock ring
2. Shift valve
3. Solenoid
19. Remove the bolt that holds the valve slide and the spring.
Figure 19
1. Bolt
20. Remove the valve slide and the spring

Figure 20
1. Spring
2. Shift valve
21. Remove the bolts that hold the pump element holder.
Figure 21
1. Bolt, 6 pcs.
2. Pump element holder
22. Draw a line with a marking pen so that the orientation of the pump element holder is determined.
Figure 22
1. Marking
23. Remove the pump element holder

Figure 23
1. Pump element holder
24. Remove the small lock ring from the motor shaft and the cam gear.
Figure 24
1. Lock ring
25. Remove the bolts that hold the motor.

Check that the O-ring for the overflow valve is not damaged.
Figure 25
1. Bolt, 3 pcs.
2. O-ring
26. Check that the groove ball bearing in the pump element holder is not damaged. If it is, change it.
Figure 26
1. Bearing
27. Mark up the three pump elements accurately.
Figure 27
1. Marking
28. Remove the cap nuts and press the pump elements inward to remove them.
Figure 28
1. Pump element
2. Cap nut
29. Dismantle the pump elements
Figure 29
NOTE!
Always use new O-rings, rubber seals, and copper washers when assembling the central lubrication unit. Overhaul kit seals
Assembling
30. Install pump elements in their holder according to earlier markings. Install the overflow valve.
Figure 30
1. Pump element
2. Position of overflow valve
31. Install new O-rings on the pump housing, 3 pcs. Install the drive motor in the pump housing with 3 bolts, install the cam gear
and the lock ring.
Figure 31
1. Lock ring
32. Install the pump element holder on the pump housing by carefully rotating the holder so that the pump pistons end up in
position against the cam gear. Check that marking pump housing to pump holder matches. Press down the holder by
alternately tightening two opposing bolts until the holder contacts the housing.
Figure 32
1. Marking from dismantling
33. Assemble the cross-over valve with new O-rings and back-up rings. Install the valve in the valve housing and carefully press
it into position. Install the lock ring. Install the solenoid, O-ring, and lock ring.
Figure 33
1. Lock ring
2. Valve housing
3. Solenoid
34. Install microswitch, connector for incoming cable harness and level sensor with connector.
Figure 34
1. Microswitch
2. Connector for incoming cable harness
3. Level sensor with connector
35. Install the rubber strip and the 4 spacers in the pump housing and install the pump unit in the pump body with 4 bolts.
Figure 35
1. Bolt, 4 pcs.
2. Pump unit
36. Install the circuit board and connect all connectors according to marking.
Figure 36
37. Install the rubber seal and bolt down the pump cover against the pump unit.
Figure 37
1. Pump cover
2. Bolt, 4 pcs.
38. Bolt down the strainer and bolt down the mixer on the motor shaft.
Figure 38
1. Mixer
39. Install the hose connections for outgoing lubrication channels.

Figure 39
1. Hose connections
40. Install the bridge and guide.
Figure 40
1. Guide
2. Tools
41. Install the rubber strip and install the grease reservoir with its piston. Install the cover, bolt it down, install the O-ring and
press on the round cover.
Figure 41
1. Grease reservoir
2. Cover
42. Install the strainer, grease nipple, and rubber cap for the tank's filling point.
Figure 42
1. Grease nipple
2. Rubber cap
43. Fill the tank with grease and make sure that all air is removed from the unit before connecting the hoses for the lubrication
channels. See: Bleeding air
Axle breather filters, replacing
Op nbr 173-408
Rear axle
1. Change the breather filter for the rear axle.
Figure 1
1. Breather filter
Front axle
2. Remove the cover plate on the front frame.

Change the breather filter for the front axle.
Figure 2
1. Breather filter
Back-up valve, checking and adjusting
Op nbr 912-018
Tools:
9993831 Support
 Hydraulic system, warming up
1. Warm up the machine according to Hydraulic system, warming up.
2. Lift the boom and secure it with 9993831 Support .
Figure 1
Securing boom
1. 9993831 Support
4. Connect the measuring equipment to the pressure check connection, marked A1, on the back of the control valve.
Figure 2
5. Start the engine. Remove the stand and lower the boom until the bucket is flat against the ground.
If no bucket is installed, use pieces of wood under the bucket attachment in order to be able to lift the machine off the ground.
6. Slowly tilt forward (so that the machine is lifted off the ground)
Read off the pressure. Correct return pressure, see Control valve, specifications.
7. Lift the boom and secure it with 9993831 Support.
8. Remove the pressure gauge and install the cover plate on the front frame.

Back-up valve, replacing
Op nbr 912-151
Tools:
Removing

NOTE!
4. Remove the back-up valve.
Figure 1
Control valve
Checking
5. Check that the O-rings and support rings are not damaged.
6. Check that the slide does not bind.
Installing
7. Install the pressure back-up valve.
8. Remove the vacuum pump, see Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump.
9. Install the cover plate.

Basic service
Op nbr 173-301
1. Check and look for leaks.
2. Check that the lap-type seatbelt is not damaged and that it stops when pulled forcefully and suddenly.
3. Check that:
the direction indicators, headlights, brake lights, and work lights work
the horn and back-up alarm work
4. Check that all warning decals and reflectors are in place. See Operator's Manual, Presentation, Information and warning
decals.
Batteries, replacing
WARNING
Batteries contain corrosive acid. Handle batteries according to instructions in Section 3 and Section Safety.
Op nbr 311-002
Removing
2. Open the battery cover.
3. Remove the terminal caps.
4. Loosen and remove the cable terminals from the battery terminals.
NOTE!
Start by removing the cable terminal from the minus terminal.
5. Loosen the clamp and remove the battery.

Weight approx. 40 kg (88 lbs).
Installing
6. Lift the battery into place and fit the clamp.
7. Clean the battery terminals and cable terminals.
8. Install the cable terminals and lube with acid-free vaseline.
10. Start the machine and check that no error messages appear.
Figure 1
Battery condition, check
Op nbr 311-005
Tools:
88890075 Battery analyzer
Figure 1
For setting the battery analyzer, see user manual for 88890075 Battery analyzer.
1. Place the machine in service position 1, according to Service position.
2. Expose and open the battery cover.
3. Check the batteries for the following:
 Leaking battery housing.

 Loose and damaged cables.
 Corroded connections.
4. Loosen the battery cables.
5. Connect the battery analyzer to the battery.

Figure 2
Battery analyzer
6. Select BATTERY TEST and run the test according to the user manual.
 BATTERY TYPE, select STANDARD.

 VEHICLE TYPE, select TRUCK (wheel loader).
 BATTERIES, select 1.
 Battery's cold cranking amperes CCA (EN), see Battery, specifications.
7. After performed test, the analyzer shows the test result and assessment of the battery's condition.
Depending on obtained assessment, take recommended actions according to the user manual.
8. Repeat above test for the other battery.
NOTE!
If other batteries are installed than what is standard for the model, read on the battery to get correct data for the battery type and cold
cranking amperes CCA .
Battery, checking
Op nbr 173-307
1. Remove the bolts at the top on the battery box and loosen the two below.
Remove the battery cover.
Figure 1
1. Bolts at top
2. Clean and then lube the cable terminals and battery terminals externally with, e.g., vaseline, as corrosion protection.
Figure 2
3. Install the battery cover.

Bleeding air
Op nbr
Pump unit, bleeding air
1. Make sure that the lubricant reservoir is full of grease.

For filling, see: Filling lubricant
2. Remove both hose connections from the pump unit's ports.
Figure 1
1. Hose connections, 2 pcs.
3. Turn the start key to ignition position
4. Press in the test button on the pump unit for at least 6 seconds.
Figure 2
1. Test button
5. Turn off the ignition when clean grease has been pressed out from the nipple.
Figure 3
1. Grease
6. Turn the start key to ignition position and press in the test button again for at least 6 seconds. Now grease will be pressed out
from the other port on the pump unit.
7. Turn off the ignition when clean grease has been pressed out from the port.
8. Reinstall the hose connections on the pump unit.
Central lubrication system, bleeding air
9. Remove one of the plugs from the distribution block that is located farthest away in the system.
Figure 4
10. Turn the start key to ignition position
11. Press in the test button on the pump unit for at least 6 seconds. Now grease will be pressed out from the port.
12. Turn off the ignition when clean grease has been pressed out from the nipple.
Figure 5
1. Grease
13. Turn the start key to ignition position and press in the test button again for at least 6 seconds. Now grease will be pressed out
from the other port on the pump unit.
Turn off the ignition when clean grease has been pressed out from the nipple.
14. Reinstall the plugs on the distribution block

Boom suspension accumulator, check and adjusting
Op nbr 916-002
Tools:
11666135 Gas filling kit
9993831 Support
2. Release the hydraulic oil pressure in the accumulator, see Boom suspension system, hydraulic oil pressure in accumulators,
depressurizing.
The gas cylinder does not have to be connected when checking and reducing the accumulator's precharge pressure.
Checking precharge pressure
3. Remove the plate in the front frame.
4. Remove the nut from the accumulator valve, positioned on the top of the accumulator.
5. Loosen the accumulator valve's Allen head screw approx. ¼ turn, use a 6 mm Allen key.
6. Screw in 11666135 Gas filling kit on the accumulator by hand. Make sure that there is an O-ring in position in the tool.
Figure 1
Figure 2
11666135 Gas filling kit, principle diagram
1. Unloading valve
2. Accumulator
3. Nitrogen gas cylinder (N₂)
4. Gas valve
5. Pressure gauge
6. Non-return valve
7. Close the unloading valve.
8. Open the gas valve. When the pressure gauge begins to indicate, the gas valve should be opened one more turn. The
pressure gauge shows the precharge pressure in the accumulator, see Boom Suspension System, specifications.
Reducing precharge pressure
9. Carefully open the unloading valve.

Gas will flow out from the tool. Reduce until the pressure matches the specification, see .Boom Suspension System,
specifications.
Increasing precharge pressure
10. Connect the tool to nitrogen gas cylinder.
11. Carefully open the gas valve on the nitrogen gas cylinder.
12. Carefully open the gas valve on the accumulator. Gas flows into the accumulator.
NOTE!
Adjust the pressure slowly, so that the gas valve is not overloaded.
13. Close the valve on the nitrogen gas cylinder, and read off achieved pressure on the pressure gauge.
14. Repeat this procedure until the correct precharge pressure has been reached, see Boom Suspension System, specifications.
Wait for approx. 5 minutes, while equalisation of temperature takes place. Again check the pressure.
Finishing
15. When the required pressure has been reached, the accumulator gas valve should be closed, clockwise.
16. Remove the tool from the accumulator. Check-tighten the Allen head bolt in the gas valve on the accumulator, see Boom
Suspension System, tightening torques.
17. Check that the gas valve does not leak. Use a soap and water solution.
18. Check the O-ring in the cap nut and install the nut on the accumulator.
20. Check the function of the Boom Suspension System according to Boom suspension system, functional check.
Boom suspension accumulator, checking
Op nbr 173-502
Tools:
9993831 Support
14290266 Hose
1. Make sure that the battery disconnector is on. Remove the cover over the electrical distribution box.
2. Remove RE08.
3. Connect terminals 30 and 87 to each other with a cable.
Figure 1
Electrical distribution box
1. Pressure check connection, Port M
4. Turn the start key to position 1 and leave it there for approx. 60 s. The accumulators are being drained. Move the lift lever
back and forth several times.

The accumulators should now be drained and the Boom Suspension System without pressure. Only a residual
pressure of approx. 3 bar (0.3 MPa) (43.5 psi) should be in the system.
6. Remove the cover in the front frame.
7. Connect the 60 bar sensor with the pressure gauge.
8. Check that the pressure has been released by connecting 88830213 Measuring equipment to port M on the valve block (V1).
Figure 2
9. To drain the residual pressure, connect 14290266 Hose on port M.

Drain the oil into a suitable container.
The gas cylinder does not have to be connected when checking and reducing the accumulator's precharge pressure.
Checking precharge pressure
10. Remove the plate in the front frame.
11. Remove the nut from the accumulator valve, positioned on the top of the accumulator.
12. Loosen the accumulator valve's Allen head screw approx. ¼ turn, use a 6 mm Allen key.
13. Screw in 11666135 Gas filling kit on the accumulator by hand. Make sure that there is an O-ring in place in the tool.
Figure 3
Figure 4
11666135 Gas filling kit, principle diagram
1. Unloading valve
2. Accumulator
3. Nitrogen gas cylinder (N₂)
4. Gas valve
5. Pressure gauge
6. Non-return valve
14. Close the unloading valve.
15. Open the gas valve. When the pressure gauge begins to indicate, the gas valve should be opened one more turn. The
pressure gauge shows the precharge pressure in the accumulator, see Boom Suspension System, specifications.
Finishing
16. Close the gas valve clockwise.
17. Remove the tool from the accumulator. Check-tighten the Allen head bolt in the gas valve on the accumulator, see Boom
Suspension System, tightening torques.
18. Check that the gas valve does not leak. Use a soap and water solution.
19. Check the O-ring in the cap nut and install the nut on the accumulator.
When Boom Suspension System, BSS (gear-dependent or speed-dependent) is engaged the symbol is activated with constant
green light in the lower part of the information display.
Figure 5
Boom Suspension System, BSS
Function check
FUNCTION CHECK IN GEAR-DEPENDENT MODE
– Fully Automatic Shifting FAPS in position (OFF), with engine running.
21. Set the button for Fully Automatic Shifting FAPS in position (OFF).
Figure 6
Fully Automatic Shifting, FAPS
22. Activate the button for Boom Suspension System (BSS) in gear-dependent mode.
Figure 7
Boom Suspension System, BSS, SW4211
23. Lift the boom until the lift arms are a little higher than parallel to the ground surface.
24. Check with gear 2, 3, and 4 in F-, R-, and N-position that:
 gear-dependent Boom Suspension System (BSS) is engaged (green symbol) in operating display 3 in the
information display unit
Figure 8
Display, 3 gear-dependent
 the lift arms make a suspension movement.
25. Check with 1st gear 1 in F-, R-, and N-position that:
 gear-dependent Boom Suspension System (BSS) is activated (white symbol) in operating display 3 in the
 the lift arms do not make a suspension movement.
26. Check with gear 2, 3, and 4(kickdown activated) in F-position that:
Figure 9
1. Kick-down function
– Fully Automatic Shifting FAPS in position (ON), with engine running.
27. Set the button for Fully Automatic Shifting FAPS in position (ON).
Figure 10
28. Perform steps 15–19 with the same expected result.
FUNCTION CHECK IN SPEED-DEPENDENT MODE

– Fully Automatic Shifting FAPS in position (OFF), with engine running.
Figure 11
30. Activate the button for Boom Suspension System (BSS) in speed-dependent mode.
Figure 12
31. Check with any gear and in N-position (stationary machine) that:
 speed-dependent Boom Suspension System (BSS) is activated (white symbol) in operating display 3 in the
Figure 13
Display, Information display, operating display 3, speed-dependent Boom Suspension System (BSS)
32. Operate the machine forward, until the speed exceeds 5 km/h (5– 20 km/h depending on parameter setting P1K11) and
check that:
 speed-dependent Boom Suspension System (BSS) is engaged (green symbol) in operating display 3 in the
33. Operate the machine in reverse, until the speed exceeds 2 km/h (2– 20 km/h depending on parameter setting P1K12 ) and
check that:
– Fully Automatic Shifting FAPS in position (ON), with engine running.
Figure 14
35. Perform steps 23, 24, and then steps 26 and 27 with the same expected result below:
 The speed must exceed 8 km/h (8– 20 km/h depending on parameter setting P1K1Z) when the machine is operated
forward.
 The speed must exceed0 km/h (0– 20 km/h depending on parameter setting P1K10 ) when the machine is operated
in reverse.
Boom suspension accumulator, reconditioning
Op nbr 916-003
Tools:
Dismantling
WARNING
Gas under high pressure!
If the accumulator precharge pressure (gas pressure) has not been released, there is gas under high pressure in the accumulator.
1. Secure the accumulator in a vice.
2. Reduce the precharging pressure in the accumulator, see Ride control accumulator, check and adjusting.
3. Unscrew the covers on both sides of the accumulator. Use two bolts (Ø 8 mm) in the cover holes and one pinch-bar.
Figure 1
1. Pinch-bar
2. Bolt or pin Ø 8 mm
4. Press the piston out of the accumulator. Press from the gas side of the accumulator, so that the piston is pushed out on the
oil side.
Checking and cleaning
5. Clean and check the cylinder tube and the piston as regards damage.
Make sure that no cleaning agent or lint from rags remain on any parts.
6. Install new O-rings on both covers.
7. Install a new O-ring (2) on the piston. Install a new seal ring on top of the O-ring on the piston.
Install a new support ring on the piston.
Figure 2
1. Support ring
2. O-ring and seal ring
Assembling
8. Lubricate the piston and the accumulator oil side with hydraulic oil.
9. Press in the piston into the accumulator.

NOTE!
The plane side of the piston should face the accumulator oil side.
10. Coat the threads on the covers and O-rings with hydraulic oil and install the covers.
11. Fill the accumulator with gas, see Ride control accumulator, check and adjusting.
Boom suspension system, functional check
Op nbr 916-001
When Boom Suspension System, BSS (gear-dependent or speed-dependent) is engaged the symbol is activated with constant
green light in the lower part of the information display.
Figure 1
Symbol, Boom Suspension System, BSS
FUNCTION CHECK IN GEAR-DEPENDENT MODE
– Fully Automatic Shifting FAPS in position (OFF) , while engine is running.
Figure 2
2. Activate the button for Boom Suspension System (BSS) in gear-dependent mode.
Figure 3
3. Lift the boom until the lift arms are a little higher than parallel to the ground surface.
4. Check with gear 2, 3, and 4 in F-, R-, and N-position that:
 gear-dependent Boom Suspension System (BSS) is engaged (green symbol) in operating display 3 in the
Figure 4
Display, Display panel, operating display 3, gear-dependent Boom Suspension System (BSS)
5. Check with 1st gear in F-, R-, and N-position that:
6. Check with gear 2, 3, and 4(kickdown activated) in F-position that:
Figure 5
1. Kick-down function
– Fully Automatic Shifting FAPS in position (ON), while engine is running.
Figure 6
8. Perform steps 2–6 with the same expected result.
FUNCTION CHECK IN SPEED-DEPENDENT MODE

– Fully Automatic Shifting FAPS in position (OFF), while engine is running.
Figure 7
10. Activate the button for Boom Suspension System (BSS) in speed-dependent mode.
Figure 8
11. Check with any gear and in N-position (stationary machine) that:
 speed-dependent Boom Suspension System, BSS is activated (white symbol) in operating display 3 in the
Figure 9
Display, Display panel, operating display 3, speed-dependent Boom Suspension System (BSS)
12. Operate the machine forward, until the speed exceeds 5 km//h (5– 20 km/h setting P1K11) and check that:
13. Operate the machine in reverse, until the speed exceeds 2 km/h (2– 20 km/h depending on parameter setting P1K12 ) and
check that:
 speed-dependent Boom Suspension System, BSS is engaged (green symbol) in operating display 3 in the
– Fully Automatic Shifting FAPS in position (ON) , while engine is running.
Figure 10
15. Perform steps 10, 11, and then step 12 and 13 with the expected result below:
 The speed must exceed 8 km/h (8– 20 km/h depending on parameter setting P1K1Z) when the machine is operated
forward.
 The speed must exceed0 km/h (0– 20 km/h depending on parameter setting P1K10 ) when the machine is operated
in reverse.
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Op nbr 916-070
Tools:
9993831 Support
14290266 Hose
 Service position 2, see Service position
1. Place the machine in service position 2, see: Service position.

2. Remove the cover over the electrical distribution box.
3. Remove RE08.
4. Connect terminals 30 and 87 to each other with a cable.
Figure 1
Electrical distribution box
5. Turn the start key to position 1 and leave it there for approx. 60 s. The accumulators are being drained. Move the lift lever
back and forth several times.

The accumulators should now be drained and the Boom Suspension System without pressure. Only a residual
pressure of approx. 3 bar (0.3 MPa) (43.5 psi) should be in the system.
7. Remove the cover in the front frame.
8. Connect the 60 bar sensor with the pressure gauge.
9. Check that the pressure has been released by connecting 88830213 Measuring equipment to port M on the valve block (V1).
Figure 2
10. To drain the residual pressure, connect 14290266 Hose on port M.

Drain the oil into a suitable container.

Boom suspension system, pressure reduction, safety valve, checking and
adjusting
Op nbr 916-006
Tools:
14290266 Hose
9993831 Support
 Service position 2 Service position

 Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
 Boom suspension system, functional check
1. Warm up the machine until the hydraulic system has reached operating temperature according to Hydraulic system, warming
up.

NOTE!
3. Release the pressure in the Boom Suspension System, see Boom suspension system, hydraulic oil pressure in
accumulators, depressurizing.

Connect the pressure gauge to the checking point on the Boom Suspension System valve block V1.
Figure 1
Valve block V1

2. Pressure reducing valve, CT8
5. Start the engine and raise the boom to end-position.

Operate the lift function against end-position and read off the pressure gauge at the same time. The pressure should increase
to the setting pressure for the pressure reducing valve, see Boom Suspension System, specifications. If correct pressure is
not reached, secure the boom with 9993831 Support and adjust on the pressure reducing valve CT8 with the engine off.
Carry out a new check after adjusting.
6. Turn off the engine and release the pressure in the accumulators, see Boom suspension system, hydraulic oil pressure in
accumulators, depressurizing, remove the pressure gauge and restore the machine.
7. Check the function of the Boom Suspension System (BSS) according to Boom suspension system, functional check.
Brake disc, replacing
Op nbr 516-005
Tools:
88830163 Lifting tool
11668010 Wheel forklift
9993875 Gauge
11668007 Standard Jack Single
Plastic hose, inside diameter approx. 6 mm (0.24 in) length approx. 1 m (40 in)
 Hub reduction, removing
 Hub reduction, installing
 Front wheel, installation
Brake disc, removing
2. Remove the hub reduction according to Hub reduction, removing.
3. Remove the brake disc.
4. Remove the plug, nipple, and wear indicator.
Figure 1
1. Wear indicator
Brake disc, installing
5. Press out the clearance adjusters using, e.g., a screwdriver.

Figure 2
1. Clearance adjusters
2. Brake piston
6. Drive in the automatic clearance adjusters with a rubber mallet until correct distance, at least distance (B), is obtained. See
Wheel brake, specification
Figure 3
1. Clearance adjusters
2. Brake piston
7. Press back the brake piston against the axle housing using two C-clamps as well as spacers.
Figure 4
8. Remove the C-clamps and install the hub reduction according to Hub reduction, installing.
9. Bleed the brake circuit, see: Brake system, bleeding.
NOTE!
This procedure is performed only if a new brake disc is installed.
Setting of wear indicator
10. Adjust the length of the wear indicator (A) according to Wheel brake, specification.
Figure 5
11. Install the wear indicator.

Start the machine and charge up the brake pressure. Turn off the engine, apply the wheel brake and lock the brake pedal
with a suitable spacer.
Install 9993875 Gauge and tighten it in all the way until it bottoms out.
Figure 6
1. 9993875 Gauge
12. Remove the gauge, still with the brakes applied. Install and tighten the plug on the wear indicator.
13. Install the wheel according to Front wheel, installation. Restore the machine.
Brake disc, replacing
Op nbr 517-005
Tools:
9993875 Gauge
11666013 Pump
11666013 Pump
Workshop crane, 1,000 kg (1,124 lbs)
 Rear wheel, removing
 Rear wheel, installing
Brake disc, removing
2. Remove the wheel, drain the oil, and remove the hub reduction according to Hub reduction, removing.
3. Remove the wear indicator.
Figure 1
1. Wear indicator
4. Remove the brake disc and the guide pins.

Figure 2
1. Brake disc
2. Brake plate
3. Clearance adjusters, 4 pcs.
4. Guide pin, 4 pcs.
5. Remove the brake plate and place it on a clean surface with the clearance adjusters facing up.
Figure 3
1. Clearance adjuster
2. Brake plate
6. Adjust the clearance adjusters located in the brake plate. See spec for dimension A. Wheel brake, specification
Figure 4
1. Clearance adjuster
2. Brake plate
Brake disc, installing
7. Install the guide pins, brake plate, and the brake disc in the hub reduction.
Figure 5
1. Brake disc
2. Brake plate
3. Guide pin, 4 pcs.
8. Install the hub reduction according to Hub reduction, installing.
9. Bleed the brake circuit, see: Brake system, bleeding.
Setting of wear indicator
10. Adjust the length of the wear indicator (A) according to Wheel brake, specification.
Figure 6
11. Install the wear indicator.

Start the machine and charge up the brake pressure. Turn off the engine, apply the wheel brake and lock the brake pedal
with a suitable spacer.
Install 9993875 Gauge and tighten it in all the way until it bottoms out.
Figure 7
1. 9993875 Gauge
12. Remove the gauge, still with the brakes applied. Install and tighten the plug on the wear indicator.
13. Install the wheel and lower the machine according to Rear wheel, installing. Restore the machine.
Brake discs, measuring wear
Op nbr 510-003
Tools:
9993831 Support
NOTE!
2. Apply the service brake and block the brake pedal in applied position with a suitable spacer.
NOTE!
The brake has to be applied during the entire wear check.
Figure 1
1. Shim
3. Check the brake pressure. Go to service mode and read off the brake pressure. The brake pressure should be over 2 MPa
(290 psi) during the whole operation.
4. Start the engine and charge the brakes if the brake pressure is too low. Turn off the engine and continue from, and including,
step 3.
5. Remove the wear indicator cap.
Figure 2
1. Indicator
6. Press in the wear indicator pin until it stops.

7. Measure the distance between surface A and B with a feeler gauge. See specifications for max. and min. values. Wheel
brake, specification.
Figure 3
1. Feeler gauge
2. Indicator pin
Figure 4
A. Nipple, flat surface

B. Indicator pin, flat surface
1. Wear indicator pin

2. Nipple
3. Brake plate
4. Brake disc
5. Brake piston
8. Install the protective cap over the wear indicator.
9. Repeat steps 5–8 for all brakes.
10. If the brake disc is worn out, change brake disc according to Brake discs, changing.
11. Release the brake pedal.

Brake piston, replacing seals
Op nbr 516-050
Tools:
9993831 Support
11666013 Pump
Bolts, M12x100, 2 pcs.
Sling, 2 m
Shackle
If the brake discs are to be changed, see also Brake discs, changing.
Removing
1. Place the machine in service position 2 according to Service position.
2. Press down the brake pedal repeatedly (30–40 times) to depressurize the brake system.
3. Apply the wheel brake and lock the brake pedal with a suitable spacer.
5. Secure the brake piston with a hook. Open the bleeder screw to bleed the brake system. Remove the brake piston using a
pry bar or similar. Brake piston's weight, approx.:15 kg (33 lbs).
Figure 1
1. Brake disc
2. Hook
6. Place the brake piston so that it does not rest on the clearance adjusters. Remove the seals from the brake piston.
Figure 2
1. Seal, inner
2. Seal, outer
7. Clean all parts thoroughly. Inspect the parts for damage and wear. Replace worn or damaged parts.
NOTE!
If the brake piston, brake disc, or thrust plate have been replaced, the clearance adjusters for the brake piston and/or the wear
indicator for the brake disc must be adjusted, see Brake discs, changing.
Installing
8. Install the seals on the brake piston as shown in the figure. Lubricate the brake piston and its position in the axle housing with
clean hydraulic oil.
Figure 3
9. Place the piston in correct position. Make sure that the piston ends up in correct position so that the indicator pin strikes the
brake piston's bigger diameter.
NOTE!
The brake piston is not completely symmetrical.
Figure 4
1. Small diameter
2. Big diameter
10. Press in the piston as shown in the figure.

Figure 5
1. Brake piston
2. Screw clamp
11. Replace the O-ring on the axle housing.
13. Bleed the brake according to Brake system, bleeding.
14. Install the wheel according to Front wheel, installation.
15. Check function of the brakes according to Brake system, checking function, retardation.
Brake piston, replacing seals
Op nbr 517-050
Tools:
11666013 Pump
11666013 Pump
Bolts M12x100, 2 pcs.
Sling, 2 m
Shackle
C-clamps, 2 pcs.
If the brake discs are to be changed, see also Brake disc, replacing.
Removing
1. Place the machine in service position 1 according to .
2. Press down the brake pedal repeatedly (30–40 times) to depressurize the brake system.
3. Apply the wheel brake and lock the brake pedal with a suitable spacer.
5. Open the air bleeder screw to bleed the brake system. Remove the brake piston using a pry bar or similar. Brake piston's
weight, approx.:6 kg (13 lbs).
Figure 1
1. Brake piston
6. Place the brake piston on a clean surface. Remove the seals from the brake piston.
Figure 2
1. Brake piston
2. Seal, inner
3. Seal, outer
7. Clean all parts thoroughly. Inspect the parts for damage and wear. Replace worn or damaged parts.
NOTE!
If the brake piston, brake disc, or thrust plate have been replaced, the clearance adjusters for the brake piston and/or the wear
indicator for the brake disc must be adjusted, see Brake disc, replacing.
Installing
8. Install the seals on the brake piston as shown in the figure. Lubricate the brake piston and its position in the axle housing with
clean hydraulic oil.
Figure 3
9. Place the piston in correct position. Make sure that the piston ends up in correct position so that the wear indicator pin strikes
the brake piston's bigger diameter up to the right according to the arrow "A".
The arrow "B" shows the position where the brake piston's position should match with the guide pins.
NOTE!
The brake piston is not completely symmetrical.
Figure 4
1. Brake piston
10. Press in the piston as shown in the figure.
Figure 5
11. Replace O-ring on the axle housing.
13. Bleed the brake according to Brake system, bleeding.
14. Install the wheel according to Rear wheel, installing.
15. Check function of the brakes according to Brake system, checking function, retardation.
Brake pressure and function, checking
Op nbr 173-310
Braking capacity, checking
1. Start the machine and charge the brake system.
2. Turn off the machine and turn the start key to position 1.
Select.
Information
Enter service mode?

NO YES
4. Press key 4 (axles) on the keypad to see the accumulator pressure.
5. Press carefully on the brake pedal until the acc. brake pressure shown on the display matches the cut-in pressure, see Brake
6. Check the braking capacity by pressing down the brake pedal all the way and then releasing it again. Repeat this four times.
7. Acc. brake pressure shown on the display may not drop below the value for low-pressure indication, see Brake system,
specifications.
If the pressure drops below the value for low-pressure indication, check the accumulators' precharge pressure.
Brake system charging, checking
Op nbr 520-036
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
Plastic hose, inside diameter approx. 6 mm, length approx. 2 m

1. If needed, bleed air from the brake system, see Brake system, bleeding.
up
3. Lock the frame joint with the frame joint lock, place blocks in front of and behind the wheels.
SELECT.
Information
Enter Service mode?

NO YES
6. Press key 4 (axles) on the keypad to check the accumulator pressure.
7. Press the brake pedal repeatedly (30–40 times) until the accumulator pressure on the display is 0.
Cut-out pressure, checking
8. Start the engine.
9. Let the engine idle until the cut-out pressure is reached and the accumulator pressure on the display stops increasing. Check
the value in Brake system, specifications.
NOTE!
During the first approx. 20 seconds the output brake pressure also increases due to an internal test.
NOTE!
The cut-out pressure cannot be adjusted. If the pressure is too low, continue by checking max. brake pressure, see below.
Cut-in pressure, checking
10. Carefully press down the brake pedal repeatedly. The accumulator pressure on the display will drop.
11. When the accumulator pressure on the display is below the cut-in pressure, the accumulator pressure on the display starts to
increase again. Check the value for the cut-in/cut-out point, and check in Brake system, specifications.
NOTE!
The cut-in pressure cannot be adjusted. If the pressure is incorrect, check pressure sensor SE5201, see SE5201, description and
measuring.
Max. brake pressure, checking
12. Run the tilt to end-position and hold the lever there.
13. Check max. brake charging pressure by reading off the accumulator pressure on the display. Check the value in Brake
14. If the pressure is incorrect, adjust according to the following instructions.
15. Turn off the engine.
Max. brake pressure, adjusting
SELECT.
18. Press key 4 (axles) on the keypad to check the accumulator pressure.
19. Press the brake pedal repeatedly (30–40 times) until the accumulator pressure on the display is 0.
Figure 1
20. Before adjusting max. brake pressure, connect the pressure gauge to the accumulator block to get a more exact value.
Figure 2
1. Pressure check connection, accumulator block
22. Then repeat the check for max. brake pressure, according to section "Max. brake pressure, checking" , but read off the value
on the pressure gauge instead of on the display.
23. Find the pressure limiting valve for max. brake pressure on the central block.
Figure 3
1. Pressure limiting valve for max. brake pressure
24. Loosen the lock nut.

NOTE!
The engine must be off!
25. Adjust the brake pressure on the pressure limiting valve.

Turning the adjusting screw half a turn clockwise increases the pressure by approx. 10 bar (1 MPa/145 psi).
26. Then repeat the check for max. brake pressure, according to section "Max. brake pressure, checking" , but read off the value
on the pressure gauge instead of on the display.

Brake system, bleeding
Op nbr 520-037
Plastic hose, inside diameter approx. 6 mm (0.236 in), length approx. 1 m (3 ft)
The brake system is divided into two circuits. This means that if only one circuit has been opened (a line has been disconnected,
etc.), only that circuit requires bleeding.
1. Check and adjust the oil level in the hydraulic oil tank.
2. Fully depress the brake pedal and block it in that position with a suitable spacer.
3. Start the engine and run it at idling speed.
4. WARNING
Oil under high pressure!
Connect the plastic hose to the bleeder nipple and carefully open the bleeder screw. Close the bleeder screw when oil free
from air flows out.
Figure 1
1. Plastic hose
2. Bleeder screw
5. Stop the engine. Adjust the oil level in the hydraulic oil tank.
6. Test the function.

Brake system, check and adjusting pressure in circuit
Op nbr 520-005
Tools:
Output brake pressure, checking
1. Turn the key to position 1.
2. Press and hold in key 8 (service) on the keypad for approx. 4 seconds. When asked if you want to enter Service mode ,
press SELECT.
Information
Enter Service mode
No Yes
3. Press key 4 (axles ) on the keypad.
5. Press down the brake pedal until it bottoms out.
6. Read off the brake pressure on the display to check the value for max. output brake pressure. Check the value in Brake
Output brake pressure, adjusting
7. If the value is not correct, connect the pressure sensor on the pressure check connection, see figure, to get a more exact
value.
Figure 1
1. Adjusting screw for output brake pressure
8. Check the pressure again, but read off the pressure on the pressure gauge.
9. Break the seal and loosen the lock nut on the adjusting screw, see figure.
10. Increase the pressure by turning the adjusting screw counter-clockwise.
11. Lock the adjusting screw with the lock nut and affix a new seal.
Brake system, checking function, retardation
Op nbr 520-002
1. The brake test must be carried out in a place where there is no risk of injuries or damage to personnel or equipment. The
ground must be clean and have good friction (dry asphalt or similar). The machine must not be loaded.
2. Press and hold in key 8 on the keypad for approx. 4 seconds. When prompted “Go to Service mode”, press SELECT.
Information
Go to Service mode
No Yes
3. Scroll to TEST and press SELECT, choose Brake test and press SELECT, choose On, press SELECT.
4. Engage gear position F and accelerate when the text “Accelerate over 20 km/h” is shown on the information display, brake
maximally when the text “Brake to standstill” is shown on the information display.
The retardation value is shown on the information display.
5. If the wheels lock and slide on the ground surface, the test has to be repeated.
6. The three latest test values are saved in Brake test log.
7. Min. acceptable retardation value see, Brake system, specifications

NOTE!
The value according to specifications is to be considered as an absolute minimum value. If a reduced brake function is
suspected, continue to check the brake system according to Brake system charging, checking and Brake discs, measuring
wear.
Cab extra prefilter cyclone type, replacing
Op nbr 173-511
1. 1. Remove the four bolts and move aside the cover.

2. Change the filter.
3. Reinstall the cover.
NOTE!
Additional options
Can not be combined with the prefilter.
Figure 1
Cab, extra prefilter
1. Bolt, 4 pcs.
2. Cover
Cab main filter, replacing
Op nbr 173-406
1. Turn the fasteners to the side and remove the cover. Remove the main filter and discard it.
NOTE!
The main filter can be a standard filter, an asbestos filter, or a carbon filter. They are replaced in the same way.
Figure 1
1. Fasteners , 4 pcs.
2. Cover over main filter
2. Install a new main filter and the casing. Close the cover.
Cab prefilter, replacing
Op nbr 173-405
1. Open the side casing.
2. Turn the fasteners to the side and remove the prefilter and discard it.
Figure 1
1. Prefilter
2. Fasteners , 2 pcs.
3. Install the new prefilter and close the cover.

Carbon dioxide in coolant system, checking
Op nbr 260-001
Tools:
9808038 Leak detector
88890300 Interface
1. Place the machine in service position.
2. Check the coolant level.
WARNING
Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling
system.
3. Open the expansion tank cap, blow out the air in the tank thoroughly by compressed air and close the cap.
4. Warm up the engine, and let the engine run during the entire test.
Preparing the test
5. Dismantle 9808038 Leak detector.

Lubricate the O-rings with silicone grease or clean vaseline.
6. Fill both chambers with reaction fluid up to the marked line.
7. Cover the inlet hole at the same time as the carbon dioxide detector is assembled so that no fluid is pressed out.
NOTE!
The carbon dioxide detector and its fluids must not be exposed to cigarette smoke, exhausts, or similar.
8. Hold the tester inclined to the mouth, exhale and pump 2 to 3 times on the rubber bulb.
The liquid shall now change its color to blue-green or green-yellow.
NOTE!
This test sensitizes the test liquid and shall be performed just before each test.
9. Suck in fresh air using the rubber bulb until the color changes again to dark blue-green.
WARNING
Risk of scalding and burns when the expansion tank cap (radiator cap) is opened due to high pressure in the cooling
system.
Checking for carbon dioxide in coolant system
10. Open the expansion tank cap and immediately place 9808038 Leak detector over the opening and pump 10–15 times with
the rubber bulb to suck in air from the tank. Wait 10–15 seconds to see if the reaction fluid changes color.
NOTE!
Do not suck in coolant into the carbon dioxide detector.
Colour of testing liquid Blue Green Yellow

(second chamber)
Interpretation CO₂ inconspicuous Undefined status CO₂ conspicuous
Color gradient Starting color [T1] Transition color ⁽ᵃ⁾ Ending color
[T1]CO2 inconspicuous
If the reaction fluid again changes color, it means that there is carbon dioxide in the cooling system. Do not reuse the used test liquid
after finishing the test process since alkaline impurities may negatively influence the sensitivity. Clean the test chambers with rinsing
liquid.
Carbon dioxide in the coolant indicates that exhaust is forced into the cooling system. This may be due to leakage by a unit injector
sleeve, leaking cylinder head gasket, or cracks in the cylinder head. These defects may also cause low compression.
To determine if compression is low, run Tech Tool operation 21006-3 Cylinder compression, test.
11. Install the expansion tank cap.

Shut down the engine.
Carbon dioxide in fuel system, check
Op nbr 230-001
Tools:
9808038 Leak detector
Carbon dioxide in fuel tank, check with carbon dioxide detector
1. Run the engine until it is reaches operating temperature.
2. Place the machine in service position.
3. Dismantle 9808038 Leak detector.

Lubricate the O-rings with silicone grease or clean vaseline.
4. Fill both chambers with reaction fluid up to the indicated line.
5. Cover the inlet hole at the same time as the carbon dioxide tester is assembled so that no fluid is pressed out.
NOTE!
The carbon dioxide detector and its fluids may not be exposed to cigarette smoke, exhausts, or similar.
Do not conduct the test on a machine that has recently been refueled.
6. Rev up the engine several times.
7. Shut off the engine and open the fuel tank cap.
Place 9808038 Leak detector over the tank opening and pump 3–5 times on the rubber bulb to draw in air from the tank. Wait
10–15 seconds to see if the reaction fluid changes color.
NOTE!
Do not draw fuel into the carbon dioxide detector.
If the reaction fluid in 9808038 Leak detector changes color, this indicates that there is carbon dioxide in the tank.
Very small quantities of carbon dioxide are often present in the machine systems, that is why the measurement should be repeated if
the first measurement generates a reaction.
8. Draw fresh air into 9808038 Leak detector by pumping a few times on the bulb. Pump until the reaction fluid has returned to
its original color.
9. Ventilate the air above the filler hole to the tank and repeat the test.
NOTE!
Do not blow with exhaled air as it contains carbon dioxide.
10. Install the fuel tank cap.

CCM, replacing
Op nbr 300-077
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
1. Set air recirculation to maximum, to get better access to connector.
2. Place the machine in service position 1, see Service position. Turn master switch to the ON position.
3. Remove the right wall cover.
Figure 1
Right wall cover
4. Remove the black air duct.
Figure 2
CCM cover
Figure 3
CCM location
5. Connect Tech Tool and perform the operation 17092-3 Replace hardware to see if it is possible to read out customer
parameter settings. (If there is no network connection at the machine, perform operation 17093-3 Program with stored
software.)
6. Turn master switch to the OFF position.
7. Change CCM.
8. Turn master switch to the ON position.
9. Connect Tech Tool and finalize the operation 17092-3. (If there is no network connection at the machine, perform operation
17093-3 Program with stored software.)
10. Unplug the Tech Tool connector from the CCM.

Climate unit, installing
Op nbr 870-013
Installing
1. Install the AC-system in the machine. Connect the coolant hoses and tighten down the heat valve. Remove the hose pliers
and check that are no leaks.
2. Plug in the connectors MO8701 for fan motor and temperature sensor SE8702 for incoming air.
3. Tighten down the climate unit.
Figure 1
1. Bolts
4. Install the evaporator, the bolts for the AC-hoses' rubber bushing, and the drain hoses for the condensation water. Plug in
connector SE8709.
Figure 2
1. Drain hoses
2. Bolt
3. Connector SE8709
5. Install the plate on the evaporator.

Figure 3
1. Plate
6. Install the CCM, connect the coolant valve, and install new cable ties.
Figure 4
1. Cable tie
2. CCM
3. Coolant valve
7. Plug in connector SE8708 for the air channel's temperature sensor. Install the ventilation channel.
Figure 5
1. Connector SE8708
2. Ventilation channel
8. Reinstall the panels beside the seat in the cab.

Figure 6
1. Panels
9. Reinstall the panel behind the seat in the cab.
Figure 7
1. Panel
Figure 8
1. Filter holder
2. Connector MO8703
3. Retaining strap
11. Test-run the machine and check the function of the cover for the damper motor, and make sure that there are no leaks.
Figure 9
1. Cover
12. Reinstall the filter and filter casing. Turn back the plastic fasteners.
Figure 10
1. Plastic fastener
2. Filter
3. Filter casing
13. Close the cover for the AC-system and check that the drain hoses are not trapped.
Figure 11
1. Cover
14. Restore the machine and test-run it.

Climate unit, removing
Op nbr 870-012
Figure 1
1. Cover
3. Turn the plastic fasteners, remove the filter and the filter casing.
Figure 2
1. Plastic fastener
2. Filter
3. Filter casing
4. Remove the filter holder and unplug the connector MO8703 for the air mixing damper's motor.
Figure 3
1. Filter holder
2. Connector MO8703
5. Remove the panel behind the seat in the cab.
Figure 4
1. Panel
6. Remove the panels beside the seat in the cab.
Figure 5
1. Panels
7. Remove the ventilation channel and unplug the connector SE8708 for the air channel's temperature sensor.
Figure 6
1. Connector SE8708
2. Ventilation channel
8. Cut the cable ties, loosen the coolant valve, and remove the CCM.
Figure 7
1. Cable tie
2. CCM
3. Coolant valve
9. Remove the plate on the evaporator.
Figure 8
1. Plate
10. Remove the bolt for the AC-hoses' rubber bushing. Remove the drain hoses for the condensation water. Unplug connector
SE8709.
Figure 9
1. Drain hoses
2. Bolt
3. Connector SE8709
11. Swing out the evaporator and move it aside.
Figure 10
Evaporator
12. Remove the bolts for the climate unit.
Figure 11
1. Bolts
13. Unplug the connectors MO8701 for fan motor and temperature sensor SE8702 for incoming air.
Figure 12
1. Connector SE8702
2. Connector MO8701
14. Clamp off incoming and outgoing coolant flow with hose pliers.
Figure 13
Hose pliers
15. Pull out the climate unit slightly and disconnect the lower coolant hose located on the heater unit.
Figure 14
1. Coolant hose
16. Disconnect the coolant hose by the heat valve.

Figure 15
1. Coolant hose
17. Temporarily connect incoming and outgoing coolant hose with the heat valve to avoid coolant spills.
Figure 16
1. Coolant hoses
18. Remove the climate unit from the machine.

Comfort drive control (CDC), angle sensor, changing
Op nbr 660-006
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
 Service position 1
 Lever steering (CDC), functional check
NOTE!
If the angle sensor has been removed, loosened or in any way moved from its position, the function must be calibrated even if the
angle sensor is not replaced.
Removing
2. Remove the mat and the front floor plate in the cab.
3. Remove the guard over the angle sensor
Figure 1
14. Flange bolt
15. Guard
4. Remove the bolt from the clamp that holds the cable harness. Remove the cable harness from the angle sensor.
Remove the sensor.
Figure 2
1. Bolt
2. Spring nut
3. Clamp
4. Cable harness
5. Sensor
NOTE!
Check that the carrier is intact and that the angle sensor's pin cannot move in the carrier.
Installing
5. Install the sensor.

Assemble the cable harness with the angle sensor and install the bolt on the clamp that holds the cable harness.
Figure 3
1. Bolt
2. Spring nut
3. Clamp
4. Cable harness
5. Sensor
NOTE!
Check that the carrier is intact and that the angle sensor's pin cannot move in the carrier.
6. Install the guard over the angle sensor.
Figure 4
14. Bolt
15. Guard
7. Install the front floor plate and mat in the cab.
9. Calibrate with Tech Tool Service tools according to operation number 64187-3 End position lever steering right/left,
calibration.
10. Test-run the machine. Check that there are no error codes. Check the function of the lever steering (Comfort Drive Control)
according to Lever steering (CDC), functional check.
Comfort drive control (CDC), solenoid valve, changing
Op nbr 660-007
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
 Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump

 Operator's seat, securing
There are two solenoid valves for Comfort Drive Control (lever steering), PWM6601A and PWM6602B. The method for replacing
solenoid valve is the same regardless of which solenoid valve is to be replaced.
Removing
1. Lock the frame joint with the frame joint lock. Place blocks in front of and behind the wheels. See also Safety when working
on hydraulic systems.
Figure 1
2. Remove the floor mat.
3. Fold the operator's seat forward, see Operator's seat, securing.
4. Remove the rear floor plate.
WARNING
Oil under high pressure!
6. Unplug the connector for the solenoid valve.

Remove the bolts that hold the solenoid valve and remove the solenoid valve.
Figure 2
1. PWM6601A
2. PWM6602B
Installing
7. Lubricate the O-rings on the solenoid valve with oil. Install the solenoid valve together with the attaching bolts.
Plug in the connector.
9. Install the rear floor plate.
10. Fold back the operator's seat, see Operator's seat, securing.
11. Install the floor mat.
13. Calibrate Comfort Drive Control (CDC, lever steering) with Tech Tool Service Tool according to operation number 64186-3,
Comfort Drive Control, complete calibration.
NOTE!
Before calibration, even a small lever deflection can result in the machine steering with full speed.
14. Test-run the machine. Check that there are no error codes. Check the function of Comfort Drive Control according to Lever
steering (CDC), functional check.
Comfort Drive Control, servo pressure, checking
Op nbr 660-012
Tools:
936446 Testing nipple
1. Block the wheels. Lock the frame joint with the frame joint lock.
2. Remove the plate on the left side of the machine under the cab.
3. Remove the plug from the PS-port on the control valve for CDC, and install 936446 Testing nipple.
Figure 1
1. PS-port
2. Strainer
4. Connect 88830213 Measuring equipment.
5. Start the engine and activate Comfort Drive Control (lever steering).
Steer against end-position and check that the pressure corresponds to Control valve, lever steering (CDC), specifications.
Note that the pressure is not adjustable.

If the pressure is too low, check that the pressure limiter and strainer are not clogged or defective.
6. Remove the measuring equipment. Reinstall the plug in the PS-port.
7. Install the plate under the cab.

Compression test
Op nbr 210-002
Tools:
9988539 Pressure gauge
88800070 Spanner
88830205 Adapter
88830205 Adapter
88830205 Adapter
88830205 Adapter
88830205 Adapter
88830205 Adapter
88830206 Counterhold
88890300 Interface
885812 Timing tool
88830207 Rotation tool
9996400 Impact puller
9998007 Adapter
 Valve cover, removing

 High pressure fuel pipes, replacing
 Injectors, replacing all
 Valves, adjusting
 Valve cover, installing
 Fuel system, bleeding
WARNING
Make sure that high-pressure fuel cannot come into contact with unprotected parts of the body when working with injection
equipment.
NOTICE
Maintain greatest possible cleanliness when working on the fuel system.
NOTICE
Plug all pipes, hoses and connections when removing.
2. NOTE!
The engine must cool down for approx. 30 minutes and the oil temperature must not exceed 80 °C (176 °F).
Relieve the high fuel pressure and remove the high pressure fuel pipes according to High pressure fuel pipes, replacing.
3. Remove the valve cover according to Valve cover, removing.
4. Remove the injectors according to Injectors, replacing all.
5. Disconnect the feed line. Attach a ø 10 mm (0.4 in.) hose to the feed line for circulating the fuel to the tank.
Figure 1
1. Feed line
2. Fuel pump
Figure 2
1. Hose for fuel circulating
6. Check that the valve clearances are correct, adjust if needed, see: Valves, adjusting.
7. Check the compression ratio as following:
 Install 88830205 Adapter in all cylinders.

 Install 9988539 Pressure gauge on one Adapter.
 Crank the engine with the starter motor for 5–10 seconds and note the compression pressure.
 Repeat the procedure for all the other cylinders.
NOTE!
The difference in compression pressure should not exceed 15%.
Figure 3
88830205 Adapter
8. Remove the compression test equipment and connect the feed line.
9. Install the injectors according to: Injectors, replacing all.
10. Install the valve cover according to Valve cover, installing.
11. Replace the high pressure pipes according to: High pressure fuel pipes, replacing
12. Bleed the fuel system, see: Fuel system, bleeding

Coolant freezing point, checking
Op nbr 173-311
Tools:
WARNING
Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant may rush
out and cause severe burns.
1. Remove the cap from the expansion tank.
Figure 1
1. Cap, expansion tank
2. Check the freezing protection with 88890105 Refractometer

Open the cover on the refractometer and place a few drops of the coolant on the glass surface. Close the cover and read off
the value against a strong light. Read off the value on the ethylene scale. The coolant should be taken from the fill point by
the expansion tank.
Figure 2
1. 88890105 Refractometer
3. The machine is delivered with a coolant mixture of 40% glycol and 60% water for optimal cooling and corrosion properties.
Therefore, always fill with the same coolant mixture regardless of outdoor temperature conditions.
See: Recommended lubricants
4. Check the coolant level at the same time. The coolant level should be between Max. and Min.
5. Install the cap on the expansion tank.

Coolant level, checking
Op nbr 173-357
WARNING
Risk of burns! Use protective work gloves.
1. The level should be between Max. and Min. on the expansion tank.
If coolant needs to be filled, do not open the cap when the coolant is warm. First let the fluid cool.
WARNING
Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant
may rush out and cause severe burns.
Figure 1
1. Fill point
2. Max.
3. – Min.
Coolant pump, replacing
Op nbr 262-002
2. Drain the coolant, see Coolant, changing.
3. Remove the cover.
Figure 1
1. Cover
4. Disconnect the fuel pipe.
Figure 2
1. Alternator belt
2. Belt pulley
3. Fuel pipe
4. Belt tensioner
5. Loosen the belt pulley bolts.
6. Lock the belt tensioner with a tool and disconnect the alternator belt from the belt pulley.
7. Remove the belt pulley.
8. Remove the bolts from the coolant pump.
Figure 3
Attaching bolts
9. Install two M6 bolts on the pump. Tighten the bolts crosswise until the coolant pump comes loose. Remove the coolant pump.
Figure 4
1. Bolts for removal
10. Install the new coolant pump.

Tighten the bolts crosswise.
11. Install the belt pulley.
12. Install the alternator belt and loosen the belt tensioner.
13. Tighten the belt pulley bolts.
14. Connect the fuel pipe.
15. Install the cover.
16. Fill coolant, see Coolant, changing.

Coolant valve, replacing
Op nbr 254-119
3. Clamp hose pliers on the coolant hoses.

Remove the coolant valve bracket.
Remove the coolant hoses and unplug the connector from the coolant valve.
Remove the coolant valve.
Figure 1
Figure 2
Removal of coolant hoses
4. Install the new coolant valve on the bracket. Connect the coolant hoses. Plug in the connector. Install the coolant valve.
5. Install the plastic cover.

Coolant, changing
Op nbr 173-457
WARNING
Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant may rush
out and cause severe burns.
Draining
1. Remove the cap from the expansion tank.
Figure 1
1. Coolant, fill point

2. Max.
3. – Min.
2. Take out the drain hose, which is located in the toolbox. Place the end of the hose in a suitable container, remove the
protective cap from the drain nipple, and connect the hose.
Coolant volume, see: Engine, fill quantities
NOTE!
Handle the coolant in an environment-friendly manner.
Figure 2
1. Drain point
3. When the coolant is drained; Remove the drain hose and install the protective cap.
Filling
4. Fill the cooling system to Max. level in the expansion tank and install the cap on the expansion tank.
5. Set the heat control to Max. heat and warm up the engine.
6. Turn off the engine and top up so that the cooling system is completely filled and bled free from air.
Volume: see Engine, fill quantities
NOTE!
Use genuine Volvo coolant.
Coolers, cleaning
Op nbr 173-373
1. Remove the lock pin and secure the frame with the condenser and hydraulic oil cooler in open position.
Figure 1
1. Strap
2. Open cooler
2. Open the fan grill.

Blow clean the coolers with compressed air.
NOTE!
The radiator/cooler core/fins may be damaged if handled carelessly.
Figure 2
V1148130
1. Fan grill
3. Install the fan grill. Remove the strap and install the lock pin.
Cooling system, pressure control
Op nbr 260-003
Tools:
88830296 Test unit
2. Connect the pressure gauge to the expansion tank as shown in the figure.
Figure 1
1. 88830296 Test unit
3. Pump approx. 200 pump strokes until the pressure reaches approx. 1 bar (14.5 psi).
4. Check the system for leaks.
5. Release the pressure.
6. Warm up the machine.

NOTE!
Leave the gauge on while warming up.
7. Pump until the pressure reaches approx. 1 bar (14.5 psi).
8. Check the system for leaks.

Cooling unit, leak detection
Op nbr 874-009
Pressure test equipment
1. Connect the blue hose from the pressure test equipment to the machine's low-pressure connection.
2. Open the valve on the pressure test equipment and fill the system with nitrogen gas to 5 bar (0.5 MPa, 72 psi). Let the
pressure act for 5 minutes.
Figure 1
Pressure test equipment
3. Fill the system with nitrogen gas to 10 bar (1 MPa, 145 psi). Let the pressure act for 10 minutes. If the pressure drops, find
the leak using leak detection spray.
4. Drain the system of nitrogen gas slowly, so that the compressor oil remains in the system.
Counterweight, fitting
Op nbr 716-002
Tools:
Swivelling lifting eyes M16, L=134 mm (5.28 in), 8 pcs.
Spacer 11400890, 8 pcs., and Nut M20, 18 mm, 8 pcs., or equivalent
Sling, 3 m, 3 pcs.
Sling, 1 m, 5 pcs.
Ratchet block 750 kg (1653 lbs)
Shackle, 4 pcs.
1. Install swivelling lifting eyes M16 with bolt length 134 mm (5.28 in) and a thread length of at least 50 mm (1.97 in), as well as
a spacer 55 mm and nut M20, or equivalent, against the counterweight. Connect the counterweight with sling and ratchet
block, see Fig. 1. The ratchet block shall be connected with sling to the towing pin. See Fig. 2.
Figure 1
1. Sling, 1 m (3.3 ft)

2. Sling, 3 m (10 ft)
3. Shackle, 4 pcs.
4. Ratchet block
5. Sling, 1 m (3.3 ft)
Figure 2
1. Sling connected to ratchet block

2. Towing pin
2. Install the counterweight on the machine with the four bolts.

Torque-tighten the bolts. See: Counterweight, tightening torques
Weight, counterweight:
730 kg (1,609 lbs) for L60G
1,330 kg (2,932 lbs) for L70G
2,400 kg (5,291 lbs) for L90G
3. Remove the sling, ratchet block, and the lifting eyes.
4. Install the tail lights and connect the electric connections.
Figure 3
1. Tail light, 2 pcs.
5. Install the protective plugs (optional equipment).

Figure 4
1. Protective plugs, 4 pcs.
6. Start the machine and check that direction indicators, brake lights, and tail lights work.
Counterweight, removing
Op nbr 716-001
Tools:
Swivelling lifting eyes M16, L=134 mm (5.28 in), 8 pcs.
Spacer 11400890, 8 pcs., and Nut M20, 18 mm, 8 pcs., or equivalent
Sling, 3 m, 3 pcs.
Sling, 1 m, 5 pcs.
Ratchet block 750 kg (1653 lbs)
Shackle, 4 pcs.
1. Remove the protective plugs from the eight holes for the grill guard (optional equipment) on the counterweight.
Clean the threads with a thread tap M16 from dirt and rust, and lube them with oil.
Figure 1
1. Protective plugs
2. Install swivelling lifting eyes M16 with bolt length 134 mm (5.28 in) and a thread length of at least 50 mm (1.97 in), as well as
a spacer 55 mm and nut M20, or equivalent, against the counterweight.
Connect sling and ratchet block to a lifting device, see Fig. 2. The ratchet block shall be connected with sling to the towing
pin, see Fig. 3.
Figure 2
1. Sling, 1 m (3.3 ft)

2. Sling, 3 m (10 ft)
3. Shackle
4. Ratchet block
5. Sling, 1 m (3.3 ft)
Figure 3
1. Sling connected to ratchet block

2. Towing pin
3. Remove the tail lights.

Mark the electric connections and disconnect them.
Figure 4
1. Tail light
4. Remove the counterweight. Weight:

approx. 730 kg (1,609 lbs) for L60G
approx. 1,330 kg (2,932 lbs) for L70G
approx. 2,400 kg (5,291 lbs) for L90G
Diesel oxidation catalyst, replacing
Op nbr 254-060
Tools:
88890300 Interface
88890305 Cable
88890253 Cable
88830214 Fixture

Figure 1
1. Dosing injector
4. NOx sensor
3. Disconnect the sensors and sensor pipes from the muffler.

Remove the attaching bolts (4 pcs.) for the bracket and remove the bolt at the exhaust pipe. Remove the bracket and place it
on the right fender.
Figure 2
1. DPF differential pressure sensor

2. Attaching bolts
4. Mark the position of the exhaust elbow, diesel oxidation catalyst (DOC), diesel particulate filter (DPF), end cover and
mounting clamps.
Figure 3
1. Exhaust elbow
2. Diesel oxidation catalyst (DOC)
3. Diesel particulate filter (DPF)
4. End cover
5. Remove the exhaust elbow.
6. Remove the attaching bolts and lift up the muffler. Attach the bolts to secure the muffler.
Figure 4
1. Bolts
7. Open the mounting clamps.

Connect a lifting device as shown and remove the muffler.
Weight: approx 21 kg (46 lb)
Figure 5
1. Lifting eye
8. Place the muffler on a work bench.
9. Remove the V-clamp. Remove the DOC.
10. Check the DPF and the end cover for wear or damage. Remove all soot and particles.
NOTE!
Take appropriate environmental action.
11. Check for damage on connections, pipes- and contact surfaces.

Figure 6
1. Bolts, mixing tube flange

2. Mounting clamp
3. Bolts, mounting clamp
4. V-clamp
5. V-clamp, mixing tube
Installing
12. Clean the contact faces on the new clamp, filter and DOC with a cleaning agent. Place a new gasket on the DOC flange.
Install the filter together with the end cover. Make sure that the holes for the lifting eyes are lined according to the markings
made earlier. Install a new V-clamp and tighten it lightly. Tap lightly with a plastic hammer on the clamp and torque-tighten
according to Inlet and exhaust system, tightening torques.
13. Install the muffler according to earlier markings.

Do not tighten the mounting clamps.
Weightapprox. 21 kg ( 43 lb)
14. Install the mixing tube loosely, to set the position of the muffler. Make sure that the flanges are aligned.
Make sure that the muffler is installed according to markings and torque-tighten the mounting clamps according to Inlet and
exhaust system, tightening torques.
15. Install the exhaust elbow. Torque-tighten according to Inlet and exhaust system, tightening torques
16. Remove the mixing tube. Install the bracket.

NOTE!
Make sure you avoid building in tensions in the joints.
17. Install the pipes and sensors. Torque-tighten according to Inlet and exhaust system, tightening torques.
Strap the cables.
NOTE!
Torque-tightening requires slotted sockets, 17 mm and 22 mm.
18. Install the mixing tube. Torque-tighten the attaching bolts and v-clamp according toInlet and exhaust system, tightening
torques .
20. NOTE!
Install the dosing injector. Torque-tighten according to Inlet and exhaust system, tightening torques.
Figure 7
21. Run Tech Tool operation 25474-3 Exhaust aftertreatment system, reset to reset the ageing value.

Diesel particulate filter, check and clean
Op nbr 254-001
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
NOTE!
Maintain cleanliness so that dirt doesn't enter the system.
NOTE!

Figure 1
1. Dosing injector
4. NOx sensor

Figure 2

2. Attaching bolts
mounting clamps.
Figure 3
1. Exhaust elbow
4. End cover
Figure 4
1. Bolts

Figure 5
1. Lifting eye
9. Remove the V-clamps. Remove the filter.
10. Check the DOC and the end cover for wear or damage. Remove all soot and particles.
NOTE!
11. Remove gasket remains from the dirty filter and clean according to Volvo CE core handling instructions. Place the filter in the
protective bag supplied with the new filter. Follow Volvo Core handling instructions.
NOTE!
Handle the filter carefully so that it is not damaged.

Figure 6

2. Mounting clamp
4. V-clamp
Installing
13. Clean the contact faces on the new clamps, filter, and DOC with a cleaning agent. Place a new gasket on the DOC flange.
Install the filter. Make sure that the holes for the lifting eyes are lined up with the markings made earlier. Install a new V-clamp
and tighten it lightly. Tap lightly with a plastic hammer on the clamp and torque-tighten according to Inlet and exhaust system,
tightening torques.
Install the end cover in the same way.
NOTE!
Do not torque-tighten the clamp for the end cover.

16. Torque-tighten the end cover v-clamp according to Inlet and exhaust system, tightening torques.
17. Install the exhaust elbow. Torque-tighten according to Inlet and exhaust system, tightening torques.
NOTE!
Strap the cables.
NOTE!
torques.
23. To reset the soot and ash load, run TechTool operation 25474-3 Exhaust aftertreatment system, reset.
Diesel particulate filter, checking and cleaning
Op nbr 173-319
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
NOTE!
NOTE!

Figure 1
1. Dosing injector
4. NOx sensor

Figure 2

2. Attaching bolts
mounting clamps.
Figure 3
1. Exhaust elbow
4. End cover
Figure 4
1. Bolts

Figure 5
1. Lifting eye
8. Remove the V-clamps. Remove the filter.
9. Check the DOC and the end cover for wear or damage. Remove all soot and particles.
NOTE!
10. Remove gasket remains from the dirty filter and clean according to Volvo CE core handling instructions. Place the filter in the
protective bag supplied with the new filter. Follow Volvo Core handling instructions.
NOTE!
Handle the filter carefully so that it is not damaged.

Figure 6

2. Mounting clamp
4. V-clamp
Installing
12. Clean the contact faces on the new clamps, filter, and DOC with a cleaning agent. Place a new gasket on the DOC flange.
Install the filter. Make sure that the holes for the lifting eyes are lined up with the markings made earlier. Install a new V-clamp
and tighten it lightly. Tap lightly with a plastic hammer on the clamp and torque-tighten according to Inlet and exhaust system,
tightening torques.
Install the end cover in the same way.
NOTE!
Do not torque-tighten the clamp for the end cover.

15. Torque-tighten the end cover v-clamp according to Inlet and exhaust system, tightening torques.
16. Install the exhaust elbow. Torque-tighten according to Inlet and exhaust system, tightening torques.
NOTE!
Strap the cables.
NOTE!
torques.
22. To reset the soot and ash load, run TechTool operation 25474-3 Exhaust aftertreatment system, reset.
Diesel particulate filter, regenerating
Op nbr 173-394
WARNING
Risk of burns.
Engine and exhaust system components get very hot and can cause severe burns.
Avoid contact with engine compartment covers, engine components and exhaust system until the engine is cooled down.
1. Warm up the engine to working temperature.
This symbol should be visible in the display panel.
2. Park the machine in a fireproof area (outdoors). Keep the engine running during the whole regeneration.
3. Apply the parking brake. Keep it applied during the whole regeneration.
4. Start the regeneration with the key pad.
This symbol is visible in the display panel during the regeneration.

NOTE!
If the regeneration isn’t performed within the service interval it may only be possible to start the regeneration by using Tech
Tool operation 25920-3 Exhaust aftertreatment system service regeneration.
Differential lock, adjusting
Op nbr 468-051
Tools:
9993831 Support
11666013 Pump
Multimeter
The differential lock is located on the front axle's left side.
2.
Figure 1
1. 11668007 Standard Jack Single, 2 pcs.
Place two jacks under the jacking points in the front frame and raise the front axle so that both front wheels are off the ground
and can rotate freely. The wheels should rotate in opposite directions.
3.
Figure 2
1. Differential lock
2. Lock nut for sensor
3. Sensor SE4608
4. Brace
Remove the brace. Unplug the connector for the sensor. Loosen the sensor's lock nut.
4.
Figure 3
1. Multimeter
2. 9990008 Measuring equipment
3. Sensor
4. Lock nut
 Connect 9990008 Measuring equipment, the multimeter, and set it to ohm and sound.
 Turn in the sensor until it closes the power circuit, the multimeter generates a sound.
 Turn out the sensor 1/2 — 3/4 turn.
 Seal with sealant, e.g., Loctite 510 or silicone rubber RTV 5242.
 Tighten the lock nut without changing the setting. Tightening torque for differential lock switch, see: Front and rear
axles, tightening torque
5. Plug in the connector and install the protection.
6. Install the brace.
7.
Figure 4
Check the function.
 Check that there are no error codes.

 Turn on the main electric power with the battery disconnector.
 Start the machine.
 Activate the foot switch. The symbol for differential lock is shown on the instrument panel.
8. Lower the machine and remove the jacks.

Differential lock, function check
Op nbr 468-006
1. Run the machine straight ahead. Press down the foot switch for the differential lock and check that the symbol for differential
lock is shown on the display.
2. Turn sharply with the differential lock engaged. Both wheels should now rotate at the same speed. The machine moves
slowly.
3. Turn sharply without differential lock. Now the wheels should rotate at different speeds. When turning left, the left wheel
rotates slower than the right.
4. Alternative method for checking, see relevant steps in Differential lock, adjusting.
Door lock cylinder, replacing
Op nbr 834-013
Removing
1. Remove the panel from the inside of the door.
Figure 1
1. Panel
2. Disconnect the wire from the lock control.

Figure 2
1. Wire for door lock
3. Remove the plate on the inside of the door.
Figure 3
1. Plate
4. Remove the handle. Remove the nut. Remove the lock cylinder.
Figure 4
1. Nut
2. Lock cylinder
3. Handle
Installing
5. Install the new lock cylinder and assemble the handle.

Figure 5
1. Nut
2. Lock cylinder
3. Handle
6. Reinstall the handle in the door and the plate with the wire.
Figure 6
1. Plate
7. Hook the wire on the lock control.

Figure 7
1. Wire for door lock
8. Close and open the door a few times to make sure that the lock device works.
Adjust fore-aft with the handle as needed.
9. Reinstall the panel on the inside of the door.
Figure 8
1. Panel
Drive axle oil, changing
Op nbr 173-452
Front axle, draining
WARNING
Risk of burns!
Hot liquids and machine parts can cause burns.
Allow the machine to cool before beginning any service.
1. Place a collection container by the final drive (differential carrier assembly) and by each drain point by the hubs. Place V-
shaped metal plates or similar that can lead the oil from the hubs into the collection containers.
Remove the plugs, clean and check for any damage. Change the O-rings as needed.
Oil volume, see: Front and rear axles, volume
NOTE!
Handle the waste oil in an environment-friendly manner.
Figure 1
1. Drain plug, axle and hub
Rear axle, draining
WARNING
Risk of burns!
Hot liquids and machine parts can cause burns.
Allow the machine to cool before beginning any service.
2. Place a collection container by the final drive (differential carrier assembly) and by each drain point by the hubs. Place V-
shaped metal plates or similar that can lead the oil from the hubs into the collection containers. Remove the plugs. All 4 for
smoother draining!
Clean and check for any damage. Change the O-rings as needed.
NOTE!
Handle the waste oil in an environment-friendly manner.
Figure 2
1. Drain plug, axle and hub
Front axle, filling
3. Check the O-ring on the drain plugs.

Install the plugs for draining.
Fill oil up to the edge by the level plug.
Figure 3
1. Level plug and fill point
Rear axle, filling
4. Check the O-ring on the drain plugs.

Install the plugs for draining.
Fill oil up to the edge by the level plug.
Volume, see: Front and rear axles, volume
Figure 4
1. Level plug and fill point

E1706
Figure 1
E1711
E1711
Figure 1
E1711
E-2001
Figure 1
E-2005
Figure 1
E-tool 2005
1. Coupling nut 931206

2. Test nipple 11054368 Thread R1/4"
3. Nipple 929315
E-2014
Figure 1
E-2015
Figure 1
E-2017
Figure 1
ECM (Engine control module), replacing non-programmed
Op nbr 200-067
Tools:
88890300 Interface
88890305 Cable
88890253 Cable

Connect Tech Tool and start operation 17093-3 Program with stored software
Figure 1
1. ECM
2. ACM
5. Unplug the connectors from the ECM.
6. Change the ECM.
7. Plug in the connectors for the ECM.

ECM (Engine control module), replacing non-programmed
Op nbr 200-067
Tools:
88890300 Interface
88890305 Cable
88890253 Cable

Connect Tech Tool and start operation 17093-3 Program with stored software

Figure 1
1. ECM
2. ACM
5. Unplug the connectors from the ECM.
6. Change the ECM.
7. Plug in the connectors for the ECM.
ECM (Engine control module), replacing pre-programmed
Op nbr 200-066
Tools:
88890300 Interface
88890305 Cable
88890253 Cable
2. The new control unit has basic set parameters for the machine. Connect Tech Tool and read out customer parameters with
the operation 17030-3 Parameter, programming. If it is possible to read out customer parameters from the old machine, save
them on the job card.
Figure 1
1. ECM
2. ACM
5. Unplug the connectors from the ECM and disconnect the cable clamps.
6. Replace the ECM.
7. Plug in the connectors for the E-ECU and install the cable harness clamps.
10. If customer parameters have been read out from the old control unit, compare these to the parameters in the new control
unit.
 Connect Tech Tool and run the operation 17030-3 Parameter, programming. Save all read parameters to job card.
 Compare parameter settings on the job cards.
 Perform operation 17030-3 Parameter, programming and change customer parameters according to job card for the
old control unit.
11. Start the machine and check that no error messages are displayed.

EGR cooler, replacing
Op nbr 293-001
 Service position 1, Service position

2. Drain the engine coolant, see Coolant, changing.
3. Remove the charge air pipe.
Figure 1
4. Remove the oil hose from the turbocharger.
Figure 2
1. Oil hose
5. Remove the insulation. Disconnect the coolant pipes from the EGR cooler.
Disconnect the venturi tube from the EGR cooler.
Figure 3
1. Venturi tube
2. Coolant pipes
6. Part the connector from the EGR actuator.
Figure 4
1. Connector
7. Remove the EGR cooler (4 bolts).
Figure 5
EGR cooler
8. Remove the EGR valve and actuator from the old EGR cooler and install it on the new EGR cooler.
Remove the reed valve (non-return valve) from the EGR cooler and install it on the new EGR cooler.
NOTE!
Clean all contact surfaces and use new gaskets.
Tightening torques, see EGR system, tightening torques.
Figure 6
1. Reed valve (non-return valve)

2. EGR valve and actuator
9. Install the EGR cooler on the engine. Tightening torques, see EGR system, tightening torques.
NOTE!
Use new connection pipes (seals)
Figure 7
EGR cooler
10. Connect the connector to the EGR actuator.
Figure 8
1. Connector
11. Connect the coolant pipes to the EGR cooler.

Connect the venturi tube to the EGR cooler.
NOTE!
Use new gasket
Tightening torque, see EGR system, tightening torques.
Figure 9
1. Venturi tube
2. Coolant pipes
12. Install the oil hose on the turbocharger. Tightening torque, see Inlet and exhaust system, tightening torques.
Figure 10
1. Oil hose
13. Install the charge air pipe.
Figure 11
14. Fill coolant, see Coolant, changing

EGR reed valve, replacing
Op nbr 293-009
1. Place the machine in service position 1, seeService position.
Figure 1
3. Remove the EGR venturi tube attaching bolts (3 pcs).
Figure 2
1. Venturi tube
2. EGR reed valve (non-return valve)
4. Remove the EGR reed valve (non-return valve) from the EGR cooler.
Figure 3
EGR reed valve (non-return valve)
5. Remove the reed valve flaps from the cover.

Clean all contact surfaces where the reed valve is to be installed.
Install the new reed valve flaps in the cover.
Figure 4
1. Reed valve flaps
6. Install the EGR reed valve on the EGR cooler.
7. Install the venturi tube using a new gasket. Tightening torque, see EGR system, tightening torques.
Figure 5
EGR valve, replacing
Op nbr 293-005
NOTE!
The EGR valve and actuator must be replaced together. Never mix components from different machines.
NOTE!
It is very important that the battery disconnector (main switch) is off during the entire operation.
2. Drain the coolant according to Coolant, changing.
3. Part the EGR actuator connector.
Figure 1
1. EGR valve
2. EGR actuator
3. EGR actuator connector
4. Remove the EGR valve and actuator from the EGR cooler.
Figure 2
EGR valve and actuator
5. Clean all mounting surfaces and install the new EGR valve and atuator on the EGR cooler with a new gasket.
6. Fill the coolant according to Coolant, changing.

EGR venturi tube, cleaning
Op nbr 293-013
Figure 1
3. Part the connectors to the temperature and pressure sensor.
Figure 2
Connectors
4. Remove the clamp and the hose from the venturi tube.
Figure 3
1. Clamp
5. Remove the venturi tube (3 bolts).

Figure 4
6. Remove the pressure— and temperature sensors.
Figure 5
7. Clean the parts carefully with a soft bristle brush and a suitable cleaning agent.
Figure 6
8. Install the sensors and install the venturi tube. Tightening torques, see EGR system, tightening torques.
NOTE!
Use new gasket
9. Install the hose on the venturi pipe and install the hose clamp.
10. Connect the connectors to the temperature and pressure sensor.

EGR Venturi tube, replacing
Op nbr 293-010
Figure 1
3. Part the connectors to the temperature and pressure sensor.
Figure 2
Connectors
4. Remove the clamp and the hose from the venturi tube.
Figure 3
1. Clamp
5. Remove the venturi tube (3 bolts).

Figure 4
Venturi tube
6. Transfer the pressure and temperature sensors to the new venturi tube. Tightening torques, see EGR system, tightening
torques.
Figure 5
Pressure and temperature sensor
7. Install the venturi tube. Tightening torques, see EGR system, tightening torques.
NOTE!
Use new gasket
Figure 6
Venturi tube
8. Install the hose on the venturi and the hose clamp.

Figure 7
1. Clamp
9. Connect the connectors to the temperature and pressure sensor.
Figure 8
Temperature and pressure sensor
Figure 9
Electric door opener, control unit, replacing
Op nbr 831-054
1. Remove the panel on the inside of the door.
2. Remove the cable ties that hold the four connectors.
Figure 1
1. Connectors, of which one is hidden.

2. Bolt, 2 pcs.
3. Control unit
3. Unplug the connectors.
4. Remove the bolts and the control unit.
5. Install the new control unit and the bolts.
6. Plug in the connectors and fasten with cable ties.
8. Install the door panel.

Electric door opener, locking motor, replacing
Op nbr 831-055
2. Remove the cable ties that hold the connectors.
Figure 1

2. Bolt, 2 pcs.
3. Control unit
4. Lock motor
3. Unplug the connector for the lock motor.
4. Remove the wire from the lock motor. Remove the bolts and the lock motor.
5. Install the lock motor and the control unit with the bolts. Install the wire in the lock motor.
6. Plug in the connector and fasten with cable ties.

Electric door opener, opening support motor, replacing
Op nbr 831-057
2. Remove the cable ties that hold the connectors.
Figure 1

2. Bolt, 2 pcs.
3. Control unit
4. Lock motor
5. Door motor
3. Unplug the connector.
4. Remove the wire from the lock motor. Remove the bolts, control unit, lock motor, and the door motor.
5. Install the door motor in the lock mechanism.
6. Install the lock motor and the control unit with the bolts. Install the wire in the lock motor.
7. Plug in the connector and fasten with cable ties.

Electric door opener, rotor switch, replacing
Op nbr 831-056
2. Remove the cable ties and unplug the connector for the switch.
Remove the switch.
Figure 1
1. Switch
2. Connector
3. Install the switch and plug in the connector. Install new cable ties.

Engine air cleaner primary filter, replacing
Op nbr 173-403

Clean the cover as well since it acts as a reservoir for the particles that are not trapped in the filter.
Figure 1
1. Cover
2. Remove the primary filter.

NOTE!
Check the interval to see if the secondary filter also needs to be changed.
NOTE!
Handle the filter in an environment-friendly and safe manner.
Figure 2
1. Primary filter
3. Install the primary filter.

Check that all hose and pipe connections from the air cleaner to the engine's induction manifold seal tight and that they are
not damaged.
Engine air cleaner secondary filter, replacing
Op nbr 173-404
1. Change the secondary filter.

NOTE!
Handle the old used filter in an environment-friendly and safe manner.
Figure 1
1. Secondary filter
Engine belt condition, checking
Op nbr 173-630
1. Remove the left plastic casing first, then the one on the right side.
Figure 1
1. Plastic casing, left side

2. Plastic casing, right side
2. Check that the belts are tensioned and that there are no cracks.
Figure 2
1. Drive belt for coolant pump

2. Drive belt for AC-compressor
3. Install the right plastic casing first, then the left casing.
Engine belts, replacing
Op nbr 200-200
1. Place the machine in service position according to Service position.
2. Remove the plastic covers.
Figure 1
1. Cover, left side

2. Cover, right side
3. Remove the AC-belt and the alternator belt.

Figure 2
AC-belt
1. Adjustment screw and lock nut
Figure 3
Alternator belt
1. Alternator belt tensioner
4. Install new alternator belt and AC-belt.
5. Install the plastic covers.

Engine hood, installing
Op nbr 821-002
Tools:
Sling 0.5 m, 1 pc.
Sling 1 m, 1 pc.
Sling 2 m, 2 pcs.
Ratchet block, 750 kg (1,653 lbs)
1. Connect sling and ratchet block as follows:
 Secure the 2 metre sling in the handles on both sides of the hood and connect them to the lifting device.
 Secure the 0.5 metre sling to the hood's hinges and connect it to the ratchet block.
 Secure the 1 metre sling to the ratchet block and connect it to the lifting device.
Engine hood, weight: 180 kg (397 lbs)
Figure 1
1. Sling 0.5 m, 1 pc.

2. Ratchet block
3. Sling 1 m, 1 pc.
4. Sling 2 m, 2 pcs.
2. Lift the hood into position and lower it straight down. If needed, adjust the hood's position with the ratchet block.
Figure 2
1. Connector for work lights
3. Install the bolts on the hood mounting.
Figure 3
1. Bolts on hood mounting
4. Remove the ratchet block, sling 0.5 m, and sling 1 m.
5. Lift the hood with the remaining lifting equipment so that there is space to install the actuator.
6. Install the pin for the upper actuator bracket and install the lock bolt.
Figure 4
1. Lock bolt
2. Pin
7. Remove the lifting device and lift the hood with the actuator.
8. Plug in the connector for the work lights.
9. If the machine is equipped with back-up camera (rear vision camera):

Insert the camera cable for the back-up camera. Plug in the connector and install cable ties around the camera cable. Install
the plastic cover for the connectors on the cab wall.
Figure 5
1. Plastic cover for connectors

2. Cover over relays in cab
10. Test-run the hood's movements.

Engine hood, removing
Op nbr 821-001
Tools:
Sling 0.5 m, 1 pc.
Sling 1 m, 1 pc.
Sling 2 m, 2 pcs.
Ratchet block, 750 kg (1,653 lbs)
1. Open the cover over the hydraulic tank.
2. If the machine is equipped with back-up camera (rear vision camera):

Remove the plastic cover for the connectors on the cab wall. Unplug the connector, loosen the cable tie, and pull out the
camera cable.
Figure 1
1. Plastic cover for connectors

2. Cover over relays in cab
Figure 2
1. Connector for back-up camera
3. Run up the hood so that the upper pin on the actuator can be reached.
4. Connect sling and ratchet block as follows:
 Secure the 2 metre sling in the handles on both sides of the hood and connect them to the lifting device.
 Secure the 0.5 metre sling to the hood's hinges and connect it to the ratchet block.
 Secure the 1 metre sling to the ratchet block and connect it to the lifting device.
Engine hood, weight: 180 kg (397 lbs)
Figure 3
1. Sling 0.5 m
2. Ratchet block
3. Sling 1 m
4. Sling 2 m, 2 pcs.
5. Actuator
5. Disconnect the actuator by removing the lock bolt for the pin for the upper actuator bracket, then remove the pin Lay down
the actuator on the air cleaner.
Figure 4
1. Lock bolt
2. Pin
6. Remove the bolts on the hood mounting.

Figure 5
1. Bolts on hood mounting
7. Carefully lift up the hood and unplug the connector for the work lights.
Figure 6
1. Connector for work lights
8. Lift the hood straight up and set it down on axle stands (3 pcs.).
Figure 7
Hood on axle stands (3 pcs.)
Engine oil and filter, changing
Op nbr 173-401
NOTE!
Take care of filters, oils and liquids in an environmentally safe way.
1. The oil should be drained from the machine when it is at operating temperature.
Loosen the cap for the oil filter, for draining.
Place a suitable container under the machine.
Figure 1
1. Oil filter
2. Connect the drain hose and drain the oil.

Volume, see: Engine, fill quantities
Figure 2
1. Drain point
3. Remove the oil filter.

Smear new engine oil on the new O-ring on the cap. Install the oil filter.
Tighten the filter according to the instructions on the filter.
4. Fill engine oil.

Volume, see: Engine, fill quantities.
5. Check the level on the oil dipstick. The level should be just below Max. on a machine that is at operating temperature.
Top up with engine oil when needed.
Figure 3
1. Oil dipstick
2. Oil fill point
Engine oil level, checking
Op nbr 173-628
1. On a cold machine the oil level should be between Max. and Min. on the oil dipstick.
Figure 1
1. Oil dipstick
2. Fill point
Engine pre cleaner cyclone type, cleaning
Op nbr 173-503
1. Remove the precleaner.
Figure 1
1. Air intake pipe

2. Precleaner
2. Blow clean with compressed air inside the air precleaner.
3. Insert your hand and check that the rotor spins freely.
4. Reinstall the precleaner.

Error codes when calibrating
The following error codes can be detected by GPMECU3 and displayed in Tech Tool when the operation 42101-3 Transmission,
calibration is performed.
The error codes originates from two areas:
 Error code, calibration

 Error code, adaptive reset
Error code, calibration
Error Description Recommended actions

code Text within “ ” is an explanation for the text
shown in Tech Tool
8 Another internal function is already
executing 1. Restart the operation up to two times.
2. Restart the machine.
“Another calibration or test function is
3. Before proceeding with the next step contact Product Support
already activated and running”
regarding machine software problem.
4. Reprogram the GPMECU3.
5. Change the control unit.
9 Invalid input data to the internal function

1. Restart the operation up to two times.
“Faulty data sent by Tech Tool or the
control unit”
3. Test with another Tech Tool computer.
regarding Tech Tool problem.
10 Function not defined in the control unit

“Faulty parameter settings or internal error
in the GPMECU3”
5. Change the control unit If the fault is repeated.
77 Engine speed too high

 Make sure that the accelerator pedal is not pressed and the hand
throttle is not activated.
78 Erroneous actuator or sensor

 Read DTCs to identify the faulty component. See Hydraulic
transmission calibration, description for relevant components.
89 Internal Error
99 Engine not running

 Start the engine.
100 Parking brake not applied

 Apply the parking brake.
101 Gear lever not in neutral
 Place the gear in neutral position.
102 Transmission oil temperature out of range

 Let the transmission oil reach correct temperature.
103 Brake pedal not pressed

 Press the brake pedal.
104 Max.. fill time reached for clutch F

1. Check clutch F solenoid valve, see PWM4213 - PWM4218,
“The time for moving the clutch piston to
description and measuring or Tech Tool operation 42111-3 Clutch
get in contact with the clutch is above the
Forward, Solenoid valve, test.
maximum limit”
2. Check transmission turbine speed sensor, see SE4213,
description and measuring.
105 Max. fill time reached for clutch R

1. Check clutch R solenoid valve, see PWM4213 - PWM4218,
Reverse, Solenoid valve, test.
maximum limit”
106 Max. fill time reached for clutch 1

1. Check clutch 1 solenoid valve, see PWM4213 - PWM4218,
1, solenoid valve, test.
maximum limit”

maximum limit”

maximum limit”

4, solenoid valve, test .
maximum limit”
110 Min. fill time reached for clutch F

get in contact with the clutch is below the
minimum limit”
111 Min. fill time reached for clutch R

minimum limit”
112 Min. fill time reached for clutch 1

minimum limit”

minimum limit”

minimum limit”

minimum limit”
116 Max. spring pressure reached for clutch F

“The pressure needed for engaging the
clutch is above the maximum limit”
117 Max. spring pressure reached for clutch R

118 Max. spring pressure reached for clutch 1



122 Min. spring pressure reached for clutch F

clutch is below the minimum limit”
123 Min. spring pressure reached for clutch R

124 Min. spring pressure reached for clutch 1




Error code, adaptive reset
Error Description Recommended actions

code Text within “ ” is an explanation for the text
shown in Tech Tool
8 Another internal function is already
executing 1. Report the problem to Product Support.
2. Use the machine as usual. The gear shifting will be adapted to the
driving style, but it will take longer time than it would if the internal
function had ended successfully.

1. Report the problem to Product Support.
89 Internal Error
1. Report the problem to Product Support.
Error codes when calibrating
The following error codes can be displayed in Tech Tool when calibrating the CDC (Comfort Drive Control). The error codes are
divided into two different types of codes:
 Message — These messages are detected by Tech Tool.

 Error codes — These codes are detected by the GPMECU2 (General Purpose Machine Electronic Control Unit 2).
Message
Message code Description Recommended check/action

510 Steering speed is higher in calibration step 2 than in step 1
(steering right and left).
 Steer the machine to the left and right a few times. 2. Check the PWM-valve for the function in
 Select Continue to resume the operation or select question.
Cancel to cancel it. 3. Check the angle sensor and linkage.
511 The steering speed to the left is higher in calibration step 2

than in step 1. 1. Restart the operation up to two times.
2. Check the PWM-valve for the function in
 Steer the machine to the left and right a few times. question.
 Select Continue” to resume the operation or select 3. Check the angle sensor and linkage.
Cancel to cancel it.
512 Steering speed to the right is higher in calibration step 2

than in step 1. 1. Restart the operation up to two times.
2. Check the PWM-valve for the function in
 Steer the machine to the left and right a few times. question.
 Select Continue” to resume the operation or select 3. Check the angle sensor and linkage.
513 Steering speed to the left is higher in calibration step 3 than

in step 1. The tool will reduce the current to decrease the 1. The tool will reduce the current to reach
speed in step 3. permitted speed, therefore the calibration
step must be repeated several times until
 Select Continue” to resume the operation or select the calibration is finished.
514 Steering speed to the right is higher in calibration step 3

than in step 1. 1. The tool will reduce the current to reach
permitted speed, therefore the calibration
 Select Continue” to resume the operation or select step must be repeated several times until
Cancel to cancel it. the calibration is finished.
Error codes
Error code Description Recommended check/action

Text within quotation marks “” is the explanation
of the text shown in Tech Tool
8 Another internal function is already executing.
“Another calibration function already in progress.” 1. Restart the operation up to two times.
3. Before continuing with the next step:
Contact your local product support..
5. Replace the GPMECU2, see GPMECU2,
changing pre-programmed ECU or
GPMECU2, changing non-programmed
ECU.
9 Invalid input data to the internal function
“Faulty data sent by Tech Tool or the control unit” 1. Restart the operation up to two times.
3. Test with another Tech Tool computer.
Contact your local product support..
ECU.

“Faulty parameter settings or internal error in the 1. Restart the operation up to two times.
GPMECU2” 2. Restart the machine.
3. Check parameters for the calibrated
function in question.
4. Install the function and restart the
operation.
Contact your local product support.
7. Replace the GPMECU2 if the malfunction
is repeated, see GPMECU2, changing pre-
programmed ECU or GPMECU2, changing
non-programmed ECU.
80 All levers not in neutral position at the start of the

operation step. 1. Check that the lever is in neutral position.
81 The lever was not moved within 30 seconds.

1. Move the lever to the end-position within
30 seconds.
82 The lever was moved in the wrong direction.

1. Move the lever in the correct direction.
83 The lever was released during ongoing operation.

1. Hold the lever against the end-position,
and release it when you have been
instructed to do so.
84 Erroneous lever sensor

1. Check the lever and cable harness for the
function in question, see SE6601,
86 Internal Error. Unable to take hydraulic control

Contact your local product support. with
regards to Tech Tool problem.
ECU.
88 No hydraulic response, start current exceeds max

value. 1. Check the PWM-valve for the function in
“Malfunction/defect in the hydraulic system that question.
causes too low or no angle change” 2. Check the sensor linkage and cable
harness for the function in question, see
SE6411, description and measuring.
3. Check main control slide and spring for the
89 Internal Error
3. Before continuing with the next step.
Contact your local product support.
5. Change the GPMECU2, see GPMECU2,
ECU.
90 Erroneous steering angle sensor

1. Check the angle sensor, angle sensor
linkage, and cable harness for the function
in question, see SE6411, description and
measuring.
96 Angle change before min current

“Malfunction/defect in the hydraulic system that 1. Check PWM-valve for the function in
causes too early angle change” question.
2. Check the angle sensor, angle sensor
linkage, and cable harness for the function
in question, see SE6411, description and
measuring.
3. Check main control slide and spring for the
Evaporator, replacing
Op nbr 874-024
Tools:
88830256 Draining tool
88830250 Refrigerant unit
9812446 Nipple
88830260 Adapter
9511207 Leak detector AC
1161629 PAG-oil
 Draining refrigerant
 Refrigerant, filling incl vacuum pumping
 Leak detector 951 1207, new model
 Air conditioning, checking performance
WARNING
Aggressive oil. Avoid contact to bare skin. Use protective gloves.
Removing
3. Drain the system of refrigerant, see Draining refrigerant.
Figure 1
Connection point for blue hose
4. Remove the filter casing with the main filter as well as the filter by turning the plastic fasteners.
Figure 2
1. Plastic fastener
2. Filter
3. Filter casing
5. Remove the filter holder and unplug connector MO8703 for the air mixing damper's motor.
Figure 3
1. Filter holder
6. Remove the plate located to the right above the evaporator.
Figure 4
1. Plate
7. Remove the bolt for the AC-hoses' rubber bushing.
Figure 5
1. Bolt
2. Drain hoses
8. Swing out the evaporator and move it aside.
Figure 6
Evaporator
9. Remove the expansion valve and the evaporator. Install new O-rings between the evaporator and the expansion valve. Lube
the O-rings with 1161629 PAG-oil. Install a rubber seal around the expansion valve.
Figure 7
1. Bolts
Installing
10. Install the evaporator and the bolt for the AC-hoses' rubber bushing.
Figure 8
1. Evaporator
2. Bolt
3. Drain hoses
11. Install the plate to the right of the evaporator.
Figure 9
1. Plate
Figure 10
1. Filter holder
2. Connector MO8703
3. Retaining strap
13. Reinstall the filter casing with the main filter as well as the filter and turn back the plastic fasteners.
Figure 11
1. Plastic fastener
2. Filter
3. Filter casing
14. Vacuum-pump and fill the system with refrigerant, see Refrigerant, filling incl vacuum pumping.
NOTE!
If the AC-system has been open for more than 10 minutes, the receiver drier must be replaced, see Receiver, replacing incl
draining and filling.
Figure 12
Connection point for blue and red hose
15. Check for leaks in the area around the compressor, see Leak detector 951 1207, new model.
16. Close the cover for the AC-system (air conditioning).
17. Check the AC-system (air conditioning), see Air conditioning, checking performance.

Exhaust pipe, flexible tube, replacing
Op nbr 252-021
Tools:
88830214 Fixture
1. Place the machine in service position 1, see: Service positions.
3. Loosen the clamps that hold the pipes before and after the flexible tube.
4. Remove the flexible tube.
5. Install 88830214 Fixture and adjust the muffler and the pipes before and after the flexible tube so that the tool fits perfectly.
Figure 1
1. 88830214 Fixture
NOTE!
Check at four spots on the pipe both before and after that the flexible pipe has contact with the fixture.
Figure 2
6. Tighten the clamps that hold the pipes before and after the flexible tube.
Tightening torques, see Inlet and exhaust system, tightening torques.
NOTE!
Make sure that the clamps are centred on the flanges. Tap carefully with a plastic hammer on the clamps if necessary.
7. Remove the fixture.

8. Replace the gaskets and the clamps and install the flexible tube.
9. Start the engine and check for leakage.

Expansion valve, replacing
Op nbr 874-025
Tools:
9812446 Nipple
88830260 Adapter
This operation also includes tools and times necessary for applicable parts of the following actions:
 Draining refrigerant
 Refrigerant, filling incl vacuum pumping
 Leak detector 951 1207, new model
 Air conditioning, checking performance
Removing
1. Place the machine in service position 1, seeService position.
3. Drain the system of refrigerant, see Draining refrigerant.
Figure 1
Connection point for blue hose
4. Remove the prefilter, metal strip, and the main filter.

Figure 2
1. Filter casing
2. Filter
5. Remove the cover plate and unplug the connector MO8703 for the air mixing damper's motor.
Figure 3
1. Cover plate
2. Connector MO8703
6. Remove the plate located to the right above the evaporator.
Figure 4
1. Plate
7. Remove the bolt for the AC-hoses' rubber bushing.
Figure 5
1. Bolt
2. Drain hoses
8. Swing out the evaporator and lay it down carefully on a soft surface.
9. Remove the hoses from the expansion valve.
Figure 6
1. Hoses
10. Remove the evaporator.
11. Remove the foam rubber around the expansion valve so that the bolts for the plate can be reached. Remove the plate.
Figure 7
1. Bolts for plate
12. Move the black rubber a little.
Figure 8
1. Rubber
13. Remove the expansion valve from the pipes.
Figure 9
1. Bolts
Installing
14. Install new O-rings on the connecting pipes. Lube the O-rings with 1161629 PAG-oil.
Figure 10
1. O-rings, 2 pcs.
15. Install the new expansion valve.
Figure 11
1. Bolts
16. Move the rubber back in place.
Figure 12
1. Rubber
17. Install the plate.

Figure 13
1. Bolts for plate
18. Use adhesive (glue) to reinstall the foam rubber
19. Lift back the evaporator to the machine and install the AC-hoses. Install new O-rings on the expansion valve. Lube the O-
rings with 1161629 PAG-oil.
20. Install the evaporator in the climate system.
21. Install the bolt for the AC-hoses' rubber bushing.
Figure 14
1. Bolt
2. Drain hoses
22. Bolt on the right plate on the evaporator.
Figure 15
1. Plate
23. Plug in connector MO8703 for the air mixing damper's motor. Install the cover plate and the retaining strap for the cover.
NOTE!
Install the retaining strap for the plastic casing with one of the bolts for the cover plate.
Figure 16
1. Filter holder
2. Connector MO8703
3. Retaining strap
24. Vacuum-pump and fill the system with refrigerant, see Refrigerant, filling incl vacuum pumping.
NOTE!
If the AC-system has been open for more than 10 minutes, the receiver drier must be replaced, see Drying filter, replacing.
Figure 17
Connection point for blue and red hose
25. Check for leaks in the area around the expansion valve, see Leak detector 951 1207, new model.
26. Install the main filter, metal strip, and the prefilter.
Figure 18
1. Plastic fastener
2. Filter
3. Filter casing
27. Close the cover for the AC-system (air conditioning).
28. Run a performance test, see Air conditioning, checking performance.

Fan motor, replacing
Op nbr 873-006
1. Remove the air conditioning from the machine in accordance with Climate unit, removing and place it on a table.
2. Remove the hose between the heater unit and heater valve.
3. Dismantle the housing by removing all clips
Figure 1
1. Clips
4. Remove the bolt holding the cables to the fan motor
Figure 2
1. Bolt for fan motor cables
5. Lift out the fan motor and replace it.

Figure 3
1. Fan motor
6. Affix the cables to the fan motor
7. Refit the cover and affix all clips. Fit the hose for the heater valve.
NOTE!
Check that the fan is fitted in the correct position.
8. Refit the climate unit in accordance with: Climate unit, installing

Feed pump, checking feed pressure
Op nbr 233-004
Tools:
1. Place the machine in service position 1, see, Service position.
2. Remove the plug and connect 936444 Testing nipple and 88830213 Measuring equipment the fuel filter housing.
Figure 1

2. 936444 Testing nipple
3. Make sure that the gear selector is in neutral position.

Start the engine and check the feed pressure.
Feed pressure, see Fuel system, specifications.
4. Remove the tools and install the plug. Restore the machine to operating condition.
Fire suppression system, actions after activation
Op nbr 992-002
Tools:
88830136 Test unit
88830252 Scale
16878117 Test unit
Nipple E-2005
NOTE!
If the system was activated using the manual actuator under the cab steps, seeFire suppression system, actions after manual
activation
Activation from control panel (CU9903) or emergency stop (SW3102):
Figure 1
1. Emergency stop (SW3102)

2. Control panel (CU9903)
1. Place the machine in Service position 1 according to Service position
2. Unplug the squib cable (MA9903)

Figure 2

2. Extinguishing agent tank
3. To check the cause of automatic system activation, connect 16878117 Test unit .
Remove the cover on the control unit.
Figure 3
1. Diagnostic tool
2. Light-emitting diodes
4. Connect 16878117 Test unit

NOTE!
Indication takes place automatically. Do not press the grey button.
5. Read off explanations for the causes of the different activations on 16878117 Test unit.
Figure 4
1. 16878117 Test unit
6. After establishing the cause of activation, reset the built-in memory.

Press the grey button on 16878117 Test unit to reset the system.
Figure 5
1. 16878117 Test unit

2. Button for resetting system
7. Remove 16878117 Test unit.
8. Replace the 9 volt battery with a new one of the same type. Run a battery test by pressing the red test-button which is
located at the top in the middle of the circuit board.
Figure 6

2. Test-button
9. Reinstall the cover on the control unit.
Cleaning engine compartment and sprinkler circuit
10. Rinse clean the engine compartment with water.
11. Disconnect the hose at the top on the tank. Plug hose and tank.
Figure 7
1. Extinguishing agent hose
12. Remove the coupling from the tank and clean.

Figure 8
Coupling
13. Connect nipple E-2005 to the outlet hose.
Figure 9
Water connection
1. Nipple E-2005
2. Outlet hose
14. To enable checking that the protective cap is in place on the nozzle under the cab floor, the operator's seat must be folded
forward and secured, and the rear floor plate must be removed.
Fold forward the operator's seat and secure it according: Operator's seat, securing
15. Rinse clean the sprinkler circuit with water. Check that water comes out from all nozzles.
Figure 10
Nozzle
16. Connect compressed air to the outlet hose.
17. Blow clean in the sprinkler circuit with dry compressed air for approx. 30 seconds until no fluid comes out from the nozzles.
18. Install the protective caps on the nozzles. 15 pcs.
Repairing and restoring
19. Visual check to find damaged area.
20. Repair any equipment that has been damaged by fire.
21. Check if the detector circuit is damaged as follows:
22. Connect 88830136 Test unit cables to the control unit as follows:
 Blue connector from test unit to the control unit's connection

 Blue connector from test unit to the detector cable's connection in the control unit
 Black connector from test unit to the gas generator cable's connection
Figure 11
1. Connector from test unit to gas generator's connection

2. 16878117 Test unit
3. Connector between test unit and control unit's connection
4. Connector from test unit to detector cable's connection
5. Control unit
23. Connect a multimeter to 88830136 Test unit and measure the resistance in the detector circuit. Resistance should be 2.8 ±
0.5 kΩ.
Figure 12
1. Multimeter
2. 88830136 Test unit
24. In case of damaged detector circuit. Replace the detector circuit as follows:
25. Remove the damaged detector circuit.
26. Install the new detector circuit.
27. Fasten the detector circuit to the sprinkler circuit with cable ties every 80–180 mm (3.5–7.1 inch). Install a short rubber hose
on the detector circuit as protection against rubbing and chafing.
NOTE!
NOTE! The detector circuit should not be bent tighter than with a radius of 50 mm. (1.97 inch)
Figure 13
Detector circuit
28. Reinstall the rear floor plate in the cab, fold back the operator's seat, install the front floor plate, and the mat.
Filling tank
29. Remove the defective outlet plate (burst disc).
Figure 14
Outlet plate (burst disc)
30. Remove the bracket for siren (SA9901) and strobe light (LA9901) on the tank.
31. Disconnect the propellant gas hose at the bottom of the tanks.
Figure 15
32. Unplug the connector and remove the gas generator cable (squib cable) (MA9903) for the propellant gas cartridge.
33. Expose the propellant gas cartridge and the pneumatic actuator by loosening the hoses and clamps. Spin off (thread) the
propellant gas cylinder from the pneumatic actuator and install the protective nut.
Figure 16
34. Dismantle the pneumatic actuator. Clean and lube the gaskets with vaseline.
Figure 17
Pneumatic actuator
1. Actuator
2. Spring
3. Pin
4. Housing
35. Assemble the trigger device. Torque 50 Nm
36. Check the pin's level. The measurement shall be in line with the sliding calipers +/- 1 mm (0.04 in) from the edge of the
pneumatic actuator.
Figure 18
37. Use a rag to clean the tank from all loose materials.
38. Press back the piston to original position with compressed air. Seal with a rag and press down the piston to the bottom. A
distinct sound is heard when it reaches the bottom.
Figure 19
39. Measure the distance from the bottom of the tank to the upper edge to make sure that the piston has reached the bottom.
Length 559± 2 mm. ( 22.0 ±0.08 in)
Figure 20
40. Check the tank for any serious damage. Scratches and minor dents are acceptable. In case of major damage, the tank shall
be replaced in order to not risk the piston's movement in the tank.
41. Install a hose on the funnel and insert the hose down into the tank. Recommended hose diameter Ø 12 mm (0.47 in). Fill the
tank with the correct amount of extinguishing fluid according to Fire suppression system, specification. Fill the tank slowly
since the fluid foams very easily.
NOTE!
The tank should be 100% full of extinguishing agent.
Figure 21
42. Install a new outlet plate (burst disc), installed with the convex side facing up.
Figure 22
Figure 23
43. Tighten down the coupling and torque-tighten. Torque 40 Nm
44. Install a decal that states the date for refilling of the tank
45. Install the tank.
WARNING
46. Check that the new propellant gas cartridge is pressurized by weighing it. Correct weight is stated on the label. Max.
deviation from the weight is -14 grams. The plug's weight should be added to the stated weight. The plug weighs 20 grams.
NOTE!
The plug should be on the propellant gas cartridge when weighing.
Figure 24
Propellant gas cartridge
1. Plug 88830138
NOTE!
Use a scale that shows accuracy in grams (oz.)
WARNING
The tube of propellent gas must not be handled loosely with connected power.
47. Connect the hose to the manual actuator.

Figure 25
1. Connection to gas generator cable

2. Connection to manual activation device.
3. Connection to tank
48. Connect the propellant gas hose at the bottom of the tank.
Figure 26
WARNING
49. Install the new pressurized propellant gas cartridge.
Figure 27
50. Install the bracket for siren (SA9901) and strobe light (LA9901) on the tank.
51. Connect the hose at the top on the tank.

Figure 28
1. Hose connection
Function check
52. Unplug the connector for the gas generator cable (squib cable) (MA9903). The following light-emitting diodes are activated on
the control panel:
 Green “On”
 Yellow “Fault actuator” lights up
Figure 29

53. Remove the detector cable connection on the control unit (blue connector). The following light-emitting diodes are activated
on the control panel.
 Green “On”
 Yellow “Fault actuator”
 Yellow “Fault detector” lights up
Figure 30

2. Detector cable
 Blue connector from test unit to the control unit's connection

Figure 31

2. 88830136 Test unit
4. Connector from test unit and detector cable's connection
5. Control unit
55. After connecting 88830136 Test unit only the green light-emitting diode is activated On on the control panel. (CU9903)
56. Press the button on 88830136 Test unit for at least 1 second to check the function of the system for siren (SA9901) and
strobe light (LA9901). The siren sounds. The strobe light flashes. One of the two red light-emitting diodes on 88830136 Test
unit flashes approx. 6 times. The following light-emitting diodes are activated on the control panel:
 Green On”
 Red Fire alarm flashes
57. Press the (Test) / Reset button for at least 1 second on the control panel (CU9903) to reset. All light-emitting diodes on the
control panel are activated.
Figure 32
1. Manual release (activation)

2. Fire alarm
3. Fault actuator
4. Fault detector
5. Manual
6. On
7. Test/Reset
0.5 kΩ.
Figure 33
1. Multimeter
2. Test unit
59. Disconnect 88830136 Test unit according to the following:
1. Disconnect blue cable from the control unit. Light-emitting diode Fault detector lights up on the control panel.
2. Disconnect the cable for the gas generator cable (squib cable). Light-emitting diode Fault actuator lights up on the
control panel.
60. When all cables have been disconnected from88830136 Test unit the following light-emitting diodes are activated on the
control panel:
 Yellow Fault actuator

 Fault detector
61. Plug in the detector cable (blue connector) on the control unit. Connect the gas generator cable (squib cable) (MA9903).
Green light-emitting diode is activated On.
Figure 34

Figure 35
1. Detector cable (blue)
62. Press the Test/ Reset) button for at least 1 second on the control panel to reset. All light-emitting diodes on the control panel
are activated.
Figure 36
1. Test-button
63. Change and replace any defective labels.
64. Fill in the service protocol according to VOE 12A1005996. Attach a signed copy for the customer.
Fire suppression system, actions after manual activation
Op nbr 992-003
Tools:
88830136 Test unit
16878117 Test unit
88830252 Scale
Nipple E-2005
NOTE!
If the system has been activated from the control panel (CU9903) or the emergency stop (SW3102), see Fire suppression system,
actions after activation
Activating with manual actuator (manual activation button) under cab steps:
Figure 1
Manual actuator

3. Tamper seal
1. Place the machine in service position 1 according to Service position
2. Unplug the gas generator cable (squib cable) (MA9903).

Figure 2

3. To check the cause of system activation, connect 16878117 Test unit .

Remove the cover on the control unit.
4. Connect 16878117 Test unit

NOTE!
Indication takes place automatically. Do not press the grey button.
Figure 3
1. 16878117 Test unit

2. Light-emitting diodes
5. Read off explanations for the causes of the different activations on 16878117 Test unit.
Figure 4
1. 16878117 Test unit
6. After establishing the cause of activation, reset the built-in memory.

Press the grey button on 16878117 Test unit.
Figure 5
1. 16878117 Test unit

2. Test-button for resetting system
7. Remove the test unit.
8. Replace the 9 volt battery with a new one of the same type. Run a battery test by pressing the red test-button which is
located at the top in the middle of the circuit board.
Figure 6

2. Test-button
Cleaning engine compartment and sprinkler circuit
10. Rinse clean the engine compartment with water.
11. Disconnect the hose at the top on the tank. Plug hose and tank.
Figure 7
1. Extinguishing agent hose
12. Remove the coupling from the tank and clean.

Figure 8
Coupling
13. Connect nipple E-2005 to the outlet hose.
Figure 9
Water connection
1. Nipple E-2005
2. Outlet hose
Fold forward the operator's seat and secure it according to: Operator's seat, securing
15. Rinse clean the sprinkler circuit with water. Check that water comes out from all nozzles.
Figure 10
Nozzle
16. Connect compressed air to the outlet hose.
17. Blow clean in the sprinkler circuit with compressed air for approx. 30 seconds until no fluid comes out from the nozzles.
18. Install the protective caps on the nozzles. 15 pcs.
Repairing and restoring
19. Do a visual check to find the damaged area.
20. Repair the equipment that has been damaged by fire.
21. Check if the detector circuit is damaged as follows:
 Blue connector from test unit to the control unit's connection.

 Blue connector from test unit to the detector cable's connection in the control unit.
Figure 11

2. 88830136 Test unit
5. Control unit
0.5 kΩ
Figure 12
1. Multimeter
2. 88830136 Test unit
24. In case of damaged detector circuit. Replace the detector circuit as follows:
25. Remove the damaged detector circuit.
26. Install the new detector circuit.
27. Fasten the detector circuit to the sprinkler circuit with cable ties every 80–180 mm (3.5–7.1 inch). Install a short rubber hose
on the detector circuit as protection against rubbing and chafing.
NOTE!
NOTE! The detector circuit should not be bent tighter than with a radius of 50 mm. (1.97 inch)
Figure 13
Detector circuit
Filling tank
29. Remove the defective outlet plate (burst disc).
Figure 14
30. Remove the bracket for siren (SA9901) and strobe light (LA9901) on the tank.
31. Disconnect the propellant gas hose from the bottom of the tank.
Figure 15
Propellant hose
32. Unplug the connector and remove the gas generator cable (squib cable) (MA9903) for the propellant gas cartridge.
33. Expose the propellant gas cartridge and the pneumatic actuator by loosening the hoses and clamps. Spin off (thread) the
propellant gas cartridge from the pneumatic actuator and install the protective nut.
Figure 16
34. Dismantle the pneumatic actuator. Clean and lube the gaskets with vaseline.
Figure 17
Pneumatic actuator
1. Pneumatic actuator
2. Spring
3. Pin
4. Housing
35. Assemble the pneumatic actuator. Tightening torque 50 Nm (30 lbf ft)
36. Use a rag to clean the tank from all loose materials.
37. Press back the piston to original position with compressed air. Seal with a rag and press down the piston to the bottom. A
distinct sound is heard when it reaches the bottom.
Figure 18
38. Measure the distance from the bottom of the tank to the upper edge to make sure that the piston has reached the bottom.
Length 734–± 2 mm ( 28.9 ±0.08 inch)
Figure 19
39. Check the tank for any serious damage. Scratches and minor dents are acceptable. In case of major damage, the tank shall
be replaced in order to not risk the piston's movement in the tank.
40. Install a hose on the funnel and insert the hose down into the tank. Recommended hose diameter Ø 12 mm (0.47 inch). Fill
the tank with the correct amount of extinguishing fluid according to Fire suppression system, specification. Weigh the tank
when filling. Fill the tank slowly since the fluid foams very easily.
NOTE!
The tank should be 100% full of extinguishing fluid.
Figure 20
Figure 21
41. Install a new outlet plate (burst disc), installed with the convex side facing up.
Figure 22
Figure 23
42. Tighten down the coupling and torque-tighten. Tightening torque 40 Nm (30 lbf ft)
43. Install a decal that states the date for refilling of the tank.
WARNING
44. Check that the new propellant gas cartridge is pressurized by weighing it. Correct weight is stated on the label. Max.
deviation from the weight is -14 grams. The plug's weight shall be added to the stated weight. The plug weighs 20 grams.
NOTE!
The plug shall be installed on the propellant gas cartridge when weighing.
Figure 24
NOTE!
WARNING
45. Connect the hose to the manual actuator.

Figure 25
1. Connection to gas generator cable

2. Connection to manual actuator
3. Connection to tank
46. Connect the propellant gas hose at the bottom of the tank.
Figure 26
WARNING
47. Install the new pressurized propellant gas cartridge.

Figure 27
48. Install the bracket for siren (SA9901) and strobe light (LA9901) on the tank.
49. Connect the hose at the top on the tank.
Figure 28
1. Hose connection
Manual actuator
50. Loosen the manual actuator and the extinguishing agent tank under the cab steps and remove the empty propellant gas
cartridge.
Figure 29
51. Dismantle the manual actuator. Clean and lube the gaskets with water-resistant vaseline. Assemble the manual actuator as
shown in the figure and check that the striker pin is in bottom position. Replace the seal.
Figure 30
Manual actuator
1. Seal
2. Pin
3. Spring
4. Housing
manual actuator.
Figure 31
Manual actuator
1. Striker pin's distance, approx. = 1 mm (0.04 tum)
53. Reinstall all parts (under the cab steps) and affix a tampering seal.
WARNING
54. Check that the new propellant gas cartridge is pressurized by weighing it. Correct weight is stated on the label or is stamped
in. The plug weighs 20 grams (0.7 oz). The weight may not deviate by more than 7 grams (0.25 oz). The plug's weight shall
be added to the stated weight. The plug weighs 20 grams.
NOTE!
55. Install the new propellant gas cartridge under the cab steps.
Function check
56. Unplug the connector for the gas generator cable (squib cable) (MA9903). The following light-emitting diodes are activated on
the control panel:
 Green On”
 Yellow Fault actuator lights up
Figure 32

57. Remove the detector cable's connection on the control unit (blue connector). The following light-emitting diodes are activated
on the control panel.
 Green On”
 Yellow Fault detector lights up
Figure 33
2. Detector cable
 Blue connector from test unit to the control unit's connection.

Figure 34

2. 88830136 Test unit
5. Control unit
59. After connecting 88830136 Test unit only the green light-emitting diode is activated On on the control panel. (CU9903)
60. Press the button on 88830136 Test unit for at least 1 second to check the function of the system for siren (SA9901) and
strobe light (LA9901). The siren sounds. The strobe light flashes. One of the two red light-emitting diodes on 88830136 Test
unit flashes approx. 6 times. The following light-emitting diodes are activated on the control panel:
 Green On”
 Red Fire alarm flashes
61. Press the button ( Test) / Reset for at least 1 second on the control panel (CU9903) to reset. All light-emitting diodes on the
control panel are activated.
Figure 35
Control panel
1. Manual release (manual activation)

2. Fire alarm
3. Fault actuator
4. Fault detector
5. Manual
6. ON
7. Test Reset
0.5 kΩ
Figure 36
1. Multimeter
2. 88830136 Test unit
63. Disconnect 88830136 Test unit according to the following:

1. Disconnect blue cable from the control unit. Light-emitting diode Fault detector lights up on the control panel.
2. Disconnect the cable to the gas generator cable (squib cable). Light-emitting diode Fault actuator lights up on the
control panel.
64. When all cables have been disconnected from 88830136 Test unit the following light-emitting diodes are activated on the
control panel:

 Fault detector
65. Connect the detector cable (blue connector) to the control unit. Connect the gas generator cable (squib cable) (MA9903) to
the control unit. Now the green light-emitting diode is activated On.
Figure 37
Gas generator cable, connection

Figure 38
Detector cable, connection
1. Detector cable
66. Press the button Test/Reset) on the control panel for at least 1 second to reset. All light-emitting diodes on the control panel
are activated.
Figure 39
1. Test-button
67. Change and replace any defective labels.
68. Fill in the service protocol according to VOE 21A1005996. Attach a signed copy for the customer.
Fire suppression system, checking
Op nbr 173-506
Tools:
88830136 Test unit
16878117 Test unit
88830138 Plug
88830138 Plug
Multimeter
Scale, max. 5 kg with ±2 gram tolerance
Foreword
1. The service instruction is only intended for service of the Volvo Fire Suppression System and only applies to machines with
systems that have been factory-installed by Volvo Construction Equipment. These machines shall not be confused with
machines that have been retrofitted and may have other types of connections and functions. Se the machine card.
Volvo Construction Equipment recommends service at a max. interval of 6 months or 1,000 operating hours, whichever
comes first. This does not apply if the local regulations prescribe more frequent intervals.
WARNING
During service, hearing protection and safety goggles must be used.
WARNING
NOTICE
Pressure vessels must always be handled with a plug.
NOTICE
When welding, and at auxiliary start-up, the central unit must be disconnected.
NOTICE
Service must be performed in consecutive order, according to the test protocol and the service instruction.
NOTE!
Service and repairs may only be performed by authorized personnel using parts and equipment intended for the system in question.
NOTE!
Some service work steps will activate the fire alarm's siren and strobe light.
NOTE!
When replacing parts, the replaced part shall always be sent for destruction. No parts may be discarded with ordinary waste or
garbage.
Preparations
Checking cable harness and detector circuit
2. Place the machine in service position 1 according to Service position
Check before service.
3. With the machine parked, only the green light-emitting diode should be on.
If green LED is not on, connect 88830136 Test unit and perform troubleshooting before service starts.
NOTE!
The test unit shall be connected when troubleshooting.
4. Start the machine and release the parking brake.

Check that yellow light-emitting diode “Manual” lights up.
Figure 1
Control panel
1. Light-emitting diode for Manual (yellow)
5. Press in green button “Test / Reset” on the control panel for at least 1 second and check that all light-emitting diodes light
up, and that the siren and strobe light are activated.
Figure 2
Control panel
1. Push-button for Test / Reset (green)
6. Reset with the button Test / Reset on the control panel.
Checking function of control unit
7. Turn off the machine and leave the battery disconnector On.
8. Unplug the connector for the gas generator cable.
Remove the detector cable connection on the control unit (blue connector)
Figure 3

2. Detector cable connection (blue connector)
9. Check that the control panel's light-emitting diodes for the error text Fault actuator, On and Fault detector are on.
Figure 4
Control panel
1. Light-emitting diode for Fault actuator (yellow)

2. Light-emitting diode for Fault detector (yellow)
3. Light-emitting diode for On (green)
10. Connect 88830136 Test unit cables on the control unit in the following order:
1. Blue connector from test unit to the control unit's connection (blue symbol ring)
2. Blue connector from test unit to the detector cable's connection in the control unit
3. Black connector from test unit to the gas generator cable's connection
Figure 5

2. 88830136 Test unit
4. Connector from test unit to control unit
5. Control unit
11. Check that the light-emitting diodes for Fault actuator and Fault detector are NOT activated on the control panel in the cab.
Figure 6
Control panel
1. Light-emitting diode for Fault actuator (yellow)

2. Light-emitting diode for Fault detector (yellow)
12. Connect a multimeter to 88830136 Test unit and measure the resistance in the detector circuits. The resistance should be 2.8
kΩ. In case of a deviating value, measure the resistors separately. Each resistor shall have a value of 5.6 kΩ.
Figure 7
1. Multimeter
2. Connection points for multimeter
13. Press the test unit's button for at least 1 second to check the function of the system for siren and strobe light. The siren
should sound and the strobe light should flash. One of the two red light-emitting diodes on the test unit should flash. On the
control panel, the green light-emitting diode On should be on (activated) and red light-emitting diode Fire Alarm should flash.
Figure 8
Control panel
1. Light-emitting diode for Fire alarm (red)

14. Reset with the button Test / Reset on the control panel.
Figure 9
Control panel
15. Press the button Manual release for at least 1 second on the control panel and check that the light-emitting diode on
88830136 Test unit flashes and that the fire alarm is activated. Reset with the button Test / Reset on the control panel.
Figure 10
Control panel
1. Light-emitting diode for Fault Detector (yellow)

2. Push-button for Test / Reset
3. Push-button for Manual / release
16. NOTE!
If the machine is equipped with the red control unit. Proceed as follows:
1. Remove the cover on the control unit.

2. Connect 16878117 Test unit with the connector so that the cable falls in the direction out from the battery as shown in
the figure.
3. Press the grey button to reset the memory.
4. Remove 16878117 Test unit
Figure 11
1. Diagnostic tool 16878117 Test unit

2. Button for resetting system
17. Remove the test unit and the multimeter. Connect the detector cable and gas generator cable to the control unit.
18. Install the protective cover on the control panel and affix a tampering seal.
Checking and inspecting extinguishing agent container
19. Visually inspect the extinguishing agent container for any physical damage.
Damaged extinguishing agent container shall be replaced.
The extinguishing agent container is marked with year of manufacture and volume.
After 10 years, the gaskets and the extinguishing agent shall be replaced. See recharging instructions at Fire suppression
system, actions after activation
Figure 12
20. Loosen the outlet hose and check that the burst disc is intact and that fluid does not leak out.
Figure 13
1. Outlet hose for propellant gas tank

2. Burst disc
21. Disconnect the propellant gas hose at the bottom of the agent tank and check that fluid does not run out. A handful of fluid is
acceptable.
Figure 14
1. Bottom hose
Checking propellant gas container and actuator as well as weighing propellant gas cartridge
22. Remove the propellant gas cartridge and the pneumatic actuator by loosening the hoses and clamps.
Figure 15
Propellant gas cartridge
23. Spin off (thread) the propellant gas container from the pneumatic actuator and install 88830138 Plug.
Figure 16
Propellant gas container
1. 88830138 Plug
24. Check that the weight of the propellant gas container corresponds to the weight stated on the label. Max. deviation from the
weight is -14 grams (0.5 oz).
Use a scale with ±2 gram tolerance.
NOTE!
The plug's weight shall be added to the stated weight.
The plug weighs 20 grams (0.7 oz).
25. Dismantle the pneumatic actuator. Clean and lube the gaskets with waterproof vaseline. Assemble the pneumatic actuator
and check that the striker pin is in bottom position. Tightening torque: 50 Nm (37 lbf ft)
Figure 17
Pneumatic actuator
1. Housing
2. Spring
3. Pin
actuator.
Figure 18
1. Pin
Checking activation cartridge and the manual actuator as well as weighing activation cartridge
27. Loosen the manual actuator and the activation cartridge under the cab steps, and remove the activation cartridge.
NOTE!
The plug's weight shall be added to the stamped-in weight.
The plug weighs 20 grams (0.7 oz).
Figure 19
28. Install 88830138 Plug on the activation cartridge. Check that the weight corresponds to the stated weight. The weight may
not deviate by more than 7 grams (0.25 oz).
Figure 20
Activation cartridge
1. 88830138 Plug
29. Dismantle the manual actuator. Clean and lube the gaskets with waterproof vaseline. Assemble the manual actuator as
shown in the figure and check that the striker pin is in bottom position. Tightening torque: 50 Nm (37 lbf ft)
Figure 21
Manual actuator
1. Tamper seal
2. Pin
3. Spring
4. Housing
actuator.
Figure 22
Manual actuator
1. Striker pin's distance = ±1 mm (0.04 in)
31. Reinstall all parts and affix a tamper seal. Tightening torque: 50 Nm (37 lbf ft).
Blowing clean hose and sprinkler system
32. Connect the outlet hose to the compressed air equipment. The air must be free from water or other fluids.
Figure 23
1. Outlet hose
2. E-2005
3. Compressed air hose
Fold forward the operator's seat and secure it according to: Operator's seat, securing
34. Make sure that all 15 protective caps are installed on the nozzles.
35. Start blowing clean and check that all protective caps come off the nozzles. Check that the flow is satisfactory in all nozzles.
When needed, remove the nozzles and clean them.
36. Follow the hose and sprinkler system, and check tightening of all couplings and nozzles. All plates that conceal pipes and
hoses must be removed before the check is performed.
Check that there are no cracks in the sprinkler system and that the fastener device for pipes and hoses is intact.
Reinstall all parts as well as reinstall the protective caps on the nozzles.
Checking cable harness and detector circuit
37. Check that the detector circuit is not damaged and that it is clamped with rubber protection, and is protected against physical
damage. The detector circuit may not be bent tighter than with a radius of 50 mm (1.97 in).
38. Check that all cables to the central unit are free from physical damage and are clamped.
Checking decals and plates
40. Check that all plates and decals are installed in the correct location and that they are in good condition.
Figure 24
Decal under footstep
1. Decal
41. Decal in cab by control panel and activation button

Figure 25
42. Decal on container
Figure 26
43. Decal on front frame if handheld fire extinguisher is installed
Figure 27
Finishing
44. Fill in the service protocol and give or send a copy to the machine owner.
45. Check that actuator and control panel are affixed with tamper seals.
46. Check that the control panel's light-emitting diode only is on with green light (On).
Replacement intervals
 The battery in the control unit shall be replaced at every service interval. Only use battery type GP CR-9V Lithium 800 mAh.
 Gas generator shall be replaced every 5 years. Counted from installation date.
 Extinguishing agent shall be replaced every 10 years. Counted from fill (charge) date
 O-rings and seal rings in agent tank shall be replaced every 10 years, or when refilling if the agent tank is older than 5 years.
 O-rings and gaskets in actuators shall be replaced when needed or at least every 10 years.
 The propellant gas cartridge and activation cartridge shall be replaced every 10 years.
Fire suppression system, component location
Figure 1

2. Emergency stop button SW3102
3. Expellant gas cartridge
4. Gas generator (Squib) MA9903
6. Siren SA9901 / LA9901
7. Tank
8. Electric battery disconnector RE3101
9. Handheld fire extinguisher
11. Actuation gas cartridge
See also:
Wiring diagram 319
Wiring diagram 915.
Front wheel, installation
Op nbr 771-003
Tools:
1. Fit the wheel.

Wheel's weight: approx. 360 kg (795 lbs).
Tightening torque wheel studs, see Wheels, tightening torques.
Figure 1
1. 11668010 Wheel forklift
2. Let down the machine and remove the jack.
Figure 2
1. 11668007 Standard Jack Single
2. Support point
NOTE!
When changing dimension of the wheels, the parameter shall be changed according to operation number 17030–3 with VCADS Pro.
4. Restore the machine and check that there are no error messages.
5. Check function according to Brake system, checking function, retardation

Front wheel, removal
Op nbr 771-002
Tools:
2. Support the axle so that the wheels can rotate.
Figure 1
1. 11668007 Standard Jack Single

2. Support point
3. Remove the wheel.

Wheel's weight: approx. 360 kg (795 lbs).
Figure 2
1. 11668010 Wheel forklift

Fuel control valve (FCV), replacing
Op nbr 237-033
Tools:
88800070 Spanner
88890300 Interface
1. Run Tech Tool operation 28407-3 Sensor values, monitoring, and read out the fuel rail pressure. Make sure that the fuel rail
pressure is below 5 MPa (725 PSI) before opening the high pressure fuel system.
3. Unplug the connectors.
Figure 1
Connectors
4. Remove the high pressure pipes (2 pcs) using 88800070 Spanner.
Figure 2
High pressure pipes
5. Remove fuel feed line.

Figure 3
Fuel feed line
6. Remove the drain hose and the fuel feed pipes.
Figure 4
1. Fuel feed pipes

2. Fuel drain hose
7. Remove the fuel control valve (2 bolts).
Figure 5
FCV
8. Install the new fuel control valve (2 bolts).

Tightening torque, see Fuel system, tightening torques.
9. Install the drain hose and the fuel feed pipes.

NOTE!
Use new high fuel feed pipes.
Figure 6
1. Fuel feed pipes

2. Fuel drain hose
10. Install the fuel feed line.
Figure 7
11. Install the high pressure pipes (2 pcs) using 88800070 Spanner.
NOTE!
Use new high pressure pipes.
Figure 8
12. Plug in the connectors.
Figure 9
Fuel filters, replacing
Op nbr 173-402
Tools:
9996671 Oil filter wrench
11666167 Disassembly tool
1. Place a container under the prefilter.

Drain the prefilter, approx. 2 litres.
Remove the water trap.
Remove the prefilter. Use 9996672 Oil filter wrench.
NOTE!
Handle the old used filters in a safe and environment-friendly manner.
2. Smear new engine oil on the new filters' filter seals and install them. Tighten according to the instructions on the filter.
Figure 1
1. Main filter
2. Hand pump
3. Prefilter
4. Water trap
3. Change the main filter.
4. The fuel system must be bled after filter change.

Turn off the electric power with the battery disconnector.
Turn the hand pump counter-clockwise so that it ends up in pumping position.
Pump approx. 200–300 strokes until you can start to feel a resistance in the hand pump.
Turn the handle clockwise until it stops.
NOTE!
Air bleeding may not be performed using the starter motor.
5. Turn on the electric power, start the engine, and let it run at low idle for a few minutes. If the engine is difficult to start, bleed
again with the hand pump.
NOTE!
The hand pump may not be used when the engine is running.
Fuel rail pressure sensor, replacing
Op nbr 237-035
Tools:
88890300 Interface
2. Unplug the connector for the fuel rail pressure sensor and remove the fuel rail pressure sensor.
Figure 1
1. Fuel rail, pressure sensor

2. Connector
3. Install the new fuel rail pressure sensor. Tightening torque, see Fuel system, tightening torques.
Plug in the connector.
Fuel rail, replacing
Op nbr 237-031
Tools:
88890300 Interface
88800070 Spanner

 Fuel system, tightening torques
 Pressure relief valve (PRV), replacing
 Fuel system, bleeding
1. Run Tech Tool operation 28407-3 Sensor values, monitoring and read out the fuel rail pressure. Make sure that the fuel rail
2. Remove the bracket.
Figure 1
1. Bracket
3. Remove the high pressure fuel pipes, see High pressure fuel pipes, replacing.
4. Disconnect the fuel hose.
Figure 2
1. Fuel hose
2. Connector, fuel rail pressure sensor
5. Disconnect the connector to the fuel rail pressure sensor.

6. Remove the fuel rail pressure sensor and the pressure relief valve from the fuel rail.
Figure 3

2. Fuel rail pressure sensor
7. NOTE!
There are spacer rings between the fuel rail and the cylinder block.
Remove the fuel rail.
Figure 4
Attaching bolts
8. Install the new fuel rail. Tightening torques, see Fuel system, tightening torques.
9. Install the fuel rail pressure sensor and the pressure relief valve according to: Pressure relief valve (PRV), replacing.
10. Install the fuel hose on the fuel rail. Tightening torques, see Fuel system, tightening torques.
11. Connect the connector to the fuel rail pressure sensor.
12. Install the high pressure fuel pipes, see High pressure fuel pipes, replacing.
13. Install the bracket.
14. Bleed the fuel system, see Fuel system, bleeding.

Fuel system, bleeding
Op nbr 233-001
1. Park the machine in service position, see Service position
2. Turn off the electric power with the battery disconnector.
3.
Figure 1
A. Hand pump on filter head.
Turn the hand pump counter-clockwise so that it ends up in pumping position. Pump approx. 200–300 strokes until you can
start to feel a resistance in the hand pump. Then turn the hand pump clockwise until it stops.
NOTE!
Air bleeding may not be performed using the starter motor.
4. Turn on the electric power, start the engine, and let it run at low idle for a few minutes. If the engine is difficult to start, bleed
again with the hand pump.
NOTE!
The hand pump may not be used when the engine is running.
Fuel tank breather filter, replacing
Op nbr 173-409
1. Change the breather filter for the fuel tank.
Figure 1
1. Breather filter
GPMECU1, changing non-programmed ECU
Op nbr 366-106
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
1. Place the machine in service position 1, see Service position Turn master switch to the ON position.
Figure 1
1. Rear wall cover.

2. Right wall cover.
3. Rear right cab post panel.
2. Note the total number of machine hours in the information display.
3. Remove the rear wall cover.
5. Remove the rear right cab post panel.
software.)
Figure 2
Rear cab wall with GPMECU:s
7. Unplug the Tech Tool connector from the GPMECU1
9. Change GPMECU1.
11. Finalize the operation 17092-3. (If there is no network connection at the machine, perform operation 17093-3 Program with
stored software.)
12. If the parameter read out failed in step 3: perform operation 38335-3 Displayed machine hours, correction.

GPMECU1, changing pre-programmed ECU
Op nbr 366-105
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
Figure 1
1. Rear wall cover.

3. Remove the rear cab wall cover.
4. Remove the right wall cover
5. Remove the rear right cab post panel.
6. The new control unit has basic set parameters for the machine. Connect Tech Tool and perform the operation 17030-3
Parameter, programming to see if it is possible to read out customer parameter settings.
Figure 2
Cab rear wall with GPMECU:s
8. Change GPMECU1.
10. Finalize the operation 17030-3 Parameter, programming.
11. Perform the operation 38335-3 Displayed machine hours, correction.

Op nbr 366-108
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
Figure 1
1. Rear wall cover.
Figure 2
software.)
4. Turn master switch to the OFF position
5. Change GPMECU2.
6. Turn master switch to the ON position

stored software.)
8. If the parameter read out failed in step 3: perform operation 38335-3 Displayed machine hours, correction.
10. After work with safety related systems the following functions checks shall be performed:


Op nbr 366-107
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
Figure 1
1. Rear wall cover.
Figure 2
Parameter, programming to see if it is possible to read out customer parameter settings.
4. Unplug the connector from the GPMECU2.
5. Turn master switch to the OFF position
6. Change GPMECU2.

8. Finalize the operation 17030–3 Parameter, programming.


Op nbr 366-109
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
Figure 1
1. Rear wall cover.
Figure 2
software.)
5. Change GPMECU3.

stored software.)
9. Calibrate the transmission according to Tech Tool operation 42101-3
10. Perform operation 42102-3 Travel direction, check.
 Transmission, function check

 Differential lock, function check

Op nbr 366-110
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
Figure 1
1. Rear wall cover.
Figure 2
3. Connect Tech Tool and perform the operation 17030-3 Parameter, programming to see if it is possible to read out customer
parameter settings.
5. Change GPMECU3.

9. Calibrate the transmission according to Tech Tool operation 42101-3
10. Perform operation 42102-3 Travel direction, check.
 Transmission, function check

 Differential lock, function check

Grease Locations
Figure 1
1. Boom
2. Frame joint, upper bearing
3. Frame joint, lower bearing
4. Steering cylinders, bearings
Figure 2
1. Boom
2. Steering cylinders, bearings
Figure 3
1. Support bearing
Heat control valve, replacing
Op nbr 873-008
Removing
1. Turn off the voltage with the battery disconnect switch.
2. Fold forward the operator's seat and lock it in place with the seatbelt. See Operator's seat, securing
Figure 1
1. Rear panel
4. Remove the right side panel in the cab.
Figure 2
1. Right side panel

2. Bolt
5. Remove the ventilation channel.
Figure 3
1. Ventilation duct
2. Bolt, 3 pcs.
6. Remove the bolt that holds the heat control valve.
Figure 4
2. Heat control valve
7. Clamp shut the hoses to the heater core with two clamping pliers.
Figure 5
1. Clamping pliers
2. Heat control valve
8. Remove the heat control valve.
Installing
9. Install the heat control valve.

Remove the clamping pliers.
10. Reinstall the side panel.
11. Reinstall the rear panel.
12. Loosen the seatbelt and return the operator's seat and plug in the connectors.
13. Check the coolant level.

Check function of the system.
Heater core, replacing
Op nbr 873-004
1. Remove the air conditioning from the machine and place it on a table. See: Climate unit, removing
2. Remove the hose between the heater unit and heater valve. Dismantle the housing by removing all clips.
Figure 1
1. Clips
2. Slang
3. Remove the heater unit and replace it.
Figure 2
1. Heater unit
4. Refit the cover and affix all clips. Fit the hose for the heater valve.
NOTE!
Check that the fan is fitted in the correct position.
Figure 3
1. Clips
2. Slang
5. Refit the climate unit in accordance with: Climate unit, installing

High pressure fuel pipes, replacing
Op nbr 237-127
Tools:
88890300 Interface
88800070 Spanner
WARNING
Fuel under high pressure!
2. Remove the high pressure pipes, using 88800070 Spanner.
Figure 1
High pressure pipes
3. Install the new high pressure pipes using 88800070 Spanner.

Tourque tighten in two steps, see Fuel system, tightening torques.
4. Bleed the fuel system according to Fuel system, bleeding.

High pressure fuel pump, replacing
Op nbr 237-032
Tools:
88800070 Spanner
88890300 Interface
 Fuel control valve (FCV), replacing
1. Remove the fuel control valve (FCV), see Fuel control valve (FCV), replacing.
2. Remove the high-pressure fuel pipe.
Figure 1
3. Remove the high-pressure pumps (2 bolts for each pump).
Figure 2
NOTE!
The pumps may be under spring tension.
4. Install the new high-pressure fuel pumps.

NOTE!
Lubricate the O-rings
Figure 3
Start with the pump that is in the lower position. Tighten the bolts.
Rotate the engine using 88830207 Rotation tool until the pump ends up in the lower position. Tighten the bolts.
Tightening torques, see Tightening torque, fuel system.
5. Install the high pressure pipe.

NOTE!
Use new high pressure pipe.
Figure 4
6. Install the fuel control valve, see Fuel control valve (FCV), replacing.
Hinge, lubricating
Op nbr 173-317
1. Remove the front cover and grease the handles' joint.
Figure 1
1. Handles
2. Grease the door's hinges.
Figure 2
1. Grease points
HMICU, changing non-programmed ECU
Op nbr 366-104
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
3. Remove the rear wall cover (1), right wall cover (2), and rear right cab post cover (3).
Figure 1
1. Rear wall cover.
3. Rear right cab post cover.
Figure 2
Rear cab wall with HMICU
4. Connect Tech Tool and perform the operation 17092-3 Replace hardware. (If there is no network connection at machine –
perform operation 17093-3 Program with stored software.)
6. Change HMICU.
8. Finalize the operation 17092-3 Replace hardware. (If there is no network connection at machine – perform operation 17093-3
Program with stored software.)
9. Perform the operation 17040-3 System date and time.
10. If the parameter read out failed in step 3: perform the operation 38355-3 Displayed machine hours, correction.

HMICU, changing pre-programmed ECU
Op nbr 366-103
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
3. Remove the rear cab wall cover (1), right wall cover (2), and rear right cab post cover (3).
Figure 1
1. Rear wall cover.
Figure 2
Cab rear wall with HMICU
4. Connect Tech Tool and perform the operation 17030-3 Parameter, programming to see if it is possible to read out customer
parameter settings.
6. Change HMICU.
9. Perform the operation 17040–3 System date and time.
10. If the parameter read out failed in step 4: perform the operation 38335–3 Displayed machine hours, correction.

Hub reduction, installing
Op nbr 461-038
Tools:
Bolts, M12x100mm, 2 pcs.
1. Connect the lifting tool to the hub reduction.

Install the brake plate, guide pins, sun gear, and the brake disc in the hub reduction. Two guide pins provided with grooves
for a screwdriver can be used to facilitate when installing.
Figure 1
1. Brake plate
2. Guide pins for brake plate
Figure 2
1. Brake disc
2. Sun gear
3. Guide pins for installing
4. 88830163 Lifting tool
NOTE!
If the brake piston, brake disc, or thrust plate have been replaced, the clearance adjusters for the brake piston and the wear indicator
for the brake disc must be adjusted, see Brake discs, changing.
2. Install the O-ring on the axle housing.

Install the hub reduction.
Hub reduction's weight, approx.: 190 kg (419 lbs)
NOTE!
Install the hub reduction according to earlier markings and check that the guide pins in the hub reduction engage with the
recesses in the brake piston.
Figure 3
3. Install and tighten down the bolts.

Tightening torques, see Front and rear axles, tightening torque.
4. Remove the lifting tool from the hub reduction.
5. Fill the axle with oil.

6. Install the wheel according to Front wheel, installation.

Hub reduction, installing
Op nbr 463-046
Tools:
1. Connect the lifting tool to the hub reduction.

Install the brake plate, guide pins, sun gear, and the brake disc in the hub reduction. Two guide pins provided with grooves
for a screwdriver can be used to facilitate when installing.
Figure 1
1. Brake plate
2. Guide pins for brake plate
Figure 2
1. Brake disc
2. Sun gear
3. Guide pins for installing
NOTE!
If the brake piston, brake disc, or thrust plate have been replaced, the clearance adjusters for the brake piston and the wear indicator
for the brake disc must be adjusted, see Brake disc, replacing.
2. Install the O-ring on the axle housing.

Install the hub reduction.
Hub reduction's weight, approx.: 190 kg (419 lbs)
NOTE!
Install the hub reduction according to earlier markings and check that the guide pins in the hub reduction engage with the
recesses in the brake piston.
Figure 3
3. Install and tighten down the bolts.

Tightening torques, see Front and rear axles, tightening torque.
4. Remove the lifting tool from the hub reduction.
5. Fill the axle with oil.

6. Install the wheel according to Rear wheel, installing.

Hub reduction, removing
Op nbr 461-037
Tools:
Sling, 2 m
Shackle
1. Remove the wheel according to Front wheel, removal.
2. Drain the axle oil.

Volume, see: Front and rear axles, volume.
3. Mark the hub reduction's position in relation to the axle housing.

Connect the lifting tool to the hub reduction. Remove the attaching bolts and remove the hub reduction.
Hub reduction's weight approx.: 190 kg (419 lbs)
NOTE!
In certain cases, the half shaft and brake disc can remain in the hub reduction.
Figure 1

Hub reduction, removing
Op nbr 463-045
Tools:
Sling, 2 m
Shackle
1. Remove the wheel according to Rear wheel, removing.
2. Drain the axle oil.

Volume, see: Front and rear axles, specifications.
3. Mark the hub reduction's position in relation to the axle housing.

Connect the lifting tool to the hub reduction. Remove the attaching bolts and remove the hub reduction.
Hub reduction's weight approx.: 190 kg (419 lbs)
NOTE!
In certain cases, the half shaft and brake disc can remain in the hub reduction.
Figure 1

Hub, replacing seal
Op nbr 461-043
Tools:
88830175 Pump
11666043 Jack
11666046 Swivel nipple
11666054 Jack
11667001 Handle
11667010 Plug
11667135 Drift plate
9809747 Puller
9993590 Gear wheel
9993713 Puller bolt
9993717 Quick nut
9993722 Support
9993757 Intermediate piece
9993770 Press tool
9993785 Gear segment
9993867 Spanner
9996239 Lifting chain
Bolts, M12x100 mm, 2 pcs.
Kukko 20–3
Lifting eye M16, 2 pcs.
Bolt M10x60, 4 pcs.
Bolt M10x45, 3 pcs.
Nut M10, 6 pcs.
Nut M16, 6 pcs.
Sling 2 m (6 ft)
Shackle
Socket 75 mm

Removing
2. Place the hub reduction on, e.g., a wooden block, min. height 200 mm (8 in), on a bench. Make sure that the hub reduction
rests on the planet carrier.
Weight, hub reduction: approx. 190 kg (420 lbs).
Remove the centre cover.
Figure 1
3. Remove the lock ring and the lock washer.
Figure 2
4. Loosen the hub nut. If necessary, use a pry bar as counterhold.
Figure 3
1. 9993590 Gear wheel

2. 9993867 Spanner
3. 9993785 Gear segment
4. Bolt M10x45, 3 pcs.
5. Nut M16, 6 pcs.
5. Remove the hub nut, washer, measuring ring (washer), and the adjusting shims.
Figure 4
6. Remove the hub retainer from the planet carrier.

Weight, hub retainer approx.:130 kg (290 lbs).
Figure 5
1. 9996239 Lifting chain
7. In some cases, a puller may have to be used.

Figure 6
1. 88830175 Pump
2. 11666054 Jack
3. 9993770 Press tool
8. Turn the hub retainer.

Weight hub retainer: approx. 130 kg (290 lbs).
9. Press the hub off the hub retainer.
Figure 7
1. Swivelling lifting eye M16, 2 pcs.

2. Shackle, 2 pcs., sling
3. Kukko 20–3
4. 11667135 Drift plate
5. 11667001 Handle
10. Lift away the hub retainer from the hub.

Hub retainer weight approx.: 70 kg (154 lbs).
Figure 8
1. Lifting eye M16, 2 pcs.
11. Remove the bearing.

Remove the hub seal.
Figure 9
1. 9809747 Puller
2. 11666043 Jack
3. 88830175 Pump
4. 11667010 Plug
12. Drive out the bearing races from the hub retainer.
NOTICE
Work carefully so that the seal is not damaged.
Installing
13. Install the new bearing races.
Figure 10
1. 11667001 Handle
14. Place a new bearing in the hub retainer. Install the new hub seal.
Smear grease on the dust lip.
NOTE!
It is very important that the correct tools are used in order to ensure the seal's function and position.
Figure 11
1. 11667001 Handle
Figure 12
1. Hub retainer
2. Dust lip
15. Place the tools in the wheel hub.

Figure 13
1. 9993713 Puller bolt

2. Nut, as alternative 9993717 Quick nut with washer under
16. Turn the wheel hub and install the hub retainer on the wheel hub.
Figure 14
17. Place the remaining tools in the hub retainer as shown in the figure.
Press together the hub and hub retainer approx. 5 mm (0.2 in). Tap on the plate so that the hub and hub retainer end up in
correct position. Repeat the procedure until the hub is level with the bearing position for the inner bearing.
Figure 15
1. 88830175 Pump
2. 11666046 Swivel nipple
3. 9993717 Quick nut
5. 11666054 Jack
Figure 16
1. 9993722 Support (short legs)

2. 11666054 Jack
5. 11667135 Drift plate (obscured)
7. 88830175 Pump
18. Remove 11667150 Drift plate, place the inner bearing in the hub retainer, install 9993722 Support on the jack and continue
pressing.
19. Press the hub onto the hub retainer. Leave a gap of approx. 10 mm (0.4 in) between the bearing race and the wheel hub.
Figure 17
1. Sliding calipers
2. Bearing race
3. Hub
NOTE!
If the wheel hub is pressed too far, a load is applied to the bearings and the measured value of the rolling resistance will be
incorrect.
20. Place the planet carrier on, e.g., a wooden block, min. height 200 mm (8 in).
Grease the planet carrier's splines.
Install the hub retainer on the planet carrier.
Align the splines.
Check that the planet carrier's splines and the hub splines mesh with each other. Check that all gears are correctly
positioned.
Weight, planet carrier approx.:40 kg (90 lbs).
Weight, hub retainer, approx.: 120 kg (265 lbs).
Figure 18
21. In some cases the parts have to be pressed together, se figure.
Figure 19
1. 9993757 Intermediate piece

2. 9993722 Support
3. 11666054 Jack
5. 88830175 Pump
22. Stop pressing when there is a gap (A) of approx. 5 mm (0.2 in)left between the wheel hub and the planet carrier.
Figure 20
NOTE!
incorrect.
23. Install the measuring ring, the washer, and the hub nut. Tighten the hub nut loosely.
Figure 21
24. Lift up the hub reduction and remove the wooden block.
Hub reduction's weight, approx.: 190 kg (420 lbs).
Figure 22
25. Tighten the hub nut and at the same time rotate the wheel hub at least 5 revolutions so that the bearings are rolled in. Tighten
and measure alternately. Stop tightening the hub nut when it makes contact with the bearing. This takes place just when the
rolling resistance increases significantly, in this example at approx. 35 Nm (25.8 lbf ft).
Figure 23
Applying

2. 9993867 Spanner
5. Nut M10, 6 pcs.
Figure 24
Measuring rolling resistance
1. Socket 75 mm
Rolling resistance, initial value, see Front and rear axles, tightening torque.
Initial value + measured value equals the final desired rolling resistance.
Example of specification: 25 Nm (18.4 lbf ft)
Measured value: 35 Nm (25.8 lbf ft)
Final value: 35 Nm + 25 Nm = 60 Nm
(18.4 lbf ft + 25.8 lbf ft =44.2 lbf ft)
26. Tighten the hub nut and at the same time rotate the wheel hub at least 5 revolutions so that the bearings are rolled in.
Alternate between tightening and measuring until the final rolling resistance is obtained, in this example approx. 60 Nm (44.2
lbf ft).
27. To determine the adjusting shims' thickness, measure the distance from the upper edge of the measuring ring (washer) to the
planet carrier's end face, and note the value, in this example 21.7 mm (0.85 in).
Figure 25
28. Lift up the hub reduction and place the wooden block between the bench and the planet carrier.
Figure 26
29. Remove the hub nut, the washer, and the measuring ring.
30. Combine shims according to the example so that these, together with the washer's thickness, have the same value as the
value that was recorded in step 25.
Example:
Measured value according to step 26 minus the measuring ring's (washer's) thickness gives the thickness for the adjusting
shims, in this example: 21.7 – 20.0 =1.7 mm (0.85 – 0.78 = 0.07 in).
Figure 27
31. Install the adjusting shims, measuring ring (washer), the washer, and the hub nut, and tighten the hub nut loosely.
32. Lift the hub reduction and remove the wooden block.
Figure 28
33. Tighten the hub nut and alternately rotate the wheel hub until the correct torque is obtained.
Tightening torque, hub nut, see Front and rear axles, tightening torque.
Figure 29

2. 9993867 Spanner
5. Nut M10, 6 pcs.
34. Rotate the hub nut approx. 5 revolutions and check that the rolling resistance is correct, that is, matches the value that was
calculated earlier, in this example 60 Nm (44.2 lbf ft).
Again check the tightening torque of the hub nut.
If the value of the rolling resistance is not correct, adjust with the adjusting shims. If the value is too high, increase the
thickness of the adjusting shims. Loosen the hub nut and press apart approx. 1 mm. If the value is too low, decrease the
thickness of the adjusting shims.
Figure 30
1. Socket 75 mm
35. Install the lock washer and the lock ring.
Figure 31
NOTE!
The lock washer is available with two different spacings.
36. Install the O-ring on the cover.

Install the cover. Check the position.
Tightening torque, cover, see Front and rear axles, tightening torque.
Figure 32

Hub, replacing seal
Op nbr 463-043
Tools:
88830175 Pump
11666043 Jack
11666046 Swivel nipple
11666054 Jack
11667001 Handle
11667010 Plug
9809747 Puller
9993590 Gear wheel
9993713 Puller bolt
9993717 Quick nut
9993722 Support
9993757 Intermediate piece
9993770 Press tool
9993785 Gear segment
9993867 Spanner
9996239 Lifting chain
Kukko 20–3
Lifting eye M16, 2 pcs.
Bolt M10x60, 4 pcs.
Bolt M10x45, 3 pcs.
Nut M10, 6 pcs.
Nut M16, 6 pcs.
Sling 2 m (6 ft)
Shackle
Socket 75 mm

Removing
2. Place the hub reduction on, e.g., a wooden block, min. height 200 mm (8 in), on a bench. Make sure that the hub reduction
rests on the planet carrier.
Weight, hub reduction: approx. 190 kg (420 lbs).
Remove the centre cover.
Figure 1
3. Remove the lock ring and the lock washer.
Figure 2
4. Loosen the hub nut. If necessary, use a pry bar as counterhold.
Figure 3

2. 9993867 Spanner
5. Nut M16, 6 pcs.
5. Remove the hub nut, washer, measuring ring (washer), and the adjusting shims.
Figure 4
6. Remove the hub retainer from the planet carrier.

Weight, hub retainer approx.:130 kg (290 lbs).
Figure 5
7. In some cases, a puller may have to be used.

Figure 6
1. 88830175 Pump
2. 11666054 Jack
3. 9993770 Press tool
8. Turn the hub retainer.

Weight hub retainer: approx. 130 kg (290 lbs).
9. Press the hub off the hub retainer.
Figure 7

2. Shackle, 2 pcs., sling
3. Kukko 20–3
5. 11667001 Handle
10. Lift away the hub retainer from the hub.

Hub retainer weight approx.: 70 kg (154 lbs).
Figure 8
1. Lifting eye M16, 2 pcs.
11. Remove the bearing.

Remove the hub seal.
Figure 9
1. 9809747 Puller
2. 11666043 Jack
3. 88830175 Pump
4. 11667010 Plug
12. Drive out the bearing races from the hub retainer.
NOTICE
Work carefully so that the seal is not damaged.
Installing
13. Install the new bearing races.
Figure 10
1. 11667001 Handle
14. Place a new bearing in the hub retainer. Install the new hub seal.
Smear grease on the dust lip.
NOTE!
It is very important that the correct tools are used in order to ensure the seal's function and position.
Figure 11
1. 11667001 Handle
Figure 12
1. Hub retainer
2. Dust lip
15. Place the tools in the wheel hub.

Figure 13

2. Nut, as alternative 9993717 Quick nut with washer under
16. Turn the wheel hub and install the hub retainer on the wheel hub.
Figure 14
17. Place the remaining tools in the hub retainer as shown in the figure.
Press together the hub and hub retainer approx. 5 mm (0.2 in). Tap on the plate so that the hub and hub retainer end up in
correct position. Repeat the procedure until the hub is level with the bearing position for the inner bearing.
Figure 15
1. 88830175 Pump
5. 11666054 Jack
Figure 16
1. 9993722 Support (short legs)

2. 11666054 Jack
5. 11667135 Drift plate (obscured)
7. 88830175 Pump
18. Remove 11667150 Drift plate, place the inner bearing in the hub retainer, install 9993722 Support on the jack and continue
pressing.
19. Press the hub onto the hub retainer. Leave a gap of approx. 10 mm (0.4 in) between the bearing race and the wheel hub.
Figure 17
1. Sliding calipers
2. Bearing race
3. Hub
NOTE!
incorrect.
20. Place the planet carrier on, e.g., a wooden block, min. height 200 mm (8 in).
Grease the planet carrier's splines.
Install the hub retainer on the planet carrier.
Align the splines.
Check that the planet carrier's splines and the hub splines mesh with each other. Check that all gears are correctly
positioned.
Weight, planet carrier approx.:40 kg (90 lbs).
Weight, hub retainer, approx.: 120 kg (265 lbs).
Figure 18
21. In some cases the parts have to be pressed together, se figure.
Figure 19
1. 9993757 Intermediate piece

2. 9993722 Support
3. 11666054 Jack
5. 88830175 Pump
22. Stop pressing when there is a gap (A) of approx. 5 mm (0.2 in)left between the wheel hub and the planet carrier.
Figure 20
NOTE!
incorrect.
23. Install the measuring ring, the washer, and the hub nut. Tighten the hub nut loosely.
Figure 21
24. Lift up the hub reduction and remove the wooden block.
Figure 22
25. Tighten the hub nut and at the same time rotate the wheel hub at least 5 revolutions so that the bearings are rolled in. Tighten
and measure alternately. Stop tightening the hub nut when it makes contact with the bearing. This takes place just when the
rolling resistance increases significantly, in this example at approx. 35 Nm (25.8 lbf ft).
Figure 23
Applying

2. 9993867 Spanner
5. Nut M10, 6 pcs.
Figure 24
Measuring rolling resistance
1. Socket 75 mm
Rolling resistance, initial value, see Front and rear axles, tightening torque.
Initial value + measured value equals the final desired rolling resistance.
Example of specification: 25 Nm (18.4 lbf ft)
Measured value: 35 Nm (25.8 lbf ft)
Final value: 35 Nm + 25 Nm = 60 Nm
(18.4 lbf ft + 25.8 lbf ft =44.2 lbf ft)
26. Tighten the hub nut and at the same time rotate the wheel hub at least 5 revolutions so that the bearings are rolled in.
Alternate between tightening and measuring until the final rolling resistance is obtained, in this example approx. 60 Nm (44.2
lbf ft).
27. To determine the adjusting shims' thickness, measure the distance from the upper edge of the measuring ring (washer) to the
planet carrier's end face, and note the value, in this example 21.7 mm (0.85 in).
Figure 25
28. Lift up the hub reduction and place the wooden block between the bench and the planet carrier.
Figure 26
29. Remove the hub nut, the washer, and the measuring ring.
30. Combine shims according to the example so that these, together with the washer's thickness, have the same value as the
value that was recorded in step 25.
Example:
Measured value according to step 26 minus the measuring ring's (washer's) thickness gives the thickness for the adjusting
shims, in this example: 21.7 – 20.0 =1.7 mm (0.85 – 0.78 = 0.07 in).
Figure 27
31. Install the adjusting shims, measuring ring (washer), the washer, and the hub nut, and tighten the hub nut loosely.
32. Lift the hub reduction and remove the wooden block.
Figure 28
33. Tighten the hub nut and alternately rotate the wheel hub until the correct torque is obtained.
Tightening torque, hub nut, see Front and rear axles, tightening torque.
Figure 29

2. 9993867 Spanner
5. Nut M10, 6 pcs.
34. Rotate the hub nut approx. 5 revolutions and check that the rolling resistance is correct, that is, matches the value that was
calculated earlier, in this example 60 Nm (44.2 lbf ft).
Again check the tightening torque of the hub nut.
If the value of the rolling resistance is not correct, adjust with the adjusting shims. If the value is too high, increase the
thickness of the adjusting shims. Loosen the hub nut and press apart approx. 1 mm. If the value is too low, decrease the
thickness of the adjusting shims.
Figure 30
1. Socket 75 mm
35. Install the lock washer and the lock ring.
Figure 31
NOTE!
The lock washer is available with two different spacings.
36. Install the O-ring on the cover.

Install the cover. Check the position.
Tightening torque, cover, see Front and rear axles, tightening torque.
Figure 32

Hydraulic couplings
Figure 1
1. Connection core
2. O–ring
3. Back-up ring
4. Nipple core
5. O–ring
6. Catches
7. Removal ring
8. Installation stop
Connecting
1. Check that the installation stop is in place and that the removal ring
runs easily in its groove.
2. Press in the male part in the female part so that the catches are
pressed outward.
Figure 2
3. Press in the male part until its installation stop makes contact with
the female part.
4. The O-ring enables the catches to spring back and lock in the male
part's flange. The coupling is now locked and cannot be
disconnected.
Figure 3
1. Installation stop
2. Plug-in side (female)
3. O–ring
4. Catch
Disconnecting
1. Remove the installation stop using a screwdriver.
Figure 4
2. Press in the male part all the way. Then the removal ring presses
out the catches.
Figure 5
3. When the male part is pulled back the removal ring runs in its
groove. The catches are released and the male part can be pulled
out completely.
Figure 6
Hydraulic oil level, checking
Op nbr 173-356
1. The level should be between Min and Max.
Figure 1
Hydraulic oil tank breather filter, replacing
Op nbr 173-412
1. Remove the cover and change insert.
Figure 1
1. Hydraulic tank, breather filter

Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Op nbr 911-040
Tools:
9809685 Cable
Metal plugs
Connecting
1. Switch on the current with the battery disconnect switch on the machine.
NOTE!
If, for some reason, it is not suitable to switch on the current with the battery disconnect switch, us cable 9809685.
2. Remove the breather filter from the air vent pipe on the hydraulic oil tank. Install the vacuum pump connection.
3. Certain machines: Disconnect the breather hose from the transmission. Plug the hose and the pipe.
Figure 1
Connecting vacuum pump
4. Start the vacuum pump.
There is now a partial vacuum in the hydraulic oil tank and some work can now be carried out on the hydraulic system without having
to drain off the hydraulic oil.
NOTE!
Never leave the vacuum pump unattended. A power failure may cause operating problems.
NOTE!
Plug all connections using metal plugs as soon as the connections have been exposed.
Disconnecting
5. Turn off the vacuum pump and remove it.
6. Install the breather hose on the transmission.
7. Install the breather filter on the hydraulic oil tank.
8. Test the function of the machine.

Hydraulic oil, changing
Op nbr 173-451
Tools:
88830268 Pump
9809685 Cable
Hose 3/4" L: 3.5 m (11.5 ft)
Metal plugs
Draining
1. Place a collection container by the machine's left side. Use the hose located in the toolbox and connect it to the longer hose.
For volume, see: Hydraulic system, volume.
2. Remove the cap and connect the hose to the drain point and drain the hydraulic oil in the container.
Remove the plug for the fill point to bleed air.
NOTE!
Handle the oil in an environment-friendly manner.
Figure 1
1. Drain point
3. Remove the hose and install the cap.
Filling
4. Use 14360000 Vacuum pump / 24V to generate a vacuum for the hydraulic tank.
 Turn on the electric power with the battery disconnector on the machine.
NOTE!
If for some reason it is not suitable to turn on the electric power with the battery disconnector, then 9809685 Cable
can be used.
 Remove the breather filter from the air breather pipe on the hydraulic oil tank. Install the vacuum pump's connection.
 Clamp off the hose from the hydraulic transmission's breather with a pair of hose pliers.
 Start the vacuum pump.
NOTE!
Never leave the vacuum pump unattended. A power failure may cause operating problems.
NOTE!
Plug all connections using metal plugs as soon as the connections have been exposed.
5. Fill with new oil.

Hydraulic oil volume, see: Hydraulic system, volume.
Figure 2
1. Fill point
2. Hose pliers (clamping pliers)
3. Hose for hydraulic transmission breather
4. Connection to vacuum pump
6. Check that the oil level is between Max. and Min. Top up if needed.
Figure 3
7. Remove the oil pump and reinstall the plug for the hydraulic oil tank's filler hole.
8. Turn off the vacuum pump and remove it.

Remove the hose pliers (clamping pliers).
Install the breather filter on the hydraulic oil tank.
Hydraulic pressure, checking
Op nbr 173-313
Tools:
Warm up the machine until the hydraulic system has reached operating temperature, approx. 60–80 °C (140–176 °F).
Check the temperature on the display.
2. Press and hold in key 8 (service) on the keypad for approx. 4 seconds. When asked if you want to enter Service Mode, press
Select.
Information
Enter Service Mode
NO YES
3. Press key 3 (hydraulics) on the keypad.
4. Check the operating temperature on the display.
6. NOTE!
If the machine is cold, use the hydraulics carefully!
Tilt forward max. angle and raise the boom.
7. Tilt back max. angle and lower the boom.
8. Turn the steering wheel to right and left full lock repeatedly.
9. Repeat steps 6, 7, and 8 until operating temperature is reached.
10. Connect the sensor 600 bar (60 MPa/8,700 psi) to 88830213 Measuring equipment.
11. Connect 88830213 Measuring equipment to the pressure check connection P2, which is located under the operator’s door.
Figure 1
1. Pressure check connection P2
12. Start the engine. Read off the standby pressure at low idle.
Check the value, see Hydraulic pump (P2), specifications.
13. Lower the boom to the ground. Hold the lowering lever forward with the engine at high idle.
NOTE!
Float mode may not be activated.
14. Read off the max. pressure for pump P2.

Working pressure, max., see Hydraulic pump (P2), specifications.
15. Release the lever, turn off the engine.

Hydraulic pump P3, checking function
Op nbr 913-059
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
Checking
3. Lock the frame joint with the frame joint lock. Place blocks in front of and behind the wheels.
4. Connect the sensor (600 bar (60 MPa/8700 psi)) to the pressure gauge.
5. Then connect the pressure gauge to the pressure check connection PFF on the central block.
Figure 1
1. PFF-connection on central block
6. Connect to Tech Tool Service Tool.

8. Press and hold in key 8 on the keypad for approx. 4 seconds.

When prompted “Go to Service mode”, press SELECT.
Information
Go to Service mode
No Yes
9. Press key 1 on the keypad.
10. Scroll to “Fan rpm".
11. Start the test 91310-3 Hydraulic pump P3, hydraulic pressure, adjust in Tech Tool Service Tool.
12. Activate “Min. displacement” to check the standby pressure. Compare the value to Hydraulic pump (P3), specifications.
13. Activate “Max. displacement” to be able to read off max. fan speed and max. pressure. Run the engine at high idle, read off
the values and compare to Hydraulic pump (P3), specifications and Cooling fan rpm, specifications.
NOTE!
Pressure and rpm can be controlled without Tech Tool Service Tool under: Service mode →Service → Test. This should be
avoided since it may give the wrong measuring results.
Standby pressure, adjusting
14. Open the engine hood and remove the left engine cover.
15. Adjust the pressure on the flow compensator. Half a revolution clockwise corresponds to an increase by 1 MPa (10 bar/145
psi).
Figure 2
1. Pressure compensator (max. pressure)

2. Flow compensator (standby pressure)
Maximum pressure, adjusting
17. Adjust the maximum pressure on the pressure compensator. Half a revolution clockwise corresponds to an increase by 5
MPa (50 bar/725 psi).
NOTE!
The engine must be off when adjusting.
Figure 3
1. Pressure compensator (max. pressure)

2. Flow compensator (standby pressure)
18. Check pressure and rpm again.

Hydraulic pump, checking and adjusting standby pressure and working pressure
Op nbr 913-001
Tools:
up.
2. Connect the sensor 600 bar (60 MPa/8,700 psi) to 88830213 Measuring equipment.
3. Connect 88830213 Measuring equipment to the pressure check connection P2, which is located under the driver’s door.
Figure 1
Central block
1. Pump P2
2. PFF
4. Start the engine. Read off the standby pressure at low idle.
Check the value, see Hydraulic pump (P2), specifications.
6. Remove the mat from the cab. Fold the operator seat forward and secure according to Operator's seat, securing.
7. Remove the rear cover in the cab floor.
8. Adjust the standby pressure on the pump's flow compensator until correct pressure is obtained. Counter-clockwise reduces
the pressure, clockwise increases the pressure. Half a revolution corresponds to approx. 8 bar (0.8 MPa) (116.0 psi).
Use an Allen key 3 mm and a 13 mm open-ended wrench.
Figure 2
Pump P2
1. Flow compensator
2. Pressure compensator
9. Start the engine. Check the standby pressure.
10. Lower the boom to the ground. Hold the lowering lever forward with the engine at high idle.
NOTE!
Float mode may not be activated.
11. Read off the max. pressure for pump P2.

Working pressure, max., see Hydraulic pump (P2), specifications.
12. Release the lever, turn off the engine.
13. Adjust the max. pressure on the pump's pressure compensator until correct pressure is obtained.
Counter-clockwise reduces the pressure, clockwise increases the pressure. 45 degrees correspond to approx. 10 bar (1.0
MPa) (145.0 psi).
Hydraulic system, bleeding
Op nbr 900-002
To be considered after replacing hydraulic components:
 The hydraulic oil tank must be inspected and cleaned from any contaminants.
 Clean the return oil filter magnetic rod (if applicable).
 The return oil filter should be inspected and changed if the filter has visible impurities. If the operating time of the machine is
over 50% of the normal filter change interval, replace the filter.
 All hydraulic oil, new and recycled, must be filled via the hydraulic oil tank return filter. In order to be able to re-use the oil, it
must be entirely free from debris and contaminants.
WARNING
Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries
1. Start the engine and run it at low idling speed for approximately 15 minutes without activating hydraulic functions.
2. Carefully actuate all working-hydraulics functions a few times using small lever movements with the engine running at low
idling speed.
NOTE!
The hydraulic cylinders should not be operated against their end-of-stroke positions.
3. Raise the boom to its upper end position, without building up pressure.
NOTE!
It is very important that pressure is not built up even though the function is operated to its end position.
4. Lower the boom.
5. Raise the boom until the tilting cylinder is horizontal to the ground.
6. Carefully tilt fully inward without building up a pressure.

Fill hydraulic oil in the hydraulic oil tank, if required.
If air bubbles are visible in the tank, leave the engine off for approx. ten minutes.
8. Bleed the brakes, see Brake system, bleeding.
9. Raise the boom fully and tilt fully outward.
NOTE!
If the lift cylinders or several components in the hydraulic system have been drained of all hydraulic oil, then the lift cylinders must be
bled using the air bleed nipples on the cylinders (1 nipple per cylinder).
10. Lower the boom and stop the engine.

Leave the engine turned off for approx. ten minutes and fill oil in the hydraulic oil tank, if required.

Bleed the steering valve by turning the steering wheel until the machine steers properly.
12. Turn the steering wheel fully to the right respectively the left several times.
13. Stop the engine and leave it turned off for at least 15 minutes.
Test-running
14. Start the engine and run it at low idling speed.

Tilt inward and outward until air bubbles are no longer visible in the hydraulic oil tank sight glass.
15. Raise and lower the boom until air bubbles are no longer visible in the hydraulic oil tank sight glass.
16. Increase the engine speed to high idling speed.
Carefully test all hydraulic functions (lifting, tilting, steering and brakes) in order to slowly building up pressure in the hydraulic
system.
17. If needed, check and adjust standby pressure and working pressure for the hydraulic oil pumps, see Hydraulic pump,
checking and adjusting standby pressure and working pressure and Hydraulic pump P3, checking function.
Hydraulic system, warming up
Op nbr 900-001
Warm up the machine until the hydraulic system has reached operating temperature, approx. 60–80 °C (140–176 °F).
Check the temperature on the display.
Select.
Information
Enter Service Mode
NO YES
3. Press key 3 (hydraulics) on the keypad.
4. Check the operating temperature on the display.
6. NOTE!
If the machine is cold, use the hydraulics carefully!
Tilt out max. angle and raise the boom.
7. Tilt in max. angle and lower the boom.
8. Turn the steering wheel to right and left full lock repeatedly.
9. Repeat steps 6, 7, and 8 until operating temperature is reached.

Hydraulic tank return oil filter and magnetic rod, cleaning and replacing
Op nbr 173-411
1.

2. Lift out and dismantle the filter insert.
3. Clean the magnetic rod.
4. Install a new filter.
5. Check the seal rings in the cover when installing.
Figure 1
1. Cover for return oil filter and magnetic rod

Hydraulic tank sediment, draining
Op nbr 173-318
Hose 3/4" L: 3.5 m (11.5 ft)
1. Remove the plate under the platform.
2. Place a collection container on the machine's left side by the cab steps. Use the hose located in the toolbox and connect it to
the longer hose.
3. Remove the cap and connect the hose to the drain point and drain the sludge in the container.
Figure 1
1. Hydraulic oil, drain point
4. Remove the drain hose and install the cap.

Install the plate.
5. The hydraulic oil level should be between Max. and Min. Top up with oil if needed.
Figure 2
Inductive sensor, lift, adjusting
Op nbr 912-932
2. Raise the boom to the desired position.
3. Apply the parking brake and turn off the engine. Leave the start key in operating position (ignition position 1).
4. Check that the distance (X) between the sensor and the boom is 3–5 mm. Otherwise, adjust by loosening one of the nuts and
moving the sensor to correct distance with the other nut.
Tighten both nuts.
Figure 1
Distance (X) between boom and sensor
5. Loosen the nut for adjusting the sensor and move the sensor to the exact position when the light-emitting diode on the back
of the sensor is not lit (exactly when the sensor is in line with the edge of the boom). Then tighten the nut.
Figure 2
1. Nut
2. Boom
6. Activate automatic lift (boom kick-out) with the switch.

Figure 3
Automatic lift (boom kick-out)
7. Start the engine and lower the boom slightly. Check the adjustment by raising the boom with the lever in the rear lock
position.
Check that the boom stops in the set position.
Inductive sensor, tilt, adjusting
Op nbr 912-933
1. Position the bucket so that the underside of the edge saver is flat against the ground (see figure).
Figure 1
1. Tilt indicators
2. Adjustment for sensor
3. Adjustment for tilt indicators
4. Indicator pin
5. Edge saver, underside flat against ground
2. Apply the parking brake and turn off the engine. Leave the start key in operating position (ignition position 1).
3. Check that the distance between the sensor and the indicator pin is 3–5 mm. Otherwise, adjust by loosening one of the nuts
and moving the sensor to correct distance with the other nut. Then tighten both nuts.
Figure 2
Distance (A) between indicator pin and sensor
4. If the bracket for the tilt position indicators needs to be moved, loosen the nut for the bracket and move the bracket until the
indicators are positioned in line. Then tighten the nut.
5. Loosen the nut for the bracket with the sensor, and slowly move the bracket to a position where the light-emitting diode is not
lit (exactly when the sensor is in line with the end of the indicator pin). Tighten the nut.
6. Check the function of the automatic tilt (bucket positioner) by activating automatic tilt with the switch.
Figure 3
Automatic tilt (bucket positioner)
7. Start the engine and lift the bucket so that the bucket can be tilted forward. Check the adjustment by first tilting the bucket
forward a bit and then tilting back the bucket with the lever in lock position. The bucket should tilt back automatically and
remain in the position that was set.
8. Lower the bucket against the ground (without tilting the bucket) and check that the edge saver's underside rests flat on the
ground once again.
Injector sleeves, replacing
Op nbr 237-017
Tools:
88800070 Spanner
88830205 Adapter
88830263 Puller
88890300 Interface
9998007 Adapter
 Injectors, replacing all
2. Drain the coolant, see: Coolant, changing.
3. Remove the injectors, see: Injectors, replacing all.
4. When removing the injector sleeves, use: 88830263 Puller. The tool kit consists of the components in the picture.
Figure 1
1. Washer
2. Bolt (hexagon type)
3. Bolt (hexagon type)
4. Washer
5. Nut (hexagon type)
6. Threaded spindle
7. Allen key
8. Conical pin
9. Hold-down device
10. Centring sleeve
11. Thread drill
12. Threaded pin
13. Spindle
14. Holder
5. Fit the thread drill into the spindle. Lock it with the threaded pin.
NOTE!
Make sure the threaded pin ens up in correct position.
Figure 2
1. Spindle
2. Thread drill
3. Threaded pin
6. Install the holder and lock it with the injector yoke. Fit the spindle into the injector sleeve.
Figure 3
1. Injector yoke
2. Injector yoke bolt
3. Holder
7. Turn the thread drill in a clockwise direction until thread cutting is complete. A thread is cut into the injector sleeve. Thread
depth approximately: 10 mm (0.39 in.).
Figure 4
1. Injector yoke
2. Spindle
8. Turn the spindle in a counter-clockwise direction with the open-ended spanner.
Figure 5
1. Injector yoke
2. Spindle
Remove the spindle.
9. Remove the threaded pin.

Figure 6
1. Thread drill
2. Threaded pin
Clean the thread drill.
10. Remove the injector yoke.

Remove the holder.
Figure 7
1. Injector yoke
2. Injector yoke bolt
3. Holder
11. Install the centring sleeve. Install the threaded spindle.

Turn the threaded spindle in a clockwise direction.
Install the nut and the washer on the threaded spindle. Turn the nut in a clockwise direction to loosen the injector sleeve.
Figure 8
1. Spindle
12. Remove the centring sleeve. Remove the injector sleeve with the threaded spindle.
Figure 9
1. Injector sleeve with threaded spindle

2. Holder
Clean the contact surfaces.
13. Fit the new injector sleeve with a new O-ring.

Figure 10
1. O-ring
2. Fitting compound
Coat the O-ring with fitting compound.
14. Screw the nut on the bolt, mount the washer, and install the bolt in the hold-down device.
Slide on the new injector sleeve. Fit the conical pin and lightly oil it.
Figure 11
1. Washer
2. Nut
3. Bolt
4. Conical pin
5. Injector sleeve
6. Hold-down device
15. Install the hold-down device.

Press the injector sleeve up to the limit stop on the hold-down device with slight pressure.
Figure 12
Hold-down device
16. Install the washer and bolt. Bolt tightening torque: 20 ±3 Nm (15 ±2 lbf ft).
Hold the bolt (2) with a suitable tool, then turn the nut evenly in a clockwise direction.
Figure 13
1. Tighten the bolt

2. Hold the bolt
3. Washer
4. Nut
17. Remove the bolt.

Remove the hold-down device.
Check the installation position of the injector sleeve.
Figure 14
1. Bolt
2. Hold-down device
18. Repeat the procedure for all the injector sleeves.
19. Install the injectors, see: Injectors, replacing all.

NOTE!
When cleaning the injector, never use a steel scraper, steel brush, or similar on the injector nozzle. There is risk that the
injector nozzle holes may be damaged or clogged, resulting in loss of power. If needed, use a rag soaked in kerosene or
similar.
20. Fill coolant, see: Coolant, changing.

Injectors, replacing all
Op nbr 237-002
Tools:
88800070 Spanner
88890300 Interface
9998007 Adapter
WARNING
Fuel under high pressure!
WARNING
Make sure that high-pressure fuel cannot come into contact with unprotected parts of the body when working with injection
equipment.
NOTICE
Maintain greatest possible cleanliness when working on the fuel system.
NOTICE
 Valve cover, removing

 Valve cover, installing
3. Remove the high pressure fuel pipes according to High pressure fuel pipes, replacing.
4. Remove the valve cover according to Valve cover, removing.
5. Disconnect the electric connections from the injectors and remove the bracket.
Figure 1
1. Bolt for the bracket
2. Electric connections for the injectors
6. Remove the nuts and the nozzles for the injectors.

If needed use 9998007 Adapter and 9996400 Impact puller.
Figure 2
Nozzles for the injectors
7. Remove the bolts on the injector yokes and remove the injectors using 88830206 Counterhold.
Figure 3
1. Bolt for the injector yoke

2. Injector
8. Write down the injector’s trim codes. Install the injectors with new O-rings and new copper gaskets. Install the injector yokes
and tighten the bolts according to step 1 in specification, see Fuel system, tightening torques.
Figure 4
1. O-ring
2. Copper gasket
9. Relieve the load on the injectors by loosing the bolts on the injector yokes.
10. NOTE!
Oil in the sealing rings. Make sure to fit the nozzles correctly in the groves in the sealing rings.
Install new nozzles with new sealing rings.
Figure 5
1. Grove in the sealing ring

2. Pin on the nozzle
Figure 6
Nozzles for the injectors
11. Install the nuts and tighten according to step 1 in specification, see Fuel system, tightening torques.
12. Tighten the injector yoke bolts according to step 2 in specification, see Fuel system, tightening torques.
13. Tighten the nuts according to step 2 in specification, see Fuel system, tightening torques.
14. Install the bracket, two bolts and connect the electric connections for the injectors. Tightening torques, see Fuel system,
tightening torques.
Figure 7
1. Bolt for the bracket

2. Electric connections for the injectors
15. Install the valve cover and the separator housing according to Valve cover, installing.
16. Install new high pressure fuel pipes, see High pressure fuel pipes, replacing.
17. Run Tech Tool operation 17030-2 Parameter, programming. Program the trim codes according to:
 P1G3O Trimcode Cylinder 1

 P1G3P Trimcode Cylinder 2
 P1G3Q Trimcode Cylinder 3
 P1G3R Trimcode Cylinder 4
 P1G3S Trimcode Cylinder 5
 P1G3T Trimcode Cylinder 6
Inlet throttle, replacing
Op nbr 254-059

Remove the charge air pipe and the charge air hose from the throttle.
Figure 1
3. Unplug the connector from the throttle.

Remove the attaching bolts.
Figure 2
1. Attaching bolts
2. Connector
4. Remove the throttle and the gasket.
Figure 3
Gasket
5. Install the new throttle. Use a new gasket. Plug in the connector.
6. Install the charge air hose and charge- air pipe on the throttle.Tightening torque, clamps:
Tghtening torque: 6 ±1 Nm (4.4 lb ft)
7. Install the plastic cover and restore the machine

Lever steering (CDC), functional check
Op nbr 660-011
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
NOTE!
This method is conditional on the pump pressures and steering pressures being according to specifications.
2. Warm up the machine until the hydraulic system reaches operating temperature, 60–80°C according to Hydraulic system,
warming up.
3. Check that lever steering (Comfort Drive Control) cannot be activated with switch SE4227 if:
 the armrest is raised, position sensor SE4227.

 SW4205 or the armrest SW4216 is in forward or reverse position.
Figure 1
SW4205
Figure 2
1. Activation CDC, SW4216

2. Steering lever
3. Kick-down button
4. Directional gear selector, SW4217
5. Armrest lever steering (CDC) SE4227
4. Release the parking brake.
5. Lower the armrest.
6. Activate lever steering (CDC), see figure.

Check that the adjacent symbol is shown on the display.
Figure 3
7. Move the steering lever so that the machine moves from right to left end-position. Check that the machine moves smoothly
and that the steering speed corresponds to the lever deflection.
Also check that the machine slows down smoothly before the end-positions.
If the machine does not move as it should, calibrate end-positions with the Tech Tool operation 64187-3 End position lever
steering right/left, calibration.
8. Move the lever so that the machine moves from left to right with rpm according to Lever steering (CDC), specifications.
Measure the time and compare it to Lever steering (CDC), specifications.
9. Move the lever to the left at the same time as you turn the steering wheel to the right. Check that the machine follows the
steering wheel and moves to the right.
Then let go of the steering wheel to check that the lever steering takes over and that the machine now moves to the left.
If the machine does not primarily follow steering wheel commands, the problem is likely a binding /jamming priority slide, see
CDC valve, lever steering, description.
10. Check that the lever steering (CDC) disengages (symbol for lever steering turns off on the display) when you:
 raise the armrest

 operate the gear selector on the steering column
Figure 4
Lift/lower function, checking
Op nbr 912-226
NOTE!
This method is valid on the condition that the servo pressure is according to specifications.
1. Start and warm up the machine, see Hydraulic system, warming up.
2. Operate the lift and lower function, and check that the system works smoothly and that lift/lower speed corresponds to the
lever deflection.
Boom kick-out (automatic lift), checking
3. Activate the button for automatic lift (boom kick-out).
Figure 1
Automatic lift (boom kick-out)
4. Lower the boom to ground level. Move the lever backwards to hold position and check that the lift arms stop.
5. Deactivate boom kick-out (automatic lift).
Float mode, checking
6. Raise the boom until the lift pistons are in horizontal position.
7. Tilt in to end-position.
8. Activate float mode (see figure).
Figure 2
Float mode
9. Then move the lowering lever forward until you feel that the magnet holds it in place.
When float mode is activated, the lift arms are held up since the attachment lock rests on a mechanical stop.
10. Tilt forward and check that the boom drops.

Figure 3
11. Tilt back and check that the boom returns back up.
Figure 4
12. Turn off float mode.
Single-acting lift, function check
13. Lower the boom to the ground.
14. Activate single-acting lift (see figure).
Figure 5
Single-acting lift
15. Tilt back against end-position and check that the boom lifts up.
16. Turn off the function for single-acting lift.
Lift and lower time, checking
17. Check lift and lower times according to Function times, specifications.
Lubrication oil pressure, checking with pressure gauge
Op nbr 221-022
Tools:
NOTE!
The engine must be warmed up before checking the oil pressure.
2. Remove the plug and install the tools.
Figure 1

3. Start the engine. Check the oil pressure, see Lubrication system, specifications.

Remove the tools and install the plug.
Lubrication, every 50 hours
Op nbr 173-303
Boom, grease
1. Grease joints that can be reached from the left side.

NOTE!
In tough conditions, these should be greased daily.
Figure 1
1. Grease points
2. Grease joints that can be reached from the right side.

NOTE!
In tough conditions, these should be greased daily.
Figure 2
1. Grease points
Op nbr 173-304
Upper frame joint bearing, steering cylinders, attachment bracket and attachments, grease
1. Grease the upper frame joint bearing and the steering cylinder's front and rear bearings on the machine's left side.
NOTE!
In aggressive/corrosive conditions, greasing should take place every 50 hours.
Figure 1
1. Steering cylinder's grease points

2. Frame joint, upper bearing
2. Grease the steering cylinder's front and rear bearings on the machine's right side.
NOTE!
Figure 2
1. Steering cylinder's grease points
3. Grease the attachment bracket, left and right side. Also grease the greased bearings on associated attachments.
NOTE!
In tough operating conditions, grease daily.
Figure 3
1. Attachment bracket's grease points

Op nbr 173-305
Propeller shaft's support bearing and universal joints, grease
1.
NOTE!
In aggressive/corrosive conditions, the universal joints should be greased every 50 hours.
Figure 1
1. Universal joints
2. Splines joint
3. Support bearing
Op nbr 173-306
Lower frame joint bearing, grease
1.
NOTE!
Grease more often as needed.
Figure 1
1. Frame joint, lower bearing

Maintenance service, every 50 hours
Op nbr 173-004
1. Place the machine in service position according to: Service position 1
2. Basic service
3. Oil-bath air cleaner reservoir oil, checking

NOTE!
Optional equipment
4. Lubrication, every 50 hours
5. Tyre wear and air pressure, checking
6. Engine oil level, checking

Op nbr 173-007
1. Place the machine in service position according to: Service position 1.
2. Basic service.
3. Oil-bath air cleaner reservoir oil, changing.

NOTE!
Optional equipment
May need to be serviced at a shorter interval.
4. Engine pre cleaner cyclone type, cleaning

NOTE!
Optional equipment
5. Lubrication, every 50 hours.
6. Lubrication, every 250 hours.
8. Engine oil level, checking
9. Restoring of the machine.

Op nbr 173-010
Tools:
2. Basic service
3. Diesel particulate filter, regenerating
4. Engine oil and filter, changing
5. Fuel filters, replacing
6. Oil-bath air cleaner reservoir oil, changing

NOTE!
Optional equipment

NOTE!
Optional equipment
8. Coolers, cleaning
9. Coolant level, checking
13. Automatic central lubrication filter, replacing

NOTE!
Optional equipment
15. Transmission oil level, checking
16. Hydraulic oil level, checking

Op nbr 173-012
Tools:
9993831 Support
88830136 Test unit
88830138 Plug
88830138 Plug
88890074 Multimeter
88890300 Interface
88890253 Cable
88890305 Cable
Feeler gauge
Hose 3/4" L: 3.5 m (11.5 ft)
1. Brake pressure and function, checking
2. Service brake, testing
3. Parking brake function, checking
5. Basic service
6. MATRIS and Tech Tool, reading
7. Parking brake pads, checking

NOTE!
Optional equipment

NOTE!
Optional equipment
13. Hydraulic tank sediment, draining
14. Engine air cleaner primary filter, replacing
16. Service brake disc wear, checking

17. Cab prefilter, replacing
18. Cab main filter, replacing

NOTE!
Optional equipment
If the machine has carbon filter or asbestos filter.
20. Engine belt condition, checking

NOTE!
Optional equipment
27. Battery, checking
29. Fire suppression system, checking

NOTE!
Optional equipment

Op nbr 173-014
Tools:
885812 Timing tool
9993831 Support
14290266 Hose
88830136 Test unit
88830138 Plug
88830138 Plug
88830214 Fixture
88890074 Multimeter
88890300 Interface
88890253 Cable
88890305 Cable
Feeler gauge
Hose 3/4" L: 3.5 m (11.5 ft)
5. Basic service

NOTE!
Optional equipment
12. Oil-bath air cleaner reservoir filter insert, cleaning

NOTE!
Optional equipment

NOTE!
Optional equipment
14. Hydraulic tank sediment, draining
15. Hydraulic tank return oil filter and magnetic rod, cleaning and replacing
16. Hydraulic oil tank breather filter, replacing
17. Valves, adjusting
19. Engine air cleaner secondary filter, replacing
20. Fuel tank breather filter, replacing
23. Boom suspension accumulator, checking

NOTE!
Optional equipment
24. Drive axle oil, changing
25. Axle breather filters, replacing
30. Coolant freezing point, checking
32. Hinge, lubricating

NOTE!
Optional equipment

NOTE!
Optional equipment

Op nbr 173-018
Tools:
885812 Timing tool
9809685 Cable
9993831 Support
14290266 Hose
88830136 Test unit
88830138 Plug
88830138 Plug
88830214 Fixture
88830268 Pump
88890074 Multimeter
88890300 Interface
88890253 Cable
88890305 Cable
Feeler gauge
Hose 3/4" L: 3.5 m (11.5 ft)
Metal plugs
5. Basic service

NOTE!
Optional equipment
12. Oil-bath air cleaner reservoir filter insert, cleaning

NOTE!
Optional equipment

NOTE!
Optional equipment
14. Hydraulic oil, changing
15. Hydraulic tank return oil filter and magnetic rod, cleaning and replacing
16. Hydraulic oil tank breather filter, replacing
17. Valves, adjusting
19. Engine air cleaner secondary filter, replacing
20. Fuel tank breather filter, replacing
23. Boom suspension accumulator, checking

NOTE!
Optional equipment
24. Transmission oil, filter and suction strainer, changing and cleaning
26. Axle breather filters, replacing
28. Cab extra prefilter cyclone type, replacing

NOTE!
Optional equipment
32. Coolant freezing point, checking
34. Hinge, lubricating

NOTE!
Optional equipment


NOTE!
Optional equipment
43. Hydraulic pressure, checking

This interval only contains the methods that supplement the relevant standard interval.See example in Foreword,Service.
Op nbr 173-019
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
1. Service position 1
2. Diesel particulate filter, checking and cleaning

Op nbr 173-022
Rubber hose ø7 mm (0.79 in) flexible rubber hose
Bucket
1. Service position 1
2. Coolant, changing
3. AdBlue®/DEF tank, breather filter, replacing
4. AdBlue®/DEF pump unit filter, replacing

Maintenance service, first 1000 hours
Op nbr 173-042
Tools:
9993831 Support

MATRIS and Tech Tool, reading
Op nbr 173-332
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
1. Connect Tech Tool Service Tool to the machine. Read off logged errors. (The read-off is saved automatically.)
2. Start MATRIS from Tech Tool and run a read-out.
3. Exporter the read-off from MATRIS.

Mechanical release of parking brake
Op nbr 176-001
WARNING
The parking brake is now non-functional. The machine may only be towed if it is connected to another vehicle by a towbar.
2. Remove the rubber protection. Use counterhold and turn the adjusting screw counter-clockwise until the inner piston's
surface is flush with the outer piston, then the parking brake has been released mechanically.
Figure 1
1. Brake disc
2. Adjusting screw
Figure 2
1. Outer piston
2. Inner piston
3. Brake pads, 2 pcs.
4. Brake disc
3. Reinstall the rubber protection.
NOTICE
Leaving the machine without resetting the parking brake function requires an out of function label on the steering wheel.
Restoring
4. Start the engine and let it idle. Release the parking brake with the switch. Remove the rubber protection and turn the
adjusting screw so that the inner piston has contact with the brake disc. Turn out 1/2 turn.
5. Check the parking brake's function according to Parking brake, function checking
Oil cooler, component location
For information on hydraulic transmission's cooling, see: Hydraulic transmission, description
Figure 1
1. Oil cooler
Oil-bath air cleaner reservoir filter insert, cleaning
Op nbr 173-505
1. Loosen the fasteners and spin loose the bottom part.
Figure 1
2. Remove the filter and clean it with diesel.
3. Place the filter in the bottom part and install the bottom part.
Oil-bath air cleaner reservoir oil, changing
Op nbr 173-514

Weight:approx. 15 kg (33 lbs)
Figure 1
2. Remove the filter and place it on a clean surface. Drain the oil into a suitable container.
Clean the included parts.
Figure 2
1. Reference level for oil

2. Oil in both bowls
3. Fill new engine oil, see: Engine, fill quantities.
4. Place the filter in the bottom part and install it.

Oil-bath air cleaner reservoir oil, checking
Op nbr 173-504

Weight:approx. 15 kg (33 lbs)
Figure 1
2. Remove the filter and place it on a clean surface. The oil level should cover both bowls.
Figure 2
1. Reference level for oil
2. Oil in both bowls
3. Place the filter in the bottom part and install it.

Operator's seat, securing
WARNING
The work involves handling heavy components - failure to stay alert may result in severe crushing injuries.
Op nbr 852-010
Raising
1.
 Remove the panel on the cab wall behind the operator's seat.
 Unplug the connectors, the connector for the servo lever does not have to be unplugged.
 Remove the bolts behind the operator's seat.
 Pull out the seatbelt and raise up the operator's seat against the steering wheel.
To raise and fold forward the operator's seat maximally, the mat and the front floor plate have to be removed.
 Secure the operator's seat with the seatbelt around the steering column.
Figure 1
Raised operator's seat
Figure 2
Securing operator's seat
1. Seatbelt
Restoring
2.
 Loosen the seatbelt and let down the operator's seat.

 Install the front floor plate and the mat, if they were removed.
 Tighten down the operator's seat.
 Plug in the connectors.
 Reinstall the panel on the cab wall behind the operator's seat.
Parking Brake - Assembly
Op nbr 550-021
Tools:
½ inch socket
C-wrench, pin 6.35 mm, diam. 76.2 mm
1. Smear a thin layer of fluid (compatible with mineral oil-based hydraulic fluid) on the seals. Install the seals.
NOTE!
The outermost O-rings, see Fig. 1, should not be lubricated.
Figure 1
2. Insert the adjusting piston in the piston and magnet unit until it is flush with the bottom of the piston and magnet unit, see Fig.
2.
Figure 2
1. Adjusting piston
2. Piston and magnet unit
3. Install the piston and magnet unit in the brake caliper.

Figure 3
1. Cup springs, 5 pcs.
4. Smear heat-resistant lubricant on the cup springs. Install them as shown in Fig. 3.
5. Install the adjusting screw in the piston and magnet unit, see Fig. 4.
Figure 4
1. Adjusting screw
6. Install the threaded cap with the C-wrench, see Tightening torque:.
Figure 5
7. Install the brake pads in the brake caliper with the distribution screw and two hex nuts.
Parking Brake - Disassembly
Op nbr 550-019
Tools:
½ inch socket
C-wrench, pin 6.35 mm, diam 76.2 mm
1. Remove the parking brake, see Parking brake assembly, removing.
2. Remove the cap using the C-wrench, see Fig. 1. Remove the cup springs.
NOTE!
Make sure that the brake is not pressurized and that the adjusting screw has been loosened before the cap is removed.
3. Press out the inner piston from the piston and magnet unit, see Fig. 2.
4. Clean, then check for any damage and wear.
5. Remove all seals.

NOTE!
Install new seals every time that the brake has been dismantled.
Figure 1
Figure 2
Parking Brake - Installation
Op nbr 550-022
Tools:
½ inch socket
Torque wrench, minimum 271.2 Nm
1–⅛ inch wrench, combination wrench
9/16 inch combination wrench
Figure 1
1. Lock nut
2. Urethane spring
3. Attaching bolt
Figure 2
1. Connection port
2. Air bleeder screw
1. Fit the brake caliper over the brake disc. Install the attaching bolts loosely to support the brake caliper.
2. Tighten the adjusting screw until the brake pads have solid contact with the brake disc to keep the brake in place. Install the
rubber cap over the adjusting screw.
3. Install washers, urethane springs, and lock nuts on the attaching bolts. Tighten the attaching bolts until they are in contact
with the urethane springs. Then tighten another ⅔ turn (approx. 1.78 mm compression) so that the urethane springs have the
correct preload.
4. Tighten the lock nuts, see Tightening torque: .
5. Connect the hydraulic hose to the connection port on the side of the brake caliper, see Fig. 2.
6. Bleed the system as follows:
1. Start the machine and release the parking brake. Open the air bleeder screw slowly, see Fig. 2. Note any air bubbles.
Close the air bleeder screw and tighten it. See Tightening torque:.
NOTE!
Use an air bleeder hose on the air bleeder screw to lead away fluid from the brake pads.
2. Repeat step 1 until there is no more air in the brake oil.
7. Adjust the pad clearance, see Parking brake, adjusting.
8. Install the splash guard (optional equipment) and cover plate on the machine's left side.
Figure 3

2. Cover plate
Parking brake assembly, removing
Op nbr 550-018
Tools:
1–⅛ in wrench, combination wrench
1. Place the machine in service position 1, see Service positions
2. Remove the splash guard (optional equipment) and the cover plate on the machine's left side, see Fig. 1.
Figure 1

2. Cover plate
3. Disconnect the hydraulic hose and plug it.
Figure 2
1. Adjusting screw
2. Attaching bolts
3. Hydraulic hose
4. Distribution screw
4. Remove the distribution screw.

5. Remove the rubber cap from the adjusting screw. Use counterhold and turn the adjusting screw counter-clockwise until the
inner piston's surface is flush with the outer piston, then the parking brake has been released mechanically.
6. Remove the brake pads.
7. Loosen the lock nuts for the attaching bolts. Pull out the upper attaching bolt slightly and secure the brake caliper with a
tensioning strap.
8. Lift out the brake caliper.

Parking brake function, checking
Op nbr 173-384
1. Apply the parking brake.
2. Turn on the ignition. Make sure that the transmission disengagement function is not activated.
3. Hold in the key for service on the keypad to access the menus for service.
Press the key for transmission on the keypad.
Select “APS settings” and then “Service”.
Press ESC on the service display unit to see the rpm on the display.
Figure 1
4. Start the engine and select gear F3.
5. Press down the accelerator pedal slowly until it bottoms out. The machine should not move.
6. If the machine moves, troubleshoot using the information in the diagnostics tab.
Parking brake pads, checking
Op nbr 173-323
1. Check the thickness of the pads. Minimum measurement is 5 mm (0.2 in).
Figure 1
X = thickness
Parking brake, adjusting
Op nbr 550-002
Figure 1
2. Inner hex nut
3. Outer hex nut
Figure 2
1. Adjusting screw
Tools:
½ inch socket
Feeler gauge, 0.25–0.40 mm
1. Start the machine and release the parking brake. Turn off the machine.
2. Loosen the outer hex nut for the distribution screw, se Fig. 1. Turn the distribution screw until the clearance between the
brake disc and the inner brake pad is 0.25–0.40 mm. Check the pad clearance with the feeler gauge.
3. Hold the distribution screw in place and tighten the outer hex nut against the inner hex nut, see Tightening torque:.
4. Turn the adjusting screw, see Fig. 2, until the clearance between the brake disc and the outer brake pad is 0.25–0.40 mm.
Check the pad clearance with the feeler gauge.
5. Start the machine, apply and release the parking brake three times. Check the clearance between the brake disc and the
brake pads, adjust if needed.
Parking brake, function checking
Op nbr 550-023
After the repair is finished, check the function according to the following.
1. Apply the parking brake.
3. Hold in the key for service on the keypad to access the menus for service.
Press the key for transmission on the keypad.
Select “APS settings” and then “Service”.
Press ESC on the service display unit to see the rpm on the display.
Figure 1
4. Start the engine and select gear F3.
5. Press down the accelerator pedal slowly until it bottoms out. The machine should not move.
6. If the machine moves, troubleshoot using the information in the diagnostics tab.
Parking brake, replacing brake pads
Op nbr 550-014
Parking brake, adjusting

NOTE!
2.
Figure 1
1. Splash guard[1]
2. Cover
Remove the splash guard [2] and the cover under the steps on the machine's left side.
3.
Figure 2
1. Adjusting screw
Start the engine and let it idle. Release the parking brake.
Remove the rubber cap and loosen the adjusting screw.
Turn off the engine.
4.
Figure 3
2. Inner hex nut
3. Outer hex nut
Loosen the nuts and remove the distribution screw. Remove the brake pads.
5. Install the new brake pads.

Install the distribution screw and nuts without locking them.
Adjusting
6. Adjust the parking brake according to Parking brake, adjusting.
7. Install the rubber cap over the adjusting screw.
8. Install the cover and the splash guard[3].
9. Remove the blocks by the wheels. Restore the machine and check that there are no error codes.
10. Check function according to Parking brake, function checking
Pressure relief valve (PRV), replacing
Op nbr 237-034
Tools:
88890300 Interface
NOTE!
When replacing the pressure relief valve, the fuel rail pressure sensor must be replaced!
3. Remove the pressure relief valve.
Figure 1
NOTE!
Collect the fuel that drains.
NOTE!
Work carefully so that no impurities enter the fuel distribution pipe.
4. Lube the O-ring, threads, and the seal edge on the new pressure relief valve with oil.
Figure 2
1. Thread
2. O-ring
3. Seal edge
5. Install the new pressure relief valve (PRV).

Tightening torque, see: Fuel system, tightening torques.
6. Unplug the connector for the fuel rail pressure sensor and replace the fuel rail pressure sensor. Plug in the connector.
Tightening torque, see Fuel system, tightening torques
NOTE!
When replacing the pressure relief valve, the fuel rail pressure sensor must be replaced!
Figure 3
1. Fuel rail, pressure sensor

2. Connector
7. Turn on the electric power with the battery disconnector.
8. Run Tech Tool operation 23768-3 Pressure relief valve, reset
9. Bleed the fuel system: See Fuel system, bleeding.
11. Check visually for any leaks in the fuel system.

Refrigerant, draining
Op nbr 874-002
Tools:
9812446 Nipple
Refrigerant cylinder
NOTICE
Service workshops in certain countries must be accredited in order to handle refrigerants and to perform service work on
the air conditioning. At an accredited workshop, there must be at least one person in a supervisory position with certified
competence. Accreditation is applied for at national authorities, according to the country’s governing legislation.
WARNING
 Wear tight-fitting goggles.

 Use rubber gloves and protect other areas of exposed skin (risk of frostbite).
 Avoid inhaling the refrigerant. Exposure to refrigerant can cause irritation of eyes, nose and throat. Inhaling concentrated
refrigerant can cause cardiac arrest.
 Never mix R134a with air when checking for leaks. If something in the system generates a spark or the system is
pressurized, the mixture may ignite.
1. Calculate the volume of the refrigerant cylinder, the cylinder may only be filled to 75%. Tare (refrigerant cylinder's empty
weight, stated on cylinder) plus net weight (refrigerant cylinder's max. content, stated on cylinder) minus the refrigerant
cylinder's present total weight (use the supplied scales) is equal to the amount of refrigerant that can be held by the
refrigerant cylinder. To find out how much refrigerant there is in the machine, see the specifications for the relevant machine
type.
Figure 1
1. 88830256 Draining tool

2. Scales
3. Refrigerant cylinder
2. Leave the refrigerant cylinder standing on the scales with the valve at the top.
3. Connect the red hose from "Discharge" on the drain tool to the refrigerant cylinder. Tighten the quick-coupling.
4. Connect the blue hose from "Suction" on the drain tool to the machine's low-pressure connection. Tighten the quick-coupling.
5. Zero the scales.
6. Open the valve on the refrigerant cylinder.

7. Open the "Discharge" valve on the drain tool.
8. Turn the middle valve on the drain tool to “Recovery”.
9. Start the drain tool by pressing the switch.
10. Open the “Suction” valve to drain the refrigerant.
11. When the “Suction” pressure gauge has reached a vacuum pressure and the scales have stopped increasing, let the drain
tool run for another five minutes.
12. Turn the middle valve to “Self-clearing” and, when the pressure gauge shows a vacuum pressure, the drain tool can be
turned off.
13. Close all valves and remove the connections from the machine.
Refrigerant, filling incl vacuum pumping
Op nbr 874-001
Tools:
88830260 Adapter
 Troubleshooting, air conditioning unit (AC)
NOTICE
Service workshops in certain countries must be accredited in order to handle refrigerants and to perform service work on
the air conditioning. At an accredited workshop, there must be at least one person in a supervisory position with certified
competence. Accreditation is applied for at national authorities, according to the country’s governing legislation.
WARNING
 Wear tight-fitting goggles.

 Use rubber gloves and protect other areas of exposed skin (risk of frostbite).
 Avoid inhaling the refrigerant. Exposure to refrigerant can cause irritation of eyes, nose and throat. Inhaling concentrated
refrigerant can cause cardiac arrest.
 Never mix R134a with air when checking for leaks. If something in the system generates a spark or the system is
pressurized, the mixture may ignite.
1. To find out how much compressor oil there is in the system, see the specifications for the relevant machine type.
2. In case of a major leak (e.g., major hose failure), most of the specified oil volume should be filled. In case of a minor leak
(e.g., a small crack), only a small amount of oil should be filled.
3. Turn 88830260 Adapter to the correct volume and fill it with the compressor oil.
NOTE!
The compressor oil should not be exposed to air more than is absolutely necessary.
4. Connect 88830260 Adapter on the machine's low-pressure connection and fill the compressor oil by joining it.
5. Check that the system seals tight before filling, see Cooling unit, leak detection.
Vacuum-pumping
6. Connect the red hose from the pressure gauge bank to the high-pressure connection on the machine. Tighten the quick-
coupling.
7. Connect the blue hose from the pressure gauge bank to the low-pressure connection on the machine. Tighten the quick-
coupling.
8. Stand the refrigerant cylinder upside-down on the scales.
9. Connect the yellow hose from the pressure gauge bank to the refrigerant cylinder. Tighten the quick-coupling.
10. Open all valves on the pressure gauge bank.
11. Start the vacuum pump. When the gauge is below 3 millibar (0.3 kPa, 0.044 psi) and does not move more than 0.20 millibar
(0.02 kPa, 0.003 psi), vacuum-pump for another 10 minutes, then vacuum-pumping is done.
Figure 1
1. Low-pressure gauge
2. High-pressure gauge
3. Vacuum gauge
12. Close all valves on the pressure gauge bank.
Filling
13. To find out how much refrigerant should be filled, see the specifications for the relevant machine type.
14. Open the valve on the refrigerant cylinder.
15. Start the scales and zero it by pressing “Tare”.
16. Open the yellow valve on the pressure gauge bank.
17. Open the blue valve pressure gauge bank to start filling.
NOTE!
If the correct refrigerant volume is not reached, close the blue valve and continue with step 18.
18. Start the machine and turn on the AC with max. fan and max. cooling.
19. Open the blue valve to continue filling.
20. When the scales show the correct refrigerant volume, close the valve on the refrigerant cylinder.
21. Check the pressure on the red and blue pressure gauges according to Troubleshooting, air conditioning unit (AC).
22. Turn off the machine.
23. Remove the connections from the machine.
24. Use 9511207 Leak detector AC and check for leaks around the connections. Install the protective caps on the connections.
Restoring of the machine
Op nbr 173-499
1. Install/close all hatches, lower/close the hood.

SCR muffler, replacing
Op nbr 254-127
Tools:
88890300 Interface
NOTICE
immediately.
NOTICE
For information about AdBlue®/DEF, see AdBlue®/DEF information.
Removing
2. Remove the sensor from the exhaust pipe.
Figure 1
1. Sensor

Figure 2
1. Dosing injector
4. NOx sensor

Figure 3

2. Attaching bolts
Figure 4
1. Mounting clamps
6. Connect a lifting device as shown and remove the SCR.

Figure 5
1. Lifting eye
Installing
8. Install the SCR.

9. Install the bracket. Do not install the attaching bolts
10. Install the mixing tube to set the position of the SCR. Make sure that the flanges are aligned.. Torque-tighten the attaching
bolts and v-clamp according to Inlet and exhaust system, tightening torques.
11. Make sure that the SCR is installed correctly and torque-tighten the mounting clamps according to Inlet and exhaust system,
tightening torques.
12. Install the bracket attaching bolts.

NOTE!
13. Install the exhaust pipe and the sensor.
NOTE!
NOTE!
Figure 6
17. To reset the soot and ash load, run TechTool operation 25474-3 Exhaust aftertreatment system, reset .
SCR system, dosing test
Op nbr 254-118
Tools:
88890300 Interface
Container
Measuring beaker
NOTE!
Let the machine cool down.
For information about AdBlue®/DEF, see AdBlue®/DEF information.
NOTICE
immediately.
1. Remove the mounting bolts from the AdBlue®/DEF-dosing injector.
Figure 1
1. Mounting bolts
2. Place the AdBlue®/DEF-dosing injector in a container as shown in the picture. Use a paper towel to cover the opening.
Figure 2
1. AdBlue®/DEF-dosing injector
2. Container
3. Run Tech Tool operation 25965-3 SCR system, dosing and follow the instructions in Tech Tool.
4. When the test is finished, compare the AdBlue®/DEF volume with specification, see Inlet and exhaust system, specification
5. Reinstall the AdBlue®/DEF-dosing injector. Tightening torque, see Inlet and exhaust system, tightening torques.
Seal for front output shaft, replacing
Op nbr 421-052
Tools:
88890180 Interface
1–⅛ in wrench, combination wrench
½ inch socket
Torque wrench, minimum 271.2 Nm
1–⅛ inch wrench, combination wrench
Service position
Parking brake assembly, removing
Parking Brake - Installation
2. Drain the transmission oil.

Volume, see: Hydraulic transmission, capacity
Removing
3. Remove the parking brake, see: Parking brake assembly, removing
4. Disconnect the propeller shaft from the hydraulic transmission and move it aside.
Remove the brake disc.
Figure 1
1. Propeller shaft
2. Bolt M12, 4 pcs.
3. Bolt, brake disc, 12 pcs.
5. Mark the drive flange's position in relation to the transmission. Remove the drive flange.
NOTE!
The marking is made to facilitate reinstallation. The propeller shaft and the output shaft easily end up in the wrong position.
If the drive flange has to be rotated to end up in correct position, lift a rear wheel and rotate the propeller shaft.
Figure 2
1. Bolt, drive flange, 2 pcs.
6. Remove the old seal ring and the O-ring. Use a pry bar.
Figure 3
1. O-ring
2. Seal ring
Installing
7. Install the new O-ring and the new seal ring. (See Figure 3.)
8. Install the drive flange according to the marking.

Tightening torque, see: Transmission, tightening torques.
Figure 4
1. Bolt, drive flange, 2 pcs.
9. Install the brake disc.
10. Install the front propeller shaft on the hydraulic transmission.

Tightening torque, see: Propeller shafts, tightening torques.
NOTE!
If the drive flange has to be rotated to end up in correct position, lift a rear wheel and rotate the output shaft.
Figure 5
1. Propeller shaft
2. Bolt M12, 4 pcs.
3. Bolt, brake disc, 12 pcs.
11. Install the parking brake, see: Parking Brake - Installation.
12. Fill oil in the hydraulic transmission.

Volume, see: Hydraulic transmission, capacity.
13. Restore the machine and check functions according to: Parking brake, function checking.
Seal for rear output shaft, replacing
Op nbr 421-054
Service position
2. Drain the transmission oil.

Volume, see Hydraulic transmission, capacity.
Removing
3. Mark the propeller shaft's and drive flange's position in relation to the axle.
Disconnect the rear propeller shaft from the hydraulic transmission and move it aside.
NOTE!
The marking is made to facilitate reinstallation. The propeller shaft and the output shaft easily end up in the wrong position. If
the drive flange has to be rotated to end up in correct position, lift a rear wheel and rotate the output shaft.
Figure 1
1. Marking
2. Bolt M12
4. Remove the drive flange.

Figure 2
1. Bolt M12
2. Drive flange
5. Remove the seal and the O-ring.
Figure 3
1. O-ring
2. Seal ring
Installing
6. Install a new O-ring and a new seal. (See Figure 3.)
7. Install the drive flange. Tightening torques, see: Transmission, tightening torques.
Figure 4
1. Bolt M12
2. Drive flange
8. Install the rear propeller shaft on the hydraulic transmission.

Tightening torque, see: Propeller shafts, tightening torques.
NOTE!
If the drive flange has to be rotated to end up in correct position, lift a rear wheel and rotate the output shaft.
Figure 5
1. Marking
2. Bolt M12
9. Fill oil in the hydraulic transmission.

Volume, see: Hydraulic transmission, capacity.

Secondary steering pump, checking and adjusting working pressure
Op nbr 647-091
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
Checking of working pressure
2. Turn the steering wheel until the machine has reached right full lock (end-position).
3. Place blocks in front of and behind the wheels.
6. Connect the computer to the test socket in the cab and start Tech Tool Service Tool .
7. Start “64721-3 Secondary steering, test” in Tech Tool Service Tool.
8. Start “Activation: secondary steering pump”.
9. Turn the steering wheel against the machine's right full lock (end-position) and, at the same time, read off the “secondary
steering pump pressure”. Compare the value to Secondary steering pump, specifications.
Adjusting working pressure
11. Remove the mat and the rear floor plate in the cab.
12. Adjust the pressure by turning the pressure adjusting screw (clockwise to increase pressure).
Figure 1
1. Secondary steering pump, pressure adjusting screw
14. Start “64721-3 Secondary steering, test” in Tech Tool Service Tool.
15. Start “Activation: secondary steering pump”.
16. Turn the steering wheel against the machine's right full lock (end-position) and, at the same time, read off the “secondary
steering pump pressure”. Compare the value to Secondary steering pump, specifications.
19. Start the engine and check that there are no error codes.
Service brake disc wear, checking
Op nbr 173-322
Feeler gauge
1. Apply the service brake and block the brake pedal in applied position with a suitable spacer.
NOTE!
The brake has to be applied during the entire wear check.
Figure 1
1. Spacer
2. Check the brake pressure. Go to service mode and read off the brake pressure. The brake pressure must be over 2 MPa (20
bar/290 psi) during the whole operation.
3. Start the engine and charge the brakes if the brake pressure is too low. Turn off the engine and continue from, and including,
step 2.
4. Remove the wear indicator cap.
Figure 2
1. Indicator
5. Press in the wear indicator pin until it stops.

6. Measure the distance between surface A and B with a feeler gauge. For max. and min. values, see: Wheel brake,
specification.
Figure 3
1. Feeler gauge
2. Indicator pin
Figure 4
A. Nipple, flat surface

B. Indicator pin, flat surface
1. Wear indicator pin

2. Nipple
3. Brake plate
4. Brake disc
5. Brake piston
7. Install the protective cap over the wear indicator.
8. Repeat steps 4–8 for all brakes.
9. If the brake disc is worn out, change brake disc according to Brake discs, changing.
10. Release the brake pedal.

Service brake, testing
Op nbr 173-383
1. The brake test must be carried out in a place where there is no risk of injuries to personnel or damage to equipment. The
ground must be clean and have good friction (dry asphalt or similar). The machine must not be loaded.
2. Press and hold in key 8 on the keypad for approx. 4 seconds. When prompted “Go to Service mode”, press SELECT.
Information
Go to Service mode
No Yes
3. Scroll to TEST and press SELECT, choose Brake test and press SELECT, choose On, press SELECT.
4. Engage gear position F and accelerate when the text “Accelerate over 20 km/h” is shown on the information display, brake
maximally when the text “Brake to standstill” is shown on the information display.
The retardation value is shown on the information display.
5. If the wheels lock and slide on the ground surface, the test has to be repeated.
6. The three latest test values are saved in Brake test log.
7. Min. acceptable retardation value see, Brake system, specifications

NOTE!
The value according to specifications is to be considered as an absolute minimum value. If reduced brake function is
suspected, continue to check the brake system.
Servo pressure, checking and adjusting
Op nbr 914-055
Tools:
Checking
2. Lock the frame joint with the frame joint lock. Place blocks in front of and behind the wheels.
Figure 1
4. Release the pressure in the servo system by moving the servo levers back and forth 10–15 times.
5. Connect the 60 bar sensor to 88830213 Measuring equipment.
6. Connect 88830213 Measuring equipment to the pressure check connection on the load lowering block.
Figure 2
1. Load lowering block

7. Start the engine. Let it run at low idle speed.

Tilt in against end-position.
Servo pressure, see Servo system, specifications.
Adjusting
9. Adjust the servo pressure on the central block's pressure reducing valve. One revolution equals approx. 0.5 MPa (5 bar, 73
psi).
Figure 3
1. Adjusting servo pressure, pressure reducing valve

2. Adjusting brake pressure, pressure reducing valve
3. Central block
10. Again check the pressure.

Servo pressure, checking at the spool in control valve
Op nbr 914-063
Tools:
9993831 Support
E-1706
 Servo pressure, checking and adjusting
NOTE!
Before checking the servo pressure by the slide, check and adjust the servo pressure, see Servo pressure, checking and adjusting.
2. Depressurize the system by moving the servo levers back and forth 10–15 times.
NOTE!
If the machine is equipped with 3rd/4th function, the start key should be in position 1.
4. Disconnect the servo line from the control valve for the function in question and install tool E-1706, 88830213 Measuring
equipment.
Figure 1
Check servo pressure by slide
1. E-1706
2. Tilt in (plus side)
3. Lift (plus side)
5. Start the engine and remove the support.

Operate the function in question against end-position and read off the servo pressure, see Servo system, specifications.
If the measured pressure is too low:

Check the servo pressure (main servo pressure), see Servo pressure, checking and adjusting, at the same time as the servo
pressure by the slide is checked. If the main servo pressure drops when the function is used, this may be caused by an internal
leakage in the control valve.

Shift valve, checking
Op nbr 993-030
Tools:
88830046 Dump body support
88830385 Adapter
88830385 Adapter
 Service positions
1. Place machine in the service position. Refer to Service positions.
2. Run up the load body and secure with 88830046 Dump body support.
3. Remove the cover on the box with the lubrication oil pump.
Figure 1
Figure 2
2. Connection between main line A and distribution block
3. Connection between main line B and distribution block
4. Test button
5. SE9901, monitor, lubrication pressure
4. Disconnect main lines A and B from the distribution block.
5. Transfer the nipples located in the block to each main line.
Figure 3
1. Main line
2. Nipple from distribution block
3. 88830385 Adapter
6. Connect 88830385 Adapter and 936439 Testing nipple to each of the two lines. Connect 88830213 Measuring equipment to
the measuring nipples.
7. Turn the ignition to position I, running position.
8. Hold in the test button on the pump for approx. 4 seconds to start a test cycle.
9. Now the pump should pump out grease in one of the lines and the pressure in the line should increase to max. level, see
Automatic lubrication system, specifications.
NOTE!
SE9901, monitor, lubrication pressure, which controls shutdown of the pump does not work when the greasing system is
disconnected.
If the pump does not reach max. pressure, one of the following may be the cause:
 Air bubbles in the grease. Bleed the system, see Bleeding air.
 Ambient temperature is too low for the grease. Replace the grease with grease adapted to the current temperature, see
Recommended lubricants.
 The pump has failed and should be replaced, see applicable parts of Automatic lubrication pump unit, reconditioning.
10. Finish the cycle by turning the ignition to the Off position 0 or by disconnecting the pump's electrical connection for a short
time.
Figure 4
1. Electrical connection
11. Turn the ignition to position I, running position.
12. Start another test cycle by holding in the test button for approx. 4 seconds. Now the pump should start in the other line and
the pressure in the measuring equipment should increase quickly to max. level, see Automatic lubrication system,
specifications, at the same time as the first line becomes pressureless. If the pressure does not drop in the first line and th
pressure does not increase in the second line, then the shift valve has failed and must be replaced, see applicable parts of
Automatic lubrication pump unit, reconditioning.
13. Finish the test by turning the ignition to the Off position 0 or by disconnecting the pump's electrical connection for a short
time.
14. Make sure that there is no residual pressure in the lines.

15. Remove the measuring equipment. Restore the lubrication oil lines and install the cover on the box for the pump.
16. Restore the machine from service position.

Shock valve lift function, checking
Op nbr 912-023
Tools:
9993825 Check valve
9993831 Support
88830175 Pump

NOTE!
2. Release the pressure in the system by moving the servo levers back and forth 10–15 times.
NOTE!
4. Remove the shock valve for the lift function and plug the hole with the plug from 9993825 Check valve.
Figure 1
Control valve, seen from underneath
1. Shock valve, lift
Check the opening pressure of the shock valve by pumping until the pressure no longer increases. Then the shock valve has
opened and the opening pressure can be read off.
Opening pressure, see Control valve, specifications.
Figure 2

2. Shock valve
3. 88830175 Pump
6. Install the shock valve on the control valve.

Shock valve, tilt function, checking
Op nbr 912-021
Tools:
9993831 Support
88830175 Pump
9993825 Check valve

NOTE!
2. Release the pressure in the system by moving the servo levers back and forth 10–15 times.
NOTE!
4. Remove the bracket that holds the control valve.
Figure 1
1. Bracket
6. Remove the shock valve for the function in question and plug the hole with the plug from 9993825 Check valve.
Figure 2
Control valve
1. Shock/anti-cavitation valve tilt out (-)

2. Shock/anti-cavitation valve tilt in (+)
Check the opening pressure of the shock valve by pumping until the pressure no longer increases. Then the shock valve has
opened and the opening pressure can be read off.
Opening pressure, see Control valve, specifications.
Figure 3

2. Shock valve
3. 88830175 Pump
8. Reinstall the shock valve on the control valve.
10. Install the bracket that holds the control valve.
11. Install the cover plate on the front frame.

Stall speed, checking
Op nbr 236-002
1. Warm up the machine until the engine and hydraulic transmission have reached operating temperature, approx. 50 °C – 90 °
C.
When checking, turn off major power consumers and the air conditioning (if installed).
WARNING
Risk of personal injury! Make sure that no persons are in front of or behind the machine.
3. Press and hold in key 8, Service, on the keypad for approx. 4 seconds.
Figure 1
Keypad
4. Press key 2, Transmission.
5. Use the arrow keys, press until the APS-mode is shown on the display, then press Select. Select Service mode and press
Select.
NOTE!
Check which APS-mode is selected before it is changed.
Figure 2
APS-mode
Figure 3
Service mode
7. Check the high idle rpm, see Engine, specifications.
8. Apply the foot brake so that the wheels lock and the machine cannot move. Select third gear, forward or reverse.
9. Apply full throttle. Read off the engine rpm, see stall speed with torque converter. Engine, specifications.
10. Restore the APS-mode, press Select, and finish with Esc.

Starter motor, replacing
Op nbr 331-018
1. Place the machine in service position, 1 see Service position
WARNING
Turn off the battery disconnect switch and remove the start key before starting to work.
Removing
2. Remove the fender on the machine’s left side.
3. Remove the side plate.
4. Mark and disconnect the control cables for the starter motor relay on the starter motor.
Figure 1
Figure 2
1. Control cables
2. Starter motor relay
3. Ground connection (2 pcs.)
4. Battery connection
5. Starter motor solenoid
5. Disconnect the battery's connection cable and ground cable for the starter motor.
6. Disconnect the cabling for the aftertreatment fuel metering unit.

Figure 3
Aftertreatment fuel, metering unit
7. Remove the bolts for the aftertreatment fuel metering unit and move it aside.
8. Remove the bolts (3 pcs.) that hold the starter motor.
9. Remove the starter motor. Weight: 14 kg (30 Ibs)
Installing
10. Use new gaskets and install the starter motor.
11. Install the bolts and connect the cabling for the aftertreatment fuel metering unit.
12. Install the battery's connection cable and ground cable for the starter motor, as well as the control cables for the starter motor
relay.Tightening torques, see Starter motor, tightening torques.
13. Install the side plate.
14. Install the fender.
15. Restore the machine to operating condition and check that no error messages appear.
Steering accumulator removed, checking
Op nbr 645-037
Tools:
88830175 Pump
E-2015
See also Safety when working on hydraulic systems.

 Accumulator, discarding
1. Connect E-2015 to removed accumulator. Connect the other tools according to the figure.
Figure 1
Checking removed accumulator
1. 88830175 Pump
2. Accumulator
3. E–2015
2. Pump oil into the accumulator.

After a few pump strokes the pressure will increase quickly up to the precharge pressure and then increase slowly.
Precharge pressure: See Steering, specifications.
The accumulator should be discarded if the precharge pressure is less than that stated in specifications, see Accumulator,
discarding.
Steering accumulator, installing
Op nbr 645-114
1. Install the accumulator on the bracket.
Figure 1
Steering accumulators
2. Remove 935486 Plug, ORFS from the hose.

Install the hose on the accumulator.
3. Reinstall the bracket with the accumulators and install the bolts.
Figure 2
1. Bolt
5. Test-run and check that the steering is smooth and responsive, and that the steering angle is proportional to the steering
wheel movement. Check that there are no leaks.
Steering accumulator, removing
Op nbr 645-113
Tools:
935486 Plug, ORFS
 Safety when working on hydraulic systems
2. Depressurize the accumulators for the steering system according to Safety when working on hydraulic systems.
3. Remove the bolts from the bracket for the accumulators, on the machine's left side.
Figure 1
1. Bolt
4. Angle out the bracket with the accumulators.
5. Disconnect the hose from the accumulator.

Install 935486 Plug, ORFS on the hose.
6. Remove the accumulator from the bracket.

Figure 2
Steering accumulators
Steering system, checking and adjusting working pressure
Op nbr 645-028
Tools:
1. Park the machine on solid and level ground.
up.
Checking standby pressure
4. Connect the sensor for 600 bar (60 MPa/8700 psi) to the gauge.
5. Connect the pressure gauge to the checking point on the steering valve.
Figure 1
Pressure check connection
7. Read off the standby pressure on the pressure gauge and check the value for standby pressure in Hydraulic pump (P2),
specifications.
Check max. steering pressure
8. Release the parking brake.
9. Turn the steering wheel to full lock (end position). Read off the pressure gauge while turning the steering wheel some more.
10. Check the value for steering pressure (P-pressure) in Steering, specifications.
11. If the value is not correct, turn the steering wheel to left full lock to exclude a problem with the shock valve.
Adjusting steering pressure
13. Adjust the steering pressure on the pressure limiting valve on the central block.
Turn the screw 30 degrees clockwise to increase the pressure approx. 10 bar (1 MPa/145 psi)
Figure 2
1. Pressure limiting valve for steering pressure on central block
15. Check the value for steering pressure (P-pressure) in Steering, specifications.
16. Turn off the engine and remove the pressure gauge.
18. Check the function of the steering system according to Steering system, function check.
Steering system, function check
Op nbr 600-001
NOTE!
This method is conditional on correct setting of pump 2.
 Steering system, checking and adjusting working pressure
1. Start the engine and warm up the machine until the hydraulic oil is at operating temperature, 60–80°C, according to Hydraulic
system, warming up.
2. Check that the steering operates smoothly and is responsive, and that the steering lock is in proportion to the steering wheel
movement.
Check the steering time
3. Turn the steering wheel to steer the machine from left to right full lock (end-position) with rpm according to Steering,
specifications. Make a note of the time that this takes.
4. Turn the steering wheel to steer the machine from right to left full lock (end-position) with rpm according to Steering,
specifications. Make a note of the time that this takes.
5. Repeat a few times to obtain a correct time. Check and compare the time to Steering, specifications.
6. If the value does not match, check the steering's max. pressure, see Steering system, checking and adjusting working
pressure.
Check the steering time with working hydraulics
7. Turn the steering wheel to steer the machine from left to right full lock (end-position) at the same time as you move the boom
from the ground to top position with rpm according to Steering, specifications. Make a note of the time that this takes.
8. Repeat a few times to obtain a correct time.
9. Check the time in Steering, specifications.
10. If the value is not correct, there may be a malfunction in the central block or pump 2.
System test
Run a system test to check the lubrication system's function or to obtain extra greasing, e.g., after washing.
The test button used to start a system test is located on the front of the pump unit.
A test cycle can only be run when the pump is between two ordinary lubrication cycles (not during an ongoing lubrication cycle).
There are two types of test cycle
Single test lubrication cycle
The pump runs one lubrication cycle, through only one main line.
Figure 1
Test button
Turn the start key to position 1.
Press in the test button for approx. 2-6 seconds.
The lubrication cycle starts, and during the whole test cycle the control light will flash (2 sec on /2 sec off) to indicate that the function
is activated.
The test cycle ends automatically.
NOTE!
If a single test lubrication cycle is used after washing greasing of main line channel A must be completed and then, without turning
the start key to position 0, press in the test button one more time to obtain lubrication in channel B.
Continuous test lubrication cycle
The pump runs an unlimited number of pump phases and continuously pumps out lubricants alternating between the main line's
channel A and channel B.
Turn the start key to position 1.
Press in the test button for more than 6 seconds (the control light will flash 0.2 sec on/0.2 sec off during the whole test cycle to
indicate that the function is activated).
The lubrication system starts a lubrication cycle via main line A, which then is followed by a lubrication cycle via main line B, and so
on.
If a problem occurs during the on-going test cycle an error code will be shown after the test cycle is finished. See Signal codes.
The test cycle does not end automatically.
End the test cycle by turning the start key to position 0.
The following Tech Tool operations are available for function group 3.
30901-3 Power supply, control unit (ECU), Check the power supply to the control units.
check
38335-3 Displayed machine hours, correction Correction of the machine hours.
Correction is performed:
 After replacing a control unit which contains the parameter machine hours
and where the original value has not been transferred from the old to the
new control unit.
 When displayed machine hours doesn’t correspond with actual operating
time.
39796-3 Telematics control unit, reset Resets the Telematics ECU to virgin mode at first setup or after transferring of the
ECU to another machine. This operation will also be used to check the current
connection status
39797-3 - Telematic system status, check Check the status of the Telematics control unit’s different communication systems.
Tilt, functional check
Op nbr 912-127
1. Start and warm up the machine, see Hydraulic system, warming up.
2. Operate the tilt function and check that the system works smoothly and that the tilt speed corresponds to the lever deflection.
3. Activate automatic tilt (bucket positioner). Tilt forward all the way. Then move the lever to the hold position and check that the
tilt movement stops at the pre-set position.
Figure 1
Automatic tilt (bucket positioner)
4. Turn off the function automatic tilt (bucket positioner).

Transmission oil level, checking
Op nbr 173-382
1. With the machine at operating temperature and the engine running at low idle, the transmission oil level should be between
Max. and Min. in the lower scale of the level glass. With the engine off and cold transmission oil, the level should be between
Max. and Min. in the upper scale of the level glass.
Figure 1
1. Fill point
2. Level glass
Transmission oil, filter and suction strainer, changing and cleaning
Op nbr 173-456
Tools:
WARNING
Risk of burns! Use protective work gloves.
Draining
1. Place a container under the transmission. Remove the drain plug and drain the oil.
Change volume, see: Hydraulic transmission, capacity
NOTE!
Handle the oil in an environment-friendly manner.
Figure 1
1. Drain plug
2. Place a container under the oil filter to collect any spills.

Remove the transmission oil filter. Use 9996671 Oil filter wrench.
NOTE!
Handle the old used filter in an environment-friendly manner.
Figure 2
1. Transmission oil filter
3. Smear new oil on the filter seal and install the filter. Tighten the filter according to the instructions on the filter.
4. Remove the oil sump. Remove the suction strainer and clean it.
Weight approx. oil sump: 11 kg (24.3 lbs)
Figure 3
1. Oil sump
Filling
5. Check the O-ring on the drain plug.

Install the suction strainer, a new gasket, the oil sump, and the drain plug.
6. Fill transmission oil at the fill point. For cold transmission oil, the level should be between Max. and Min. on the upper scale of
the level glass.
Warm up the machine to approx. 70 °C.
For warm transmission oil, the level should be between Max. and Min. on the lower scale of the level glass.
Change volume, see: Hydraulic transmission, capacity.
Figure 4
1. Fill point
2. Level
Transmission, calibration
Op nbr 421-099
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
Calibration shall be run
1. After changing transmission.

2. After dismantling and assembling, even without replacing parts.
3. After changing GPMECU3.
Calibration is performed with Tech Tool
1. Place the machine in service position 1 according to Service position. Leave the battery disconnector on. The machine does
not have to cool down.
Hold in the key for service on the keypad to access the menus for service.
Press the key for transmission on the keypad. Select “APS settings” and then “Service".
Figure 1
3. Select “Oil temperature".

Start the engine. Apply the service brake, engage 3rd gear Forward, and give full throttle. Warm up the transmission to 80 °C
(176 °F).
Figure 2
4. Calibrate the transmission with Tech Tool according to: 42101-3 Transmission, calibration.
5. After finished calibration, perform a function check, see Transmission, function check.
Op nbr 421-100
1. Check the oil level before start.
2. Start the machine and check that there are no active error messages for the transmission.
3. Warm up the transmission. Check the oil level with warm transmission.
4. Operate the machine and check that gearshifting works. Forward/Reverse as well as all gears (1–4) in all APS-modes
(positions). Press the key for transmission on the keypad to select and shift APS-mode.
5. Activate transmission disengagement and operate the machine. During braking, the transmission should be disengaged.
6. After finished test, check that there are no error messages.

Troubleshooting, air conditioning unit (AC)
Troubleshooting should be performed on a warmed up machine and at an ambient temperature of at least +20 °C (77 °F).
1. Check the AC-compressor belt's tension and condition.

2. Check that the cab's recirculation filter is intact and clean.
Clean or replace if needed.
3. Check that the evaporator and condenser are clean and allow free flow of air.
4. Check that the evaporator is fastened securely and that it is undamaged, as well as that other seals in and around the AC-
unit are in good condition.
5. Set the temperature control for the heater unit to Min. position and the recirculation control to Max. position.
6. Start the engine, engine speed approx. 1,000 rpm.
7. Start the AC-unit and set the cab fan to Max. speed.
8. Check that the AC-compressor's magnet clutch is engaged, that is, that the hub rotates. Listen to hear that the magnet clutch
engages.
9. Check that the heat control valve closes the coolant flow through the radiator. Feel with your hands that the pipes or hoses
are not warm.
10. Check that any air valves are intact and that the plastic foam seals seal against the valves.
11. Check the thermostat's function. When the compressor cuts out in the cyclical cut-in/cut-out sequence, the temperature
measured on the compressor's suction pipe by the evaporator should be 1 ±1 °C (32 — 35.6 °F) when the ambient
temperature is +25 °C (77 °F) or lower.
12. Check the pressure in the system using the pressure gauge kit on the recycling station, see: Refrigerant, filling incl vacuum
pumping.
Diagnosis of abnormal pressure gauge readings

NOTE!
The pressure gauge valves must be screwed in completely.
NOTE!
Grey on the pressure gauges show normal range.
Black arrow is in normal range and grey arrow is outside normal range.
Figure 1
Malfunction Possible cause

A = Low-pressure is too high. Compressor's magnet clutch slips or does not engage.
B = High-pressure is normal or too low. Expansion valve is blocked in open position.
The compressor's suction pressure valve is defective.
The compressor is damaged.
Figure 2

A = Low-pressure is too low The thermostat is defective.
B = High-pressure is high or normal. Expansion valve is closed, that is, blocked or clogged.
Receiver drier is full of moisture.
Stop in refrigerant line between filter and expansion valve.
Figure 3

A = Low-pressure is normal or too low. Warm air enters evaporator or cab.
B = High-pressure is normal. Warm water enters the heating system's heat exchanger.
Ice forming in evaporator unit.
Figure 4

A = Low-pressure is too high or normal. Possible normal operating pressure at high ambient temperature
(>43 °C)
B = High-pressure is too high. Too much refrigerant filled (30–35% more than prescribed
amount)
Impurities in condenser.
Stop in high-pressure side between compressor, condenser, and
filter.
NOTE!
Stop can only be in the area around the service connection for
the high-pressure. Not on the low-pressure side.
Figure 5

A = Low-pressure is normal or too low. Possible normal operating pressure at low ambient
temperatures.
B = High-pressure is too low. Small refrigerant volume, 70 - 75% below normal volume.
Expansion valve is closed (blocked) or clogged.
Stop on low-pressure or high-pressure side between filter and
evaporator.
Stop between compressor and condenser or condenser and
filter, however, for high-pressure side.
Figure 6

Pressure gauges for low-pressure or high-pressure show same Defective compressor.
value.
A possible cause is incorrect alignment of the belt pulleys, the
drive belt slips.
The compressor's magnet clutch slips or is defective.
Turbocharger, replacing
Op nbr 255-071
NOTICE
NOTICE
Figure 1
3. Disconnect the oil pressure pipe.
Figure 2
1. Oil pressure pipe

2. Oil return hose
3. Clamp
4. Bracket
4. Disconnect the return oil hose.
5. Remove the insulation.
6. Remove the clamp.
7. Loosen the bolts for the exhaust pipe bracket.
8. Remove the turbocharger.

Figure 3
Attaching bolts
9. Clean the contact surface on the exhaust manifold.
10. Install the new turbocharger. Tightening torque, see Inlet and exhaust system, tightening torques.
NOTE!
Use a new gasket and a new clamp!
11. Tighten the bolts for the exhaust pipe bracket.
12. Install the clamp.
13. Install the bracket for the oil pressure pipe.
14. Install the heat insulation.
15. Install the return oil hose. Tightening torque, see Inlet and exhaust system, tightening torques.
NOTE!
Use a new gasket!
16. Connect the oil pressure pipe. Tightening torque, see Inlet and exhaust system, tightening torques.
NOTE!
Use new washers!

Tyre wear and air pressure, checking
Op nbr 173-338
WARNING
Tires installed on a split rim may explode and cause very severe injuries.
1. A few simple rules when inflating tires

• Never stand to the side of the tire when inflating tires installed on split rims. Use a self-attaching air chuck with a hose long
enough to enable you to stand outside the trajectory path and danger zone when inflating tires, see figure.
• Make sure that no persons are inside the danger zone when inflating the tire.
• When measuring tire pressure, the machine must be without load.
• Spare tires should only be inflated enough to keep the rim's parts in place.
• Secure a loose wheel with a cage, cables, or chains before inflating it with air. Before removing the cage, check that the tire
is installed correctly on the rim. Any adjustments are done on a completely deflated tire.
• Do not try to adjust side rings or lock rings when the tire is pressurized.
• Tires run with less than 80% of normal pressure, or where the rim or tire can be suspected of being damaged, may not be
inflated with the wheel installed on the machine.
Figure 1
2. For pressure in tires, see the Operator's Manual (Specifications - wheels) or the tire manufacturer's recommendations.
Update of automatic lubrication system
Op nbr
Adapter cable 17213655 is required when updating the central lubrication system.
1. Loosen the lubrication hoses and cable connection from the old pump unit and remove it.
2. Install the new pump unit and connect the lubrication hoses.
3. Connect adapter cable 17213655 between the pump unit and the existing cable harness.
4. Connect a PC and check the parameter settings for each machine model. See parameter settings: Parameter settings
5. If the system pressure sensor is not replaced with a new resistor 22 kΩ, the parameter setting: "Enable PS without resistor"
shall be highlighted in the section "Timer activation options" under the tab "Parameters". See figure
Figure 1
Parameter settings
Valve cover, installing
Op nbr 214-038
1. Clean all sealing surfaces.
2. Install the valve cover. Tightening torques, see Engine, tighten torques.
Figure 1
Valve cover
3. Install the plastic cover panel. It is only fastened with two clips.
Figure 2
Plastic cover panel
4. Install the crankcase ventilation housing.
Figure 3
Crankcase ventilation
5. Connect the fuel injector connectors and place the cable harness in posittion. Install the cable harness cover.
Figure 4
1. Fuel injector connector

2. Cable harness cover
6. Connect the main connectors and the connector to the inlet manifold temperature sensor.
Figure 5
1. Main connectors (2 pcs)

2. Connector to inlet manifold temperature sensor
7. Remove the bolts and lower the muffler. Install the bolts.
Figure 6
1. Bolts
8. Install the exhaust elbow.
Figure 7
Valve cover, removing
Op nbr 214-037
2. Markup the position of the exhaust elbow and remove the clamp
Figure 1
3. Remove the bolts and lift up the muffler. Attach the bolts to secure the muffler.
Figure 2
1. Bolts
4. Unplug the main connectors and the inlet manifold temperature sensor using a screw driver.
Figure 3
1. Main connectors (2 pcs)

2. Inlet manifold temperature sensor
5. Remove the cable harness cover and unplug the fuel injector connectors. Move the cable harness aside.
Figure 4
1. Fuel injector connector

2. Cable harness cover
6. Remove the crankcase ventilation housing from the valve cover and move it aside.
Figure 5
Crankcase ventilation
7. Remove the plastic cover panel. It is only fastened with clips. Loosen the two sensor cables to access to the valve cover's
bolts.
NOTICE
Carefully clean around the valve cover to prevent dirt and debris from getting into the engine while work is in
progress.
Figure 6
Plastic cover panel
Remove the valve cover bolts. Part the clamp for the air filter. Remove the valve cover.
Figure 7
Valve cover
NOTE!
The valve cover gasket is vulcanized together with the cable channel. Be careful when removing the valve cover. Make sure
that the valve cover gasket remains on the engine.
Valves, adjusting
Op nbr 173-314
Tools:
885812 Timing tool
88830214 Fixture

NOTE!
Figure 1
1. Intermediate wall
2. Install 88830207 Rotation tool over the attaching bolts for the belt pulley.
Figure 2
1. 88830207 Rotation tool
3. Loosen the clamps that hold the pipes before and after the flexible tube.
4. Remove the flexible tube.
5.
Figure 3
1. Bolt
7. Remove the bolts and remove the plastic cover. Remove the dust seal by pressing lightly on the pressure points and then
raise the dust seal at the lifting points.
Figure 4
1. Plastic cover
2. Dust seal
8. Loosen the bolts for the oil separator for the crankhouse ventilation. Unplug the connectors.
Figure 5
1. Oil separator
2. Connector
9. NOTICE
Observe the greatest possible cleanliness!
Remove the valve cover.
10. Rotate the crankshaft with 88830207 Rotation tool to the position where the valves on cylinder 6 overlap eachother. Mark the
position on the vibration damper to easier find the position for overlapping later in the operation.
Figure 6
Overlapping means that the exhaust valve is about to open and the inlet valve is about to close. In this position it should not
be possible to rotate any of the push rods by hand for the cylinder in question.
11. Adjust the valve clearance for each cylinder according to the gray markings in the figure. Procedure for adjusting:
1. Loosen the adjusting screw's lock screw on the rocker arm.

2. Install the timing tool on the adjusting screw.
3. Turn the adjusting screw by hand just until zero clearance is obtained between rocker arm and valve. Set the timing
tool to zero.
NOTE!
Make sure that the adjusting screw is not pulled too tight.
4. Turn the adjusting screw counter-clockwise 75° ±10° for inlet valve and 120° ± 10° for exhaust valve
5. Hold the adjusting screw in position and at the same time tighten the lock nut. Tightening torque: See Engine, tighten
torques
Figure 7
Grey-marked valves are only adjustable when the valves for cylinder 6 overlap.
 White arrows = inlet valves

 Black arrows = exhaust valves
12. Rotate the crankshaft with 88830207 Rotation tool until the valves for cylinder number 1 overlap eachother.
Figure 8
13. Adjust the valve clearance for each cylinder according to the gray markings in the figure.
Figure 9

14. Install the valve cover and tighten the bolts according to specification.
Tightening torque, see Engine, tighten torques.
15. Connect the connectors and install the oil separator.
Figure 10
1. Oil separator
2. Connector
16. Install the plastic cover and the dust cover.

Figure 11
1. Plastic cover
2. Dust seal
Figure 12
1. Bolt
18. Install 88830214 Fixture and adjust the muffler and the pipes before and after the flexible tube so that the tool fits perfectly.
Figure 13
1. 88830214 Fixture
NOTE!
Check at four spots on the pipe both before and after that the flexible pipe has contact with the fixture.
Figure 14
19. Tighten the clamps that hold the pipes before and after the flexible tube.
NOTE!
Make sure that the clamps are centred on the flanges. Tap carefully with a plastic hammer on the clamps if necessary.
20. Remove the fixture.
21. Replace the gaskets and the clamps and install the flexible tube.
22. Start the engine and check for leakage.
23. Remove 88830207 Rotation tool and install the intermediate wall.
Figure 15
Valves, adjusting
Op nbr 214-012
Tools:
885812 Timing tool
NOTE!
2. Lift the hood.
Figure 1
4. Install 88830207 Rotation tool over the attaching bolts for the belt pulley.
Figure 2
1. 88830207 Rotation tool
5. Loosen the clamps and remove the flexible tube, see Exhaust pipe, flexible tube, replacing.
Figure 3
1. Bolt
7. Remove the bolts and remove the plastic cover. Remove the dust seal by pressing lightly on the pressure points and then
raise the dust seal at the lifting points.
Figure 4
1. Plastic cover
2. Dust seal
8. Loosen the bolts for the oil separator for the crankhouse ventilation. Unplug the connectors.
Figure 5
1. Oil separator
2. Connector
9. NOTICE
Observe the greatest possible cleanliness!
Remove the valve cover.
10. Rotate the crankshaft with 88830207 Rotation tool to the position where the valves on cylinder 6 overlap eachother. Mark the
position on the vibration damper to easier find the position for overlapping later in the operation.
Figure 6
Overlapping means that the exhaust valve is about to close and the inlet valve is about to open. In this position it should not
11. Adjust the valve clearance for each cylinder according to the gray markings in the figure. Procedure for adjusting:
1. Loosen the adjusting screw's lock screw on the rocker arm.

2. Install the timing tool on the adjusting screw.
3. Turn the adjusting screw by hand just until zero clearance is obtained between rocker arm and valve. Set the timing
tool to zero.
NOTE!
Make sure that the adjusting screw is not pulled too tight.
4. Turn the adjusting screw counter-clockwise 75° ±15° for inlet valve and 120° ± 15° for exhaust valve
5. Hold the adjusting screw in position and at the same time tighten the lock nut. Tightening torque: See Valve system,
specification
Figure 7

12. Rotate the crankshaft with 88830207 Rotation tool until the valves for cylinder number 1 overlap eachother.
Figure 8
13. Adjust the valve clearance for each cylinder according to the gray markings in the figure.
Figure 9

14. Install the valve cover and tighten the bolts according to specification.
Tightening torque, see Engine, tighten torques.
15. Connect the connectors and install the oil separator.
Figure 10
1. Oil separator
2. Connector
16. Install the plastic cover and the dust cover.

Figure 11
1. Plastic cover
2. Dust seal
Figure 12
1. Bolt
18. Install the flexible tube and the exhaust pipe. Use new gaskets and clamps. See Exhaust pipe, flexible tube, replacing.
19. Remove 88830207 Rotation tool and install the intermediate wall.
Figure 13

W-ECU, replacing, non-programmed
Op nbr 398-005
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
1. Place the machine in service position 1, see Service position. Turn master switch to the “ON” position.
Figure 1
Right wall cover.
Figure 2
WECU location.
3. Connect Tech Tool and perform the operation 17092-3 Replace hardware (If there is no network connection at the machine,
perform operation 17093-3 Program with stored software.)
4. Turn master switch to the “OFF” position.
5. Change WECU.
6. Turn master switch to the “ON” position.

stored software.)
8. Perform operation 39796-3 Telematics control unit, reset.

W-ECU, replacing, pre-programmed
Op nbr 398-006
Tools:
88890300 Interface
88890253 Cable
88890305 Cable
1. Place the machine in service position 1, see Service position. Turn master switch to the “ON” position.
2. Remove the right cab wall cover.
Figure 1
Right wall cover.
Figure 2
WECU location.
Parameter, programming.
4. Turn master switch to the “OFF” position.
5. Change WECU.
6. Turn master switch to the “ON” position.

8. Perform the operation 39796-3 Telematics control unit, reset.

Window pane, installation
Installing window panes
Glue the window panes according to Windows, general, gluing.
Glue joint line type B shall be used in all cases.
Glue joint line type A shall be used at the top of the front window panes on both sides.
Figure 1
Glue joint line, type A
Figure 2
Glue joint line, type A
NOTE!
Old glue may cause problems.
Open time, glue (time from application to joining):
2–component glue — 3 minutes
1–component glue — 7 minutes
Apply glue between the front and side window pane by the screen print.
NOTE!
Avoid getting glue on the rubber strip.
Figure 3
1. Rear window
2. Door window
Rear window (1): First install the pane at the bottom edge, then press in at the top edge. Then press in evenly all around.
Door window (2): First install the pane at the top edge, then press in at the bottom edge. Then press in evenly all around.
Front side window, left (1): First install the pane at the top edge, then press in at the bottom edge. Press on the glue surfaces. Fill
gaps with glue according to Windows, general, gluing, smooth out the glue.
Figure 4
1. Front side window, left

2. Front windshield
Front windshield (2): First install the pane at the top edge, then press in at the bottom edge. Then press in evenly all around.
Figure 5
1. Small front side window, right

2. Side window, right
3. Front side window, right
Small front side window, right (1): Install the window pane, then press in evenly all around.
Side window, right (2): First install the pane at the bottom edge, then press in at the bottom edge. Then press in evenly all around.
Front side window, right (3): First install the panes at the top edge, then press in at the bottom edge. Press on the glue surfaces. Fill
gaps with glue according to: Windows, general, gluing, smooth out the glue.
Displacement of the front windows may be max. 4 mm (0.16 in), measured on the screen print in the windows' bottom edge.
Figure 6
Windscreen, replacing
Op nbr 843-002
Tools:
88830062 Wire unwinding device
88890051 Dispensing gun
9812521 Two cup suction lifter
9812521 Two cup suction lifter
Working platforms, 2 pcs
Adhesive
Sealant
Scraper with cut-out
Spacer
Figure 1
1. Ratchet handle 7. Blade for seam scraper

2. Parabolic chisel 8. Winch
3. Winch special 9. Mounting tool
4. Wire inserter 10. Safety glasses
5. Extension 11. Plastic cover
6. Seam scraper 12. Guide pins
Conditions
See Windows, general and play the instruction DVD supplied in the case before commencing work.
1. Park the machine in service position 1, see Service position
2. Place the two working platforms next to the cab.
3. Remove the windscreen wiper.
4. Remove any work lights.

5. Remove the screws for the roof and raise the roof at the front edge approximately 100 mm and secure it so that the front
window can be accessed.
Removal
6. Cut off the sealant, with a snap-blade for example, along the pane joint as a V-joint and especially in the corners of the
panes.
Figure 2
Scraping
7. Roll out about 6 metres of wire from the wire holder and cut.
WARNING
Risk of cuts! Wear safety glasses and use protective gloves.
8. Push the wire inserter between the pane and frame at the left-hand upper corner from the inside.
Hold the tip near to the panel otherwise there is a risk of the pane cracking.
Figure 3
1. Wire inserter
9. Insert both the wire ends in the wire inserter's hole and bend the wire tips backwards.
Figure 4
Wire inserter
10. Pull in the wires and then straighten the wire ends.
11. Place the wire along the join around the pane. Keep the wire in place with pins, which are positioned so that the wire runs
past the pins.
Apply a piece of tape at the lower edge of the pane to keep the pane in place when detached.
Figure 5
1. Cutting wire
2. Guide pin
12. Position the winch on the inside at the upper right-hand corner.
Figure 6
Winch position
13. Bend the wire ends and hook the wire in the winch drum and tension the wire.
14. Using the wire, cut along the join until the wire is directly above the winch.
NOTE!
When transferring the winch, the line reel must be braked by hand to prevent the wire from rolling up. Release the interlock with the
other hand.
15. Transfer the winch to a new position at the lower right-hand corner.
Figure 7
Winch position
Figure 8
16. Using the wire, cut along the joint until the wire is directly above the winch. Guide the wire by hand when at the join between
the panes.
17. Place the other winch at the lower left-hand corner.

Figure 9
Twin winches
18. Using the wire, cut along the joint until the wire is directly above the winch. Guide the wire by hand when at the join between
the panes.
19. Place both winches at the bottom, on the pane.
Figure 10
Twin winches
1. Cutting wires
20. Place the plastic protection at the bottom, on the pane to prevent damaging the instrument panel.
Figure 11
1. Parabolic chisel
2. Plastic cover
21. Using the wire, cut along the join with one winch until the wire reaches the pane. Use the parabolic chisel. Carry out the same
on the other side.
Use two glass lifters and lift the pane out. Weight approx.: 20 kg (40 lbs).
Installing
22. Cut the adhesive bead cleanly using the steel blade knife. Save about 3 mm (0.12 in) thickness of the old adhesive bead.
Turn the smoothing edge towards the adhesive bead for best results.
23. Place spacers, approx. 3 pcs on the panel under the pane.
Figure 12
1. Spacer
24. Mark the centre with a dash on the upper edge of the cab and the pane.
25. Heat the adhesive to a maximum of 70 °C (160 °F). Apply the adhesive using a glue gun and supplied nozzle to the upper
and lower edges of the cab.
Apply a thicker bead to the cab's upper angled corner.
26. Position the pane with the glass lifter. Weight approx.: 20 kg (40 lbs) Insert the upper edge first and then press the entire
pane into place. Adjust the pane according to the dash.
27. Apply a 50 mm (2 in) wide piece of masking tape 2 mm (0.08 in) from the glass edge on the outside and 0.5 mm (0.02) on the
inside of the pane.
28. Seal the joints between the panes from the outside with a generous amount of sealant. Ensure that the joints are properly
filled. The sealant must flow out onto the inside of the pane.
Figure 13
29. Smooth out the sealant on the outside using the cut-out of the plastic scraper. Ensure that there is enough extra sealant so
that the join takes the same shape as the cut-out on the scraper.
The corner of the scraper is used on the inside to remove any excess sealant.
Figure 14
30. Remove the masking tape by pulling it at right angles from the join.
31. Allow the adhesive and sealant to dry for: 1 day at 20 °C (70 °F).
32. Reinstall and screw the roof back into place.
33. Reinstall any work lights.
34. Install the windscreen wiper.
35. Clean the pane.

CE-marking, EMC-directive
CE-marking
(Declaration of Conformity, and CE–marking, only machines marketed within the EU/EEA). This machine is CE–marked. This means
that when delivered the machine meets the applicable “Essential Health and Safety Requirements”, as stated in EU's so-called
Machine Safety Directive, 98/37/EC. Any person who makes changes that affect machine safety is also responsible for the same,
and that governing legislation/standards are fulfilled.
As proof that the requirements are met, an EU Declaration of Conformity, issued by Volvo CE, is supplied with each separate
machine. This EU declaration also covers attachments and equipment manufactured by Volvo CE. The documentation is a valuable
document, which should be kept safe and retained for at least 10 years. The document should always accompany the machine
when it is sold.
If the machine is used for other purposes or with other attachments than described in this manual, safety must be maintained at all
times and in each individual case. The person carrying out such action is also responsible for the action which, in some cases, may
require a new CE-marking and the issue of a new EU Declaration of Conformity.
The EU's EMC–directive
The electronic equipment of the machine may in some cases cause interference with other electronic equipment, or the equipment
may be adversely affected by external electromagnetic interference, which may constitute safety risks.
The EU's EMC–directive on "Electromagnetic compatibility" provides a general description of what demands can be made of the
machine from a safety perspective, where permitted limit values have been determined and stated according to international
standards.
A machine or device which meets the requirements should be CE-marked. Our machines have been specifically tested for
electromagnetic interference. The CE marking of the machine and the declaration of conformity also cover the EMC directive.
If other electronic equipment is fitted to this machine, the equipment must be CE-marked and tested on the machine with regard to
electromagnetic interference.
EU's noise directive
Within the EU there is a noise directive, dictating that the machine may not have noise values that exceed a certain level. Values are
given on a decal that can be read from the outside of the machine. Also, every machine is delivered with a noise certificate where
Volvo CE ensures that the machine meets governing legislation. It is also important that this certificate accompanies the
machine when it is sold. It is also important that no changes are made to the machine's noise-damping components in order to
meet the limit values.
NOTE!
Modification of or removal of material which affects sound, e.g., noise-insulating, noise-dampening, or noise-absorbing materials, is
not allowed. Also, it is not permitted to make openings/holes in the cab or engine compartment as this may increase the noise level in
the cab.
Unauthorized modifications to the cab's roll-over protective structure (ROPS/FOPS)
Never make any unauthorized modifications to the ROPS, such as lowering the roof height, drilling, welding on fire extinguisher
brackets, radio antenna or other equipment.
Such unauthorized modifications will affect the structural strength of the ROPS cab and will void the certification.
The Roll Over Protective Structure (ROPS) has been approved following testing and meets standards according to ISO 3471-1.
The cab's roof is also tested and approved according to the standard for FOPS (Falling object protective structure, protection from
falling objects) according to ISO 3449.
All planned modifications of the cab's supporting construction must be discussed in advance with Volvo CE's engineering department
to determine if the modification can be performed without affecting the approval.
It is important that all persons in your organization, including management, are made fully aware of these rules involving ROPS.
If anyone in your company discovers that a certain machine has been modified in a non-approved manner, your company
must notify the customer and manufacturer in writing regarding the applicable machine and how it was modified.
Checking function
After work in a safety-related electrical system, a function check shall be performed to meet the standards in ISO 15998.
Safety-related electrical system
Systems that are covered by function check for safety-related electrical system:
 Comfort Drive Control, CDC. For checking, see Lever steering (CDC), functional check.
 Parking brake. For checking, see Parking brake, function checking.
 Service brakes. For checking, see Brake system, checking function, retardation.
 Transmission. For checking, see Transmission, function check.
 Differential lock. For checking, see Differential lock, function check
 Attachment lock. For checking, see Attachment locking, functional check
 Boom Suspension System. For checking, see Boom suspension system, functional check
Checklist after a fire or heat exposure
 As a precaution, seal rings (O-rings or axle/shaft seals) should always be handled as if they were made of fluor rubber, see
also section “Fluor rubber”.
WARNING
Avoid splashing when washing a machine damaged by fire. For this reason, never use high-pressure washing
equipment.
 Never touch burned components or parts with your bare hands when there is a risk that you may be exposed to contact with
melted polymers. First, wash thoroughly with plenty of lime water (a solution or a suspension of calcium hydroxide, i.e. slaked
lime).
Use thick, protective gloves made of rubber and wear goggles that are certain to protect your eyes.
 Seek medical attention if your skin may have come in contact with burnt fluor rubber. The skin should be treated with
Hydrofluoric Acid Burn Jelly or similar.
Symptoms may not appear until several hours after contact with burnt fluor rubber.
 Discard protective gloves, rags and other items that may have come into contact with burnt fluor rubber.
 Ensure good ventilation during the work.
 In case of splash in eyes: rinse immediately with plenty of water for at least 15 minutes. Contact a doctor.
Decontamination
Start decontamination as soon as possible. Certain substances spread quickly in the environment.
Decontamination after leakage/spill
Use suitable absorbent materials to absorb leaking oil or fuel, e.g., absorbent mats.
Prevent leaking oil/fuel from draining into sewers, storm drains, etc..
Contaminated soil and ground materials must be removed and collected in suitable containers.
Collected soil and absorbent materials should be submitted for disposal and destruction.
Decontamination after an accident
If possible, seal leaks from the machine.
Contain the leakage area with booms.
Add absorbent materials, e.g., Absol granulate or bark shavings/chips.
Stop leaking fluids so that they do not drain into sewers, storm drains, or ditches.
Collect the absorbent material and the layer of top soil, and place in sealed containers for transport to disposal and destruction.
Decontamination after a fire
Decontaminate in the same way as after an accident.
NOTE!
Be aware that certain substances can become poisonous and toxic following a fire. See Health hazards with paint, plastics and
rubber.
See also Checklist after a fire or heat exposure.
Environmental handling for the future
Figure 1
The world stands before gigantic challenges on environmental matters where clean water, climate change, and use of chemicals are
some of the most important issues. Volvo has an important function in meeting these challenges and contributing to a more
ecologically sustainable development. Quality, safety and environment are Volvo core values and have for a long time been integral
parts of our company and our products.
Volvo Construction Equipment works with continuous improvement of the machines' environmental performance. An important factor
to retain the machine's performance is the service offered by the workshops. This service manual contains recommendations,
warning texts, etc. to facilitate your work for the environment.
Environmentally hazardous fluids
Pay attention to leakage of fuel, oils and other fluids from the machine that may contaminate the environment.
Take appropriate actions to seal the leak immediately and decontaminate contaminated ground as soon as possible.
SeeDecontamination.
Oils and fuels
When emptying/draining oils and fuels, take appropriate actions so that unnecessary spills are avoided. In places where containers
for draining cannot be used, use a pump or hose for safe handling.
Air conditioning
Refrigerant R134a contains substances that affect the greenhouse effect and may never be released into the open air.
Service personnel who work with refrigerants must know the laws/rules that apply in the local country but also international rules.
Special training is recommended for all service work on the air conditioning. Many countries require certification from an authority for
such work. See also Safety when working with air conditioning refrigerant
Environmentally safe handling
Always choose an environmentally friendly alternative where one is available, e.g., biodegradable oils.
Always follow national and local environmental regulations.
All waste shall be brought to a waste handling company, approved by the authorities.
Oils and fluids
Oils and fluids, e.g., coolant, that are not reused shall be collected in tight-sealing containers and left for destruction.
Filters
Oil and fuel filters shall be drained and put into sealed containers before they are left for destruction.
Refrigerant R134a
Refrigerant R134a contains substances that affect the greenhouse effect and may never be released into the open air. Shall be
recycled according to instructions in separate component manual for the air conditioning.
Batteries
WARNING
Risk of chemical burns.
Contact with battery acid causes serious chemical burns.
Always wear personal protective gloves, goggles and clothing when handling batteries.
Figure 1
Corrosive acid
Batteries contain environmentally hazardous substances and corrosive acid. Shall be left for recycling.
Chemicals
Chemicals, paints, glue, cleaning agents, etc. shall be left for recycling and destruction.
Rubber and plastics
Rubber materials and plastics may not be burned. Shall be left for recycling.
Tires shall be handled according to special rules.
Electronics
Electrical and electronic waste, e.g., circuit boards and bulbs, shall be left for recycling.
Fire prevention measures
General
Figure 1
Fire extinguisher's recommended position on left front fender
1. Fire extinguisher
 There is always a risk of fire. Find out which type of fire extinguisher to use, where it is located and how to use it.
The fire extinguisher in the machine should be located as shown in the figure or in a compartment that can be locked.
 Fire-fighting equipment installed in or on the machine must be maintained in working order. Such equipment should be
regarded as a complement to the operator's own efforts in case of a fire.
The equipment should not be considered as a replacement of the operator's own fire fighting efforts.
 Fire extinguishers mounted on the machine or used when working on the machine must fulfil certain requirements. See the
Operator's Manual.
 At the slightest sign of fire, if the situation allows it and keeping in mind your own safety, take the following action:
 drive the machine away from the danger area.

 lower the lift arms to their bottom position so that the attachment rests on the ground.
 stop the engine by turning the ignition key to the "0" position.
 leave the cab.
 turn off the battery disconnect switch.
 start fighting the fire and call the fire department if necessary.
Figure 2
Smoking and open flames are absolutely forbidden when filling fuel or any time diesel fuel is in contact with the
open air.
 Smoking or open flames are absolutely forbidden close to the machine when filling fuel or at any time the fuel system is in
contact with the open air.
 Diesel fuel is flammable and must not be used for cleaning. Use an approved solvent instead.
 Remember that certain solvents can cause skin rashes and are usually flammable. Avoid inhaling solvent vapour.
 Engine starting aids are flammable. Store such items in cool and adequately ventilated areas. Remember that such aids must
not be used in combination with electric preheating of induction air.
Cleanliness
 Cleanliness is a decisive factor for operational reliability of the machine's systems. Therefore, keep the servicing area clean.
Oil or water make floors and steps slippery and are also dangerous in combination with electrical systems or tools. Oily
clothes or clothes drenched in grease constitute a serious fire hazard.
 Check daily that the machine and equipment, such as underbody skid plates, are free from dirt and oil. This reduces the risk
of fire and makes it easier to detect defective components or loose parts.
NOTICE
If a high-pressure washer is used when cleaning, work carefully since damage may be caused to electrical
components and insulation of the electrical cabling even at relatively moderate water pressure and temperature.
Protect electrical cabling in a suitable manner.
 Keep the machine especially clean when operating in environments with fire hazards, such as saw mills, garbage dumps, etc.
In such environments, suitable equipment to reduce the risk of accumulation of material and spontaneous combustion should
be fitted (for example muffler guard, radiator screen, heavy-duty cyclone pre-cleaner, etc.).
Electrical system
 Check electrical cables with regard to chafing damage and make sure that they cannot be damaged in such a way. This
applies particularly to unfused electrical cables, which are red.
For example, electrical cables between:
 Batteries
 Battery–starter motor
 Alternator–starter motor
 Cable to engine preheating coil.
 When unfused cables have been disconnected, it is important to check that they are re-connected and clamped in such a
way that they cannot be exposed to chafing. Unfused cables must not rest against oil and fuel hoses.
 When fitting any optional equipment, make sure that all cables (circuits) are connected across a fuse and routed and
clamped so that there is no risk of chafing.
Fuel, hydraulic and brake systems
 Check to make sure that there is no chafing damage to fuel, hydraulic and brake hoses.
Welding and grinding
 Welding and grinding on the machine may only be performed on well-cleaned areas and not in places filled with combustible
fluids, e.g., tanks, hydraulic pipes.
Work with extra care when welding and grinding near flammable objects.
 Never weld on a painted surface without first removing the paint. Welding on a painted surface generates, in addition to
health-hazardous vapours, technically inferior welds which may lead to future failures, with subsequent accidents.
Use personal protective equipment and, where possible, air extraction shall be used to handle gases from welding and
grinding.
Actions after a fire: see Checklist after a fire or heat exposure.

Health hazards with paint, plastics and rubber
Work on painted surfaces
Never weld or cut with a torch on painted surfaces. All paint decomposes when heated and generates a vast number of different
substances that may be irritating and, in case of repeated exposure, be very hazardous to health
The following safety actions must be taken:
 Remove the paint by sandblasting at least 10 cm (4 in) around the welding or cutting point (use breathing mask).
If the paint cannot be removed by sandblasting, it must be removed in another way, such as with paint solvent.
NOTE!
If the paint is removed with a paint solvent, use an air extractor, face mask/breathing protection and protective gloves.
 Grinding machines with high-speed grinding discs also heat the paint and should only be used if equipped with an air
extractor. Also wear a face mask or other breathing protection.
Rubber and plastics
WARNING
When heated, rubber and plastics can give off substances that are hazardous to personal health and the environment.
The following safety rules must be followed:
 Do not weld or cut with a torch near polymer materials (plastics and rubber) without first protecting them from the heat.
 Never burn polymer materials when scrapping them.
 Be careful when handling machines that have been exposed to fire or other intense heat. See also Checklist after a fire or
heat exposure.
 Always use gloves, safety goggles and a face mask or other breathing protection.
Fluor rubber
WARNING
Risk of serious corrosive injuries!
WARNING
When hydrogen fluoride rubber is heated, there is a risk of hydrogen fluoride gas build-up already at approx. 320 °C (610 °
F). When inhaled, the gas is extremely corrosive to respiratory tracts.
Certain seals designed to withstand high operating temperatures (i.e. in engines, transmissions, axles, brakes, hydraulic motors and
pumps) may be made of fluor rubber which, when heated to high temperatures, forms hydrogen fluoride and hydrofluoric acid.
Hydrofluoric acid is highly acidic and corrosive. It cannot be rinsed or washed off the skin and causes very severe burn and corrosive
injuries that take a very long time to heal. As a rule, injures tissue must be removed surgically.
Hydrofluoric acid may remain on machine parts for a very long time (several years) after a fire.
NOTE!
In case of contact with hydrofluoric acid, it may take several hours before any symptoms appear.
If swelling, redness, or burning pain appears, and contact with heated fluor rubber is suspected as the cause, seek immediate
medical attention.
If a machine or a component for a machine has been burnt in a fire or has been exposed to other intense heat, it may only be
handled by specially trained service personnel.
For all handling of machines after a fire, wear heavy-duty, neoprene rubber gloves and effective protective goggles. See Checklist
after a fire or heat exposure.
WARNING
Burning of painted parts, plastic or rubber parts constitutes a health hazard.
See Environmentally safe handling
Decontamination
The area around a heated machine part that is suspected to be made of fluor rubber shall be decontaminated by thorough and ample
washing with lime water (a solution or suspension of calcium hydroxide, that is, slaked lime) in water. After completing the
decontamination work, wash the gloves in the lime water and then discard them.
If the machine has been exposed to a fire or other intense heat, the safety actions in the following checklist shall be followed
unconditionally at all times: Checklist after a fire or heat exposure
Asbestos information
The components in Volvo CE's machines are free from asbestos, that is why it is important to use genuine Volvo spare parts.
Safety concerns everybody!
Always follow the instructions in the machine's operator's manual which supplements this Service Manual.
The Operator's Manual must always be kept in the cab for easy reference.
Volvo designs and manufactures machines with a high level of safety as well as effectiveness. All this work may be wasted if anyone
who is about to perform service on any of our machines does not read the safety instructions, or does not follow them, e.g., does not
replace guards, climbs on slippery machine parts instead of using a ladder, grabs a hold of hoses instead of handles or uses the
wrong tools for the job.
In order to maintain safe and efficient function, always use genuine Volvo spare parts intended and adapted for the machine. If other
spare parts than genuine Volvo are used then Volvo Construction Equipment cannot be held responsible for machine damage, and
warranty claims will be denied.
Machines seldom cause accidents, instead people often do.
A safety-conscious person and a well-maintained machine make for a safe, effective and profitable combination.
Those who do not follow the safety instructions and observe the warnings in this manual must make sure that their work
method is safe. Otherwise, there is a great risk of accidents, perhaps even accidents that result in fatalities.
WARNING
WARNING SYMBOL
This symbol is shown at various points throughout the manual. The appearance of it means "Warning, stay alert! Your safety may be
involved!"
Get to know the capacity and limits of your machine!
Safety rules when servicing
This section covers general safety rules when checking and servicing.
Other rules, information and warning texts are given in the Operator's manual.
CE marking
This machine is CE-marked. This means that, when delivered, the machine meets the applicable "Essential Health and Safety
Requirements", which are given in the EU Machine Safety Directive. If changes are made that affect the safety of the machine, the
person making the changes is responsible for the same.
Therefore, the following applies:
 Install communication equipment (two-way radio), mobile phone unit, etc. according to the manufacturer's instructions in
order to eliminate interference with electronic systems and components intended for the machine's function. See further CE-
marking, EMC-directive.
 When retro-fitting equipment in or on the cab; do not drill, weld or cut in the cab structure since such actions may impair the
operator's protection in case of roll-over. See further CE-marking, EMC-directive.
Before beginning any service work:

Service work performed incorrectly is hazardous.
Make sure that you have sufficient knowledge, correct information, correct tools and correct equipment before carrying out the
service in a correct manner.
Repair or replace damaged tools and equipment.
Place the machine in service position 1 or 2 acc. to: Service position
NOTICE
When lifting the machine, the frame joint should be locked and the marked eyes intended for lifting should be used.
NOTE!
No work should be carried out on the machine before the required knowledge is acquired.
Figure 1
Read the Operator's manual, plates and instructions before you operate the machine.
General
 Machine working in a environmentally contaminated area, see Working in environmentally contaminated areas
See also Checklist after a fire or heat exposure.
 If someone is to take over the job that you have started, make sure that this person is informed about what part of the work
has been completed and what remains to be done.
 When high-pressure washing the machine, do not aim the water jet directly at anti-slip surfaces or decals that are glued on.
WARNING
Only walk or step on the machine's prepared stepping surfaces, see operator's manual.
Figure 2
Do not step on the engine hood
 Never wear loose fitting clothing, for example, a scarf or jewellery, that can get caught and cause injury when working on the
machine.
 Always use a hard hat, safety glasses, gloves, protective work shoes and other protective items as required by the work
situation.
Figure 3
Protective equipment
 Always stop the engine when servicing the machine unless instructions on plates or in this manual state otherwise.
 Do not stand near the frame joint unless it has been locked with the frame joint lock.
NOTICE
There is a risk of crushing even with the engine off if the machine is equipped with an electric secondary steering
pump.
 Turn off the engine before opening engine covers, radiator casing, etc. Make sure that no tools or other objects that can
cause damage are forgotten in the machine.
 Keep engine covers, etc. closed when the engine is running and when the machine is operating.
Safety when handling accumulators
WARNING
If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious personal
injuries.
Before an accumulator is removed from the machine, the system must first always be depressurized, see Safety when working on
hydraulic systems.
Some accumulators contain pressure even if they are removed from the machine, so-called pre-charge pressure. Therefore, be very
careful during all handling and work with accumulators.
The pre-charge pressure must be lowered to atmospheric pressure before working on a piston accumulator.
Avoid exposing the accumulator to high temperatures and careless handling.
WARNING
care.
Discarded accumulators shall be punctured before they are scrapped to avoid the risk of explosion. See Accumulator, discarding.
Safety when handling oils and fuel
 When changing oil in engine, hydraulic system or transmission: Keep in mind that the oil may be hot and can cause scalding
or burn injuries.
 Engine, hydraulic and transmission oils as well as diesel fuel have a corrosive effect on mucous membranes, for example, in
eyes and throat and on skin. Therefore, take special care to keep such oils away from these sensitive body parts.
 When emptying/draining oils or fuel, steps must be taken to avoid unnecessary spills. In places where a container for
collecting the liquid cannot be used, use a pump or connect a hose to ensure safe handling. Oil released or spilled on the
ground will harm the environment and could also cause a fire.
Waste oils/fluids shall always be taken care of by a company authorized for this work. See Environmentally safe handling
 Remember the fire hazard!
Safety when handling the machine
Volvo Construction Equipment is only responsible if:
 the machine has been used correctly and has been maintained according to recommendations in the service manuals and
the machine's Operator's manual.
 prescribed service and inspections have been performed at the specified intervals.
 lubricant recommendations in the manual have been followed.
 no safety seals have been opened by an unauthorized person.
 all modifications and repairs have been performed in the manner prescribed by Volvo.
 only genuine Volvo parts/accessories, or attachments that fulfil Volvo's requirements have been used.
WARNING
Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating the
machine.
It is important that the operator reads and follows the instructions in the machine's Operator's Manual.
An untrained operator may cause serious injuries and fatalities.
Never operate a machine for which there is no Operator's Manual available.
Learn to understand the warning plates, symbols and operating instructions for the machine before you start operating.
A few simple safety rules
General
 Repair malfunctions or defects that affect safety as soon as possible.
Figure 1
Entering/leaving the machine
 Always wear a hard hat, protective goggles, gloves, work shoes and other safety items that your work requires.
 Avoid standing in front of or behind the machine when the engine is running.
 Always use a rubber window scraper or brush with a long handle when cleaning the outside of the windows in order to avoid
unnecessary climbing on the machine.
 When servicing the machine, i.e. changing light bulbs, a ladder may be needed.
 Make sure that stepping surfaces, service areas, handles and slip-protection are clean and free from oil, diesel fuel, dirt and
ice and that they're replaced if they are defective or missing.
 Check at regular intervals that all slip-protection is firmly attached. If not, these shall be attached or replaced.
 Always face the machine and use the steps and handrails when entering or leaving the machine. Use two hands and one
foot, or two feet and one hand. Do not jump!
Before operating
Figure 2
Read the Operator's Manual, plates and instructions before you operate the machine.
 Read the Operator's manual before you operate the machine! Follow the instructions for operating and perform the indicated
recommended actions before operating.
Some important rules below:
 Perform a control light test before starting the engine by turning the ignition key to position I, see Operator's Manual.
 Perform all safety checks prescribed in the Operator's manual.
WARNING
Never operate the machine if you are tired or under the influence of alcohol, medicine or other drugs.
 Before starting the engine indoors, make sure that the extraction capacity of the ventilation system is sufficient. The machine
is equipped with a diesel engine and the exhausts may be hazardous to your health. Make sure that ventilation is sufficient,
and avoid running the engine indoors for longer than necessary where ventilation is insufficient.
 Read all plates and instructions on the machine and in the Operator's manual before you operate or perform service on the
machine. Each one of these contains important information regarding safety, handling and service.
 Use the seat belt during all operation.
 Always sit in the operator's seat when you start the engine.
 The machine must be fully functional before it's put into operation, that is, all defects that may cause eventual accidents must
have been repaired.
 Never operate the machine for long periods without ventilation, or with a completely closed cab without the fan on (to avoid
lack of oxygen).
 Only step and stand on surfaces with slip-protected treads and hold on to the available handles and handrails.
Hip-type seatbelt
Figure 3
Use the seat belt during all operation
 If the seatbelt needs washing: Use a mild soap solution when washing and let the belt dry while it's fully pulled out before it's
rolled up. Make sure that the belt is installed correctly.
 Replace the seatbelt immediately if it's worn, damaged or the machine has been involved in an accident where the belt had to
take some strain.
 Modifications of the belt or its mountings is never permitted.
 The hip-type seatbelt is intended for one adult, not more.
 Always keep the belt rolled up when not in use.
When the engine is running
 Respect the warning lights. The red lights require immediate attention or consideration, see instructions in the Operator's
manual in the section Instruments.
 Apply the parking brake and make sure that the attachment/attachment bracket rests on the ground.
 Move the gear selector to neutral before you leave the machine.
WARNING
Risk of crushing injuries
 Do not stand near the frame joint unless it has been locked with the frame joint lock.
 Empty and tilt back the attachment before operating the machine on a road.
 Stop the engine and lower the attachment so that it rests on the ground before you leave the machine unattended.
When there is a risk of roll-over

The cab is the operator's protection and meets the standards for roll-over protection according to test standards, (ROPS), see further
CE-marking, EMC-directive Prerequisite for protection is that the operator uses the lap-type seat belt and remains in the cab in case
of a roll-over. Therefore, hold on to the steering wheel if the machine rolls over. Do not jump!
Falling objects
The cab is dimensioned to fulfill the requirements for objects falling on to the cab roof according to given test methods (that is, FOPS,
see further CE-marking, EMC-directive
Emergency exits from cab
The cab has two emergency exits, the door and the right side window.
Actions before recovering and towing
See Section 1, Towing
Actions after recovering and towing
WARNING
Do not forget to unlock the frame joint lock and secure it in the running position when the machine is to be operated again.
See Section 1, Service and Maintenance
Safety when lifting and supporting complete machine
Place the machine in service position, see Safety rules when servicing
Always use jacks and support equipment with sufficient capacity.
It is important to support the front and/or rear axle in a safe way before doing other work.
WARNING
Entering or working under the machine is not allowed when the machine is only supported on jacks.
Always work on one axle at a time, e.g., when changing wheel, changing brakes.
Method for front axle
Lift the machine with the machine's lift arms.
Place support stands at the designated support points according to the example.
Figure 1
1. Stand jack
2. Support point
Recommended method for rear axle

Prevent the rear axle from oscillating by locking it with jacks or wooden blocks between the frame and axle on both sides.
NOTE!
Do not forget to remove the oscillation lock before lowering the machine.
The machine must be secured with axle stands or stand jacks with sufficient capacity, 5-15 tons.
Support on each side under the rear frame's edge (not the belly plate) on an even and sufficiently large surface, see example in
figure.
Figure 2
Support points
1. 11668007 Hydraulic jack
With both wheels raised it is easier to rotate the hubs to get the wheel nuts in place.
Alternative method for rear axle
If there is no stand jack available, two garage jacks can be used instead (L150-L220).
NOTE!
Make sure that there is enough room for positioning axle stands.
Figure 3
On smaller machines (L50-L120), use a garage jack under the differential carrier assembly. Do not forget to lock the axle to prevent
oscillation. Place the axle stands under the frame's rear edge.
Figure 4
Support points
Do not use a jack with a small lifting surface under the differential carrier assembly.
Use a wheel trolley for safe handling of the wheels.
Figure 5
1. 11668010 Wheel trolley
Safety when working on hydraulic systems
The hydraulic systems on our loaders work at very high pressures, up to approx. 42 MPa (420 bar), (6,090 psi). In order to
prevent serious injuries, it is very important that the systems are maintained correctly and that all personnel who come into contact
with the machines act very carefully and pay special attention to any defects.
Persons who follow the guidelines below, and also place the machine in Service position when required Service position , have laid a
good foundation for avoiding accidents.
General
 Never adjust a pressure limiting valve to a higher pressure than that recommended by the manufacturer.
 A hydraulic hose that leaks, 'sweats', swells, or is damaged mechanically, shall be replaced as soon as possible to not have
an impact on safety and/or the environment. Replace the hose immediately! Pay attention to any leaks from hydraulic hoses
and connections. Take action to repair the leak before the part bursts!
WARNING
If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious personal
injuries.
WARNING
Leaking high-pressure hydraulic hoses may cause severe injuries. Fine jets have high penetrating capacity on bare skin.
Check for any leaks using a steel plate or a stiff board, never use your hands.
Only check-tighten leaking couplings and connections after the system has been completely depressurized.
Safety when handling accumulators
WARNING
care.
All pressure tanks must be opened carefully so that any residual pressure is released.
Discarded pressure accumulators shall be punctured before they are scrapped to prevent any risk of explosion. See Accumulator,
discarding, Accumulator, discarding and Accumulator, boom suspension system, discarding.
Before an accumulator is removed from the machine, the system must always be depressurized, see section Depressurizing
(releasing pressure).
Certain accumulators contain pressure even if they have been removed from the machine, a so-called precharge pressure.
Therefore, be extremely careful during all handling and work with accumulators.
Before any work is done on a piston accumulator, the precharge pressure must be reduced to atmospheric pressure.
Avoid exposing the accumulator to high temperatures and careless handling.
Depressurizing (releasing pressure)
An accumulated pressure remains in the system when the engine has been turned off. Before hose couplings, plugs, etc., in the
hydraulic, steering, fan, or brake systems may be opened, the residual pressure in the system must be reduced, by so-called
depressurizing.
The start key must be in position 1.
NOTE!
The machine and boom can move when the machine has been turned off due to the accumulator pressure.
NOTE!
The machine can be steered slightly also when it has been turned off due to the accumulator pressure.
 The accumulators for the Boom Suspension System (BSS) are depressurized according to: Boom suspension system,
hydraulic oil pressure in accumulators, depressurizing.
 The accumulators for the brake system are depressurized by pressing down the brake pedal 30–40 times.
In order to make sure that no residual pressure remains, connect (14290266 Hose) on the accumulator block's pressure
check connection to release any residual pressure.
 The accumulators for the automatic brake system RBB (Reverse By Braking) are depressurized by connecting (14290266
Hose) on the automatic brake valve's pressure check connection, port M, thereby lowering the pressure.
 The accumulators for the servo system are depressurized by moving the servo levers back and forth 10–15 times.
 The accumulators for the steering system are depressurized by turning the steering wheel back and forth 10 times to the right
and left.
Safety when working with air conditioning refrigerant
General
Special competence is required for service work and more involved work which requires opening of the air conditioning system.
Many countries also require special training and official authority approval. Find out about governing regulations for your country and
follow them!
Refrigerant R134a is used in the air conditioning unit, see also Section 8.
The type of refrigerant and the amount to be filled are shown on the type plate.
NOTE!
R134a adds to the greenhouse effect and should never be intentionally released into the open air.
Personal protective equipment
Figure 1
Protective goggles and gloves should be worn when there is a risk of contact with refrigerant.
When there is a risk of skin contact with refrigerant, use:
Tight-fitting protective goggles and protective gloves, and protect other bare skin (risk of frostbite).
Risks
WARNING
The gases have no smell and may cause serious damage to the lungs already at low concentrations.
Refrigerant R134a may, if incorrectly handled, cause serious personal injuries as well as damage to the environment. Therefore,
great care must be taken in all work with air conditioning units! The rules given below may be a great help to avoid injuries to all who
come into contact with refrigerants.
WARNING
Risk of frostbite! Wear protective work gloves.
 In liquid form the refrigerant may cause:

Frostbite.
 When in the form of a gas and at low concentration, the gas may:
Have some effect, especially on the nervous system.
 When in the form of a gas and at high concentration it may:
Have an anaesthetic effect.
 The air conditioning unit is pressurized and the refrigerant can unintentionally leak out. Never disconnect hoses or remove
the filler plug on the compressor.
If you suspect a leak, certified and trained personnel at a licensed workshop should be contacted for troubleshooting and
repair.
 The refrigerant gas is heavier than air and will sink to the floor. Therefore, make sure that any escaped gas is ventilated
before work is started in any low-lying areas.
Smoking, welding or other open flames are not allowed in a workplace where work with refrigerant is in progress. The refrigerant gas
will then burn and form a toxic gas which is very dangerous to inhale. The gases formed when heating the refrigerant have a pungent
smell at high concentrations.
The symptoms may appear several hours (perhaps up to 24 hours) after exposure to the gases.
Action in case of accidents
Inhalation
If escape of gas is suspected, leave the area, try to find fresh air and move affected persons out of the danger area. Small amounts
of vapour from refrigerant R134a may have some effect especially on the nervous system. In large amounts, the gas may have an
anaesthetic effect. In serious cases, seek immediate medical attention.
Skin contact
In case of frostbite, flush with lukewarm water for a long time. If a large amount of liquid refrigerant comes into contact with
unprotected skin, the injured area should be carefully warmed with lukewarm water or warm clothes.
Seek medical attention immediately if symptoms persist.
Splash in eyes
Flush with warm water until the irritation ceases. Seek immediate medical attention.
Safety when working with batteries
Figure 1
Battery charging
WARNING
Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine. In addition, batteries give off
hydrogen gas when they are loaded (supplying electricity) or being charged.
Together with the oxygen in the air, hydrogen gas forms a very explosive mixture.
This combination, corrosive acid and explosive gas, means a high risk of accidents during all work with batteries used in vehicles.
Therefore, it is very important that you take great care and follow the rules below when you are working with batteries.
Follow these instructions when charging batteries:
 Batteries give off explosive gases. Never smoke near batteries.
Figure 2
Do not smoke near batteries!
 Begin by disconnecting the ground lead when removing a battery. In order to reduce the risk of sparks that can cause fire,
always connect the ground lead last when fitting a battery.
 Never tilt a battery to any great extent in any direction. Battery electrolyte may leak out.
 Do not connect a discharged battery in series with a fully charged battery. The current surge can cause the batteries to
explode.
 Do not allow metal objects (such as tools, rings, wristwatches) to come in contact with battery terminals. Risk of fire and
personal injury.
 Always cover the top of the battery with a rag or other non-conducting material when you work close to the batteries.
 Always refit the terminal caps on the batteries.
 Batteries contain substances hazardous to health and the environment. Therefore, discarded batteries be handled according
to governing local/national regulations. See Environmentally safe handling
Charging batteries
Explosion hazard
When a battery is being charged, an explosive mixture of oxygen and hydrogen is formed. A short circuit, open flame or spark near
the battery can cause a powerful explosion. Always turn off the charging current before disconnecting the charging clamps. Ventilate
well, especially if the battery is charged in a confined space.
WARNING
Figure 3
Corrosive acid
Corrosive sulphuric acid
The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin must be removed immediately. Wash with
soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and
seek immediate medical attention.
Service position 1
Op nbr 173-302
Tools:
Wedge VOE11020526, 4 pcs.
1. Park the machine on a horizontal, smooth, and hard ground surface, and prepare it for service by placing it in service position
1 as shown in the figure:
Figure 1
Service position 1
1. Connect the frame joint lock.

2. Lower the attachment and let it rest on the ground.
3. Apply the parking brake and turn off the engine.
4. WARNING
If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious
personal injuries.
To depressurize; turn the start key to ignition position (1).
Carefully release the pressure in pressure lines and pressure tanks to avoid risks. See Safety when working on hydraulic
systems
5. Remove the start key.
6. Fasten a yellow-black warning tag to the steering wheel (in the USA a red flag can be used instead).
7. Block the wheels, e.g., with wedges.
8. Open the engine hood and turn off the battery disconnector.
9. Let the machine cool down.
WARNING
If work must be done on the machine before it has cooled down; beware of hot fluids and hot components that can
cause severe burns.
Service position 2
Op nbr 173-371
Tools:
9993831 Support
Wedge VOE11020526, 4 pcs.
1. Park the machine on a horizontal, smooth, and hard ground surface, and prepare it for service by placing it in service position
2 as shown in the figure:
Figure 1
Service position 2
1. Connect the frame joint lock.

2. Lift up and tilt the bucket forward. Secure the boom on supports. See Working under raised boom.
3. Apply the parking brake and turn off the engine.
To depressurize; turn the start key to ignition position (1).
4. WARNING
If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious
personal injuries.
Carefully release the pressure in pressure lines and pressure tanks to avoid risks. See Safety when working on hydraulic
systems
5. Remove the start key.
6. Fasten a yellow-black warning tag to the steering wheel (in the USA a red flag can be used instead).
7. Raise the plate.
8. Block the wheels, e.g., with wedges.
9. Open the engine hood and turn off the battery disconnector.
10. Let the machine cool down.
WARNING
If work must be done on the machine before it has cooled down; beware of hot fluids and hot components that can
cause severe burns.
Some simple rules regarding tyre handling
WARNING
Tires installed on a split rim may explode and cause very severe injuries.
Inflating tyres
Figure 1
Never stand by the side of the tire when inflating (principle illustration for front and rear tires).
 Never stand by the side of the tyre when inflating tyres mounted on a split rim. Use a self-locking air-chuck with a hose long
enough to allow you to stand outside the dangerous area when inflating, see figure.
 Make sure that no persons are in the dangerous area when inflating the tyre.
 The machine should be without load when checking tyre pressure.
 Spare tyres should only be inflated with enough air to keep the rim parts in place.
 Secure a loose wheel with a cage, cables or chains before you inflate it with air. Before removing the cage, check that the
tyre is mounted correctly on the rim. Only adjust on a deflated tyre.
 Do not attempt to adjust side or lock rings when the tyre is inflated with air.
 Tyres used at less than 80% of normal pressure and rims or tyres suspected of being damaged should not be inflated with
the wheel attached to the machine.
Fitting tyres and rims
 Only trained personnel should handle tyres.

 Deflate the tire before removing it from the rim.
 Never fit a tyre on a rim if the tyre is not clearly recommended for the rim.
 Never assemble rim parts for different dimensions and never use damaged or defective parts.
 Be careful if you are using reconditioned wheel parts. Incorrect welding, heating or soldering of the parts may cause them to
weaken and result in failure of the part.
 Make sure that the lock ring groove in the rim is free from dirt, rust and any debris before fitting the ring.
 Use the lubricant that is recommended by the tyre manufacturer when mounting it on the rim.
Repairing tyres and rims
 Never cut, weld nor heat the wheel parts in any manner.
 Exercise caution when using bead breakers and hydraulic jacks. Remain outside the hazard zone when removing foreign
objects from the tyres. A bead breaker that releases can cause severe personal injury and may result in death.
Starting with booster batteries
The following must be observed when starting with booster batteries:
NOTE!
Check that the booster batteries or other current sources have the same voltage as the standard batteries.
WARNING
The batteries could explode due to the current surge if a fully charged battery is connected to a completely discharged
battery. Since the batteries contain sulphuric acid, this could result in personal injuries.
Take the following actions:
1. Turn off the battery disconnector.

2. Remove the bolts and the cover for the battery box.
3. Remove the terminal cap from the right battery's positive (plus) terminal
4. Connect the positive cable from the booster batteries or the other power source to the right battery's positive terminal
Figure 1
1. Battery terminal 24 volt
5. Connect the negative cable from the booster battery to the intended grounding point above the battery box. Wait 1–2 minutes
before turning on the battery disconnector.
Figure 2
1. Battery box
2. Grounding point
6. Turn on the battery disconnector.

8. Let the engine run at increased idle 1–2 minutes before the booster cables are disconnected. Start by removing the booster
battery's negative cable from the grounding point.
9. Reinstall the terminal cap on the battery terminal.
10. Reinstall the cover for the battery box.
Waste handling
Contribute to careful use of natural resources by following the steps below when handling waste.
If possible, deposit the waste for recycling.
REUSE of products is the best from an environmental aspect.
MATERIAL RECYCLING for use in new products is a good environmental alternative.
ENERGY RECOVERY by burning combustible materials is a good alternative when recycling is not possible.
DESTRUCTION is used for hazardous waste. Destruction is performed in special facilities.
DEPOSITION is the worst from an environmental aspect and should be avoided as much as possible.
STORAGE is a temporary measure until a suitable recycling method has been developed.
Working in environmentally contaminated areas
Machines that are used in environmentally contaminated and/or health-hazardous areas shall be specially equipped for operation in
such an environment.
Used cab and engine air filters from machines working in environments with asbestos or other hazardous dust shall be put into tight-
sealing plastic bags that the new filters come in, then leave the used filters for destruction.
Working under raised boom
Always secure the loader linkage with Support 999 3831 (2 pcs. L250, L350) before starting to work. Position the support on an even
and firm ground surface.
Figure 1
Securing the boom (L250, L350)
999 3831 Support (2 pcs.)
WARNING
Note the exact positioning of the support against the lifting arm!
If the support is positioned too far forward, it may be knocked out of position when the attachment bracket is tilted forward.
Figure 2
Securing the boom
1. 999 3831 Support

Language Code Product Group No. Version Date
GB WLO 874 84 1 11/06/2012
Applies to
Wheel Loaders
AC compressor, fill with oil

WARNING
This Service Bulletin is to be considered as technical information only and is not subject to any reimbursement programs outside
normal warranty.
Cause
Remanufactured AC compressors are not filled with oil when delivered from the warehouse. Investigations of failed remanufactured
AC compressors have shown that approximately 40% suffers from lack of oil. The most common reason for claiming remanufactured
AC compressors is seized AC compressor.
Action
To make sure the remanufactured AC compressor is filled with oil before installing it to the machine, a tag with information about the
need to fill the AC compressor with oil prior to installation has been added.
Figure 1
Tag on remanufactured AC compressor
The service operation 874–006 will be updated with information about making sure the compressor is filled with oil prior to
installation.
GB ART/WLO 210 8 4 06/05/2008
Applies to
Wheel Loaders, Articulated Haulers
Action to be taken in case of abnormal lubricating oil consumption

WARNING
Introduction
The oil consumption is in many cases used as a measure of the condition of the engine. Normally all engines use a certain amount of
oil. The film of oil that lubricates the upper piston rings is combusted at the same time as the fuel, which gradually causes the oil level
to drop. There are of course also other factors that affects the oil consumption, e.g. operating conditions and the condition of the
engine. Here follows a short description of influencing factors, checking and measuring methods and which action can be taken to
manage any problems.
Factors influencing the oil consumption
Larger engines have as a rule a higher oil consumption than small engines.
Oil has the ability to penetrate the smallest openings. Therefore, proceed as follows:
 Check for oil leakage around the engine and components

 Check for oil leakage at the turbocharger
 Check for oil leakage at induction manifold / charge air pipe
 Take a lubricating oil sample
All affected bolts should be check-tightened.

A too high oil level causes more oil to be thrown up on the cylinder walls and this increases the oil consumption. The oil level should
be kept slightly below the full mark on the oil dipstick. Only check the oil level a few minutes after the engine has stopped to allow the
oil to run back to the sump, see Fig. 1.
Figure 1
Too thin oil will result in a higher oil consumption because of difficulties of maintaining a sealing film of oil between piston rings and
cylinder wall at high temperatures. Too thick oil provides unsatisfactory lubrication and thereby increased wear, which in the long run
will result in increased oil consumption. Always use the recommended oil grade and type according to the Operator's Manual.
Continuously high engine speed will result in warmer and thereby thinner oil. Increased oil consumption as described above.
Frequent use of engine retarding causes increased oil consumption.
Also long periods of idling / operating at low speed may cause increased oil consumption.
Faulty and worn piston rings, oil scraper rings, ring grooves, pistons, cylinders, valve guides result in high oil consumption, as oil
leaks into the combustion chamber.
Abnormally low oil consumption
Some attention should also be given to low oil consumption, because the low oil consumption may be illusory. Used up oil may have
been compensated through condensation water, coolant or fuel dilution, thus keeping the level unchanged. Intermixed coolant gives
the oil a greyish tint, whereas intermixed fuel does not show. These factors result in impaired lubrication and should lead to more
frequent oil changes. Intermixed fuel also mean an additional safety risk as the flash point of the oil is lowered. Take samples of
lubricating oil and have them analysed.
Checking and estimating oil consumption
The duration of the check / test period should be at least 250 hours (suitably between two oil changes and filter replacements) in
order to avoid jumping to conclusions and taking unnecessary action. On an engine that has reached working temperature, the oil
dipstick can be read off three minutes after stop. If the engine has been started, but not reached working temperature, wait for at
least five minutes.
 Copy the enclosed report form and make a note of the hour recorder reading at the start of the test period.
 Begin with full fuel tank and new oil filled to the upper marking on oil the dipstick.
 Note the hour recorder reading and amounts every time you fill fuel, oil or coolant.
 Do not top up the oil until the level has reached the minimum line.
 Never fill oil to above the maximum line.
 In case the oil is changed during the test period, check the oil level before draining and then fill to the same level.
 At the end of the test period, top up with oil to the maximum line and make a note of the amount.
Add up the noted information which then forms the base for calculating the oil consumption. The oil consumption is always stated as
a relation between consumed oil and the amount of used fuel during the same period.
Example: An engine has during 250 hours used 18 litres of oil and 3000 litres of fuel.
18/3000 x 100 % = 0.6 %
Normal consumption
A new or fully overhauled engine often uses more oil than a run-in engine. Only after 1000–1500 operating hours, when the piston
rings have bedded-in in the cylinders, is it possible correctly to determine the oil consumption.
 Oil consumption of 0.3% or less = OK at full-load operation

 Oil consumption of 0.3–0.75% = OK at light-load operation
 If these limit values are exceeded, proceed as follows:
Carefully check the oil consumption (see instructions on the previous page) and contact the respective dealer regarding
whether any action can be approved as a warranty job. A copy of the report form should be enclosed with the claim.
Figure 2
GB ART/BHL/WLO 160 65 2 02/03/2010
Applies to
Articulated Haulers, Backhoe Loaders, Wheel Loaders
Alternative lubricants for axles with wet brakes

WARNING
normal warranty.
Cause
97303, WB101
Volvo Wet Brake Transaxle Oil 97303, WB101 is intended for use in axles with built in wet brakes. For these applications Volvo
Wet Brake Transaxle Oil (Volvo product denomination), should be used.
Action
Performance requirements for Volvo Wet Brake Transaxle Oil 97303 are described in Volvo Construction Equipment Standard
1273,03.
NOTE!
Using non-approved products may affect warranties in case of component problems.
Volvo Super Wet Brake Transaxle Oil 97304, WB102
Volvo Super Wet Brake Transaxle Oil 97304, WB102 is intended for long drain intervals or severe service in axles with built in wet
brakes. WB102 gives lower fuel consumption, maximizes machine performance and improves the durability of the machine. For
these applications, Volvo Super Wet Brake Transaxle Oil (Volvo product denomination), should be used.
Performance requirements for Volvo Super Wet Brake Transaxle Oil 97304 are described in Volvo Construction Equipment Standard
1273,04.
If Volvo Super Wet Brake Transaxle Oil is not available, then Volvo Wet Brake Transaxle Oil, WB101, can be used as an alternative.
NOTE!
Only when using Volvo Super Wet Brake Transaxle Oil WB102 will the machine achieve maximum performance and service life, as
well as the best possible fuel economy. Service intervals may also be shorter when using other oil than Volvo Super Wet Brake
Transaxle Oil WB102
In the future, Volvo Construction Equipment will not officially state alternative products.
GB WLO 993 6 1 03/06/2008
Applies to
Wheel Loaders
Automatic greasing systems of foreign manufacture

WARNING
normal warranty.
Cause and action
It has come to our attention that our customers and dealers are equipping our machines with automatic greasing systems of foreign
manufacture. The following is our policy with regards to this:
Among factors that determine the lifespan of bearings and bushings are: the type of lubrication used, dosage, frequency and
operational reliability of the lubricating apparatus. Warranty responsibility presumes that we can influence factors that affect lifespan
and thereby the overall quality impression given by the machine.
Operational reliability is regularly discussed with current subsuppliers of our factory-installed automatic greasing systems with a view
to optimising quality. These suppliers have been specially selected because they are able to supply a product that corresponds to our
quality requirements.
Consequently warranty liability concerning abnormal bearing and bushing wear and also other matters related to lubrication is
acceptable only where the machine is equipped with automatic greasing systems supplied and approved by Volvo Construction
Equipment.
GB ART/WLO 160 64 2 11/10/2011
Applies to
Articulated Haulers, Wheel Loaders
Automatic transmission lubricants

WARNING
normal warranty.
NOTE!
The special lubricants (SAE10W and 30) are required to be used for L330E andL350F.
Cause and action
Volvo Automatic Transmission Fluid AT101(Volvo transmission oil 97341)
AT101 is intended for use in automatic transmissions in trucks and construction equipment. AT101 is required for filling/topping up at
service where we earlier made demands that the transmission oil should meet quality standards Dexron II, Dexron III, or other
Dexron levels.
Performance requirements for AT101 are described in Volvo Corporate Standard 1273,41.
The recommended oil change interval for AT101 is:
 1000 h for Articulated Haulers, E-Series.

 2000 h for Wheel Loaders, F-series.
— L220F with serial number 8026– excluded!
AT101 not approved, instead AT102 MUST be used.
— All Wheel Loaders equipped with Optishift excluded!
AT101 not approved, instead AT102 MUST be used
NOTE!
For L330E and L350F must the Volvo Super Transmission Oil (SAE 10W and 30) be used with service interval 1000h.
A new type of transmission oil has been introduced:
Volvo Automatic Transmission Fluid AT102. (Volvo transmission oil 97342)
Performance requirements for AT102 are described in Volvo Corporate Standard 1273,42.
Volvo Automatic Transmission Fluid AT102 is factory fill for F-series Articulated Haulers and G-series Wheel Loaders.
NOTE!
The recommendation is to use AT102 when changing transmission oil for:
 Articulated Haulers, E-Series and F-Series.

 Wheel Loaders, F-series and G-series. (L350F excluded!)
The recommended oil change interval for AT102 is:
 2000h for Articulated Haulers, E-series and F-Series.

 4000h for Wheel Loaders, F-series and G-series (L350F excluded!)
When changing oil on machines where AT101 has been used, small amounts of remaining old oil can be mixed with the new oil
AT102 without causing damage.
AT102 can also be used in connection with service on earlier generations equipped with HT-transmissions.
NOTE!
For L350F must the Volvo Super Transmission Oil (SAE 10W and 30) be used with service interval 1000h.
Part number for AT101 in the different markets:
Europe and international

VOE 11706206 20 litres (5,3 US gal)
VOE 11706207 208 litres (55 US gal)
North America
VOE 11710960 1 US gal
VOE 11988312 5 US gal
VOE 11988313 55 US gal
VOE 11988305 Bulk / 1 US gal each
VOE 11716497 Bulk / 1 litres each
China
Korea
Brazil
SBR 11915161 18 litres (4,8 US gal)
SBR 11915162 208 litres (55 US gal)
Part number for AT102
North America
VOE 15143347 5 gal
VOE 15143064 1 US gal
VOE 15143389 55 US gal
VOE 15143406 Bulk / 1 litres each
VOE 15143493 Bulk / 1 US gal each
Europe / INT / Asia

GB WLO 321 25 1 06/17/2013
Applies to
Wheel Loaders
Battery and alternator test procedure

NOTE!
normal warranty.
Cause
Some alternators without any failure have been returned. Also batteries without failure have been replaced.
Action
Before replacing alternators and/or batteries, follow the work instruction in this Service bulletin. Both alternator and battery can be
checked under field conditions to find the root cause by following the work instruction.
The work instruction is valid for all 24 Volt machines.
Work instruction
Tools Part No.

Multimeter 88890074
Clip-on ampere meter 88890091
Battery capacity check
Op nbr
1.
Figure 1
The battery should not be used for minimum 2 hours before the test.
2. Test the battery voltage.
Battery voltage Equivalent approx. capacity

25.44 V 100%
24.24 V 50%
23.20 V 5–10%
NOTE!
If the battery voltage is low, check if the batteries need to be charged. If so, check the battery voltage again after charging. If
the voltage is still low, the batteries are damaged and should be replaced.
Alternator check
Op nbr
1. Check the battery voltage (see above).

2. Start the engine and raise the engine rpm for a short time (charging warning lamp off).
3. Switch off all possible electrical consumers.
4. Monitor the battery voltage for approx. 2 minutes on low idle.
5. The battery voltage should increase depending on the battery capacity. The voltage should reach between 26.00 V – 28.50 V.
NOTE!
If the battery voltage does not increase with the engine running, the alternator is damaged and should be replaced.
Alternator output check
Figure 2
Op nbr
1. Install the clip-on ampere meter (testing range 100 A) on the alternator wire B+, connect the clip-on ampere meter to the
multimeter for displaying the value.
2. Start the engine and raise the engine rpm for a short time, check that the charging warning lamp is off.
3. With the engine on low idle, check the alternator output current on the multimeter. Note the value.
4. Switch on as many electrical consumers as possible, e.g. the cab fan on max speed and lamps (head lamps, working lamp
on cab and fenders).
5. Raise the engine rpm to maximum (high idle).
6. With the engine on high idle and electrical consumers on, check the alternator output current on the multimeter. Note the
value. The output value on high idle should be higher than on low idle. (Each lamp raises the current with approx. 2.5 A. If
work lamp on cab front and fenders are on at the same time as the headlamps and fan, the high idle value shall be 10–20 A
higher.)
7. After check, shut down the engine and remove tools.
NOTE!
If the alternator output is the same, or not significantly higher on high idle with electrical consumers on than on low idle, the alternator
is damaged.
GB WLO 173 5 2 03/23/2012
Applies to
Wheel Loaders
Cleaning of the machine

WARNING
normal warranty.
Cause
 Information concerning corrosion protective coating applied to all Volvo Construction Equipment.
 Information concerning removal of the corrosion protective coating once the machines arrive at the Volvo Dealership.
Action
The corrosion protective coating that is applied to all Construction Equipment is a proven coating that provides excellent protection to
metal exposed to harsh outdoor conditions.
There is a trend to use more and stronger chemicals with a pressure water jet. It is important that the proper mixture of concentration
with water is correct. Use of higher concentration of chemicals and washing sponges with hard surfaces for frequent use will remove
the surface protection.
Volvo Construction Equipment is using the following rust protection:
 Rust protector Dinitrol 4010 is mainly used under the cabin, for zink coated tubes, fittings and around the engine. It is sprayed
over the whole engine and it is durable for up to 160 °C (320 °F). This protection is almost impossible to remove and should
not be removed. Strong solvents will damage the paint work inside and outside.
 If the rust protector has to be removed on outside painted surfaces, hot water under high pressure is recommended.
We advice you to follow below recommendations for cleaning

The machine should be cleaned regularly using conventional car wash products or conventional machine wash products to minimize
the risk of damage to the lacquer and other surfaces on the machine.
In order to minimize damage caused by road/sea salts or other corrosion compounds on newly delivered machines Volvo
Construction Equipment requires that the machine be thoroughly washed within 2 days of arrival.
Recommendations for cleaning the machine
 Place the machine in a cleaning area where washing chemicals are normally collected.
 Use a normal car wash/machine wash product. Follow the instruction with the product.
 The water temperature must not exceed 60 °C (140 °F).
 If a pressure water jet is used, keep at least a 20–30 cm (8–12 in) distance between the nozzle and the machine surface.
 Use a sponge with a soft surface.
 Always finish with a complete wash only with just water.
NOTE!
If a high-pressure jet is used for cleaning, take great care. The electrical components and electrical leads can be damaged even at a
fairly low pressure and temperature. Protect electrical leads in an appropriate way. The engine should be turned off and the battery
disconnect switch switched off.
Removal of asphalt or other special hard dirt
 Use Whitespirit or conventional degreaser in a cold process. Follow the recommendation for use of the product.
 All removal (cleaning) should be followed by a normal wash procedure with the cleaner and be finished by a complete wash
with only water.
 Please keep in mind that the use of degreaser agents may require special places for this work or you have to clean up the
remains from the washing.
Keep the equipment in a good condition
 Frequent cleaning of the equipment.

 Polishing of surfaces, especially areas such as Cab or other similar once a year.
 Damaged surfaces should be repaired with recommended paint products as needed.
 Because of UV rays machines are best kept under cover for better paint protection. Machines stored in open hot sun light
could dull the paint work if not regularly cleaned and waxed.
Cleaning engine compartment, instruction
 Machines operating in dusty environment or environment exposed to fire hazards, e. g. wood-processing, woodchip handling
or grain handling and animal feed industries require daily attention and cleaning of the engine compartment and surrounding
areas.
 When operating in other environments, inspection and cleaning is required at least once a week.
WARNING
Beware of rotating parts. Keep a safe distance.
WARNING
The engine must not be running when cleaning as rotating parts may cause injuries.
Please pay attention to the following:
 Loose material is removed with, for example, compressed air.

 Cleaning should preferably be carried out at the end of the working shift before the machine is parked.
 Begin with the highest areas and end with the lowest on top of the fuel tank and areas near the fuel tank.
 Use personal protective equipment such as protective goggles, gloves and respirator.
 After cleaning, check and rectify any leaks. Close all covers and hoods.
GB ART/EXC/WLO 160 118 1 08/28/2014
Applies to
Excavators, Wheel Loaders, Articulated Haulers
DEF/AdBlue/AUS32 sampling, method

NOTE!
normal warranty.
Cause and action
Figure 1
Sample kit (Black) including sample bottle.
A new test for AdBlue/DEF sampling has been developed.

Applies to models
Valid for all products specified in the header of this Service bulletin equipped with Tier 4 Final engines.
Required parts
Designation Qty. Part no.

AdBlue sample kit (Black) As required VOE17412114 (Europe)
Work instructions
Sampling technique
It is vital to take a correct sample for receiving representative result of the analysis. Irrespective if you want to take the sample from
the AdBlue/DEF tank on the machine or a storage tank the technique is the same.
AdBlue/DEF sampling with vacuum pump
If sampling on a machine - Please note that there is a strainer in the filler tube that has to be removed.
Op nbr
1. Use a new hose for each sampling. Cut the hose to a suitable length and connect it to the vacuum pump.
2. Install the sample bottle on the vacuum pump.
3. Insert the hose in the tank. Make sure that the sample is not taken from the bottom. The sample should be taken slightly
above the middle range of the liquid.
Figure 2
Example of AdBlue/DEF sampling.
4. Draw up liquid to flush the hose.
5. Remove the sample bottle and empty it. Make sure that the AdBlue/DEF is taken care of in an environmentally safe way.
6. Install the sample bottle on the vacuum pump and fill the sample bottle ¾ full.
7. Attach one label on the sample bottle and one on the submission form.
Submission form
Fill in the Submission form. The Submission form can be downloaded from the Oil Analysis web site.
It’s important to fill in the submission form correctly. Fill in the top section as normal with machine data etc.
There is no prefilled fields for AdBlue/DEF system, please use the field Others and write in “AdBlue/DEF”.
In the comments field you should fill in where the sample is taken. AdBlue/DEF tank on machine, Storage tank id: xx etc.
Tick in from where the sample is sent in at the bottom and send the sample to the laboratory together with the submission form.
Figure 3
Example of how to fill in Submission form

GB WLO 260 11 1 12/20/2006
Applies to
Wheel Loaders
Discontinued recommendation for usage of anti-corrosion agent in cooling

system
WARNING
normal warranty.
Corrosion-protection with part no. 1129709 will be removed from stock since it does not meet the standards from Volvo Construction
Equipment and shall not be used in Volvo engines. The corrosion-protection cannot be combined with the coolant Volvo Coolant
VCS. Only coolants recommended by Volvo shall be used in our engines to obtain correct heat transfer and to avoid cavitation as
well as corrosion on aluminum, copper, brass, steel, and soldering.
GB WLO 366 94 5 04/25/2014
Applies to
Wheel Loaders
ECU, functional check

NOTE!
normal warranty.
Cause
The purpose of this service bulletin is to provide support to ongoing quality investigation on ECUs.
Action
To increase the value of the information concerning ECUs, the described work instruction has to be performed before any
troubleshooting work is started based on symptoms.
The information collected according to the work instructions makes up the basis for a support request and shall be attached to the
Techline call that is sent to the regional support.
Work instructions
Op nbr
1. Fill in table 1, "Machine data".
2. Read off the active and saved error codes, vehicle information test, as well as parameter read-off using VCADS Pro and
attach the job card with the completed tables in this service bulletin. (Error codes, vehicle information test, parameter) Save
the job card in the following text format:
“machine model”-”machine serial number”-”read-off date”.xml
Example: L110F-3971–20081215.XML Document.
3. Do a function check of the machine according to table 2, 3, 4, 5 "Function check". When the test is finished (Designation),
enter an "X" in the right column if read-off was performed. If any deviations are detected during the "Function test", describe
how the malfunction behaves or how to reproduce it to give maximal information for continued investigation.
4. Attach the completed tables in this SB together with TechTool job card if there is a Techline call.
Machine data
Model Serial no. Machine hours Customer
Function check with VCADS Pro
Group Op. no. Designation OK

1. Service and maintenance Yes No
17 - Service and 17012-3 Error codes
maintenance
Remark if not OK:
...............................................................................................................
...............................................................................................................
17034-3 Vehicle information, test
Remark if not OK:
...............................................................................................................
...............................................................................................................
17030-3 Parameter, programming
Remark if not OK:
...............................................................................................................
...............................................................................................................

2. Engine and engine mounting equipment Yes No
25 - Intake and 25410–3 Air pump exhaust aftertreatment test.
exhaust system. Turbo 25456–3 Exhaust aftertreatment, diagnostic
25411–3 Burner exhaust after treatment test
25412–3 Components ASU, test
25537–3 Variable geometry turbo function test
Remark if not OK:
...............................................................................................................
...............................................................................................................
27– 27102-3 Accelerator pedal, test
Remark if not OK:
...............................................................................................................
...............................................................................................................
28– 28407-3 Sensor values monitoring
Remark if not OK:
...............................................................................................................
...............................................................................................................

3. Electrical system and Instruments Yes No
30- General 30901-3 Voltage feed control unit (ECU), check
Remark if not OK:
...............................................................................................................
...............................................................................................................
38– Instrument 38117–3 Instrument test
Remark if not OK:
...............................................................................................................
...............................................................................................................
39– Miscellaneous 39797–3 CareTrack status check
Remark if not OK:
...............................................................................................................
...............................................................................................................

8. Body, cab and interior Yes No
87- Temperature and 87373-3 ECC input and output signals status, test
control system 87376–3 Sensor values, ECC check
Remark if not OK:
...............................................................................................................
...............................................................................................................
Questions regarding machine's behaviour: Yes No

Is the loader equipped with "NON-VOLVO" optional equipment?
What optional equipment is used or installed?
.............................................................................................................................................
.............................................................................................................................................
What defects/malfunctions are there?
Description:
.............................................................................................................................................
.............................................................................................................................................
.............................................................................................................................................
When does the problem/error message occur?
After "Turning on ignition"? after ...... seconds
During start attempt? after ...... seconds
After "Engine running"? after ...... seconds
After activation of a function (state which function)?
Other:
.............................................................................................................................................
.............................................................................................................................................
Any specific situations that result in the problem?
If YES, which?
...........................................................................................................
...........................................................................................................
What operating modes were selected for the machine when the problem occurred? (E.g., CDC, automatic lift and tilt, etc.)
.............................................................................................................................................
.............................................................................................................................................
Note during which special situation or activation of function that the problem occurs.
.............................................................................................................................................
.............................................................................................................................................
What other functions are activated?
.............................................................................................................................................
.............................................................................................................................................
How often does the problem occur?
Seldom (no pattern)
Sometimes
Regularly
Periodically
Other:
....................................................................................................................
....................................................................................................................
Questions Y N
regarding e o
machine's s
behaviour:
Does the engine's
behaviour change
when the problem
occurs?
Does the I-ECU
work as it should
when the problem
occurs?
Does the
machine's
functions work as
they should when
the problem
occurs?
What does not work?
.....................................
.....................................
.....................................
..............................
.....................................
.....................................
.....................................
..............................
If central Y N
warning e o
generates alarm: s
Red central
warning
Amber
central
warning
Buzzer
Display message:
.....................................
.....................................
.....................................
..............................
.....................................
.....................................
.....................................
..............................
Important information
before the ECU is
replaced:
First, the relevant ECU
shall always be
reprogrammed (with
existing software)
before the ECU is
replaced and normal
diagnostics of cable
harnesses, ECU
connectors and pins,
etc. has been
performed. If new ECU
+ programming of the
same solves the
problem, then reinstall
the old ECU. If the
problem returns the
root cause may be
traced to the ECU and
not the machine
configuration.
Replaced ECU:
Part Serial
number number:
: ..............
............ ..............
............ ..............
............ ....
..
Replaced ECU:
Part Serial
number number:
: ..............
............ ..............
............ ..............
............ ....
..
Notes:
.....................................
.....................................
.....................................
..............................
.....................................
.....................................
.....................................
..............................
.....................................
.....................................
.....................................
..............................
Yes No
Are additional components replaced during this repair time?
Notes:
.............................................................................................................................................
.............................................................................................................................................
Has the machine had problems in the past that led to replacement of components in the electric
system?
Notes:
.............................................................................................................................................
.............................................................................................................................................
Has the machine been in for repair again after ECU exchange with similar symptoms as before the
ECU change?
Notes:
.............................................................................................................................................
.............................................................................................................................................
Name of person submitting information: …………………………............................................................…………

In case of a ''Techline call'' regarding problems that concern an ECU, the completed document as well as TechTool job card can be
requested from regional or global technical support.
NOTE!
Causing part in the Techline call shall be the part number of the ECU that was replaced.
GB WLO 926 18 1 11/07/2006
Applies to
Wheel Loaders
Fork arms, information warranty matters, altered procedures

WARNING
normal warranty.
Cause and action
If fork arms are the subject of a claim and need to be replaced, photographs and a copy of the report on the last page of this SB
should be sent to the regional office and from there passed on to the marketing person who is responsible for technical questions at
Volvo Construction Equipment AB Customer Support Division. A copy of a filled-in report is required for each repair.
NOTE!
The report is also available in Word format in Techline. It can be downloaded, filled in digitally and sent in by E-mail.
The report must contain machine data, which type of claim is intended and an explanatory text about the cause of the replacement.
In case of a break, the fracture area and the position of the break must be photographed. The fracture area must be photographed at
the latest within one week. It is important that a sharp photograph is obtained. After photographing, spray the fracture area with anti-
rust agent.
NOTE!
The fork arms must then be stored for six months in order to be available for further investigation.
A precondition for the damage to be considered as a warranty matter is that the requested information has been filled in on the report
on the last page.
Fork arms, which are replaced because of wear or incorrect use, will not be compensated through a claim.
Report, fork arms, information regarding warranty matters
Machine type
Serial number, machine
Operating time, hours
Time of usage, fork arms (approximate):
Type number of fork arms:
Serial number of fork arms (stamped-in on the side of the fork
arm):
Date of repair:
Claim number:
Factory warranty
Parts warranty
Cause of repair:
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
NOTE!
Attach a photograph of the fracture area taken within a week of when the fracture occurred and one photograph taken at a greater
distance showing the location of the fracture on the fork arm.
GB ART/BHL/CEX/ 160 72 1 08/28/2014
COA/COS/CWL/
EXC/GRD/MET/
MEW/PAT/PAW/
PIP/SSL/WLO
Applies to
Articulated Haulers, Backhoe Loaders, Compact Excavators, Asphalt Compactors, Soil Compactors, Compact Wheel Loaders,
Excavators, Motor Graders, Tracked Milling Equipment, Wheeled Milling Equipment, Tracked Pavers, Wheeled Pavers, Pipelayers,
Skid Steer Loaders, Wheel Loaders
Fuel sampling, method

WARNING
normal warranty.
Cause and action
A new test for fuel sampling has been developed.
Figure 1
Sample kit including aluminum sample bottle
Applies to models
Valid for all product lines specified in the header of this Service bulletin.
Required parts
Designation Qty. New Part No.

Fuel sample kit (Europe) As required VOE17210950
Work instructions
Sampling technique
It is vital to take a correct sample for receiving representative result of the analysis. Irrespective if you want to take the sample from
the fuel tank on the machine or a storage tank the technique is the same. Please note that on some machines there is a strainer in
the filler tube that has to be removed.
Op nbr
1. Fuel sampling with vacuum pump

Use a new hose for each sampling. Cut the hose to a suitable length and connect it to the vacuum pump.
2. Install the fuel sample bottle on the vacuum pump.
3. Insert the hose in the fuel tank. Make sure that the sample is not taken from the bottom. The fuel sample should be taken
slightly above the middle range of the fuel.
Figure 2
Example of fuel sampling
4. Draw up fuel to flush the hose.
5. Remove the sample bottle and empty it. Make sure that the fuel is taken care of in an environmentally safe way
6. Install the sample bottle on the vacuum pump and fill the sample bottle ¾ full. The sample bottle is made of aluminium and
makes it a bit tricky to control the volume that is sampled.
7. Attach one label on the sample bottle and one on the submission form.
Submission form
Fill in the Submission form. It’s important to fill in the submission form correctly. Fill in the top section as normal with machine data
etc.
There is no prefilled fields for fuel system, please use the field Others and write in “Fuel, Sulphur”.
In the comments field you should fill in where the fuel sample is taken. Fuel tank on machine, Storage tank id: xx etc.
Tick in from where the sample is sent in at the bottom and send the sample to the laboratory together with the submission form.
Figure 3
Example of how to fill in Submission form
GB WLO 913 47 1 03/11/2010
Applies to
Wheel Loaders
Greasing of hydraulic pump drive shaft

WARNING
normal warranty.
Cause and action
For some time now standard procedure has been to grease the hydraulic pumps' drive shaft in connection with bolting down the
pumps on the transmission when installing them on the assembly lines in our different factories.
The purpose of this is to increase the service life and to counteract wear of the pump shaft's splines joint as well as the
corresponding drive sleeve in the transmission's power take-off.
For the same reason we want to recommend use of splines grease in connection with changing or repairing hydraulic pumps in the
field.
Part Part number Quantity Temperature range

Ultra grease lithium complex ep2 VOE 15026328 400 g - 20° C — + 150° C
(Splines grease)
GB WLO 945 89 1 09/14/2011
Applies to
Wheel Loaders
Instructions for crack in lifting frame

WARNING
normal warranty.
Cause and action
In the event of wheel loader frame cracks, it is necessary to have the correct information for investigation follow up.
It is important to have correct information to access the problem properly.
Clear photos, both close up shots and overview shots, to identify the crack in relation to the total lifting frame are needed.
These photos are required in your Techline report along with other descriptive information.
Casting numbers as show on following pages are also required to identify production runs.
Portions of lifting frames may be requested to be returned for examination.
Rust proof any cracks in the lifting frame immediately to preserve original metallurgy, as rusted/corroded metal are extremely difficult
to analyse.
Coat the crack areas with oil to protect the metal.
Figure 1
Broken not corroded link
Examples of casting numbers.

Figure 2
Casting number 1
Figure 3
Casting number 2
Figure 4
Casting number 3
GB WLO 810 14 3 09/29/2014
Applies to
L60F Volvo, L60G Volvo, L60H Volvo, L70F Volvo, L70G Volvo, L70H Volvo, L90F Volvo, L90G Volvo, L90H Volvo, L110F Volvo,
L110G Volvo, L110H Volvo, L120F Volvo, L120G Volvo, L120H Volvo, L150F Volvo, L150G Volvo, L150H Volvo, L180F HL Volvo,
L180F Volvo, L180G HL Volvo, L180G Volvo, L180H HL Volvo, L180H Volvo, L220F Volvo, L220G Volvo, L220H Volvo, L250G
Volvo, L250H Volvo, L350F Volvo
Instructions for drilling in ROPS structure

WARNING
normal warranty.
It is permissible to drill holes in the ROPS structure on the wheel loaders within marked areas, see Fig. 1. At the most four holes with
a maximum diameter of 9.5 mm (0.374 in) may be drilled within each area and there must be at least 100 mm (3.937 in) between the
holes.
Figure 1
GB WLO 000 122 2 05/31/2011
Applies to
Wheel Loaders
Instructions for shielded metal arc welding

WARNING
Scope
These instructions have been provided to ensure that modifications or repairs involving welding on Volvo Wheel Loader"s machines
will be of the highest quality.
These are general welding instructions that must be supplemented with drawings, sketches and specifications from
Volvo CE Customer Support.
In cases where the use of MIG, TIG, Fluxcore or submerged arc welding is required, contact VCE Customer Support for approval.
Welder competence, qualifications and requirements
Unless otherwise specified or approved, all welding must be carried out by a welder whose competence meets the requirements
according to the American Welding Society, Specification D1.1 or D14.3, or ASME Pressure Vessel Code, Section IX.
NOTE!
Each country has its own welding standards and specifications. All welding must carried out by a competent welder in order to meet
the requirements specified by the country where the work is to be carried out.
Base materials
Refer to drawings, sketches and specifications which are made available by VCE Customer Support.
Filler materials (Coated electrodes)
Electrode classification must be according designations on accompanying drawings, sketches or specifications which are made
available by VCE Customer Support.
The welding electrodes must meet the following requirements:
EN 499-95 E 42 4 B 42 H5
Swedish National Standard 79 SS 3211-H10
AWS A5. 1-91 E 7018-M
DIN 1913-84 E 51 55 B10 120
ISO 2560-73 E 51 5 B 120 20 H
These electrodes may be used:
 E 8018: AWS A5.5, class E 8018-D3

 E 9018: AWS A5.5, class E 9018-D1 or E 9018-M
 E 10018: AWS A5.5, class E 10018-D2 or E 10018-M
 E 11018: AWS A5.5, class E 11018-M
 OK 67.45 (EN 1600 E 18 8 Mn B, AWS A5.4) ESAB
 OK 68.81 (EN 1600 E 29 9R 32,SFA7AWS A5.4) ESAB
 Elgaloy Mix 18 (EN 1600 E 18 8 Mn R 53,AWS A5.4-92)), ELGA
Electrode sizes
The electrode size must be adapted and be suitable for the type of material, type of weld joint, welding position and other
circumstances affecting the work.
The maximum size of electrodes and current strength are as follows:
Position 3.17 mm 3.97 mm 4.76 mm 6.35 mm

1/8" 5/32" 3/16" 1/4"
Flat/horizontal 100/150 175/225 225/275 350
Vertical 120/140 140/160 - -
Overhead 110/135 140/170 - -
6.35 mm (1/4") max. diameter for horizontal fillet welds.

6.35 mm (1/4") max. diameter for root passes or fillet welds made in the flat position and for weld joints made in the flat position with
backing bar (root passes) and with an root opening of 6.35 mm (1/4") or greater.
3.97 mm (5/32") max. diameter for welding made in the vertical and overhead positions.
Care and storage of electrodes
Electrodes in hermetically sealed containers may be used immediately from the container for a specific period of time after the
container has been opened.
Time periods are as follows:
E7018 - 4 hours
E8018 - 2 hours
E9018 - 1 hours
E10018- 30 minutes
E11018- 30 minutes
All electrodes which are not used within the above specified times must be stored in an oven at a temperature of at least
121 ºCelsius (250 ºF).
Electrodes which have been exposed to the atmosphere for a longer time than specified above, must be dried for at least one hour at
a temperature between 371 and 427 ºC (700 and 800 ºF) before they are used.
Preparation of materials
The surface, which is to be welded, must be free from moisture, slag, rust, paint, grease, oil or other foreign material which prevent
proper welding.
In cases where original parts have been removed by carbon arc welding, all oxides, slag and carbon deposits must be removed by
grinding to remove sharp undercuts, cracks, nicks or gouges. This is to be followed by welding and grinding if required to provide a
smooth and even surface.
Assembling
Aligning parts:
Parts to be joined by fillet welding must be placed as close together as piratically possible.
The distance between the two parts must normally not exceed 3.17 mm (1/8"). If the distance exceeds 1.58 mm (1/16"), the leg of the
filled weld must be increased by the distance between the parts.
All parts must be supported to provide the best possible alignment between the parts and to minimise stresses on tack welds and
root passes.
Tack welds are subjected to the same quality requirements and limitations as the final welds.
All tack welds must be thoroughly cleaned from slag prior to incorporating them in the final welds.
Cracked or faulty tack welds must be removed by grinding prior to final welding.
Position
The pieces to be welded should be placed flat where possible.
Preheating and temperature of the work pieces
 Interpass temperature – the temperature throughout the material
The material to be welded must be preheated, when required, to reach a minimum preheating temperature which is specified in
supplemental drawings, sketches and specifications supplied by VCE Customer Support
Unless otherwise specified, the temperature must not be less than 10 ºC (50 ºF).
The preheating temperature must be measured 75 mm (3") from the centre line of the weld and at the opposite side of the work piece
from where the heat was supplied. This technique will assists in ensuring that the heat has penetrated through the material.
Maximum interpass temperature are 204 ºC (400 ºF) unless otherwise specified. If possible all welding should be carried out in an
order that balances the supplied heat during the progress of the welding.
A device for measuring the surface temperature is to be used to check the preheating temperature and the interpass temperature
throughout the material. In cases where temperature sensitive crayons are used, all remaining crayon residue or other contaminants
must removed from the surface to be welded.
Welding must not be carried out when the workpiece is exposed to strong wind, draught or moisture.
Electrical specifications
Use direct current, reverse polarity (electrode positive) at amperages and voltages recommended by the electrode manufacturer.
The ground connection must be safely secured as close to the point of welding as possible. Do not connect the ground connection so
that the electrical current of the welding circuit has to pass across a bearing. For example, when welding on the front frame of the
wheel loader, do not attach the ground connection to the rear frame.
Welding technique
Electrode handling:
The arc length must be kept as small as possible during the entire welding work.
All welding beads, except vertical ones, are to be deposited as stringer beads, the width of which must not exceed four times the
diameter of the electrode. When welding vertically, a partial weaving technique may be used.
The width should be limited to twice the diameter of the electrode. When starting a new electrode, back puddle slightly to heat
surrounding base material and to fill the crater in the previous welding bead.
Fill all arc craters at the end of each bead.
Interpass Cleaning
Slag must be removed from all welding beads before starting on the next bead.
Remove all visible defects such as cracks, pores and undercuts by grinding before beginning the next bead.
Welding bead size
Groove welds:
The maximum thickness of layers deposited after the root pass in fillet welds and all layers of groove welds is:
6 mm (1/4") for root passes of groove welds.

3 mm (1/8") for subsequent layers of welds made in the flat position.
5 mm (3/16") for subsequent layers of welds made in the vertically, overhead and horizontal positions.
Fillet welds:
The maximum size of fillet welds which may be made in one pass is:
10 mm (3/8") in the flat position.

8 mm (5/16") in the horizontal or overhead positions.
12 mm (1/2") in the vertical position.
Welding sequence
The welding sequence must be arranged so as to minimise distortion and shrinkage.
If possible, all welds should be made in a sequence that balances the applied heat of welding while welding progresses. Backstep
welding technique is recommended.
Backstep welding technique
Figure 1
Backstep welding
 Weld in the direction of the arrow

 X = Start
 (n ) = Welding sequence
Peening
Welded metal may be peened after each pass, while the bead is still very hot to reduce stresses and distortion. Peening can be
carried out using a heavy hammer (especially intended for peening), but it is much more effective to use a 7 or a 9 kg (15 or 20 Ib) air
hammer with a blunt chisel point tip with a diameter of 6.35 mm (1/4") to peen each layer of welded metal.
NOTE!
Peening is not permissible on the first or final layers.
Back gouging
Complete joint penetration groove welds made without the use of steel backing must have the root gouged down to sound metal
before welding is started from the other side. Gouging may be done by grinding or carbon-arc cutting. Gouging with oxy-fuel gas
cutting torch is not permitted.
Inspection
The surface of the final weld beads must be free of slag, abrupt peaks or valleys, overlaps or undercuts and the surface must be
smooth and even.
All completed welded joints should be magnetic particle inspected.
Additional inspection requirements may be specified by accompanying instructions for assembling, sketches or drawings which are
made available by VCE Customer Support.
This SB is to be considered as a technical information and comprises normal warranties within the rules for the same.
GB ART/BHL/CEX/ 000 313 2 05/29/2013
COA/COS/CWL/
EXC/GRD/MET/
MEW/PAT/PAW/
WLO
Applies to
Backhoe Loaders, Compact Excavators, Asphalt Compactors, Soil Compactors, Tracked Milling Equipment, Wheeled Milling
Equipment, Tracked Pavers, Wheeled Pavers, Articulated Haulers, Compact Wheel Loaders, Excavators, Motor Graders, Wheel
Loaders
New TechTool/VCADS Pro interface

NOTE!
Cause and action
A new interface for TechTool/VCADS Pro is introduced. Two kits are available, but each part included in the kits can be ordered as a
single part, see table on the next page.
The kits are also available as special tools with the same numbers as the kits; 17279144 and 17279159.
Figure 1
Kit, VOE17279144
A. Tool (Interface), VOE88890300

B. Cable, VOE88890305
C. Cable, VOE88890306
Figure 2
Kit, VOE17279159
A. Tool (Interface), VOE88890300

B. Cable, VOE88890305
C. Cable, VOE88890306
D. Adapter, VOE9993832
Required parts
Designation Qty. New Part No. Discontinued Part No.

Kit, including:[T1] 1 VOE17279144 VOE11716274
Tool (Interface) 1 VOE88890300 VOE88890180
Cable 1 VOE88890305 –
Cable 1 VOE88890306 –
Kit, including:[T2] 1 VOE17279159 VOE11716484
Tool (Interface) 1 VOE88890300 VOE88890180
Cable 1 VOE88890305 –
Cable 1 VOE88890306 –
Adapter 1 VOE9993832 –
[T1] or Special tool 17279144
[T2] or Special tool 17279159

GB WLO 000 356 1 01/12/2015
Applies to
New wheel loaders, L60H, L70H and L90H
Figure 1
NOTE!
normal warranty.
Cause and action
Volvo CE introduces new wheel loader models, L60H, L70H and L90H, with improved performance, comfort, efficiency and fulfilment
of environmental requirements. This is made possible by integrating innovative changes to various aspects of the machines.
The new series wheel loaders feature a 6–litres Tier4f/Stage IV engine fulfilling the current environmental regulations. The engine
hood is redesigned in order to accommodate the new engine installation, and a new display/dashboard is introduced.
L90H comes with increased engine power and torque, wheel base and hydraulic flow rate for better stability, increased fuel efficiency
and smoother harmony between drive train and hydraulics.
Machine data
Model Serial No. Serial No. Product identification number

ARV SHP
L60H 11005 – 621002 – 33055
L70H 12006 – 622002 – 33056
L90H 1301 – 623002 – 33057
Components
Model Front axle Rear axle Transmission Engine

L60H AWB 15 AWB 15 HTE 125 D6J
Summary of new standard features
Engine D6J, Stage IV/Tier 4f compliant engine

Electrical system Maintenance free batteries, new main switch, new travel lights
Service and design Redesigned engine hood
Frame, L90H Increased wheel base by 50 mm (2 in)
Hydraulics, L90H Increased flow rate by 5.5%
Volvo engine D6J – Stage IV/Tier 4 Final

The engine is a straight 6–cylinder, four stroke, turbocharged diesel engine with direct fuel injection and charge air cooler. The engine
meets US Tier4 final and California Tier4 final emission requirements and EU Stage IV emission requirements.
The engine uses a common rail fuel system controlled by the Engine Control Module (ECM). Engines with Advanced Combustion
Technology (ACT) feature split injection and turbocharger with mechanical wastegate. The Exhaust Aftertreatment System (EATS) is
equipped with a Diesel Oxidation Catalyst (DOC), a Diesel Particulate Filter (DPF) and a Selective Catalytic Reduction (SCR) system
to reduce the emissions. Cooled Exhaust Gas Recirculation (EGR) also reduces the emissions.
Figure 2
EATS unit
Figure 3
EATS unti
The DPF muffler section consists of two main components; the diesel oxidation catalyst (DOC) at the inlet and the diesel particulate
filter (DPF). The muffler features three temperature sensors, one before DOC, one before DPF, one after DPF and a differential
pressure sensor over the DPF.
The DPF is used to trap the PM (particulate matter) that is formed during the combustion in the diesel engine.
The diesel oxidation catalyst (DOC) owes its name to its ability to promote oxidation of several exhaust gas components by oxygen,
which is present in ample quantities in diesel exhaust. The oxidation catalyst is coated with a high loading of an active catalyst,
palladium. Palladium is prone to sulfur poisoning and therefore ultra low sulfur fuels have to be used in order to get the desired
catalytic reaction.
The DOC is not a filter; the exhausts are just passing straight through. Any service or cleaning of the DOC are not required.
Figure 4
AdBlue®/DEF dosing injector is integrated between DPF/DOC and SCR. The AdBlue®/DEF is injected, the fluid vaporizes and is
mixed with exhaust gases. This process facilitates a good mixture of AdBlue®/DEF and exhaust gases which is required for optimal
NOx reduction in the SCR, and minimizes the build up of crystals.
SCR
Figure 5
SCR
The engine has a muffler containing one selective catalytic reduction (SCR) catalyst. The SCR reduces nitrogen oxides (NOx) using
AdBlue®/DEF that is injected into the exhausts in the mixing chamber between the DPF and SCR. There are two sensors for
measuring the NOx level, one before and one after the SCR catalyst.
At the end of the SCR catalyst there is a different coating, ASC (Ammonia Slip Catalyst) where ammonia transforms into water and
the smell of ammonia is removed.
The differential pressure sensor on the venturi tube measures the amount of exhaust to the inlet manifold. In addition to reducing the
NOx-content, the engine is further equipped with an exhaust aftertreatment system in form of an SCR-system.
Figure 6
EGR
1. Inlet throttle
2. EGR control valve and actuator
3. EGR differential pressure sensor
4. EGR cooler
5. EGR temperature sensor
6. EGR venturi tube
7. Charge air cooler
8. Charge air cooler outlet temperature sensor
9. Mixing chamber
Sensors
Figure 7
1. SCR
2. AdBlue/DEF metering injector
3. Diesel engine
4. AdBlue/DEF tank
5. Coolant valve
6. AdBlue/DEF pump unit
7. Turbocharger
8. Temperature sensor before DOC
9. Temperature sensor before DPF
10. Differential pressure sensor across DPF and DOC
11. NOx-sensor after SCR
12. Pressure sensor after DPF
13. Temperature sensor after DPF
14. NOx-sensor before SCR
15. Temperature and pressure sensor
16. AdBlue/DEF quality, temperature, and level sensor
New electronic network with new ECUs

This new electronic platform is significantly faster and has a larger storage capacity. The ECUs previously called V-ECU and V2–
ECU are replaced by GPMECU1, 2 and 3 (General Purpose Module Electronic Control Unit).
The main function of each GPMECU
 GPMECU1: brake, windscreen wipers

 GPMECU2: CDC
 GPMECU3: transmission, parking brake
HMICU (Human Machine Interface Control Unit) replaces the I-ECU, which was a combined ECU and display. HMICU is separate
from the display unit. The display is connected to HMICU with a can bus. The ECM replaces the previous E-ECU.
The diagnostic socket is replaced by an OBD II (OBD 2) socket (On Board Diagnostic II).
Figure 8
The communication buses are replaced by BB1 and BB2 (Backbone 1&2).
The CAN7 bus is still used to communicate with the NOx sensors SE2513 and SE2533.
FX1079 that consists of the AdBlue®/DEF tank temperature, tank level and AdBlue®/DEF quality sensors SE2536, SE2537 and
SE2541.
New tools
To administrate software, read out error codes, alter parameter settings, a new tool, TechTool2, is developed and required.
A new adapter together with a new adapter cable is available. A new adapter cable for the earlier version of adapter is also available.
Part number, adapter Part number, adapter cable OBD2

88890300 New adapter 88890304 OBD2 cable (to new adapter)
88890020 Older adapter 88890026 OBD2 cable (to older adapter)
Specifications
L60H L70H L90H

Engine designation Volvo D6J
Max. power at 1400–1800 rpm (23.3–30.0 122 kW (164 hp) 127 kW (170 hp) 137 kW (184 hp)
r/s) ISO 9249, SAE J1349, net
Max. power at 1400–1800 rpm (23.3–30.0 122 kW (164 hp) 127 kW (170 hp) 137 kW (184 hp)
r/s) ISO 9249, SAE J1349, gross
Max. torque at 1400 rpm (23.3 r/s) ISO 820 Nm 860 Nm 880 Nm
9249, SAE J1349, net
Max. torque at 1400 rpm (23.3 r/s) ISO 820 Nm 860 Nm 880 Nm
9249, SAE J1349, gross
Economic operating range 800–1600 rpm (13.3–26.6 r/s)
Number of cylinders 6
Cylinder volume 5.7 litres (1.5 US gal)
Idle speed, low 700 rpm (11.67 r/s)
Idle speed, high 2375 rpm (39.6 r/s)
Air cleaner Air cleaning in 3 steps; cyclone cleaner — primary filter — secondary filter
Fuel tank (refill capacity) 234 litres (61.8 US gal)
AdBlue®/DEF tank (refill capacity) 25 litres (6.6 US gal)
Tyre size 17.5R25, 20.5R25 20.5R25 600/65R25 20.5R25 650/65R25
600/65R25
Specifications, hydraulics
Pump 2 (P2), specifications

Type Axial piston pump, variable displacement
L60H L70H L90H
Displacement 85 cm³ (5.3 in³) 90 cm³ (5.5 in³) 100 cm³ (5.8 in³)
Max. working pressure (high idle) 26 ±0.5 MPa (3770 ±73 psi) 31 ±0.5 MPa (4496 ±73 psi)
Standby pressure (low idle) 3.6 ±0.3 MPa (522 ±43 psi)
Flow at 1900 rpm at 10 MPa (1450 psi) 145 litres/min (38.3 US gal/ 154 litres/min (40.7 US gal/ 162 litres/min (42.8 US gal/
pressure min) min) min)
Pump 3 (P3), specifications

Type Axial piston pump, variable displacement
L60H L70H L90H
Displacement 18 cm³ (1.1 in³)
Max. working pressure (high 21 ±0.5 MPa (3046 ±72 psi)
idle)
Standby pressure (low idle) 1.6 ±0.3 MPa (232 ±44 psi)
Flow at 1900 rpm at 10 MPa 33 litres/min (8.7 US gal/min)
(1450 psi) pressure
New operator interface

A display unit with a new interface has been introduced. In addition to a new appearance, a gauge for AdBlue®/DEF has also been
added as well as separate gauges for engine speed and vehicle speed.
The digital display has three different display modes which can be altered by the operator depending of which information is relevant
for the operator.
Figure 9
Figure 10
GB ART/WLO 160 36 1 10/08/2007
Applies to
Articulated Haulers, Wheel Loaders
Oil sampling, method

WARNING
normal warranty.
Cause and action
In order to achieve an oil analysis that is as correct as possible it is important that the oil is taken from the machine in a correct way
(see also Oil sampling, sampling points) and that the form for the oil analysis is filled in correctly.
Form for oil analysis
Fill in the boxes for the respective samples with regard to oil brand, number of operating hours for the oil and the oil grade.
Figure 1
Example of filled in boxes and attached label for engine oil sample
Attach identical labels in the intended box on the form and on the bottle with the oil sample.
Figure 2
Oil-sample bottle with attached label
Fill in to which workshop the test results should be sent.
Figure 3
Example of to where the test result is to be sent
Send off the sample immediate according to local procedures in order to get the test result as early as possible.
Figure 4
Example of a filled-in form for an oil sample
Instructions for vacuum pump
Use a new hose for each sampling.
Store the pump in a clean place, when it is not used.
Figure 5
1. 941363 Hose
2. Lock nut
3. 11411003 Vacuum pump
4. Oil-sample bottle
Installing hose
Figure 6
Installing hose
1. Cut a hose to a suitable length.

2. Insert the hose through the head of the vacuum pump.
The hose should protrude 4 cm (1.6 in) outside the base of the pump head.
3. Tighten the lock nut.
Removing hose
Figure 7
Removing hose
1. Loosen the lock nut.

2. Cut off the hose above the lock nut and pull the hose out of the pump.
NOTE!
Check that the hose ends do not contaminate the pump head with oil.
3. Take care of the hose in an environmentally safe way.
Cleaning vacuum pump
Figure 8
Vacuum pump
1. O-ring
2. Diaphragm
3. Cylinder
4. O-ring
5. O-ring
6. Lock nut
The vacuum pump must be cleaned after each sampling to prevent any residual oil in the vacuum pump from contaminating future oil
samples.
1. Dismantle the vacuum pump.

2. Wipe the parts with a clean lint-free paper or rag. Apply a thin coat of silicone grease to the O-rings. When required, use
compressed air for cleaning.
3. Assemble the vacuum pump and test its function.
NOTE!
The vacuum pump must not be cleaned with diesel fuel, petrol or cleaning agent.
Oil sampling methods
The following applies to all methods:
 Make sure that oil-sample bottle is completely clean.

 Operate the machine until all systems have reached normal working temperature.
During the warming-up, all functions should be operated. It is important that all functions connected to the hydraulic system
are operated to their respective end positions.
 Take the oil samples immediately after the warming up.
 Seal the oil-sample bottle thoroughly to avoid contamination and loss of oil during the transport.
A) Oil sample method with hose (pressurised system)

This method is used for engine, transmission and working hydraulics.
Tools:
14025152 Hose with nipple
Figure 9
Example of sampling method with hose
2. Connect the hose to the machine so that oil begins to run out into the hose.
NOTE!
Collect the oil that is running out in a suitable vessel.
Drain off 2–4 dl (6.8–13.6 US fl oz) into the vessel.
3. Slacken the hose connection to stop the oil flow.
4. Remove the vessel with the oil and make sure that it is taken care of in an environmentally safe way.
5. Make sure that it is possible to collect oil in the oil-sample bottle.
6. Tighten the hose connection again and fill the sample bottle 3/4 full.
7. Put the cap on oil-sample bottle.
Attach one label to the bottle and one label to the form for oil analysis.
8. Remove the hose.
9. Stop the engine.
B) Oil sample method with vacuum pump

The same method is used for axles, engine, dropbox and hub reduction gears.
Tools:
11411003 Vacuum pump
941363 Hose
1. Cut the hose to a suitable length and connect it to the vacuum pump.
Figure 10
Example of test method with vacuum pump.
2. Install oil-sample bottle on the vacuum pump.
3. Insert the hose at the testing point.
NOTE!
Make sure that the oil sample is not taken from the bottom, but rather in the middle or within the working range of the oil.
4. Draw up oil to flush out the hose.
5. Remove the oil-sample bottle and empty it. Make sure that the oil is taken care of in an environmentally safe way.
6. Install oil-sample bottle on the vacuum pump and fill the sample bottle 3/4 full.
7. Remove the oil-sample bottle and put on the cap.
C) Oil sample method with quick-action coupling (pressurised systems), earlier machines
This method is used for engine, transmission and working hydraulics on earlier machines with TEMA-coupling.
Tools:
Snap-on coupling
941363 Hose
Figure 11
Snap-on coupling
1. 9993522 Test nipple

2. 947083 Gasket
3. 963804 Nipple
4. 976928 Gasket
5. 4881092 Nipple
6. 4871469 Air vent valve
1. Cut the hose to a suitable length and connect it to the quick-action coupling.
NOTE!
A new hose should be used for each sampling.
Figure 12
Example of sampling method with quick-action coupling
3. Connect the quick-action coupling to the machine and open the breather valve so that oil begins to run out into the hose.
NOTE!
Collect the oil that is running out in a suitable vessel.
Drain off 2–4 dl (6.8–13.6 US fl oz) into the vessel.
4. Close the breather valve to stop the oil flow.
5. Remove the vessel with the oil and make sure that it is taken care of in an environmentally safe way.
6. Make sure that it is possible to collect oil in the oil-sample bottle.
7. Open the breather valve again and fill the sample bottle 3/4 full.
8. Close the breather valve.
9. Put the cap on the oil-sample bottle.
10. Remove the quick-action coupling.
11. Stop the engine.
GB ART/BHL/CEX/ 910 24 1 04/29/2010
COA/COS/CWL/
EXC/GRD/MET/
PAT/PAW/SSL/WLO
Applies to
Wheel Loaders, Compact Wheel Loaders, Motor Graders, A25D 4x4 Volvo, A25D Volvo, A25E 4x4 Volvo, A25E Volvo, A30D Volvo,
A30E Volvo, A35D Volvo, A35E FS Volvo, A35E Volvo, A40D Volvo, A40E FS Volvo, A40E Volvo, T450D Volvo, Tracked Pavers,
Wheeled Pavers, Asphalt Compactors, Soil Compactors, Tracked Milling Equipment, Backhoe Loaders, Compact Excavators,
Excavators, Skid Steer Loaders
Portable/refillable O-ring kits

WARNING
normal warranty.
Figure 1
Cause and action

A new O-ring kit has been introduced and replaces the earlier one that has not reached the quality expected of a Volvo spare part.
The O-rings in the new kit are all made of HNBR material. The O-rings in the earlier kit only met this quality level to a certain extent.
As well, the box for the O-rings is of a new design which prevents the O-rings from being mixed up if the box should be dropped
accidentally, for example.
Designation Earlier part number New part number

O-ring kit VOE 11708294 VOE 15155158
GB ART/GRD/WLO 000 155 1 10/26/2007
Applies to
Wheel Loaders, Articulated Haulers, G930 Volvo, G940 Volvo, G946 Volvo, G960 Volvo, G970 Volvo, G976 Volvo, G990 Volvo
Quality of illustrations in technical reports

WARNING
normal warranty.
Cause
Although, today, it is general practice to use a digital camera and/or scanner when producing pictures, it may be appropriate to
determine a reasonable level of quality of such material. As Techline is now beginning to be used to greater extent it is even more
important that the information made available in this way, is relevant and easy to interpret.
If the pictures are to be of any help to us during discussions with design engineers, suppliers or our own factories, these pictures
must clearly show the problem in question.
If used correctly, the digital camera is an excellent tool which greatly improves our understanding of the written word.
Picture size
Depending on what is to be shown, the size of the picture may of course vary. However, sizes smaller than 800*600 pixels are not
recommended. The picture can then also be printed with good results and be viewed on paper. A JPG picture in colour of this size
requires approximately 300 kb when storing. This means that it is possible to store 4 pictures in a Techline call.
Focus
On most digital cameras it is possible to preview the image immediately after it has been taken. Use this function and check that the
image is sharp in the right place. If this is not the case, take another picture. If the picture does not clearly show what is intended, it is
of no use.
Figure 1
Picture with good sharpness
Figure 2
Picture with poor sharpness
NOTE!
If there are any doubts as to what the picture describes, it sometimes may be necessary to add notes or comments to enable those
who have to analyse the picture to understand what is intended. It is possible to do this in most picture editing programmes available
on the market.
Figure 3
Example of how notes or comments can be presented in a picture (it is also OK to insert text boxes, arrows, circles etc. to
describe the picture)
1. Example of note/comment
2. Example of note/comment
Figure 4
Example of general layout picture
If it is not clear which part or component is shown in the picture, it can be illustrated by inserting a general layout picture.
NOTE!
This layout should be used when the report applies to attachments, i.e.buckets etc. Insert then a picture of the product identification
plate.
How many pictures?
As a rule it can be said that it is the quality of the pictures that determines the value of the pictures not the quantity. Try to show what
is important with as few pictures as possible. It is also not a good idea to enclose several pictures showing the same thing. The
thinking behind each picture must be to convey important information.
GB ART/EXC/GRD/ 160 117 1 09/10/2013
WLO
Applies to
Excavators, Motor Graders, Wheel Loaders, Articulated Haulers
Recommendations for Oil Sampling Intervals

NOTE!
normal warranty.
Cause and action

Oil analysis detects contamination and fluid degradation before these conditions cause equipment failure.
Figure 1
The success of an oil analysis program is the regularity of the oil sampling.
Based on our technical experience Volvo CE recommends the below intervals and numbers of samples when you start up your Volvo
Oil Analysis program.
When you have got experienced on your actual market you may change the sampling intervals according to your knowledge about
the need.
The Wear limitations or Monitoring limits for Volvo components can be found in Service Bulletins:
ART 160ART8K
EXC 160EXC8K
GRD 160GRD60K
WLO 160WLO27K
Oil Sampling Intervals

Articulated Haulers
Hours Engine * Transm. DropBox Axle FD Hydraulic Brake cooling Coolant

500 1 1
1000 1 3 1 1 12 month
Wheel Loaders
Hours Engine* Transm. Axle FD Hydraulic Coolant

500 1 1
1000 2 1 12 month
Excavators
Hours Engine* Axle (EW) Gearbox Swing Travel Hydraulic Pump Coolant
(EW) Gearbox Gearbox Gearbox
500 1
1000 2 1 1 (2)[T1] 2 1 1 12 month
[T1]Excavators with 2 Swing gearboxes
Motor Graders
Hours Engine* Transm. Pump Axle FD Tandem Hydrualic All Wheel Engine Coolant
Gearbox Drive Clutch
(G700) Hydr. (G700)
(G700)
500 1 1
1000 1 1 2 1 1 1 12 month
NOTE!
*If you have an oil drain interval for the engine less than 500 hours it’s recommended to take an oil sample at every engine oil
exchange.
GB WLO 925 24 1 01/03/2011
Applies to
Wheel Loaders
Repair instructions for attachments

WARNING
normal warranty.
Cause and action
In some cases it is necessary to repair Volvo manufactured attachments e.g. buckets due to cracks or other problems. The timeframe
for respons is approx. 1 week.
If a repair instruction is needed a request must be sent using Techline. In order to get a fast and correct repair instruction the
following information needs to be added to the Techline call:
 Information about model, serial number and attachment.

 Photo of the ID-plate of the attachment. Make certain all photo information on the ID plate is clear and readable.
Figure 1
 Photo showing the complete attachment with the cracked/worn parts highlighted.
Figure 2
 Close up photo of the crack/wear.

Figure 3
 Photo of the site, if possible showing the machine in action.
Figure 4
GB ART/BHL/CEX/ 000 204 1 10/29/2008
CWL/SSL/WLO
Applies to
Articulated Haulers, Wheel Loaders, Skid Steer Loaders, Compact Wheel Loaders, Compact Excavators, Backhoe Loaders
Reporting of product misuse & near-miss report

WARNING
normal warranty.
A Product misuse & near-miss report is used to report an unplanned event that did not result in injury, illness, or damage - but had
the potential to do so. Any use of a product that Volvo CE has specifically warned against in its instructions is a misuse. Only a
fortunate break in the chain of events prevented an injury, fatality or damage.
To support our effort in building safe products, and because of increasing demands by various authorities, we would like to
encourage you to report each Product misuse & near-miss with this report. The report documents events which you have become
aware of and VCE machines have been involved. We regard the report as a mutual obligation to report and to follow up on such
misuse and near-miss occurrences.
Please copy and fill in the enclosed form.
NOTE!
The report is also available in Word format in Techline. It can be downloaded, filled in digitally and sent in by E-mail. Send the form to
the respective VCE regional office to be forwarded on to the person responsible for the market and technical matters at Volvo
Construction Equipment AB Customer Support Division
The description of the Product misuse & near-miss report must be objective. Personal opinions should be avoided. However, it is of
great importance that facts are reported.
OK to write:The insulation burnt off at...
Do not write: The damage was probably caused by the fact that the insulation was damaged at...
Also other observations should be noted in the report, for example lack of maintenance, carelessness and other circumstances which
may be of importance. For example, slippery conditions, poor visibility, previous repairs etc.
Figure 1
How to fill in the form
English text in the form How to fill in the form

Machine model Fill in the machine model.
Serial number Fill in the serial number of the machine.
Customer's name Fill in the name and address of the owner or user of the
machine.
Site location Fill in the name of the location where the event occurred.
Date identified Fill in the date this event was seen.
Person(s) involved Fill in the names of the people involved in this event.
Identify the misuse and/or the near miss Fill in all information about what was seen, how this was a
hazard and what could have happened.
Instructions or comments provided Fill in the instruction or comments you provided to avoid this type
of event and to whom this was given.
Reported by Fill in the name of the person completing this report. .
Representing Fill in the name and address of your company.
GB ART/COA/COS/ 000 294 9 01/15/2015
CWL/EXC/GRD/
PAT/PAW/PIP/SSL/
WLO
Applies to
Asphalt Compactors, Soil Compactors, Compact Wheel Loaders, Tracked Pavers, Wheeled Pavers, Pipelayers, Wheel Loaders,
Excavators, Motor Graders, Skid Steer Loaders, Articulated Haulers
Reports
NOTE!
normal warranty.
Cause and action
To facilitate root cause analysis and recovery handling, technical support and warranty department need reports when claiming some
focused items.
The requests for the different reports have been sent out in different service bulletins and this service bulletin is only a summary.
Requested reports
These referenced service bulletins must be filled out completely, otherwise warranty claim will not be approved. The respective
dealer/distributor must send a completed form to the regional tech support through Techline within five days of the date of inspection.
Item Product SB number Applies to models Latest release

Engine issues SSL 210SSL61K MC110C, MC115C, MC125C, 2014–08–22
Inspection form for engine MC135C, MC155C, MCT110C,
failure or suspected failure MCT125C, MCT135C, MCT145C
Oil consumption ART 210ART8 All Articulated Haulers 2008-06-05
Action to be taken in case of
abnormal lubricating oil
consumption
EXC 220EXC2K All Excavators 2014-01-13
Check method on engine oil
consumption
WLO 210WLO8 All Wheel Loaders 2008-06-05
Action to be taken in case of
abnormal lubricating oil
consumption
Dropped cylinder EXC 212EXC12K EC160C, EC180C, EC210B, 2014-10-29
liners D6/D7 Exhaust gas leakage EC210C, EC235C, EC240B,
into the cooling system EC240C, EC290B, EC290C,
ECR235C, ECR305C, EW160C,
EW180C, EW210C, EW230C,
FC2121C, FC2421C, FC2924C,
FC3329C
GRD 212GRD13K G930, G940, G946, G960 2014-11-05
D6/D7 Exhaust gas leakage
into the cooling system
WLO 212WLO13K L110E, L110F, L120E, L120F, L60E, 2014-11-05
D6/D7 Exhaust gas leakage L60F, L70E, L70F, L90E, L90F
into the cooling system
Broken cylinder liner EXC 212EXC18K EC200B, EC210B, EC210C, EC210C, 2013-03-15
D6E Cylinder liner broken EW145B, EW180C, EW230C,
FC2421C
WLO 212WLO18K L60F, L70F, L90F 2013-03-15
D6E Cylinder liner broken
Camshaft, EXC 214EXC33K EC160C, EC180C, EC200B, EC210B, 2013-03-15
insufficient hardening D6E Camshaft, insufficient EC210C, EC235C, ECR235C,
hardening EW145B, EW160C, EW180C,
EW210C, EW230C, FC2421C
214EXC40K EC250D, EC300D, PL3005D 2014-03-05
D8H Camshaft, insufficient
hardening
WLO 214WLO33K L60F, L70F, L90F 2013-03-15
D6E Camshaft, insufficient
hardening
214WLO40K L110G, L120G 2014-03-05
hardening
GRD 214GRD40K G930B, G940B, G946B, G960B 2014-03-05
hardening
Camshaft, hardening COS/COA/ 214COA/COS/CWL/EXC/ L110G, L120G, G930B, G940B, 2014-12-19
process update CWL/EXC/ GRD/PAT/PAW/PIP/WLO43K G946B, G960B, L45G, L50G,
GRD/PAT/ EW140D, EW160C, EW160D,
PAW, PIP/ EW180C, EW180D, EW210C,
WLO EW210D, EW145B, EC140D,
EC160C, EC160D, EC180C,
EC180D, EC210B, EC210C,
EC220D, EC235C, EC235D,
EC240B, EC240C, EC250D, EC290B,
EC290C, EC300D, EC350D,
ECR145D, ECR235C, ECR235D,
ECR305C, FC2121C, FC2421C,
FC2924C, FC3329C, ABG7820B,
ABG8820B, P5770C ABG, P5870C
ABG, P6820C ABG, P6870C ABG,
P7110, P7170, P7820C ABG,
P8720B, P8820C ABG, DD110B,
DD120B, DD140B, SD115, SD135
Transmission ART 420ART41K A25D, A25D 4x4, A25E, A25E 4x4, 2011-12-07
Transmission, inspection A30, A30C, A30D, A30E, A35, A35C,
form A35D, A35E, A35E FS, A40, A40D,
A40E, A40E FS, T450D
420ART61K A25D, A25D 4x4, A25E, A25E 4x4, 2011-11-30
Transmission, functional A30D, A30E, A35D, A35E, A35E FS,
check A40D, A40E, A40E FS
420ART81Kv2 A25F, A25G, A30F, A30G, A35F, A35F 2014-11-12
Transmission, inspection FS, A35G, A35G FS, A40F, A40F FS,
form A40G, A40G FS
420ART82Kv2 A25F, A25G, A30F, A30G, A35F, A35F 2014-11-12
Transmission, functional FS, A35G, A35G FS, A40F, A40F FS,
check A40G, A40G FS
GRD 421GRD117 G930, G940, G946, G960, G970, 2010-03-04
Transmission pressure test G976, G990
procedure and test sheet
Electric servo lever/ WLO 914WLO68K L110F, L110G, L120F, L120G, L150F, 2013-03-19
Angle sensor Control measurement for L150G, L180F, L180G, L220F, L220G,
electric servo lever and tilt/lift L250G, L350F
angle sensor
Central lubrication WLO 993WLO19K L110F, L110G, L120F, L120G, L150F, 2014–11–13
pump Repair report for central L150G, L180F, L180FHL, L180G,
lubrication pumps L180GHL, L220F, L350F, L220G,
L250G, L60F, L60G, L70F, L70G,
L90F, L90G, L110H, L120H, L150H,
L180H, L180HHL, L220H, L250H
See specific bulletins for more information about how and when to make the reports.
GB WLO 900 8 1 06/21/2007
Applies to
Wheel Loaders
Seals
WARNING
normal warranty.
Cause
”O-ring Face Seal fittings” (ORFS) have been used for about 20 years and have assisted in eliminating leaks in coupling systems.
The ORFS coupling has always been a matter of discussion because of its ability of ”loosing” the O-ring during transport or
installation. After the problem of lost O-rings was solved through the introduction of CORG, encased O-rings, the next step in the
development was finding a way of solving the problem with O-rings that slipped out of their location during installation of pipes.
(missing infotext)
A trapezoidal seal, Trap Seal, has turned out to counteract the tendency of seals slipping out of their locations during installation of
pipes.
Figure 1
Trapezoidal seal, Trap Seal
The seal is trapezoidal for optimum seal between pipe and coupling. This eliminates the risk of the seal falling out or becoming
pinched during installation. The Trap Seal is symmetrical and can be installed from either side.
When installing trapezoidal seals, it is important to make sure that the seal is correctly installed.
Figure 2
Correctly installed trapezoidal seal
As spare part, both standard shaped O-ring as well as trapezoidal seal may be used, if the coupling is of the CORG-type. Today
trapezoidal seals are used to some extent in production, but will be gradually introduced fully.
GB WLO 770 3 1 04/30/2012
Applies to
Wheel Loaders
Tyres, various types

WARNING
normal warranty.
This information is to be used as a guideline for the correct use and replacement matching of tyres on all wheel loaders.
There is no difference between a new and a worn tyre as regards the rolling circumference of one and the same tyre.
The rolling circumference can vary considerably between tyre manufacturers and the application type of tyre used on the the
equipment, (loader tyres, transport tyres, and tyres intended for specific applications).
If tyres from different manufacturers or types are used on the same machine the drivetrain components may be damaged by
changed ratios by tyre differences.
In most cases, tyres can be mixed from different manufacturers providing that the same tyre classification type is the same, for
example 26.5 R25 L3.
The designation represents the following:

26.5 = Tyre width
R = Radial tyre
25 = Rim diameter
L = Loader and Dozer (Wheel Loader)
3 = Industrial code (application)
Problem can arise when a different types of tyres are mixed on a machine. An example of this is installing a 26.5 R25 L3 tyre from
one manufacturer, with a 26.5 R25 L4 from another manufacturer or with a 26.5 R25 L5 tyre.
NOTE!
L5 tyres should not be mixed with other tyre codes on the machine.
The tyre code designation represents the following:

L2 = Traction
L3 = Rock (non aggressive material)
L4 = Rock deep tread
L5 = Rock extra deep tread (aggressive material)
The rolling circumference between the example tyres shown will be greater than what is allowed. Using tyres intended for other
applications can result in premature tyre wear and drivetrain issues.
Similar problems can occur when re threaded tyres are used. When installing re threaded tyres, make certain the same type of tyre
size and type is replaced.
It is not recommended to use tyres with a difference in rolling circumference that exceeds 1.5% ratio side to side and 2% ratio front to
rear.
Figure 1
Max. permissible differences in rolling circumference
The tyre rolling circumference cannot be measure in a practical manner. Specification data from the tyre manufacturer must be
obtained, then a calculation made, using the allowable variation percentages given.
Example:
Tyres on front axle: 23.5R25 RT–3B L3(rolling circumference = 4855 mm)
Tyres on rear axle: 23.5R25 GP–4D L4 (rolling circumference = 4880 mm)
Calculation: 4880 / 4855 = 1.005 ≈ 0.5%
Conclusion: The difference of the rolling circumference between front and rear axle is 0.5%. It is acceptable to mix these tyres since
the difference is within max. permissible difference.
NOTE!
Remember that e.g. chains affects the rolling circumference.
GB ART/BHL/CEX/ 000 241 2 04/19/2013
COA/COS/CWL/
EXC/GRD/MET/
MEW/PAT/PAW/
PIP/SSL/WLO
Applies to
Pipelayers, Wheeled Pavers, Tracked Pavers, Wheeled Milling Equipment, Wheel Loaders, Skid Steer Loaders, Excavators, Motor
Graders, Articulated Haulers, Compact Wheel Loaders, Soil Compactors, Compact Excavators, Tracked Milling Equipment, Asphalt
Compactors, Backhoe Loaders
Volvo Product incident/accident report & Interview Form

NOTE!
normal warranty.
Cause and action
In our efforts to build safe products and due to different governing authorities' requirements Volvo needs you to report every incident/
accident or when there has been any risk of an incident/accident that becomes known to you where any Volvo machines have been
involved.
NOTE!
Make sure to pay attention to laws and regulations in the country where the machine concerned operates.
For legal information and advice contact your Regional office.
Scope
Volvo CE defines a reportable incident/accident as:
“An unexpected and/or undesired event resulting in (or which reasonably could have resulted in) personal injury, death and/or
property damage (to the machine itself or otherwise).”
Priority
It is of utmost importance that reports are sent in quickly and that they contain as many facts as possible about the incident/accident.
This helps us rapidly evaluate the event and determine what actions are appropriate.
We consider it a mutual obligation that incidents/accidents are reported and followed up.
NOTE!
Important! Swift reporting is very important, especially in connection with fires when clues and any evidence may be destroyed
quickly by the elements (rain, snow, wind, etc.)
Depending upon the nature of the event, it may be necessary to contact Volvo CE immediately to gain direction on how to proceed
further. If Volvo CE employees are not available to conduct an immediate inspection we may need to ask the Dealer personnel to
conduct a product inspection to assist with the investigation and/or preserve the evidence.
Reporting
 Within 24 hours after the incident/accident occurred or after first receipt of information regarding such an event, the regional
manager at Volvo CE's technical support department shall have been informed about the incident/accident.
 The completed report shall be submitted within three working days after the occurrence of the accident/incident.
 In order for Volvo to consider performing an incident inspection/fire inspection the machine must be undisturbed. No repair
may be started, nor may parts or components have been removed from the machine until clearance is given from Volvo CE.
Decision of clearance/inspection will be notified by Volvo CE within five working days.
 The report will be used by Volvo CE in our continuous work to improve the safety and quality of Volvo CE products. It may
also be used as important information for decisions regarding economical compensation or in a legal process.
 NOTE!
 Any reimbursement request may be rejected if parts, components or remains connected to the incident have been
removed or destroyed due to work in or on the machine.
 Any reimbursement request may be rejected due to delayed reporting to Volvo CE's technical support department.
 Any reimbursement request will be rejected due to lack of reporting.
Copy and fill in the form below.

NOTE!
The report is also available as an editable pdf-form in Techline (SB 000 WLO 241 K_GB). It can be downloaded, filled in, and e-
mailed (do not send it through Techline)
IMPORTANT!
Send the form to the relevant regional office. The regional office is responsible for forwarding all information to the relevant
area manager for technical matters at Volvo Construction Equipment.
NOTE!
For Region North America, the report must be sent to e-mail: incidentreport@volvo.com.
Description of the incident/accident
Be objective in describing the event. Avoid personal opinions and/or speculations! It is extremely important to record the facts simply
and completely.
Include observations about other conditions and circumstances that may be helpful in understanding the event.
To make it possible for Volvo CE to make an initial evaluation of the incident/accident, attach photographs as well.
Take as many photos as possible, close-ups and from a distance. Describe, in detail, what is shown in each of the photos.
These photos may be of invaluable help in the initial phase of an investigation.
To save the completed form digitally, it must be printed out as a file and saved digitally!
NOTE!
Only reports written in English are accepted.
Machine type
Machine serial number
Operating hours
Delivery date
Dealer
Address, dealer
Contact information
(Name, phone number,
e-mail)
Machine owner
Machine owner's
address
Contact information
(Name, phone number,
e-mail)
Machine operator's
name
Witness/witnesses Name
(s) & address(es)
Insurance company:
Insurance case number:
No bodily injury Bodily injury Fatality

Material (machine) damage Subsequent damage, loss of
property (other)
Machine, condition (New,

Average, Poor)
Machine's present
location?
Involved component or
part.
Component's serial
number & part number
Date & time of incident/

accident
Accident location
Information received by
(visiting, telephone,
other)
From (name, phone
number)
Report completed by
Title
Date
Compile and send in the report within three working days after the event.
For North America only, e-mail the report to incidentreport@volvo.com.
Description of incident/accident
.................................................................................................................................................................................................................
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Foreword
The following applies to the use of Volvo Construction Equipment guideline times
Listed times indicate guideline times for maintenance and repairs of machines manufactured by Volvo
CE (Volvo Construction Equipment AB).
Guideline time is the time that the mechanic normally needs to perform an operation according to
the instructions normally found in each machine's service manual or component manual, and that is
performed according to the conditions listed below.
Feedback address for Time Guide: servicemanuals@volvo.com
Applicability
The time for performing an operation varies with a number of parameters, e.g., environment (where
the work is done), training and equipment. Guideline times are developed with the following
conditions:
• Workshop in an indoor environment with a solid and level concrete floor.

• Workshop equipped with lifting device that has lifting capacity and lifting height adapted to a
majority of operations (except lifting complete machine units/machine frames) performed on
machines handled by the workshop.
• Use of approved support and lifting equipment, in addition to the equipment indicated in each
machine's service manual.
• Workshop equipped with compressed air, electricity and lighting.
• Use of indicated Volvo CE special tools.
• Tools stored in easily accessed location, in the immediate vicinity of the workplace.
• Where applicable, oils/fluids are handled in an environmentally correct manner.
For guideline times to apply it is required, in addition to the above conditions, that the mechanic has
the training and experience required for the machine and the work that is being done (e.g., Basic
Course Electricity and hydraulics as well as machine course step 1 Volvo CE Service school).
Guideline times apply when one person performs the operation. However, in the operations actions
may be performed that require help from another person. In these cases, the time for that step which
requires two persons has been doubled. The guideline times do not apply if more than one mechanic
performs the entire operation.
Actions not included in guideline times are:
• Transport of machine to and from workshop site.

• Troubleshooting not described as a separate operation.
• Retrieval of spare parts, consumables and tools that are not stored in easily accessed location.
• Washing of the whole or parts of the machine before repair/maintenance.
• Actions that due to deformation, corrosion or external damage increase the repair time.
• Additional work that due to retrofitted equipment reduces access, unless these work steps are
mentioned in the method description in each service manual.
Other
For every operation there is an operation number, heading and guideline time. The description for
how the work is done is normally found in the service manual for each machine under the
corresponding operation number.
12/12/2014 Volvo Construction Equipment 1

Foreword
New format of operation number
In the time guide, each operation number has a heading with a three-digit function group number
(see function group below) as well as a three-digit running number.
Example: Op no. 210-070 Engine removing
210- 070
Function group Running number (Sequential number)
Example of discontinued op. no. is 21070 alt. 21070-1 (Engine removing).
Function group:
According to Volvo Construction Equipment function group index, where the first digit indicates
section and is divided in the following functions, which follows the same design as other service
information:
1. Standard parts, service

2. Engine with mounting and equipment
3. Elec.system; Warning system; Information system; Instrumentsl
4. Power transmission
5. Brakes
6. Steering
7. Frame; Springs; Damping; Axle suspension; Wheel/track unit
8. Machinery house; Cab; Exterior trim parts anywhere
9. Hydraulic system; Digging/handling/grading equipment; Misc. Equip. hydraulics
The second and third digit (10) indicate sub-group, which in turn divides the functions within the group,
also this follows the same design as other service information.
Running number:
Running number or sequential number 001 to 899 (in the example 070) is a number to identify each
operation.
Other
Equipment:
Running number 901 to 999 are reserved for installation times for equipment (installation
instructions).
Earlier (discontinued) format of operation numbers:

From 2005-03-08, only the new format for operation numbers shall be used, with the exception of
operations for VCADS Pro. Already published service information makes use of the earlier format for
operation numbers.
VCADS Pro:
For the time being, VCADS Pro operations will adhere to the same design as before, XXXXX-X, and
will have a code digit (-3) for test procedures.
2 Volvo Construction Equipment 12/12/2014

Contents
Foreword ......................................................................................................................................... 1
A25F (SN 300000–) ......................................................................................................................... 7
A25G ............................................................................................................................................. 17
A30F (SN 300000–) ....................................................................................................................... 27
A30G ............................................................................................................................................. 37
A35F (SN 300000–) ....................................................................................................................... 47
A35F FS (SN 300000–) ................................................................................................................. 55
A35G ............................................................................................................................................. 65
A35G FS ........................................................................................................................................ 75
A40F (SN 300000–) ....................................................................................................................... 85
A40F FS (SN 300000–) ................................................................................................................. 93
A40G ........................................................................................................................................... 103
A40G FS ...................................................................................................................................... 113
ABG5820 ..................................................................................................................................... 123
ABG7820B ................................................................................................................................... 127
ABG8820B ................................................................................................................................... 131
BL60B .......................................................................................................................................... 135
BL61B .......................................................................................................................................... 143
BL70B .......................................................................................................................................... 151
BL71B .......................................................................................................................................... 159
DD100 ......................................................................................................................................... 167
DD110B ....................................................................................................................................... 173
DD120 ......................................................................................................................................... 177
DD120B ....................................................................................................................................... 181
DD140 ......................................................................................................................................... 185
DD140B ....................................................................................................................................... 189
DD25B ......................................................................................................................................... 193
EC140D L .................................................................................................................................... 197
EC140D LM ................................................................................................................................. 205
EC15C ......................................................................................................................................... 213
EC160D L .................................................................................................................................... 219
EC160D NL ................................................................................................................................. 227
EC17C ......................................................................................................................................... 235
EC180D L .................................................................................................................................... 241
EC18C ......................................................................................................................................... 249
EC20C ......................................................................................................................................... 255
EC220D L .................................................................................................................................... 261
EC220D LR ................................................................................................................................. 275
EC220D N ................................................................................................................................... 289
EC220D NL ................................................................................................................................. 299
EC235D NL ................................................................................................................................. 309
EC250D L .................................................................................................................................... 317
EC250D LR ................................................................................................................................. 331
EC250D NL ................................................................................................................................. 345
EC250E L .................................................................................................................................... 355
EC250E LD .................................................................................................................................. 363
EC250E LR .................................................................................................................................. 371
EC250E NL .................................................................................................................................. 379
EC250E NLD ............................................................................................................................... 387
EC27C ......................................................................................................................................... 395
EC300D L .................................................................................................................................... 401
EC300D LD ................................................................................................................................. 413
EC300D LR ................................................................................................................................. 423
EC300D NL ................................................................................................................................. 435

Contents
EC300D WH ................................................................................................................................ 445

EC300E L .................................................................................................................................... 453
EC300E LD .................................................................................................................................. 461
EC300E LR .................................................................................................................................. 469
EC300E NL .................................................................................................................................. 477
EC300E NLD ............................................................................................................................... 485
EC340D L .................................................................................................................................... 493
EC350E L .................................................................................................................................... 501
EC35C ......................................................................................................................................... 509
EC380D HR ................................................................................................................................. 515
EC380D L .................................................................................................................................... 523
EC380D NL ................................................................................................................................. 537
EC380E HR ................................................................................................................................. 547
EC380E L .................................................................................................................................... 555
EC380E LD .................................................................................................................................. 563
EC380E LR .................................................................................................................................. 571
EC380E NL .................................................................................................................................. 579
EC380E NLD ............................................................................................................................... 587
EC480D HR ................................................................................................................................. 595
EC480D L .................................................................................................................................... 603
EC480E L .................................................................................................................................... 617
EC480E LD .................................................................................................................................. 625
EC480E LR .................................................................................................................................. 633
EC55C ......................................................................................................................................... 641
EC60C ......................................................................................................................................... 649
EC80D ......................................................................................................................................... 653
ECR25D ...................................................................................................................................... 659
ECR38 ......................................................................................................................................... 665
ECR50D ...................................................................................................................................... 671
ECR58D ...................................................................................................................................... 677
ECR88D ...................................................................................................................................... 683
EW140D ...................................................................................................................................... 689
EW160D ...................................................................................................................................... 699
EW180D ...................................................................................................................................... 709
EW205D ...................................................................................................................................... 719
EW210D ...................................................................................................................................... 727
EW230C ...................................................................................................................................... 737
EW60C ........................................................................................................................................ 745
G930 ............................................................................................................................................ 751
G930C ......................................................................................................................................... 763
G940 ............................................................................................................................................ 767
G940C ......................................................................................................................................... 779
G946 ............................................................................................................................................ 783
G946C ......................................................................................................................................... 795
G960 ............................................................................................................................................ 799
G960C ......................................................................................................................................... 811
G970 ............................................................................................................................................ 815
G976 ............................................................................................................................................ 827
G990 ............................................................................................................................................ 839
L110H .......................................................................................................................................... 851
L120H .......................................................................................................................................... 859
L150H .......................................................................................................................................... 867
L180H .......................................................................................................................................... 875
L180H HL .................................................................................................................................... 883

Contents
L20F ............................................................................................................................................ 891

L220H .......................................................................................................................................... 895
L250H .......................................................................................................................................... 903
L25F ............................................................................................................................................ 911
L30G ............................................................................................................................................ 915
L350F .......................................................................................................................................... 919
L35G ............................................................................................................................................ 927
L40B ............................................................................................................................................ 931
L45G ............................................................................................................................................ 939
L50G ............................................................................................................................................ 945
L60H ............................................................................................................................................ 951
L70H ............................................................................................................................................ 957
L90H ............................................................................................................................................ 963
MC105C ...................................................................................................................................... 969
MC110C ...................................................................................................................................... 971
MC115C ...................................................................................................................................... 973
MC135C ...................................................................................................................................... 975
MC155C ...................................................................................................................................... 977
MC60C ........................................................................................................................................ 979
MC70C ........................................................................................................................................ 981
MC85C ........................................................................................................................................ 983
MC95C ........................................................................................................................................ 985
MCT110C .................................................................................................................................... 987
MCT125C .................................................................................................................................... 989
MCT135C .................................................................................................................................... 991
MCT145C .................................................................................................................................... 993
MCT85C ...................................................................................................................................... 995
MCT95C ...................................................................................................................................... 997
MT2000 ....................................................................................................................................... 999
MW500 ...................................................................................................................................... 1013
Omni 1000 ................................................................................................................................. 1019
Omni 318 ................................................................................................................................... 1021
P4370B ...................................................................................................................................... 1023
P5770C ABG ............................................................................................................................. 1025
P5870C ABG ............................................................................................................................. 1031
P6820C ABG ............................................................................................................................. 1037
P6870C ABG ............................................................................................................................. 1045
P7110 ........................................................................................................................................ 1051
P7170 ........................................................................................................................................ 1057
P7820C ABG ............................................................................................................................. 1063
P8820C ABG ............................................................................................................................. 1071
PF2181 ...................................................................................................................................... 1079
PF4410 ...................................................................................................................................... 1083
PT125 ........................................................................................................................................ 1087
PT220 ........................................................................................................................................ 1091
SD105 ........................................................................................................................................ 1099
SD110 ........................................................................................................................................ 1105
SD115 ........................................................................................................................................ 1119
SD130 ........................................................................................................................................ 1125
SD135 ........................................................................................................................................ 1131
SD160 ........................................................................................................................................ 1137
SD200 ........................................................................................................................................ 1139
SD45 .......................................................................................................................................... 1143
SD70 .......................................................................................................................................... 1147

Contents
SD75 .......................................................................................................................................... 1151

Ultimat 200 ................................................................................................................................ 1157
VB78 ETC .................................................................................................................................. 1161
VB78 GTC ................................................................................................................................. 1163
VB88 ETC .................................................................................................................................. 1165
VB88 GTC ................................................................................................................................. 1167
VDT-V78 ETC ............................................................................................................................ 1169
VDT-V78 GTC ........................................................................................................................... 1171
VDT-V88 ETC ............................................................................................................................ 1173
VDT-V88 GTC ........................................................................................................................... 1175

A25F (SN 300000–)
Op.no. time (h) Notes
0 GENERAL
09 MISCELLANEOUS
090-001 0.70 Engine, basic check
1 STANDARD PARTS, SERVICE

17 SERVICE
173-007 0.60 Maintenance service, every 250 hours
173-042 2.50 Maintenance service, first 1000 hours
173-457 1.25 Coolant, changing
176-002 0.70 Propeller shafts, removing
19 GENERAL
191-021 0.20 Service position 1
2 ENGINE WITH MOUNTING AND EQUIPMENT

20 GENERAL
200-068 2.00 E-ECU, MID 128, changing non-programmed
ECU
200-070 1.50 E-ECU, MID 128, changing pre-programmed ECU
21 ENGINE
210-002 8.50 Compression test
210-073 11.00 Engine and transmission, removing
210-074 13.00 Engine and transmission, mounting
210-092 0.50 Engine rotation speed sensor (camshaft),
replacing
214-012 3.00 Valves, adjusting
215-042 8.00 Camshaft, replacing
215-043 2.50 Camshaft setting, checking
216-014 1.75 Crankshaft, replacing front oil seal
216-018 18.00 Crankshaft, replacing rear oil seal
216-049 1.75 Crankshaft, axial clearance, checking
218-001 1.50 Rubber cushion, replacing
218-007 4.00 Engine mounting rear, changing

A25F (SN 300000–)
22 LUBRICATING SYSTEM
221-020 1.00 Lubrication pressure rocker arm shaft, check
221-022 0.60 Lubrication oil pressure, checking with pressure
gauge
23 FUEL SYSTEM
230-001 0.50 Carbon dioxide in fuel system, check
230-002 0.70 Air in fuel system, checking
233-001 1.25 Fuel system, bleeding
233-004 0.80 Feed pump, checking feed pressure
236-002 0.90 Stall speed, checking
237-007 1.25 Overflow valve, replacing
237-010 0.90 Unit injectors, adjusting pretension
237-012 7.50 Unit injector, replacing
237-017 11.00 Injector sleeves, replacing
25 INLET SYSTEM; EXHAUST SYSTEM

254-022 1.00 ACM (After treatment control module), replacing,
non-programmed
pre-programmed
255-002 1.25 Turbocharger, inspection
255-071 2.00 Turbocharger, replacing
258-016 1.00 Cooling fan motor, intercooler, checking/adjusting
low rpm
high rpm
26 COOLING SYSTEM
260-001 0.50 Carbon dioxide in coolant system, checking
263-063 1.25 Cooling fan motor, radiator, checking/adjusting
low rpm
263-092 1.25 Cooling fan motor, radiator, checking high rpm
3 ELEC. SYSTEM; WARNING SYSTEM;

INFORMATION SYSTEM; INSTRUMENTS
30 GENERAL
300-075 1.00 HMIM, MID 140, changing pre-programmed ECU
300-076 1.25 HMIM, MID 140, changing non-programmed ECU
31 BATTERY
311-002 1.00 Batteries, replacing
32 ALTERNATOR; CHARGE REGULATOR

321-002 1.25 Alternator, replacing incl function check

A25F (SN 300000–)
33 STARTING SYSTEM
331-018 1.75 Starter motor, replacing
35 LIGHTING
352-001 0.40 Lamp bulb, replacing
352-002 0.50 Headlights, adjusting
352-024 0.60 Headlight, complete, changing (high beam 1 pc.)
incl. setting
352-060 0.60 Headlight, complete, changing (low beam 1 pc.)
incl. setting/adjustment
353-051 0.60 Tail lamp, replacing
36 OTHER ELECTRICAL EQUIPMENT

361-005 0.60 Flasher lamp front glass or bulb, replacing
361-006 0.60 Flasher lamp sidelight glass or bulb, replacing
363-002 2.00 Windscreen wiper front, replacing motor
366-064 1.25 V-ECU, MID 187, changing non-programmed
ECU
366-066 1.00 V-ECU, MID 187, changing pre-programmed ECU
366-111 0.90 Engine Gateway, MID 165, replacing non-
programmed ECU
366-112 0.90 Engine gateway, MID 165, replacing pre-
programmed ECU
38 INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM

386-008 0.60 Engine rotation speed sensor, replacing
39 MISCELLANEOUS
398-001 0.50 CareTrack antenna, replacing
398-002 1.00 W-ECU, MID142, changing pre-programmed ECU
398-003 1.00 W-ECU, MID142, changing non-programmed
ECU
4 POWER TRANSMISSION
42 TRANSMISSION, HYDRAULIC CONTROL
421-002 0.70 Transmission oil pressure, checking
421-046 2.50 PWM-valve control system, changing
421-054 2.00 Seal for rear output shaft, replacing
421-062 1.50 Induction sensor for turbine speed, changing
421-070 8.00 Transmission, removing
421-072 9.50 Transmission, installing
421-083 1.25 Transmission, remove from a non mounted engine
421-084 1.50 Transmission, fitting on a non mounted engine

A25F (SN 300000–)
43 GEARBOX,
434-002 1.75 Dropbox, replacing seal for front otput shaft
434-004 2.00 Dropbox, replacing seal for rear output shaft
434-064 0.60 Differential lock longitudinal, adjustment of sender
unit
434-073 3.50 Dropbox, installing
434-074 3.00 Dropbox, removing
436-001 7.00 Dropbox rubber bushing, replacing
46 FRONT AXLE; REAR AXLE

461-011 6.00 Centre gear , removing and fitting
461-046 1.75 Input shaft, seal, replacing
463-011 5.50 Centre gear, removing and fitting
463-045 3.00 Hub reduction, removing
463-046 4.00 Hub reduction, installing
463-047 0.90 Hub reduction gear, disassembly and assembly
463-048 0.90 Dog clutch 6-wheel drive, adjusting
463-049 3.00 Output shaft, bearing and seal, replacing
464-014 1.50 Input shaft seal, replacing
468-062 0.70 Transverse differential lock/axle, checking and
adjusting
5 BRAKE
51 WHEEL BRAKE
516-005 5.00 Brake disc, replacing
52 HYDRAULIC BRAKE SYSTEM

520-001 0.70 Brake system, checking function, hydraulic
520-010 0.10 Brake system, relieve pressure
520-037 0.90 Brake system, bleeding
523-045 1.75 Pump unit brake cooling, replacing
525-008 3.50 Foot brake valve, replacing
527-001 0.10 Accumulator removed, checking charging
pressure
527-002 1.25 Accumulator, replacing
55 PARKING BRAKE
550-002 1.75 Parking brake, adjusting
550-005 3.00 Parking brake, replacing brake disc
550-009 1.50 Spring brake cylinder, replacing
550-014 1.50 Parking brake, replacing brake pads

A25F (SN 300000–)
550-015 0.30 Parking brake, manually releasing

550-023 0.20 Parking brake, function checking
553-000 0.50 Load and dump brake, working pressure, checking
and adjusting
553-001 0.40 Load and Dump brake, servo pressure, checking
553-002 0.30 Load and Dump brake, function check
56 COMPRESSED-AIR BRAKE
561-004 2.50 Compressor, replacing
561-023 0.30 Relief/Cut-in pressure, check
561-024 0.30 Relief/Cut-in pressure, adjusting
59 MISCELLANEOUS
590-001 0.30 Quick coupling compressed air, replacing
6 STEERING
64 STEERING
642-026 3.00 Steering gear, replacing
642-058 1.25 Steering gear, check.and adj.
643-010 1.75 Steering linkage, checking and adjusting
643-012 0.40 Steering angle, checking and adjusting
643-013 0.90 Steering times, checking and adjusting
643-014 1.00 Steering valve, neutral position, checking and
adjusting
643-017 2.50 Lever bracket, steering bearing, replacing
645-004 1.00 Steering cylinder, removing
645-005 1.75 Steering cylinder, installing
645-019 2.00 Steering system, bleeding
645-052 1.00 Steering cylinder removed, reconditioning excl
replacing bearings
645-054 0.60 Steering cylinder, replacing bearings
645-084 1.25 Damping cylinder, checking spring force
645-085 1.25 Damping cylinder, changing seal
647-095 1.00 Auxiliary steering, adjusting working- and stand-by
pressure
647-096 1.00 Auxiliary steering, hydraulic pump, removing
647-097 2.00 Auxiliary steering, hydraulic pump, installation

A25F (SN 300000–)
7 FRAME; SPRINGS; DAMPING; AXLE SUSPENSION;

WHEEL/TRACK UNIT
71 FRAME
715-015 0.90 Protecting plate, removal
715-016 1.50 Protecting plate, installation
72 SUSPENSION
720-020 0.70 Hydraulic cylinder bushing, suspension system,
replacing
720-021 1.75 Hydraulic cylinder, suspension system, overhaul
725-001 1.00 Suspension cylinder, removal
725-002 0.90 Suspension cylinder, installation
725-010 1.75 Suspension cylinder (GHS), oil changing
725-012 0.20 Suspension cylinder (GHS), discarding
725-015 0.80 Suspension cylinder (GHS), checking and
adjusting
74 FRAME LINK
741-001 6.00 Frame joint, separating machine
741-040 1.50 Frame joint bearing, replacing (machine
separated)
741-044 4.50 Hitch, removing
741-045 6.00 Hitch, installing
741-046 2.00 Steering joint bearing, replacing (Hitch removed)
742-040 5.00 Steering joint, replacing bearings
75 AXLE SUSPENSION
751-001 1.75 A-frame bushing, tractor unit, replacing
751-013 1.00 Cross stay, rubber bushing, replacing
751-014 0.40 Cross stay, removing
751-015 0.40 Cross stay, installing
756-024 2.00 Bogie beam, changing rubber spring, one side
(front)
756-027 2.00 A-frame bushing, front on load unit, changing
756-028 2.50 A-frame bushing, rear on load unit, changing
756-029 0.90 Bogie beam, changing rubber bushing on
removed beam
77 WHEELS; TRACKS; TYRE; HUB; DRUM

771-007 0.70 Wheel, installing
771-008 0.70 Wheel, removing

A25F (SN 300000–)
8 MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS

ANYWHERE
81 CAB, NAKED; CANOPY
810-001 3.00 Cab, removing
810-002 3.50 Cab, installing
82 ENGINE HOOD; MUDGUARD; FOOT STEP

821-001 0.80 Engine hood, removing
821-002 0.70 Engine hood, installing
821-035 0.60 Hood pump, oil, changing
821-060 0.70 Electric hood pump, changing
83 DOORS; HATCH; COVER PLATE, (all)

831-004 1.25 Door, replacing
831-006 0.60 Door lock, replacing
831-007 0.50 Door, gas spring, replacing
84 TRIM PART, OUTSIDE; GLASS; SEALING MOULDING

843-002 3.00 Windscreen, replacing
843-012 3.00 Rear window, replacing
843-013 3.00 Side window, replacing
843-014 3.00 Side window, rear, replacing
843-048 2.00 Door window, replacing
85 CAB INTERIOR/UPHOLSTERY
852-003 0.70 Operator's seat, removing
852-004 0.70 Operator's seat, installing
852-092 0.50 Operator's seat, shock absorber, replacing
852-096 1.50 Operator's seat, air bellows, replacing
852-097 1.50 Compressor operator’s seat, replacing
87 AIR CONDITIONING UNIT

870-010 0.80 ECC, MID 146, changing pre-programmed ECU
870-011 0.80 ECC, MID 146, changing non-programmed ECU
870-015 1.25 Cab heating/cab ventilation timer, pump, replacing
873-004 4.00 Heater core, replacing
873-006 4.00 Fan motor, replacing
873-008 3.00 Heat control valve, replacing
873-009 0.50 Heat control, replacing
874-001 1.75 Refrigerant, filling incl vacuum pumping
874-002 1.25 Refrigerant, draining
874-003 0.30 Cooling unit, performance test
874-006 4.00 Compressor, replacing incl draining and filling

A25F (SN 300000–)
874-010 4.00 Condenser, replacing incl draining and filling

874-011 3.50 Receiver, replacing incl draining and filling
874-012 5.00 Evaporator, replacing incl draining and filling
874-059 5.50 Evaporator, cleaning
875-013 2.00 Auxiliary heater, replacing
9 HYDRAULIC SYSTEM; DIGGING/ HANDLING/

GRADING EQUIPM.; MISC. EQUIP.
90 GENERAL
900-002 0.40 Hydraulic system, bleeding
900-003 0.10 Hydraulic system, relieve pressure
900-005 0.30 Vacuum pump, connection
900-006 0.20 Vacuum pump, disconnection
900-031 1.00 V2-ECU, MID 249, changing non-programmed
ECU
900-032 0.90 V2-ECU, MID 249, changing pre-programmed
ECU
91 WORKING HYDRAULICS; SERVO HYDRAULICS

912-078 0.60 Dump lever, changing
912-115 4.50 Steering and tipping valve, removal
912-116 4.50 Steering and tipping valve, installation
913-003 0.90 Hydraulic pump, checking and adjusting standby
pressure
913-004 0.80 Hydraulic pump, checking and adjusting max
working pressure
working pressure
913-007 0.30 Hydraulic pump (removed), changing shaft seal
913-023 0.90 Pump, removal
913-024 1.50 Pump, installation
913-042 0.50 Working pumps, checking function
913-068 1.50 Pump regulator, checking
914-094 0.70 Dump function, checking pressure
95 LOAD CARRIER
951-005 1.00 Hoist cylinder bearing, changing
951-006 3.00 Hoist cylinder removed, reconditioning
951-007 1.00 Hoist cylinder, removal
951-008 1.00 Hoist cylinder, installation
951-011 0.30 Cylinder, rear flap, gas pressure, checking and
adjusting
951-030 0.40 Dump body alternative, lowering

A25F (SN 300000–)

951-040 2.00 Dump body joint, changing tipping bearing
951-041 2.50 Dump body, adjusting against frame
951-042 0.20 Dump body angle sensor, calibration
99 MISCELLANEOUS
993-025 2.50 Automatic lubrication pump unit, reconditioning
993-030 0.80 Shift valve, checking

A25G
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A25G
gauge
23 FUEL SYSTEM

non-programmed
pre-programmed
254-056 0.80 NOx sensor, replacing
254-103 1.75 AdBlue®/DEF tank, tank armature, replacing
254-107 1.25 AdBlue®/DEF pump unit, replacing
254-114 1.25 AdBlue®/DEF, draining
254-118 1.50 SCR system, dosing test
254-120 1.25 AdBlue®/DEF dosing injector, replacing
254-121 0.50 AdBlue®/DEF quality, checking
low rpm
high rpm
26 COOLING SYSTEM
low rpm

A25G

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting

ECU
programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU

A25G
43 GEARBOX,
unit

adjusting
5 BRAKE
51 WHEEL BRAKE


A25G

pressure
55 PARKING BRAKE
and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting
replacing bearings

A25G

pressure

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
replacing
adjusting
74 FRAME LINK
separated)
75 AXLE SUSPENSION
(front)

A25G

removed beam


ANYWHERE





A25G


90 GENERAL
ECU
ECU

pressure
working pressure
working pressure
95 LOAD CARRIER

A25G

adjusting
99 MISCELLANEOUS

A30F (SN 300000–)
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A30F (SN 300000–)
gauge
23 FUEL SYSTEM

non-programmed
pre-programmed
low rpm
high rpm
26 COOLING SYSTEM
low rpm

30 GENERAL
31 BATTERY


A30F (SN 300000–)
33 STARTING SYSTEM
35 LIGHTING
incl. setting

ECU
programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU

A30F (SN 300000–)
43 GEARBOX,
unit

adjusting
5 BRAKE
51 WHEEL BRAKE

pressure
55 PARKING BRAKE

A30F (SN 300000–)

and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting
replacing bearings
pressure

A30F (SN 300000–)

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
replacing
adjusting
74 FRAME LINK
separated)
75 AXLE SUSPENSION
(front)
removed beam


A30F (SN 300000–)

ANYWHERE





A30F (SN 300000–)


90 GENERAL
ECU
ECU

pressure
working pressure
working pressure
95 LOAD CARRIER
adjusting

A30F (SN 300000–)

99 MISCELLANEOUS

A30G
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A30G
gauge
23 FUEL SYSTEM

non-programmed
pre-programmed
low rpm
high rpm
26 COOLING SYSTEM
low rpm

A30G

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting

ECU
programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU

A30G
43 GEARBOX,
unit

adjusting
5 BRAKE
51 WHEEL BRAKE


A30G

pressure
55 PARKING BRAKE
and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting
replacing bearings

A30G

pressure

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
replacing
adjusting
74 FRAME LINK
separated)
75 AXLE SUSPENSION
(front)

A30G

removed beam


ANYWHERE





A30G


90 GENERAL
ECU
ECU

pressure
working pressure
working pressure
95 LOAD CARRIER

A30G

adjusting
99 MISCELLANEOUS

A35F (SN 300000–)
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A35F (SN 300000–)
gauge
23 FUEL SYSTEM

non-programmed
pre-programmed
low rpm
high rpm
26 COOLING SYSTEM
262-008 2.50 Secondary coolant pump, replacing
low rpm

30 GENERAL
31 BATTERY

A35F (SN 300000–)

35 LIGHTING
incl. setting

ECU
programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU

A35F (SN 300000–)
43 GEARBOX,
unit

463-016 13.00 Dog clutch 6x6, checking and adjusting
463-079 3.00 Output shaft 6-wheel drive, sealing and bearing,
replacing
463-100 0.40 Rotation speed sensor, replacing
463-101 0.40 Rotation speed sensor, adjusting
5 BRAKE
pressure
55 PARKING BRAKE

A35F (SN 300000–)

and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting
replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME
711-001 3.00 Frame extension, removing
711-002 4.00 Frame extension, installing

A35F (SN 300000–)
74 FRAME LINK
separated)
75 AXLE SUSPENSION
(front)
removed beam
756-030 7.00 Bogie beam, changing


ANYWHERE



A35F (SN 300000–)



90 GENERAL

A35F (SN 300000–)

ECU
ECU

911-912 1.75 Rubber connection, suction line, replacing
pressure
working pressure
working pressure
913-052 1.00 Hydraulic pump, removing
913-053 1.75 Hydraulic pump, installing
94 UNIT, LOAD HANDLING

948-002 2.50 Load cell, replacing
95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A35F FS (SN 300000–)

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
gauge

A35F FS (SN 300000–)
23 FUEL SYSTEM

non-programmed
pre-programmed
low rpm
high rpm
26 COOLING SYSTEM
low rpm

30 GENERAL
31 BATTERY


A35F FS (SN 300000–)
33 STARTING SYSTEM
35 LIGHTING
incl. setting

ECU
programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU

A35F FS (SN 300000–)
43 GEARBOX,
unit

replacing
5 BRAKE
pressure
55 PARKING BRAKE

A35F FS (SN 300000–)

and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting
replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME

A35F FS (SN 300000–)
72 SUSPENSION
720-008 1.25 Position sensor, complete replacement
720-010 0.50 Forced Raising/lowering, Full suspension
720-011 0.30 Relieve pressure
720-012 0.80 Manual lowering
720-013 0.20 Suspension system, bleeding air
replacing
720-022 1.50 Accumulator, suspension system, overhaul
720-023 0.60 Hydraulic pump, max pressure, checking and
adjusting
725-003 0.60 Accumulator, removal
725-004 1.25 Accumulator, installation
725-008 1.50 Position sensor front, replacing
725-009 0.80 Accumulator, precharge pressure, checking and
adjusting
726-006 2.00 Accumulator bank, removal
726-007 1.75 Accumulator bank, installation
726-008 1.25 Position sensor rear, replacing
adjusting
74 FRAME LINK
separated)
75 AXLE SUSPENSION

A35F FS (SN 300000–)



ANYWHERE




A35F FS (SN 300000–)


90 GENERAL
ECU
ECU

pressure
working pressure
working pressure

A35F FS (SN 300000–)

95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A35G
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A35G
gauge
23 FUEL SYSTEM

254-001 2.50 Diesel particulate filter, check and clean
non-programmed
pre-programmed
254-064 1.50 High pressure air system, pressure, checking
254-069 0.40 Exhaust aftertreatment system fuel flow, checking
254-102 1.25 AdBlue®/DEF nozzle, replacing
254-104 0.70 Aftertreatment fuel nozzle, replacing
254-105 1.50 EATS cooling fan, replacing
254-106 1.75 AdBlue®/DEF hoses, replacing
254-108 3.00 Aftertreatment fuel dosing unit, replacing
254-117 1.25 AdBlue®/DEF pump unit, components, replacing
255-003 1.50 Actuator, variable turbocharger, replacing
low rpm
high rpm

A35G
26 COOLING SYSTEM
low rpm
29 Miscellaneous
293-001 4.50 EGR cooler, replacing
293-002 2.50 EGR cooler, pressure test
293-004 6.50 EGR cooler, cleaning
293-005 1.00 EGR valve, replacing
293-013 0.90 EGR venturi tube, cleaning

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting

ECU

A35G

programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU
43 GEARBOX,
unit

replacing

A35G

5 BRAKE
pressure
55 PARKING BRAKE
and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting

A35G

replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK
separated)
75 AXLE SUSPENSION
(front)
removed beam

A35G


ANYWHERE





A35G


90 GENERAL
ECU
ECU

pressure
working pressure
working pressure


A35G
95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A35G FS
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A35G FS

gauge
23 FUEL SYSTEM

non-programmed
pre-programmed
low rpm
high rpm

A35G FS
26 COOLING SYSTEM
low rpm
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting

ECU

A35G FS

programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU
43 GEARBOX,
unit

replacing

A35G FS

5 BRAKE
pressure
55 PARKING BRAKE
and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting

A35G FS

replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
replacing
adjusting
adjusting

A35G FS

adjusting
74 FRAME LINK
separated)
75 AXLE SUSPENSION


ANYWHERE


A35G FS




90 GENERAL

A35G FS

ECU
ECU

pressure
working pressure
working pressure
95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A40F (SN 300000–)
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A40F (SN 300000–)
gauge
23 FUEL SYSTEM

non-programmed
pre-programmed
low rpm
high rpm
26 COOLING SYSTEM
low rpm

30 GENERAL
31 BATTERY

A40F (SN 300000–)

35 LIGHTING
incl. setting

ECU
programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU

A40F (SN 300000–)
43 GEARBOX,
unit

replacing
5 BRAKE
pressure
55 PARKING BRAKE

A40F (SN 300000–)

and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting
replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME

A40F (SN 300000–)
74 FRAME LINK
separated)
75 AXLE SUSPENSION
(front)
removed beam


ANYWHERE



A40F (SN 300000–)



90 GENERAL

A40F (SN 300000–)

ECU
ECU

pressure
working pressure
working pressure

95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A40F FS (SN 300000–)

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
gauge

A40F FS (SN 300000–)
23 FUEL SYSTEM

non-programmed
pre-programmed
low rpm
high rpm
26 COOLING SYSTEM
low rpm

30 GENERAL
31 BATTERY


A40F FS (SN 300000–)
33 STARTING SYSTEM
35 LIGHTING
incl. setting

ECU
programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU

A40F FS (SN 300000–)
43 GEARBOX,
unit

replacing
5 BRAKE
pressure
55 PARKING BRAKE

A40F FS (SN 300000–)

and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting
replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME

A40F FS (SN 300000–)
72 SUSPENSION
replacing
adjusting
adjusting
adjusting
74 FRAME LINK
separated)
75 AXLE SUSPENSION

A40F FS (SN 300000–)



ANYWHERE




A40F FS (SN 300000–)


90 GENERAL
ECU
ECU

pressure
working pressure
working pressure

A40F FS (SN 300000–)

95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A40G
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A40G
gauge
23 FUEL SYSTEM

non-programmed
pre-programmed
low rpm
high rpm

A40G
26 COOLING SYSTEM
low rpm
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting

ECU

A40G

programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU
43 GEARBOX,
unit

replacing

A40G

5 BRAKE
pressure
55 PARKING BRAKE
and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting

A40G

replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK
separated)
75 AXLE SUSPENSION
(front)
removed beam

A40G


ANYWHERE





A40G


90 GENERAL
ECU
ECU

pressure
working pressure
working pressure


A40G
95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A40G FS
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A40G FS

gauge
23 FUEL SYSTEM

non-programmed
pre-programmed
low rpm
high rpm

A40G FS
26 COOLING SYSTEM
low rpm
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting

ECU

A40G FS

programmed ECU
programmed ECU

39 MISCELLANEOUS
ECU
43 GEARBOX,
unit

replacing

A40G FS

5 BRAKE
pressure
55 PARKING BRAKE
and adjusting
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting

A40G FS

replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
replacing
adjusting
adjusting

A40G FS

adjusting
74 FRAME LINK
separated)
75 AXLE SUSPENSION


ANYWHERE


A40G FS




90 GENERAL

A40G FS

ECU
ECU

pressure
working pressure
working pressure
95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

ABG5820

17 SERVICE
172-002 3.00 Warranty inspection 100 hours 701261 - 999999
173-001 2.00 Maintenance service, as required 701261 - 999999
173-003 1.00 Maintenance service, every 10 hours 701261 - 999999
19 GENERAL
191-022 2.50 Service position 2 701261 - 999999

30 GENERAL
301-001 0.40 Control panel, software update
301-003 0.40 Machine, Calibration
301-004 0.20 Control panel, parameter setting

387-032 1.50 Main control unit memory battery, replacing 17309 - 999999
44 HYDROSTATIC DRIVE
441-111 4.00 Track motor, replacing

ABG5820

WHEEL/TRACK UNIT
775-009 5.00 Front idler, removing
775-010 4.50 Front idler, installing
775-025 1.50 Assembling the guide sprocket
775-034 6.00 Track chain assembly, removing
775-035 9.50 Track chain assembly, installing
775-051 1.25 Top roller, replacing one
775-062 1.00 Bottom roller, removing
775-063 0.90 Bottom roller, installing
775-074 0.30 Track pad, removing
775-075 0.20 Track pad, installing
775-080 1.50 Track tension cylinder, replacing
775-095 0.70 Track tension, adjusting
775-108 0.40 Road scraper, removing
775-109 0.20 Road scraper, installing

ANYWHERE
810-051 3.00 Canopy, removal
810-052 4.50 Canopy, installation

98 FUNCTION FOR ROAD CONSTRUCTION
982-001 1.00 Tow arm, removing
982-002 0.80 Tow arm, installing
982-003 2.50 Screed, removing
982-004 3.00 Screed, installing
983-042 1.50 Conveyor cover, removing
983-043 1.75 Conveyor cover, installing
983-052 3.00 Conveyor chain, removing
983-053 2.50 Conveyor chain, installing
983-055 5.00 Conveyor floor plate, removing
983-056 2.50 Conveyor floor plate, installing

ABG5820
983-057 7.50 Conveyor drive shaft, removing

983-058 6.50 Conveyor drive shaft, installing
983-065 1.50 Auger bearing hanger, removing
983-066 0.90 Auger bearing hanger, installing
983-067 4.50 Auger bearing, removing
983-068 2.50 Auger bearing, installing
983-069 3.50 Auger shaft, removing
983-070 1.00 Auger shaft, installing
983-101 2.50 Auger drive chain, replacing
983-102 1.75 Auger motor, removing
983-103 1.50 Auger motor, installing
983-118 0.60 Conveyor drive chain, removing
983-119 0.60 Conveyor drive chain, installing
983-120 1.75 Conveyor idler assembly, removing
983-121 1.50 Conveyor idler assembly, installing
983-122 1.75 Conveyor idler assembly, disassembly and
assembly
983-142 0.30 Auger flight, removing
983-143 0.10 Auger flight, installing

ABG7820B

17 SERVICE
19 GENERAL

30 GENERAL
33 STARTING SYSTEM
331-016 1.50 Starter motor, removing
331-017 1.00 Starter motor, installing

360-012 1.25 Generator screed heating regulator, checking

387-032 1.50 Main control unit memory battery, replacing

ABG7820B

WHEEL/TRACK UNIT

ANYWHERE


ABG7820B

assembly
986-010 1.75 Generator screed heating, checking

ABG8820B

17 SERVICE
19 GENERAL

30 GENERAL
33 STARTING SYSTEM



ABG8820B

WHEEL/TRACK UNIT

ANYWHERE

912-180 0.70 Valve block, removing
912-181 0.60 Valve block, installing
912-240 0.70 Valve block, chain tensioner, removing
912-241 0.70 Valve block, chain tensioner, installing
912-242 0.70 Valve block, brake valve, removing
912-243 0.60 Valve block, brake valve, installing

ABG8820B
912-246 1.25 Valve block, auger, removing

912-247 1.25 Valve block, auger, installing
912-250 1.25 Valve block, conveyor/vibration, removing
912-251 1.50 Valve block, conveyor/vibration, installing
912-252 1.75 Valve block, cylinder functions, removing
912-253 1.75 Valve block, cylinder functions, installing
912-254 0.60 Valve block, leveling, removing
912-255 0.70 Valve block, leveling, installing
912-256 0.50 Valve block, hopper wing lock, removing
912-257 0.30 Valve block, hopper wing lock, installing
912-258 0.90 Valve block, screed assist, removing
912-259 0.90 Valve block, screed assist, installing
912-260 0.50 Valve block, screed anti-climbing lock, removing
912-261 0.50 Valve block, screed anti-climbing lock, installing
912-262 0.90 Valve block, fan, removing
912-263 0.90 Valve block, fan, installing
912-264 0.70 Valve block, screed tensioner, removing
912-265 0.70 Valve block, screed tensioner, installing
912-266 0.90 Valve block, screed extension, height adjustment,
removing
installing
912-268 0.90 Valve block, screed load, removing
912-269 0.90 Valve block, screed load, installing


ABG8820B

assembly

BL60B

17 SERVICE
173-002 0.60 Maintenance service, daily
173-036 7.50 Maintenance service, first 100 hours 2121123 - 2130000
19 GENERAL

20 GENERAL
200-068 1.25 E-ECU, MID 128, changing non-programmed 130101 - 140000
ECU
200-070 0.90 E-ECU, MID 128, changing pre-programmed ECU130101 - 140000
21 ENGINE
210-070 6.00 Engine, removing 2121123 - 2130000
210-070 4.50 Engine, removing 130101 - 140000
210-072 6.00 Engine, installing 2121123 - 2130000
210-083 0.60 Engine protection plates, removing and installing 130101 - 140000
212-071 0.50 Crankcase ventilation separator, replacing 130101 - 140000
214-012 2.50 Valves, adjusting 130101 - 140000

BL60B
218-009 1.25 Engine mounts, replacing 2121123 - 2130000
221-021 0.40 Lubrication oil pressure, checking 2121123 - 2130000
23 FUEL SYSTEM
233-001 0.10 Fuel system, bleeding 2121123 - 2130000
233-002 0.40 Feed pump, replacing 130101 - 140000
233-011 0.80 Fuel pump, removing 2121123 - 2130000
233-012 0.70 Fuel pump, installing 2121123 - 2130000
233-014 0.40 Fuel filters, replacing 2121123 - 2130000
234-011 0.60 Fuel tank, removing
234-012 0.60 Fuel tank, installing
236-079 2.00 Injection pumps, changing 130101 - 140000
237-002 3.50 Injectors, replacing all 130101 - 140000
237-040 0.40 Overflow pipe, checking for leakage 130101 - 140000
239-001 0.60 Fuel cooler, replacing 130101 - 140000

252-020 1.50 Silencer, replacing 2121123 - 2130000
252-021 0.40 Exhaust pipe, flexible tube, replacing 2121123 - 2130000
252-023 0.60 Exhaust pipe, replacing 130101 - 140000
254-001 3.00 Diesel particulate filter, check and clean 130101 - 140000
256-010 0.40 Air cleaner, removing 130101 - 140000
256-011 0.40 Air cleaner, installing 2121123 - 2130000
258-023 0.90 Charge air cooler, removing 130101 - 140000
258-024 0.90 Charge air cooler, installing 130101 - 140000
26 COOLING SYSTEM
261-011 2.00 Radiator, removing 2121123 - 2130000
261-012 0.50 Radiator hose upper, replacing 130101 - 140000
261-013 1.25 Radiator, installing 130101 - 140000
261-014 0.80 Radiator hoses lower, replacing 130101 - 140000
261-018 0.70 Expansion tank, replacing 130101 - 140000
263-012 0.80 Fan belt and/or alternator belt, replacing 130101 - 140000

BL60B
263-013 0.80 Fan belt and/or alternator belt, checking and 130101 - 140000
adjusting tension
263-084 2.50 Fan shroud, replacing 130101 - 140000
27 ENGINE CONTROL
271-002 0.60 Throttle control cable, removal 2121123 - 2130000
271-003 0.80 Throttle control cable, installation 2121123 - 2130000
29 Miscellaneous
293-002 2.00 EGR cooler, pressure test 130101 - 140000

31 BATTERY

366-064 2.00 V-ECU, MID 187, changing non-programmed 130101 - 140000
ECU
366-066 1.50 V-ECU, MID 187, changing pre-programmed ECU130101 - 140000
367-052 0.80 V-ECU, replacing 2121123 - 2130000
367-056 0.60 I-ECU, replacing
41 CLUTCH; TORQUE CONVERTER
414-004 5.50 Torque converter, removal
414-005 4.50 Torque converter, installation

421-025 0.70 Transmission solenoid, replacing
421-070 5.50 Transmission, removing 130101 - 140000
421-072 4.50 Transmission, installing 2121123 - 2130000
421-090 0.90 Oil filler pipe, replacing 2121123 - 2130000
421-098 2.00 Powershift Transmission (option), oil pressures,
checking
421-101 2.00 Hydraulic control valve, reconditioning

BL60B
43 GEARBOX,
431-038 5.50 Gearbox, removing 2121123 - 2130000
431-039 4.50 Gearbox, installing 2121123 - 2130000
431-070 0.90 4WD control valve, reconditioning
431-128 1.50 Transmission 2WD, oil pressures, checking
432-087 0.50 T-ECU, replacing
45 PROPELLER SHAFT
451-004 0.80 Propeller shaft, rear, replacing
451-010 0.60 Propeller shaft, front, replacing

460-002 1.75 Axle suspension, adjusting axial clearance
461-002 2.00 Axle, removing
461-003 2.00 Axle, installing
5 BRAKE
51 WHEEL BRAKE
510-005 0.20 Service brakes, function check
517-004 4.00 Brake disc, replacing both sides

520-003 0.80 Service brake pressure, checking
525-005 1.25 Foot brake valve, removal
525-006 1.25 Foot brake valve, installation
55 PARKING BRAKE
550-001 1.00 Parking brake, replacing control cable
550-024 0.40 Parking brake cable, adjusting
6 STEERING
60 GENERAL
600-001 0.70 Steering system, function check

BL60B
62 STEERING AXLE
622-080 1.75 Toe - in, checking and adjusting
64 STEERING
641-001 0.40 Steering wheel, replacing
641-026 0.70 Steering column, removing 2121123 - 2130000
641-027 0.70 Steering column, installing 2121123 - 2130000
645-003 0.60 Steering system working pressure, checking
645-022 1.00 Steering valve, removal
645-023 1.75 Steering valve, installation
645-077 0.40 Steering cylinder removed, reconditioning incl
replacing bearings

WHEEL/TRACK UNIT
71 FRAME
716-001 0.60 Counterweight, removing 2121123 - 2130000
716-002 0.60 Counterweight, fitting 2121123 - 2130000
716-004 0.30 Additional counterweight, removing
716-005 0.30 Additional counterweight, installing

771-002 0.50 Front wheel, removal
771-003 0.40 Front wheel, installation
771-004 0.50 Rear wheel, removing
771-005 0.50 Rear wheel, installing

ANYWHERE
821-001 0.40 Engine hood, removing 130101 - 140000
821-002 0.40 Engine hood, installing 2121123 - 2130000

BL60B
851-010 0.70 Front console, removing 130101 - 140000
851-011 0.60 Front console, installing 130101 - 140000

870-005 0.40 Cab filter box, assembly
874-007 0.40 Belt, replacing 130101 - 140000

90 GENERAL
900-031 1.75 V2-ECU, MID 249, changing non-programmed 130101 - 140000
ECU
900-032 1.00 V2-ECU, MID 249, changing pre-programmed 130101 - 140000
ECU

910-002 1.75 Hydraulic system, bleeding air
911-013 1.50 Hydraulic oil cooler, removing 130101 - 140000
911-014 1.25 Hydraulic oil cooler, installing 130101 - 140000
912-044 1.75 Main valve block, loader, removal
912-045 1.50 Main valve block, loader, installation
912-047 2.50 Main valve block, backhoe, removal
912-048 2.50 Main valve block, backhoe, installation
912-129 0.20 Hydraulic cylinders, cleaning
913-010 2.50 Hydraulic pump, replacing
915-002 2.00 Control lever, changing
916-002 0.30 Boom suspension accumulator, check and
adjusting
92 MECHANICAL EQUIPMENT/ATTACHMENT
925-001 1.50 Multi-purpose bucket cylinder, replacing
925-002 1.25 Multi-purpose bucket cylinder, reconditioning
925-011 1.50 Bucket assembly, replacing

945-017 1.25 Lift cylinder, reconditioning
945-018 0.80 Lift cylinder, removing

BL60B
945-019 1.00 Lift cylinder, installing

945-020 1.25 Tilt cylinder, reconditioning
945-021 0.90 Tilt cylinder, removing
945-022 0.80 Tilt cylinder, installing
97 UNIT, DIGGING
971-087 1.50 Boom swing cylinder, removing
971-088 1.50 Boom swing cylinder, installing
971-096 1.25 Swing cylinder, renovation
972-021 0.70 Stabilisers, removal hydraulic cylinder
972-022 1.25 Stabilisers, reconditioning hydraulic cylinder
972-023 0.70 Stabilisers, installation hydraulic cylinder
974-015 1.75 Boom, changing bushing
974-031 0.90 Boom cylinder, removal
974-032 0.80 Boom cylinder, installation
974-033 1.25 Boom cylinder, renovation
975-014 1.00 Dipper arm cylinder, removal
975-015 1.00 Dipper arm cylinder, installation
975-016 1.25 Dipper arm cylinder, renovation
975-052 0.80 Extendible dipper arm cylinder, removal
975-054 0.80 Extendible dipper arm cylinder, installation
975-057 1.25 Extendible dipper arm cylinder, renovation
975-062 1.00 Bucket cylinder, removal
975-065 0.80 Bucket cylinder, installation
975-066 1.25 Bucket cylinder, renovation

BL61B

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
210-070 6.00 Engine, removing 1202054 - 1210000
210-070 4.50 Engine, removing 230101 - 240000

BL61B

23 FUEL SYSTEM

26 COOLING SYSTEM

BL61B
adjusting tension
27 ENGINE CONTROL
29 Miscellaneous

31 BATTERY

ECU
367-052 0.80 V-ECU, replacing 1202054 - 1210000

421-098 2.00 Powershift Transmission (option), oil pressures, 1202054 - 1202233
checking

BL61B

checking
checking
43 GEARBOX,
431-128 1.50 Transmission 2WD, oil pressures, checking 1202234 - 1210000
45 PROPELLER SHAFT

5 BRAKE
51 WHEEL BRAKE

55 PARKING BRAKE

BL61B
550-023 0.20 Parking brake, function checking 1202054 - 1202233

6 STEERING
60 GENERAL
62 STEERING AXLE
64 STEERING
replacing bearings

WHEEL/TRACK UNIT
71 FRAME


BL61B

ANYWHERE

874-007 0.40 Belt, replacing 230101 - 240000

90 GENERAL
ECU
ECU

912-038 0.50 Hose rupture valve, checking
912-044 1.75 Main valve block, loader, removal
912-045 1.50 Main valve block, loader, installation
912-047 2.50 Main valve block, backhoe, removal
912-048 2.50 Main valve block, backhoe, installation

BL61B

adjusting

97 UNIT, DIGGING
972-013 0.30 Stabilisers, adjusting wearpads
972-090 0.50 Stabiliser wear pads, replacing

BL70B

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
210-070 6.00 Engine, removing 2326013 - 2330000
210-070 4.50 Engine, removing 330101 - 340000

BL70B
23 FUEL SYSTEM

26 COOLING SYSTEM

BL70B
adjusting tension
27 ENGINE CONTROL
29 Miscellaneous

30 GENERAL
302-130 0.50 Loader lever, electrical measuring
31 BATTERY

ECU
367-052 0.80 V-ECU, replacing 2326013 - 2330000


BL70B
421-098 2.00 Powershift Transmission (option), oil pressures,

checking
43 GEARBOX,
45 PROPELLER SHAFT

5 BRAKE
51 WHEEL BRAKE

55 PARKING BRAKE
6 STEERING
60 GENERAL

BL70B
62 STEERING AXLE
64 STEERING
replacing bearings

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

BL70B

874-007 0.40 Belt, replacing 330101 - 340000

90 GENERAL
ECU
ECU

912-041 3.00 Main valve block, removal
912-042 3.00 Main valve block, installation
913-010 3.50 Hydraulic pump, replacing 330101 - 340000
913-031 0.70 Flow regulation valve, changing 2326013 - 2330000
914-031 0.70 Servo pump, removal 2326013 - 2330000
914-032 0.50 Servo pump, installation 2326013 - 2330000
914-058 2.50 Servo valve, replacing
adjusting

BL70B

97 UNIT, DIGGING

BL71B

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
210-070 6.00 Engine, removing 1415047 - 1420000
210-070 4.50 Engine, removing 430101 - 440000

BL71B

23 FUEL SYSTEM

26 COOLING SYSTEM

BL71B
adjusting tension
27 ENGINE CONTROL
29 Miscellaneous

30 GENERAL
302-130 0.50 Loader lever, electrical measuring
31 BATTERY

ECU
367-052 0.80 V-ECU, replacing 1415047 - 1420000


BL71B

checking
checking
checking
43 GEARBOX,
45 PROPELLER SHAFT

5 BRAKE
51 WHEEL BRAKE

55 PARKING BRAKE

BL71B

6 STEERING
60 GENERAL
62 STEERING AXLE
64 STEERING
replacing bearings

WHEEL/TRACK UNIT
71 FRAME


BL71B

ANYWHERE

874-007 0.40 Belt, replacing 430101 - 440000

90 GENERAL
ECU
ECU


BL71B

914-031 0.70 Servo pump, removal 1415047 - 1420000
914-032 0.50 Servo pump, installation 1415047 - 1420000
adjusting

97 UNIT, DIGGING
974-084 0.40 Boom lock cylinder, replacing

BL71B

DD100

17 SERVICE

21 ENGINE
210-070 7.00 Engine, removing
210-072 6.50 Engine, installing
218-009 3.50 Engine mounts, replacing
23 FUEL SYSTEM
234-017 0.70 Fuel tank lid,cover plate gasket, replacing
234-019 0.40 Fuel tank sight gauge, replacing
234-043 0.80 Fuel tank lid, replacing
235-005 1.50 Fuel lines, replacing

252-020 0.40 Silencer, replacing
252-021 0.50 Exhaust pipe, flexible tube, replacing
256-010 0.40 Air cleaner, removing
256-011 0.30 Air cleaner, installing
256-012 0.30 Air cleaner vacuum indicator, replacing
256-020 0.30 Pre-cleaner, replacing
258-023 1.25 Charge air cooler, removing
258-024 1.25 Charge air cooler, installing
258-025 0.30 Charge air cooler pipe, removing
258-026 0.20 Charge air cooler pipe, installing
26 COOLING SYSTEM
261-011 1.25 Radiator, removing
261-012 1.00 Radiator hose upper, replacing
261-013 1.25 Radiator, installing
261-014 1.00 Radiator hoses lower, replacing
261-018 1.25 Expansion tank, replacing
261-022 1.25 Cooling package, removing
261-023 1.25 Cooling package, installing
263-012 2.50 Fan belt and/or alternator belt, replacing

DD100
263-041 2.50 Cooling fan, replacing

263-042 3.00 Fan shroud, replacing

31 BATTERY
35 LIGHTING
352-009 0.30 Head lamp, replacing
353-050 0.40 Licence plate lamp, replacing
356-050 0.30 Work lamp, replacing

362-002 0.40 Horn, replacing
362-016 0.50 Horn switch, replacing
362-041 0.40 Rotating beacon, replacing
362-052 0.40 Dual function alarm, replacing
362-053 0.40 Back up alarm, replacing
364-004 0.60 Switch, replacing
364-011 0.50 Reverse alarm switch, replacing
364-013 0.50 Emergency stop switch, replacing
364-014 0.40 Ignition switch, replacing
364-015 0.50 Indicator lamp High beam , replacing
364-050 0.40 Relay (general), replacing
364-063 0.70 Circuit backer, replacing
364-065 0.50 Drum selection switch, replacing
364-066 0.50 Turn signal switch, replacing
364-067 0.50 Hazard light switch, replacing
366-094 0.50 Diode, replacing

DD100
37 CABLE; FUSE; RELAY

371-011 9.00 Main wire harness, replacing
371-011 11.00 Main wire harness, replacing
371-021 2.50 Instrument wire harness, replacing
371-040 0.80 Battery cable negative, replacing
371-041 0.90 Battery cable +, replacing
371-046 0.40 Seat switch wiring harness, replacing
371-047 1.00 Water tank wiring harness, replacing
371-048 1.50 FSR wiring harness, replacing
371-050 3.50 Tail lamp harness, replacing
371-051 1.75 Sensor wire harness, replacing
372-020 0.40 Fuse (general), replacing
372-026 0.40 Flasher relay, replacing
372-051 0.40 Latching relay, replacing
372-054 0.50 Auto vibration control relay, replacing

380-002 0.50 Water flow control, replacing
380-006 4.00 Vibration controller, replacing
380-006 4.00 Vibration controller, replacing
383-001 0.60 Hour meter, replacing
387-022 0.60 Impact meter gauge, replacing
387-023 0.60 Volt meter gauge, replacing
387-024 0.60 Engine water temperature gauge, replacing
387-025 0.50 Engine-stop indicator, replacing
387-026 0.50 Check-engine indicator, replacing
387-027 0.50 Seat belt indicator, replacing
387-028 0.50 Turn signal light indicator (left and right), replacing
387-041 0.60 Engine oil pressure gauge, replacing
387-049 0.60 Speedometer, replacing
387-050 0.60 VPM meter gauge, replacing
424-003 1.50 Propulsion control cable, replacing
424-005 0.40 Neutral safety switch, replacing
424-021 1.50 Control group assembly, replacing

DD100
43 GEARBOX,
431-031 15.00 Pump gearbox coupling assembly, replacing
431-038 7.00 Gearbox, removing
431-039 7.50 Gearbox, installing
441-061 0.80 Thermal bypass valve, replacing
442-068 0.80 Loop flushing valve, replacing
442-080 0.50 Drum drive motor speed sensor, replacing
442-082 1.75 Propulsion pump, removing
442-083 1.75 Propulsion pump, installing
442-164 1.75 Propulsion pump coupling, installing
442-165 2.50 Vibration pump coupling, removing
442-166 2.50 Vibration pump coupling, installing
5 BRAKE
525-014 0.60 Brake solenoid valve, replacing
55 PARKING BRAKE
551-012 0.40 Parking brake pressure switch, replacing
6 STEERING
64 STEERING
641-001 0.30 Steering wheel, replacing 50001 - 50322
641-026 0.40 Steering column, removing
641-027 0.50 Steering column, installing
645-016 0.90 Steering pump, removing
645-017 0.80 Steering pump, installing

WHEEL/TRACK UNIT
71 FRAME
711-040 1.25 Hydraulic oil level gauge, replacing

DD100
711-041 0.70 Hydraulic tank lid, cover plate gasket, replacing

711-042 0.30 Hydraulic tank breather cap, replacing

777-003 2.50 Vibration pump, removing
777-004 3.00 Vibration pump, installing
777-005 0.40 Vibration motor, removing
777-006 0.50 Vibration motor, installing
777-007 4.00 Eccentric weight, removing
777-008 4.50 Eccentric weight, installing
777-014 8.00 Carrier bearings, replacing
777-015 10.00 Eccentric weight, overhaul
777-018 6.50 Drum drive motor, replacing
777-021 2.00 Smooth drum scrapers, replacing
777-025 3.00 Carrier, removing
777-026 3.50 Carrier, installing
777-073 8.00 Carrier V-ring seal, replacing
777-081 1.00 Drum shock mount (single), replacing
777-081 0.90 Drum shock mount (single), replacing
777-082 2.50 Drum assembly (front), removing
777-083 3.50 Drum assembly (front), installing
777-084 1.75 Drum assembly (rear), removing
777-085 2.50 Drum assembly (rear), installing

ANYWHERE
818-010 1.50 Operator's platform mounts, replacing

821-029 0.60 Engine hood hinge, replacing
821-031 0.60 Engine hood, changing gas spring
827-003 0.50 Hand rail, removing
827-004 0.60 Hand rail, installing

837-001 0.60 Deck plate, removing
837-002 0.70 Deck plate, installing

DD100
86 PROTECTIVE EQUIPMENT, not specified in a special group

867-002 0.80 ROPS (Roll Over Protection), removing
867-003 1.25 ROPS (Roll Over Protection), installing
88 INTERIOR EQUIPMENT
881-003 2.50 Instrument panel, replacing (left)
881-005 2.00 Instrument panel, replacing (right)
881-008 4.50 Instrument console bearing, replacing
884-001 0.40 Seat safety belt, replacing

911-013 1.50 Hydraulic oil cooler, removing
911-014 1.50 Hydraulic oil cooler, installing
911-036 1.75 Hydraulic oil tank, removing
911-037 1.50 Hydraulic oil tank, installing

985-001 0.30 Water system assembly, removing
985-001 0.50 Water system assembly, removing
985-002 0.30 Water system assembly, installing
985-002 0.50 Water system assembly, installing
985-003 0.40 Water tank, removing
985-004 0.50 Water tank, installing
985-007 0.50 Water pump, removing 50001 - 50488
985-007 0.40 Water pump, removing 50489 - 99999
985-008 0.50 Water pump, installing 50001 - 50488
985-008 0.50 Water pump, installing 50489 - 99999
985-016 0.80 Water spray system components, replacing
985-017 0.50 Water strainer, replacing
985-018 0.60 Ball valve, replacing
985-019 0.50 Water level indicator, replacing
985-020 0.50 Water tank mounting straps, replacing
988-087 2.50 Drum drive, removing
988-088 2.50 Drum drive, installing

DD110B

17 SERVICE

20 GENERAL
ECU
21 ENGINE
replacing
210-093 0.60 Engine rotation speed sensor (crank shaft),
replacing
212-071 0.50 Crankcase ventilation separator, replacing
gauge
23 FUEL SYSTEM
233-008 1.50 Fuel pump, replacing
237-002 4.00 Injectors, replacing all
237-034 0.80 Pressure relief valve (PRV), replacing
237-035 0.90 Fuel rail pressure sensor, replacing
237-124 0.50 High pressure fuel system, pressure relief

non-programmed

DD110B

pre-programmed
254-031 0.80 Air pump, replacing
254-033 1.50 Burner, replacing
254-038 1.50 DPF inlet temperature sensor, replacing
254-039 1.50 DPF outlet temperature sensor, replacing
254-043 0.50 Spark plug control unit, replacing
254-044 0.30 Glow plug, replacing
254-046 0.30 Spark plug, replacing
254-048 0.30 Spark plug cable, replacing
254-050 0.90 Fuel metering unit A, replacing
254-051 2.50 Fuel metering unit B, replacing
254-055 1.50 DPF bracket, replacing
255-009 0.40 Waste gate, testing
26 COOLING SYSTEM
262-002 1.75 Coolant pump, replacing
262-098 1.25 Thermostat, replacing
29 Miscellaneous
293-008 2.50 EGR Actuator, replacing

30 GENERAL
300-072 1.50 I-ECU, MID 140, changing non-programmed ECU
300-074 1.00 I-ECU, MID 140, changing pre-programmed ECU

ECU
424-004 0.60 Propulsion control lever, replacing

DD110B

442-153 0.30 Propulsion pump charge pressure, checking
442-154 0.40 Propulsion pump system pressure, checking
442-159 0.30 Propel, calibrating
5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING
645-006 0.70 Steering cylinder, replacing
645-018 0.30 Steering pressure, checking
645-082 1.50 Steering valve, replacing

WHEEL/TRACK UNIT
777-001 2.00 Drum, removing
777-002 2.00 Drum, installing
777-013 11.00 Eccentric weight bearings, replacing
777-086 0.30 Vibration pump charge pressure, checking
777-087 0.50 Vibration system pressure, checking

DD110B
777-089 0.40 Vibration pump charge pressure relief valve,

adjusting
replacing
777-091 0.70 Vibration pump SCR (system check/relief) valve,
replacing
777-093 2.50 Drum drive assembly, removing
777-094 2.50 Drum drive assembly, installing


DD120

17 SERVICE
173-078 0.20 Engine, air cleaner maintenance
173-089 0.70 Drum carrier, changing oil
173-451 1.25 Hydraulic oil, changing

21 ENGINE
23 FUEL SYSTEM
233-014 0.30 Fuel filters, replacing
235-002 1.25 Fuel line, water separator, check and drain

256-003 0.40 Air cleaner, primary filter replacing
256-004 0.40 Air cleaner, secondary filter replacing
26 COOLING SYSTEM
261-008 5.00 Radiator, replacing

DD120

31 BATTERY

321-003 1.50 Alternator, removing
321-004 1.75 Alternator, installing
33 STARTING SYSTEM
334-011 1.25 Starter switch (engine start switch), replacing

362-003 0.30 Reverse alarm, replacing
366-071 0.60 Electric and hydraulic control unit, replacing

386-011 1.75 Fuel level sender, replacing
421-088 4.00 Two speed valve solenoid and cartridge, replacing
440-021 1.25 Hydrostatic controller, removing
440-022 1.25 Hydrostatic controller, installing
441-035 4.50 Drive motor, removing
442-021 3.50 Hydrostatic pump, removing
442-022 3.00 Hydrostatic pump, installing
442-045 3.00 Pump coupling, removing
442-046 2.50 Pump coupling, installing
442-090 2.50 Vibration speed sensor, replacing
5 BRAKE
55 PARKING BRAKE

DD120
6 STEERING
64 STEERING
641-021 4.50 Adjustable steering column, replacing
645-031 3.00 Steering control unit, removing
645-035 3.50 Steering control unit, installing

WHEEL/TRACK UNIT
777-009 2.00 Drum shock mount, replacing
777-010 13.00 Eccentric shaft coupling, replacing
777-011 3.50 Torque hub, removing
777-012 6.50 Torque hub, installing

ANYWHERE


DD120


911-003 0.70 Hydraulic oil filter, replacing
911-040 0.40 Hydraulic oil tank, vacuum-pumping, connecting
and disconnecting pump
911-051 0.20 Breather, replacing

985-007 1.25 Water pump, removing
985-008 1.25 Water pump, installing

DD120B

17 SERVICE

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

non-programmed

DD120B

pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

30 GENERAL

ECU

DD120B

5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING

WHEEL/TRACK UNIT
adjusting

DD120B

replacing
replacing


DD140

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

26 COOLING SYSTEM

DD140

31 BATTERY

33 STARTING SYSTEM


5 BRAKE
55 PARKING BRAKE

DD140
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

ANYWHERE


DD140




DD140B

17 SERVICE

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

non-programmed

DD140B

pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

30 GENERAL

ECU

DD140B

5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING
645-112 2.50 Steering actuation valve, replacing

WHEEL/TRACK UNIT
adjusting

DD140B

replacing
replacing


DD25B

17 SERVICE
173-313 0.20 Hydraulic pressure, checking
19 GENERAL
191-020 0.20 Service position

21 ENGINE
gauge
23 FUEL SYSTEM
233-011 0.40 Fuel pump, removing
233-012 0.20 Fuel pump, installing
237-030 4.00 High pressure fuel pump, checking
237-032 3.50 High pressure fuel pump, replacing
237-126 1.00 Fuel injector, testing

26 COOLING SYSTEM

DD25B

35 LIGHTING


371-044 0.40 Battery disconnector, removal
371-045 0.20 Battery disconnector, installation
441-036 1.50 Drive motor, installing
442-160 1.00 Travel lever throttle cable, removing
442-161 1.25 Travel lever throttle cable, installing
442-162 0.60 Travel lever throttle cable, adjusting
5 BRAKE
55 PARKING BRAKE
550-026 0.30 Parking brake, activate manually
550-027 0.30 Parking brake, deactivate manually
6 STEERING
64 STEERING

DD25B

WHEEL/TRACK UNIT
74 FRAME LINK
740-001 2.00 Articulation hinge, disassembly
740-002 2.50 Articulation hinge, assembly

777-034 0.50 Scraper strip, replacing
777-035 0.40 Scraper set, removing
777-036 0.30 Scraper set, installing
777-039 0.50 Offset drum, adjusting
777-042 5.00 Eccentric shaft, removing
777-043 5.50 Eccentric shaft, installing
777-044 1.50 Travel bearings, removing
777-045 1.75 Travel bearings, installing
777-078 1.25 Drum rubber cushions, replacing
777-079 3.50 Eccentric shaft bearings, removing
777-080 2.50 Eccentric shaft bearings, installing

ANYWHERE


DD25B



EC140D L

17 SERVICE
173-079 0.60 Swing motor gearbox, changing oil
173-101 0.40 Track motor gearbox, changing oil
173-401 0.50 Engine oil and filter, changing
173-412 0.20 Hydraulic oil tank breather filter, replacing
173-649 0.20 Hydraulic oil return filter, replacing

20 GENERAL
ECU
21 ENGINE
217-005 1.50 Oil level sensor, changing
gauge
23 FUEL SYSTEM
234-041 0.50 Fuel filling pump, removing
234-042 0.50 Fuel filling pump, installing

EC140D L

non-programmed
pre-programmed
254-047 0.40 Spark plug, checking
256-001 0.30 Air cleaner, cleaning filter element
256-006 1.00 Preheating coil, replacing
258-002 4.50 Intercooler, replacing
26 COOLING SYSTEM
261-002 0.10 Coolant, checking anti-freeze resistance
261-016 0.60 Radiator hoses all, replacing
263-022 1.25 Fan belt and/or alternator-, compressor belt,
replacing all belts

30 GENERAL
31 BATTERY
311-001 0.80 Battery charging capacity, checking
311-006 0.60 Earth lead to battery, replacing

321-075 0.50 Alternator, test

EC140D L
33 STARTING SYSTEM
331-021 0.30 Starter motor, tests
331-081 0.30 Starter relay, replacing
334-002 0.70 Starter switch, testing
35 LIGHTING
356-056 0.50 Work lighting, replacing one head lamp assy

362-051 0.50 Travel alarm, replacing
363-003 0.90 Windscreen wiper, replacing switch
363-004 0.50 Windscreen flusher pump, replacing
363-091 0.50 Windscreen wiper, replacing controller
364-003 0.60 Control lockout lever switch, replacing
ECU
367-075 0.90 Engine speed control switch, replacing

371-043 0.80 Battery disconnector, replacing
371-090 3.50 Engine wire harness, replacing
372-002 0.50 Electrical distribution box, circuit board replacing

386-006 1.50 Engine temperature sensor, replacing
386-007 0.60 Engine oil pressure sensor, replacing
386-017 0.50 Hydraulic oil temperature sensor, replacing
replacing
39 MISCELLANEOUS
393-001 0.50 Voltage converter, replacing
393-021 0.60 Radio, replacing
395-021 0.70 Antenna, replacing
395-031 0.40 Speaker, replacing
398-002 0.90 W-ECU, MID142, changing pre-programmed ECU210036 - 240000

EC140D L

398-003 1.50 W-ECU, MID142, changing non-programmed 210036 - 240000
ECU
ECU
398-004 0.50 CareTrack battery, replacing
43 GEARBOX,
431-021 4.50 Swing gearbox, replacing
431-026 2.50 Swing gearbox removed, replacing seal
431-027 4.00 Swing gearbox removed, replacing shaft
431-053 6.50 Swing unit, replacing
431-117 1.25 Track gearbox, replacing cover
431-127 5.00 Track unit, replacing
441-021 3.00 Swing motor, replacing
441-022 0.90 Swing motor relief valve, replacing
441-024 1.50 Swing motor, replacing plate (brake)
441-025 1.50 Swing motor, replacing brake piston seal
441-026 0.40 Swing motor removed, replacing seal
441-112 0.70 Track motor relief valve, replacing
443-037 5.50 Center passage, replacing
443-038 7.00 Center passage, replacing seal kit
49 MISCELLANEOUS
492-021 11.00 Swing ring gear, replacing
492-031 3.00 Swing ring gear outer seal, replacing 210286 - 240000
492-032 9.00 Swing ring gear inner seal, replacing 210001 - 210285
492-091 0.40 Ring gear grease pipe, replacing

WHEEL/TRACK UNIT
71 FRAME
710-001 3.50 Superstructure, removing
710-002 4.50 Superstructure, installing
716-001 0.70 Counterweight, removing

EC140D L
716-002 0.90 Counterweight, fitting

775-011 3.00 Front idler, replacing one
775-021 3.50 Sprocket, replacing one
775-036 9.50 Track links, replacing
775-061 1.50 Bottom roller, replacing one
775-066 3.00 Bottom roller, replacing seal
775-071 0.90 Track guard, replacing one
775-081 3.00 Track recoil spring (tensioner) assembly,
replacing

ANYWHERE

821-005 0.90 Engine hood, replacing

841-061 0.30 Rear-view mirror, changing
852-008 1.25 Seat, replacing
852-012 1.75 Longitudinal adjustment cable, replacing
852-013 0.60 Longitudinal suspension cable, replacing
852-089 0.30 Seat cushion, replacing
852-090 0.60 Backrest, replacing
852-091 2.50 Seat support, replacing

870-001 5.00 Cooler and Heater assembly, replacing

EC140D L
872-001 0.50 Cab filter, replacing

873-011 0.70 Air mix door actuator, replacing
874-013 3.00 Expansion valve, replacing incl draining and filling
874-016 0.30 Compressor, replacing magnetic clutch
(compressor removed)
874-094 0.60 Vent actuator, replacing
874-095 0.60 Mode (foot) actuator, replacing
874-096 0.60 Intake actuator, replacing

911-005 1.75 Pump suction hose and pipe, replacing
911-011 4.00 Oil cooler, replacing
911-015 0.40 Oil level gauge, replacing
911-024 0.40 Pipe and hose (pump - valve), replacing
911-033 2.50 Oil cooler line bypass valve (check valve),
replacing
911-038 2.50 Hydraulic oil tank, replacing
912-001 8.50 Control valve, replacing
912-067 0.90 Main pressure relief valve, replacing
912-073 0.70 Rupture valve, replacing (dipper arm cylinder)
912-160 0.90 Port relief valve pressure, checking and adjusting
913-029 0.50 Pump regulator, replacing
914-041 0.80 Proportional solenoid valve (power shift),
replacing
914-060 0.80 Servo pump, replacing

EC140D L
914-081 1.75 Remote control valve (lever), replacing

914-084 1.75 Remote control valve (pedal), replacing
914-091 1.50 Solenoid valve, replacing
916-096 0.80 Hammer and shear pedal valve (RCV), replacing
924-005 0.80 Quickfit, removal
924-006 1.00 Quickfit, installation
925-013 1.00 Bucket assembly, installation
97 UNIT, DIGGING
974-010 12.00 Boom, replacing
974-013 4.50 Boom, removal
974-014 5.50 Boom, installation
974-021 3.00 Boom cylinder, replacing
974-038 3.50 Lower boom cylinder bushing, replacing
974-039 3.50 Upper boom cylinder bushing, replacing
975-006 1.25 Dipper arm connecting rod, removal
975-007 1.25 Dipper arm connecting rod, installation
975-011 3.00 Dipper arm, removal
975-012 3.00 Dipper arm, installation
975-024 1.50 Dipper arm connecting rod, replacing
975-025 3.00 Dipper arm cylinder, replacing
975-028 1.50 Connecting rod yoke, replacing
975-032 1.25 Connecting rod yoke, removal
975-035 1.25 Connecting rod yoke, installation
975-039 8.00 Dipper arm, replacing
975-040 3.50 Dipper arm cylinder bushing on boom, replacing
975-042 3.50 Dipper arm cylinder bushing on dipper arm,
replacing
975-061 2.00 Bucket cylinder, replacing
975-072 3.00 Bucket cylinder bushing on dipper arm, changing
975-073 3.00 Bucket cylinder bushing lever-link, replacing

EC140D LM

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC140D LM

non-programmed
pre-programmed
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY


EC140D LM
33 STARTING SYSTEM
35 LIGHTING

ECU


replacing
39 MISCELLANEOUS

EC140D LM

ECU
ECU
43 GEARBOX,
431-115 1.75 Track gearbox (removed), replacing floating seal
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

EC140D LM


replacing

ANYWHERE




EC140D LM


replacing
replacing

EC140D LM

97 UNIT, DIGGING
replacing

EC15C

17 SERVICE
172-002 2.00 Warranty inspection 100 hours
173-093 0.30 Track tension, checking
19 GENERAL

21 ENGINE
211-002 6.00 Cylinder head, replacing gasket
211-079 3.00 Cylinder head, removing
214-036 1.25 Valve covers, fitting new gasket
214-037 0.60 Valve cover, removing
214-038 0.60 Valve cover, installing
23 FUEL SYSTEM
236-001 0.30 Idling speed, checking and adjusting
236-030 1.25 Injection timing, checking
236-070 3.00 Injection pump, removing

252-017 0.50 Silencer, removing
252-018 0.60 Silencer, installing

EC15C

26 COOLING SYSTEM
261-020 0.20 Expansion tank, removing
261-021 0.10 Expansion tank, installing
263-013 0.20 Fan belt and/or alternator belt, checking and
adjusting tension
27 ENGINE CONTROL
272-020 0.30 Throttle control cable, removing
272-021 0.40 Throttle control cable, installing
272-024 0.20 Throttle controls, setting
273-021 0.30 Stop magnet, replacing

31 BATTERY
311-005 0.60 Battery condition, check

33 STARTING SYSTEM
333-002 0.80 Glow plug, removal
333-003 0.60 Glow plug, installation
35 LIGHTING


EC15C

367-057 0.40 A-ECU (anti theft), replacing

441-030 1.50 Swing motor, removing
441-031 2.00 Swing motor, installing
441-034 3.00 Swing motor removed, overhaul
441-113 1.25 Track motor, removing
441-114 1.50 Track motor, installing
443-034 2.00 Centre passage, removing
443-035 2.00 Centre passage, installing
49 MISCELLANEOUS
492-023 3.50 Swing ring, removing
492-024 4.50 Swing ring, installing

WHEEL/TRACK UNIT
775-022 0.40 Sprocket, removal
775-023 0.70 Sprocket, installation
775-041 0.30 Rubber track, removing
775-042 0.40 Rubber track, installing
775-092 0.30 Chain guide, removing
775-093 0.30 Chain guide, installing

ANYWHERE

EC15C
810-004 2.50 Cab platform, removal

810-005 3.00 Cab platform, installation


912-088 2.00 Main Control Valve - Disassembly
912-089 2.00 Main Control Valve - Assembly
912-091 3.00 Main control valve, removal
912-092 2.50 Main control valve, installation
912-117 0.70 LS-pressure relief valve, replacing
912-150 0.60 Working pressure, checking and adjusting
912-174 0.40 Flushing valve, replacing
912-175 0.30 Secondary pressure limiting valve, replacing
912-176 0.30 Anti-cavitation check valve, replacing
913-006 0.40 LS (load sense) pressure, checking
913-031 0.40 Flow regulation valve, changing
914-047 0.40 Servo accumulator, removal
914-048 0.50 Servo accumulator, installation
914-057 0.40 Servo pressure, check
914-064 0.40 Servo valve, removal
914-065 0.60 Servo valve, installation
914-104 0.70 Travel valve (pedal), removing
914-105 0.90 Travel valve (pedal), installing
915-004 0.40 Control lever, removal
915-005 0.60 Control lever, installation

EC15C
97 UNIT, DIGGING

EC160D L

17 SERVICE
220001 - 220453
220001 - 220453
220001 - 220453

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC160D L


non-programmed
pre-programmed
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

EC160D L

33 STARTING SYSTEM
35 LIGHTING

ECU


replacing
39 MISCELLANEOUS

EC160D L

ECU
ECU
43 GEARBOX,
443-039 1.00 Center passage hose (valve – center passage),
replacing
443-040 1.50 Center passage hose (center passage – motor),
replacing
49 MISCELLANEOUS
492-031 3.00 Swing ring gear outer seal, replacing
492-032 9.00 Swing ring gear inner seal, replacing

WHEEL/TRACK UNIT
71 FRAME

EC160D L


replacing

ANYWHERE




EC160D L


replacing
912-071 0.80 Rupture valve, replacing (boom cylinder)
replacing

EC160D L

925-012 0.60 Bucket assembly, removal
97 UNIT, DIGGING

EC160D NL

17 SERVICE
210001 - 220000

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC160D NL

non-programmed
pre-programmed
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY


EC160D NL
33 STARTING SYSTEM
35 LIGHTING

ECU


replacing
39 MISCELLANEOUS

EC160D NL

ECU
ECU
43 GEARBOX,
replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

EC160D NL

replacing

ANYWHERE




EC160D NL


replacing
replacing

EC160D NL
97 UNIT, DIGGING

EC17C

17 SERVICE
19 GENERAL

21 ENGINE
23 FUEL SYSTEM


EC17C

26 COOLING SYSTEM
adjusting tension
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC17C


441-014 3.50 Travel motor removed, overhaul
49 MISCELLANEOUS

WHEEL/TRACK UNIT

ANYWHERE

EC17C



90 GENERAL
900-034 0.30 H-ECU (hydraulic), replacing pre-programmed
ECU

914-055 0.70 Servo pressure, checking and adjusting

EC17C

97 UNIT, DIGGING

EC180D L

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC180D L

non-programmed
pre-programmed
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY


EC180D L
33 STARTING SYSTEM
35 LIGHTING

ECU


replacing
39 MISCELLANEOUS

EC180D L

ECU
ECU
43 GEARBOX,
replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

EC180D L

replacing

ANYWHERE




EC180D L


replacing
replacing

EC180D L
97 UNIT, DIGGING

EC18C

17 SERVICE
19 GENERAL

21 ENGINE
23 FUEL SYSTEM


EC18C

26 COOLING SYSTEM
adjusting tension
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC18C


49 MISCELLANEOUS

WHEEL/TRACK UNIT

ANYWHERE

EC18C



90 GENERAL
ECU

913-064 0.90 Hydraulic pump, power control checking

EC18C

97 UNIT, DIGGING

EC20C

17 SERVICE
19 GENERAL

21 ENGINE
23 FUEL SYSTEM


EC20C

26 COOLING SYSTEM
adjusting tension
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC20C


49 MISCELLANEOUS

WHEEL/TRACK UNIT

ANYWHERE

EC20C



90 GENERAL
ECU


EC20C

916-060 0.30 Calibration of X1 hydraulic with flow control
97 UNIT, DIGGING

EC220D L

17 SERVICE
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 220848
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000

EC220D L

220849 - 230000
220001 - 220848
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
173-401 0.60 Engine oil and filter, changing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000

20 GENERAL
ECU 240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
ECU 220001 - 230000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
21 ENGINE
210-070 5.00 Engine, removing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
210-070 5.50 Engine, removing 210001 - 220000

EC220D L
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
230001 - 240000
220001 - 230000
250001 - 260000
270001 - 280000
260001 - 270000
217-005 1.50 Oil level sensor, changing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
221-022 0.80 Lubrication oil pressure, checking with pressure 210001 - 220000
gauge 220001 - 230000
gauge 240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
223-006 1.25 Oil cooler, replacing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
23 FUEL SYSTEM
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
233-004 0.60 Feed pump, checking feed pressure 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000

EC220D L

220001 - 230000
237-124 0.70 High pressure fuel system, pressure relief 210001 - 220000
220001 - 230000

240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
254-022 0.90 ACM (After treatment control module), replacing, 210001 - 220000
non-programmed 220001 - 230000
pre-programmed 220001 - 230000
254-031 0.90 Air pump, replacing 210001 - 220000
220001 - 230000
254-033 1.50 Burner, replacing 210001 - 220000
220001 - 230000
254-046 0.30 Spark plug, replacing 210001 - 220000
220001 - 230000
254-047 0.40 Spark plug, checking 210001 - 220000
220001 - 230000
254-056 0.60 NOx sensor, replacing 210001 - 220000
220001 - 230000
255-071 2.50 Turbocharger, replacing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
256-006 0.70 Preheating coil, replacing 210001 - 220000
220001 - 230000
240001 - 250000

EC220D L
250001 - 260000
270001 - 310000
260001 - 270000
258-002 4.50 Intercooler, replacing 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
26 COOLING SYSTEM
261-004 0.60 Coolant, changing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
261-008 5.00 Radiator, replacing 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
261-016 0.60 Radiator hoses all, replacing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
262-098 0.90 Thermostat, replacing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000

EC220D L
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
263-022 0.80 Fan belt and/or alternator-, compressor belt, 210001 - 220000
replacing all belts 220001 - 230000
250001 - 260000
270001 - 310000
260001 - 270000

30 GENERAL
31 BATTERY
311-001 0.80 Battery charging capacity, checking 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
311-002 1.00 Batteries, replacing 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
311-006 0.50 Earth lead to battery, replacing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000

321-002 1.25 Alternator, replacing incl function check 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000

EC220D L
260001 - 270000
33 STARTING SYSTEM
331-018 4.00 Starter motor, replacing 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
35 LIGHTING

363-004 0.50 Windscreen flusher pump, replacing 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
364-056 0.80 Pre-heating relay, replacing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
ECU

371-043 0.60 Battery disconnector, replacing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000

EC220D L
260001 - 270000
220001 - 230000
371-090 2.00 Engine wire harness, replacing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000

386-006 1.50 Engine temperature sensor, replacing 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
386-038 0.60 Engine rotation speed sensor, replacing 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
386-088 0.90 Engine rotation speed sensor (camshaft), 210001 - 220000
replacing 220001 - 230000
replacing 240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
39 MISCELLANEOUS
ECU

EC220D L

ECU
43 GEARBOX,
441-112 0.70 Track motor relief valve, replacing 210001 - 210677
220001 - 230000
270001 - 270380
280001 - 280079
270381 - 310000
280080 - 310000
49 MISCELLANEOUS
220554 - 230000
230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 220553

EC220D L
220554 - 230000
230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 220553
492-095 0.70 Swing ring gear cover, removal 220001 - 230000
210001 - 220000
492-096 0.70 Swing ring gear cover, installation 220001 - 230000
210001 - 220000

WHEEL/TRACK UNIT
71 FRAME
715-019 0.60 Boom cylinder protecting guard, removal 220001 - 230000
210001 - 220000
715-020 1.25 Boom cylinder protecting guard, installation 220001 - 230000
210001 - 220000
715-023 0.90 Bucket cylinder protecting guard, removal 220001 - 230000
210001 - 220000
715-024 1.25 Bucket cylinder protecting guard, installation 220001 - 230000
210001 - 220000
716-003 2.00 Counterweight, replacing

replacing
775-094 1.75 Full track guard, replacing

EC220D L

ANYWHERE
810-070 1.00 Electric pedal control on X1 (on/off), replacing 270001 - 310000
810-071 0.90 Electric pedal control on X1 (proportional), 270001 - 310000
replacing



870-001 5.00 Cooler and Heater assembly, replacing 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
874-006 1.75 Compressor, replacing incl draining and filling 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000

EC220D L
270001 - 310000
260001 - 270000
874-010 1.75 Condenser, replacing incl draining and filling 210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
874-011 1.50 Receiver, replacing incl draining and filling 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
874-012 3.00 Evaporator, replacing incl draining and filling 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
874-013 3.00 Expansion valve, replacing incl draining and filling210001 - 220000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000

911-005 1.75 Pump suction hose and pipe, replacing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000

EC220D L
260001 - 270000
220001 - 230000
replacing
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
replacing
916-096 0.80 Hammer and shear pedal valve (RCV), replacing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
924-040 0.80 Quickfit, replacing

EC220D L
97 UNIT, DIGGING
replacing
99 MISCELLANEOUS
992-002 5.50 Fire suppression system, actions after activation
992-003 6.50 Fire suppression system, actions after manual
activation

EC220D LR

17 SERVICE
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 220848
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000

EC220D LR

220001 - 220848
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220849 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000

20 GENERAL
ECU 240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
ECU 220001 - 230000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
21 ENGINE
210-070 5.00 Engine, removing 230001 - 240000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
210-070 5.50 Engine, removing 210001 - 220000

EC220D LR
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
230001 - 240000
220001 - 230000
250001 - 260000
270001 - 280000
260001 - 270000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
gauge 220001 - 230000
gauge 240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
23 FUEL SYSTEM
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000

EC220D LR

220001 - 230000
220001 - 230000

240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 250000

EC220D LR
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
26 COOLING SYSTEM
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000

EC220D LR
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
250001 - 260000
270001 - 310000
260001 - 270000

30 GENERAL
31 BATTERY
220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
220001 - 230000

240001 - 250000
250001 - 260000
260001 - 270000

EC220D LR
270001 - 310000
33 STARTING SYSTEM
220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
35 LIGHTING

220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
ECU

240001 - 250000
250001 - 260000
260001 - 270000

EC220D LR
270001 - 310000
220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
220001 - 230000

220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
replacing 220001 - 230000
replacing 240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
39 MISCELLANEOUS
ECU

EC220D LR

ECU
43 GEARBOX,
220001 - 230000
270001 - 270380
280001 - 280079
270381 - 310000
280080 - 310000
49 MISCELLANEOUS
220554 - 230000
270001 - 310000
250001 - 260000
240001 - 250000
230001 - 240000
210001 - 210310
220001 - 220553

EC220D LR
220554 - 230000
270001 - 310000
250001 - 260000
240001 - 250000
230001 - 240000
210001 - 210310
220001 - 220553

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing


EC220D LR


220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
240001 - 250000
250001 - 260000
260001 - 270000

EC220D LR
270001 - 310000
220001 - 230000
220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000
220001 - 230000
240001 - 250000
250001 - 260000
260001 - 270000
270001 - 310000

240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
replacing

EC220D LR

220001 - 230000
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
replacing
240001 - 250000
250001 - 260000
270001 - 310000
260001 - 270000
97 UNIT, DIGGING

EC220D LR

replacing

EC220D N

17 SERVICE
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 220848
220001 - 230000
220001 - 230000
220001 - 220848
220849 - 230000
220001 - 230000

20 GENERAL
ECU 220001 - 230000
220001 - 230000
21 ENGINE
210-070 5.50 Engine, removing 210001 - 220000
220001 - 230000
220001 - 230000

EC220D N

220001 - 230000
220001 - 230000
gauge 220001 - 230000
23 FUEL SYSTEM
220001 - 230000
220001 - 230000

220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000

EC220D N
26 COOLING SYSTEM
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000

30 GENERAL
31 BATTERY
220001 - 230000
220001 - 230000
220001 - 230000

33 STARTING SYSTEM
220001 - 230000
35 LIGHTING

EC220D N

220001 - 230000
ECU

220001 - 230000
220001 - 230000

220001 - 230000
220001 - 230000
replacing 220001 - 230000
39 MISCELLANEOUS
ECU

EC220D N

ECU
43 GEARBOX,
431-021 5.50 Swing gearbox, replacing 220001 - 230000
210001 - 220000
431-026 0.50 Swing gearbox removed, replacing seal 220001 - 230000
210001 - 220000
431-027 2.50 Swing gearbox removed, replacing shaft 220001 - 230000
210001 - 220000
431-031 4.00 Pump gearbox coupling assembly, replacing 220001 - 230000
210001 - 220000
431-053 6.50 Swing unit, replacing 220001 - 230000
210001 - 220000
431-115 1.75 Track gearbox (removed), replacing floating seal 220001 - 230000
210001 - 220000
431-117 1.25 Track gearbox, replacing cover 220001 - 230000
210001 - 220000
431-127 6.50 Track unit, replacing 210001 - 220000
220001 - 230000
441-021 2.50 Swing motor, replacing 220001 - 230000
210001 - 220000
441-022 0.80 Swing motor relief valve, replacing 220001 - 230000
210001 - 220000
441-024 1.50 Swing motor, replacing plate (brake) 220001 - 230000
210001 - 220000
441-025 1.50 Swing motor, replacing brake piston seal 220001 - 230000
210001 - 220000
441-026 0.30 Swing motor removed, replacing seal 220001 - 230000
210001 - 220000
270381 - 310000
280080 - 310000
210001 - 210677
270001 - 270380
280001 - 280079
443-037 5.50 Center passage, replacing 220001 - 230000
210001 - 220000
443-038 7.00 Center passage, replacing seal kit 220001 - 230000
210001 - 220000

EC220D N
49 MISCELLANEOUS
492-021 11.00 Swing ring gear, replacing 220001 - 230000
210001 - 220000
220554 - 230000
220001 - 220553
260001 - 270000
270001 - 310000
250001 - 260000
240001 - 250000
230001 - 240000
220554 - 230000
220001 - 220553
260001 - 270000
270001 - 310000
250001 - 260000
240001 - 250000
230001 - 240000
492-091 0.40 Ring gear grease pipe, replacing 220001 - 230000
210001 - 220000

WHEEL/TRACK UNIT
71 FRAME
710-001 3.50 Superstructure, removing 220001 - 230000
210001 - 220000
710-002 4.50 Superstructure, installing 220001 - 230000
210001 - 220000
716-003 2.00 Counterweight, replacing 220001 - 230000
210001 - 220000

775-011 3.00 Front idler, replacing one 220001 - 230000
210001 - 220000
775-021 3.50 Sprocket, replacing one 220001 - 230000
210001 - 220000
775-034 1.25 Track chain assembly, removing 220001 - 230000
210001 - 220000
775-035 1.75 Track chain assembly, installing 220001 - 230000
210001 - 220000
775-036 9.50 Track links, replacing 220001 - 230000
210001 - 220000
775-051 1.00 Top roller, replacing one 220001 - 230000

EC220D N
210001 - 220000
775-061 1.50 Bottom roller, replacing one 220001 - 230000
210001 - 220000
775-066 3.00 Bottom roller, replacing seal 220001 - 230000
210001 - 220000
775-081 3.00 Track recoil spring (tensioner) assembly, 220001 - 230000
replacing 210001 - 220000

ANYWHERE
replacing



220001 - 230000

EC220D N

220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000

220001 - 230000
replacing
220001 - 230000

EC220D N

replacing
97 UNIT, DIGGING
replacing

EC220D N

EC220D NL

17 SERVICE
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 210539
210001 - 220000
210001 - 220000
210001 - 210539
210540 - 220000
210001 - 220000

20 GENERAL
ECU 210001 - 220000
210001 - 220000
21 ENGINE
210-070 5.50 Engine, removing 220001 - 230000
210001 - 220000
210001 - 220000

EC220D NL

210001 - 220000
210001 - 220000
gauge 210001 - 220000
23 FUEL SYSTEM
210001 - 220000
210001 - 220000

210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000

EC220D NL
26 COOLING SYSTEM
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000

30 GENERAL
31 BATTERY
220001 - 230000
220001 - 230000
220001 - 230000

33 STARTING SYSTEM
220001 - 230000
35 LIGHTING

EC220D NL

220001 - 230000
ECU

220001 - 230000
220001 - 230000

220001 - 230000
220001 - 230000
replacing 220001 - 230000
39 MISCELLANEOUS
ECU

EC220D NL

ECU
43 GEARBOX,
210001 - 220000
431-026 0.50 Swing gearbox removed, replacing seal 220001 - 230000
210001 - 220000
431-027 2.50 Swing gearbox removed, replacing shaft 220001 - 230000
210001 - 220000
210001 - 220000
431-053 6.50 Swing unit, replacing 220001 - 230000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
210001 - 220000
270381 - 310000
280080 - 310000
220001 - 230000
270001 - 270380
280001 - 280079
210001 - 220000
210001 - 220000

EC220D NL
49 MISCELLANEOUS
492-021 11.00 Swing ring gear, replacing 220001 - 230000
210001 - 220000
220554 - 230000
210001 - 210310
220554 - 230000
210001 - 210310
210001 - 220000
210001 - 220000
210001 - 220000

WHEEL/TRACK UNIT
71 FRAME
710-001 3.50 Superstructure, removing 220001 - 230000
210001 - 220000
710-002 4.50 Superstructure, installing 220001 - 230000
210001 - 220000
716-003 2.00 Counterweight, replacing 220001 - 230000
210001 - 220000

775-011 3.00 Front idler, replacing one 220001 - 230000
210001 - 220000
775-021 3.50 Sprocket, replacing one 220001 - 230000
210001 - 220000
210001 - 220000
210001 - 220000
775-036 9.50 Track links, replacing 220001 - 230000
210001 - 220000
775-051 1.00 Top roller, replacing one 220001 - 230000
210001 - 220000
210001 - 220000
210001 - 220000

EC220D NL
775-071 0.90 Track guard, replacing one 220001 - 230000

210001 - 220000
775-081 3.00 Track recoil spring (tensioner) assembly, 220001 - 230000
replacing 210001 - 220000
775-094 1.75 Full track guard, replacing 220001 - 230000
210001 - 220000

ANYWHERE
replacing



220001 - 230000

EC220D NL
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000

220001 - 230000
replacing
220001 - 230000

EC220D NL

replacing
97 UNIT, DIGGING
replacing

EC220D NL

EC235D NL

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC235D NL

non-programmed
pre-programmed
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

EC235D NL

33 STARTING SYSTEM
35 LIGHTING

ECU


replacing
39 MISCELLANEOUS

EC235D NL

ECU
ECU
43 GEARBOX,
49 MISCELLANEOUS

EC235D NL

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE



EC235D NL


replacing

EC235D NL

replacing
97 UNIT, DIGGING
replacing

EC235D NL


EC250D L

17 SERVICE
173-002 0.80 Maintenance service, daily 210001 - 220000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000

EC250D L
270001 - 310000
240001 - 260000
260001 - 270000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000

20 GENERAL
ECU 220001 - 230000
ECU 270001 - 310000
240001 - 260000
260001 - 270000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
21 ENGINE
210-002 4.00 Compression test 210001 - 220000
220001 - 230000
210-070 4.50 Engine, removing 210001 - 210009
210-070 4.50 Engine, removing 230001 - 240000
270001 - 310000
240001 - 260000
260001 - 270000
210-070 4.50 Engine, removing 210001 - 220000

EC250D L
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
280001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
gauge 270001 - 310000
240001 - 260000
260001 - 270000
gauge 220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
23 FUEL SYSTEM
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000

EC250D L
220001 - 230000

270001 - 310000
240001 - 260000
260001 - 270000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
254-066 0.40 Exhaust Aftertreatment System, T-junction, 210001 - 220000
replacing 220001 - 230000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
270001 - 310000
240001 - 260000

EC250D L
260001 - 270000
220001 - 230000
26 COOLING SYSTEM
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
270001 - 310000
240001 - 260000
260001 - 270000
270001 - 310000
240001 - 260000
260001 - 270000
220001 - 230000
240001 - 260000
260001 - 270000

EC250D L
29 Miscellaneous
293-001 3.00 EGR cooler, replacing 210001 - 220000
220001 - 230000
293-004 3.00 EGR cooler, cleaning 210001 - 220000
220001 - 230000
293-005 3.00 EGR valve, replacing 210001 - 220000
220001 - 230000

30 GENERAL
31 BATTERY
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000

240001 - 260000
270001 - 310000
260001 - 270000
33 STARTING SYSTEM
240001 - 260000
270001 - 310000
260001 - 270000
331-081 0.30 Starter relay, replacing 230001 - 240000

EC250D L
240001 - 260000
270001 - 310000
260001 - 270000
35 LIGHTING

240001 - 260000
270001 - 310000
260001 - 270000
364-056 0.80 Pre-heating relay, replacing
ECU

240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000

240001 - 260000
270001 - 310000
260001 - 270000

EC250D L

386-007 0.60 Engine oil pressure sensor, replacing 230001 - 240000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
replacing 240001 - 260000
270001 - 310000
260001 - 270000
replacing
39 MISCELLANEOUS
ECU
ECU
43 GEARBOX,

EC250D L
210001 - 210441
270001 - 310000
240001 - 260000
230001 - 240000
210443 - 220000
49 MISCELLANEOUS
210001 - 220000
210001 - 220000

WHEEL/TRACK UNIT
71 FRAME
715-020 1.25 Boom cylinder protecting guard, installation
715-023 0.90 Bucket cylinder protecting guard, removal
715-024 1.00 Bucket cylinder protecting guard, installation


EC250D L

replacing

ANYWHERE
810-070 1.00 Electric pedal control on X1 (on/off), replacing
810-071 0.90 Electric pedal control on X1 (proportional),
replacing



240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000

EC250D L

240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000


EC250D L

replacing
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
replacing
914-051 0.30 Accumulator, replacing 230001 - 240000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
914-091 1.00 Solenoid valve, replacing 230001 - 240000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000

EC250D L

97 UNIT, DIGGING
replacing
99 MISCELLANEOUS
activation

EC250D LR

17 SERVICE
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000

EC250D LR
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000

20 GENERAL
ECU 220001 - 230000
ECU 240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
21 ENGINE
220001 - 230000
210-070 4.50 Engine, removing 230001 - 240000
240001 - 260000
270001 - 310000
260001 - 270000
210-070 4.50 Engine, removing 210001 - 220000
220001 - 230000

EC250D LR

240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
280001 - 310000
270001 - 280000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
gauge 240001 - 260000
270001 - 310000
260001 - 270000
gauge 220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
23 FUEL SYSTEM
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000

EC250D LR

240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
replacing 220001 - 230000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000

EC250D LR

220001 - 230000
26 COOLING SYSTEM
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
270001 - 310000
260001 - 270000

EC250D LR
29 Miscellaneous
220001 - 230000
220001 - 230000

30 GENERAL
31 BATTERY
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000

240001 - 260000
270001 - 310000
260001 - 270000
33 STARTING SYSTEM
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000

EC250D LR
260001 - 270000
35 LIGHTING

240001 - 260000
270001 - 310000
260001 - 270000
ECU

240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000

240001 - 260000
270001 - 310000
260001 - 270000

EC250D LR
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
replacing 240001 - 260000
270001 - 310000
260001 - 270000
replacing
39 MISCELLANEOUS
ECU
ECU
43 GEARBOX,

EC250D LR

210001 - 210441
270001 - 310000
240001 - 260000
230001 - 240000
210443 - 220000
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

EC250D LR

ANYWHERE
replacing



240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000

EC250D LR
220001 - 230000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000

replacing

EC250D LR

220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
replacing
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
220001 - 230000
240001 - 260000
270001 - 310000
260001 - 270000
97 UNIT, DIGGING

EC250D LR

replacing

EC250D NL

17 SERVICE
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000

20 GENERAL
ECU 220001 - 230000
220001 - 230000
21 ENGINE
220001 - 230000
210-070 4.50 Engine, removing 210001 - 220000
220001 - 230000

EC250D NL
220001 - 230000
220001 - 230000
220001 - 230000
gauge 220001 - 230000
23 FUEL SYSTEM
220001 - 230000
220001 - 230000
220001 - 230000

220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
replacing 220001 - 230000
220001 - 230000

EC250D NL
220001 - 230000
220001 - 230000
26 COOLING SYSTEM
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000
29 Miscellaneous
220001 - 230000
220001 - 230000
220001 - 230000

30 GENERAL
31 BATTERY
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000

EC250D NL
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000

240001 - 260000
270001 - 310000
260001 - 270000
33 STARTING SYSTEM
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
35 LIGHTING

240001 - 260000
270001 - 310000
260001 - 270000
ECU

EC250D NL



240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
240001 - 260000
270001 - 310000
260001 - 270000
replacing 240001 - 260000
270001 - 310000
260001 - 270000
replacing
39 MISCELLANEOUS
ECU
ECU

EC250D NL
43 GEARBOX,
210001 - 210441
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME


EC250D NL

replacing

ANYWHERE
replacing



220001 - 230000
220001 - 230000

EC250D NL
220001 - 230000
220001 - 230000
220001 - 230000
220001 - 230000

replacing
220001 - 230000
replacing
220001 - 230000

EC250D NL

220001 - 230000
97 UNIT, DIGGING
replacing

EC250E L

17 SERVICE
173-319 2.50 Diesel particulate filter, checking and cleaning
173-332 0.40 MATRIS and Tech Tool, reading

20 GENERAL
200-066 1.50 ECM (Engine control module), replacing pre-
programmed
200-067 2.00 ECM (Engine control module), replacing non-
programmed
200-200 0.60 Engine belts, replacing
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

EC250E L

237-031 1.25 Fuel rail, replacing
237-033 1.25 Fuel control valve (FCV), replacing
237-127 0.80 High pressure fuel pipes, replacing

non-programmed
pre-programmed
254-059 0.40 Inlet throttle, replacing
254-060 1.75 Diesel oxidation catalyst, replacing
254-112 3.00 AdBlue®/DEF tank, replacing
254-119 0.40 Coolant valve, replacing
254-124 0.30 AdBlue®/DEF pump unit, filter, replacing
254-126 0.80 AdBlue®/DEF mixing tube, replacing
254-127 2.00 SCR muffler, replacing
26 COOLING SYSTEM
29 Miscellaneous

EC250E L

293-009 1.25 EGR reed valve, replacing
293-010 0.70 EGR Venturi tube, replacing

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

366-103 0.80 HMICU, changing pre-programmed ECU
366-104 1.50 HMICU, changing non-programmed ECU
366-105 0.70 GPMECU1, changing pre-programmed ECU
366-106 1.25 GPMECU1, changing non-programmed ECU

371-092 0.70 Electrical battery disconnect switch, replacing

EC250E L

39 MISCELLANEOUS
398-005 1.25 W-ECU, replacing, non-programmed
398-006 0.90 W-ECU, replacing, pre-programmed
43 GEARBOX,
49 MISCELLANEOUS

EC250E L
492-095 0.70 Swing ring gear cover, removal

492-096 0.70 Swing ring gear cover, installation

WHEEL/TRACK UNIT
71 FRAME
715-019 0.60 Boom cylinder protecting guard, removal

replacing

ANYWHERE
replacing

827-091 1.00 Tool box assembly, replacing


EC250E L

870-017 1.75 CCM, changing non-programmed ECU
870-018 1.75 CCM, changing pre-programmed ECU

replacing
911-035 1.75 Oil cooler fan pump, replacing

EC250E L

913-085 1.75 Power take-off (PTO), replacing
replacing
97 UNIT, DIGGING
replacing
99 MISCELLANEOUS
activation

EC250E LD

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

EC250E LD


non-programmed
pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

EC250E LD


31 BATTERY

33 STARTING SYSTEM
35 LIGHTING



EC250E LD

39 MISCELLANEOUS
43 GEARBOX,
49 MISCELLANEOUS

EC250E LD


WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC250E LD


replacing

EC250E LD

replacing
97 UNIT, DIGGING
replacing

EC250E LR

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

EC250E LR


non-programmed
pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

EC250E LR


31 BATTERY

33 STARTING SYSTEM
35 LIGHTING



EC250E LR

39 MISCELLANEOUS
43 GEARBOX,
49 MISCELLANEOUS

EC250E LR

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC250E LR


replacing

EC250E LR

replacing
97 UNIT, DIGGING
replacing

EC250E NL

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

EC250E NL


non-programmed
pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

EC250E NL


31 BATTERY

33 STARTING SYSTEM
35 LIGHTING



EC250E NL

39 MISCELLANEOUS
43 GEARBOX,
49 MISCELLANEOUS

EC250E NL

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC250E NL


replacing

EC250E NL

replacing
97 UNIT, DIGGING
replacing

EC250E NLD

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

EC250E NLD


non-programmed
pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

EC250E NLD


31 BATTERY

33 STARTING SYSTEM
35 LIGHTING



EC250E NLD

39 MISCELLANEOUS
43 GEARBOX,
49 MISCELLANEOUS

EC250E NLD


WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC250E NLD


replacing

EC250E NLD

replacing
97 UNIT, DIGGING
replacing

EC27C

17 SERVICE
173-059 0.60 Engine, changing oil and filter
173-073 0.80 Hydraulic oil tank, changing oil
173-081 0.70 Travel motor gearbox, changing oil
19 GENERAL

21 ENGINE
221-014 3.50 Oil pump, replacing
23 FUEL SYSTEM

EC27C

26 COOLING SYSTEM
262-005 0.80 Coolant pump, removing
262-006 0.90 Coolant pump, installing
adjusting tension
27 ENGINE CONTROL
275-014 0.20 Automatic idling device, removing
275-015 0.30 Automatic idling device, installing

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

367-052 0.40 V-ECU, replacing


EC27C
39 MISCELLANEOUS
390-902 2.50 CareTrack, installing new
441-030 3.50 Swing motor, removing 3374 - 4613
441-031 5.00 Swing motor, installing 1 - 4613
441-033 0.90 Swing motor, replacing counterbalance valve 4614 - 9999

WHEEL/TRACK UNIT
71 FRAME

775-052 0.30 Top roller, removal
775-053 0.30 Top roller, installation

EC27C

ANYWHERE
810-004 3.00 Cab platform, removal 1 - 3373
810-005 3.50 Cab platform, installation 1 - 4613
810-013 0.40 Cab, roof panel, removing
810-014 0.40 Cab, roof panel, installing

852-011 0.40 Seat retention cable, replacement 1 - 4613
881-001 0.10 Instrument console, removing
881-002 0.20 Instrument console, installing

90 GENERAL
ECU

912-088 2.00 Main Control Valve - Disassembly 1 - 3373
912-089 2.50 Main Control Valve - Assembly 4614 - 9999
912-091 2.50 Main control valve, removal 4614 - 9999

EC27C

912-092 2.00 Main control valve, installation 1 - 4613
912-117 0.70 LS-pressure relief valve, replacing 3374 - 9999
912-141 5.00 Directional valve, drive, disassembling spool and 1 - 3373
replacing seals
replacing seals
912-142 4.50 Directional valve, dozer blade, disassembling 1 - 3373
spool and replacing seals
912-143 0.50 Load check valve, replacing 3374 - 9999
912-160 0.70 Port relief valve pressure, checking and adjusting3374 - 9999
912-167 4.50 Directional valve, hydraulically operated, 1 - 3373
disassembling spool and replacing seals
912-168 0.50 Compensator valve, replacing 3374 - 9999
912-175 0.60 Secondary pressure limiting valve, replacing 3374 - 9999
pressure
913-006 0.30 LS (load sense) pressure, checking 1 - 4613
913-065 0.40 Hydraulic pump, power control adjusting
913-066 0.40 FR pressure control valve, checking and adjusting
914-047 0.30 Servo accumulator, removal 1 - 3373
914-048 0.50 Servo accumulator, installation 3374 - 9999
914-064 0.60 Servo valve, removal 3374 - 9999

EC27C

914-104 0.50 Travel valve (pedal), removing 4614 - 9999
914-105 0.60 Travel valve (pedal), installing 4614 - 9999
915-004 0.90 Control lever, removal 1 - 3373
97 UNIT, DIGGING
974-013 1.75 Boom, removal 1 - 3373
974-013 1.75 Boom, removal 3374 - 9999
974-031 0.50 Boom cylinder, removal 1 - 3373
975-011 0.70 Dipper arm, removal 1 - 3373
975-014 0.40 Dipper arm cylinder, removal 1 - 3373
975-062 0.40 Bucket cylinder, removal 1 - 3373

EC300D L

17 SERVICE
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000

EC300D L
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000

20 GENERAL
ECU
ECU 270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
21 ENGINE
210-070 4.50 Engine, removing 230001 - 250000
270001 - 310000
250001 - 260000
260001 - 270000
210-070 4.50 Engine, removing 210001 - 230000
270001 - 310000
250001 - 260000
260001 - 270000
280001 - 310000
250001 - 260000
260001 - 270000

EC300D L

270001 - 310000
250001 - 260000
260001 - 270000
gauge 270001 - 310000
250001 - 260000
260001 - 270000
gauge
270001 - 310000
250001 - 260000
260001 - 270000
23 FUEL SYSTEM
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000

270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
non-programmed
pre-programmed

EC300D L

replacing
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
26 COOLING SYSTEM
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000

EC300D L
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
replacing all belts
250001 - 260000
260001 - 270000
29 Miscellaneous

30 GENERAL
31 BATTERY
250001 - 260000
260001 - 270000
230001 - 250000
250001 - 260000
260001 - 270000
230001 - 250000
250001 - 260000
260001 - 270000
230001 - 250000

EC300D L

250001 - 260000
260001 - 270000
230001 - 250000
33 STARTING SYSTEM
250001 - 260000
260001 - 270000
230001 - 250000
250001 - 260000
260001 - 270000
230001 - 250000
35 LIGHTING

250001 - 260000
260001 - 270000
230001 - 250000
ECU


EC300D L


250001 - 260000
260001 - 270000
230001 - 250000
250001 - 260000
260001 - 270000
230001 - 250000
250001 - 260000
260001 - 270000
230001 - 250000
replacing 250001 - 260000
260001 - 270000
230001 - 250000
replacing
39 MISCELLANEOUS
ECU
ECU

EC300D L
43 GEARBOX,
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME


EC300D L

replacing

ANYWHERE
replacing



250001 - 260000
260001 - 270000
230001 - 250000

EC300D L

250001 - 260000
260001 - 270000
230001 - 250000
250001 - 260000
260001 - 270000
230001 - 250000
250001 - 260000
260001 - 270000
230001 - 250000
250001 - 260000
260001 - 270000
230001 - 250000
250001 - 260000
260001 - 270000
230001 - 250000

replacing

EC300D L

250001 - 270000
230001 - 250000
260001 - 270000
replacing
250001 - 270000
230001 - 250000
260001 - 270000
250001 - 270000
230001 - 250000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
97 UNIT, DIGGING
970-006 1.50 Digging equipment, removal

EC300D L
970-007 1.75 Digging equipment, installation

replacing
99 MISCELLANEOUS
activation

EC300D LD

17 SERVICE

20 GENERAL
ECU
21 ENGINE
210-070 4.50 Engine, removing 210001 - 230000
gauge
23 FUEL SYSTEM

EC300D LD


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM
replacing all belts
29 Miscellaneous

EC300D LD

30 GENERAL
31 BATTERY
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000

270001 - 310000
250001 - 260000
260001 - 270000
33 STARTING SYSTEM
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
35 LIGHTING


EC300D LD

270001 - 310000
250001 - 260000
260001 - 270000
ECU


270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
replacing 270001 - 310000
250001 - 260000
260001 - 270000
replacing

EC300D LD
39 MISCELLANEOUS
ECU
ECU
43 GEARBOX,
49 MISCELLANEOUS

EC300D LD

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC300D LD


replacing

EC300D LD

replacing
97 UNIT, DIGGING

EC300D LD

replacing

EC300D LR

17 SERVICE
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000

EC300D LR
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000

20 GENERAL
ECU
ECU 270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
21 ENGINE
210-070 4.50 Engine, removing 230001 - 250000
270001 - 310000
250001 - 260000
260001 - 270000
210-070 4.50 Engine, removing 210001 - 230000
270001 - 310000
250001 - 260000
260001 - 270000
260001 - 270000
270001 - 280000

EC300D LR
270001 - 310000
250001 - 260000
260001 - 270000
gauge 270001 - 310000
250001 - 260000
260001 - 270000
gauge
270001 - 310000
250001 - 260000
260001 - 270000
23 FUEL SYSTEM
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000

270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
non-programmed
pre-programmed

EC300D LR

replacing
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
26 COOLING SYSTEM
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000

EC300D LR

270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
replacing all belts
250001 - 260000
260001 - 270000
29 Miscellaneous

30 GENERAL
31 BATTERY
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000


EC300D LR
270001 - 310000
250001 - 260000
260001 - 270000
33 STARTING SYSTEM
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
35 LIGHTING

270001 - 310000
250001 - 260000
260001 - 270000
ECU


EC300D LR

270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
replacing 270001 - 310000
250001 - 260000
260001 - 270000
replacing
39 MISCELLANEOUS
ECU
ECU
43 GEARBOX,

EC300D LR

49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

EC300D LR

ANYWHERE
replacing



270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000

EC300D LR
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000

replacing

EC300D LR

270001 - 310000
230001 - 250000
260001 - 270000
replacing
270001 - 310000
230001 - 250000
260001 - 270000
270001 - 310000
230001 - 250000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
97 UNIT, DIGGING

EC300D LR

replacing

EC300D NL

17 SERVICE

20 GENERAL
ECU
21 ENGINE
210-070 4.50 Engine, removing 210001 - 230000
gauge
23 FUEL SYSTEM

EC300D NL


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM
replacing all belts
29 Miscellaneous

EC300D NL

30 GENERAL
31 BATTERY
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000

270001 - 310000
250001 - 260000
260001 - 270000
33 STARTING SYSTEM
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
35 LIGHTING

EC300D NL

270001 - 310000
250001 - 260000
260001 - 270000
ECU


270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000
270001 - 310000
250001 - 260000
260001 - 270000

EC300D NL

replacing 270001 - 310000
250001 - 260000
260001 - 270000
replacing
39 MISCELLANEOUS
ECU
ECU
43 GEARBOX,
49 MISCELLANEOUS

EC300D NL

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC300D NL


replacing

EC300D NL

replacing
97 UNIT, DIGGING

EC300D NL

replacing

EC300D WH

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC300D WH


non-programmed
pre-programmed
254-066 0.40 Exhaust Aftertreatment System, T-junction,
replacing
26 COOLING SYSTEM
replacing all belts
29 Miscellaneous

EC300D WH

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU



EC300D WH

replacing
39 MISCELLANEOUS
ECU
ECU
43 GEARBOX,
49 MISCELLANEOUS

EC300D WH

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC300D WH




EC300D WH

replacing
replacing
97 UNIT, DIGGING

EC300D WH

replacing

EC300E L

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

EC300E L


non-programmed
pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

EC300E L


31 BATTERY

33 STARTING SYSTEM
35 LIGHTING



EC300E L

39 MISCELLANEOUS
43 GEARBOX,
49 MISCELLANEOUS

EC300E L

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC300E L


replacing

EC300E L

replacing
97 UNIT, DIGGING
replacing
99 MISCELLANEOUS
activation

EC300E LD

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

EC300E LD


non-programmed
pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

EC300E LD


31 BATTERY

33 STARTING SYSTEM
35 LIGHTING



EC300E LD

39 MISCELLANEOUS
43 GEARBOX,
49 MISCELLANEOUS

EC300E LD


WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC300E LD



replacing

EC300E LD

replacing
97 UNIT, DIGGING
replacing

EC300E LR

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

EC300E LR


non-programmed
pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

EC300E LR


31 BATTERY

33 STARTING SYSTEM
35 LIGHTING



EC300E LR

39 MISCELLANEOUS
43 GEARBOX,
49 MISCELLANEOUS

EC300E LR

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC300E LR



replacing

EC300E LR

replacing
97 UNIT, DIGGING
replacing

EC300E NL

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

EC300E NL


non-programmed
pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

EC300E NL


31 BATTERY

33 STARTING SYSTEM
35 LIGHTING



EC300E NL

39 MISCELLANEOUS
43 GEARBOX,
49 MISCELLANEOUS

EC300E NL

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC300E NL



replacing

EC300E NL

replacing
97 UNIT, DIGGING
replacing

EC300E NLD

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

EC300E NLD


non-programmed
pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

EC300E NLD


31 BATTERY

33 STARTING SYSTEM
35 LIGHTING



EC300E NLD

39 MISCELLANEOUS
43 GEARBOX,
49 MISCELLANEOUS

EC300E NLD


WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC300E NLD



replacing

EC300E NLD

replacing
97 UNIT, DIGGING
replacing

EC340D L

17 SERVICE
171-002 3.00 Delivery Inspection, according to Inspection
Programme

20 GENERAL
200-009 1.75 VCADS Pro, MID 128, programming E-ECU
ECU
21 ENGINE
214-092 9.50 Rocker arms, replacing
gauge

EC340D L
23 FUEL SYSTEM
233-010 1.25 Fuel pump, inspection

254-021 3.00 Atomization unit, replacing
non-programmed
pre-programmed
254-061 3.50 Exhaust aftertreatment system, fuel pump,
replacing
254-063 2.50 Aftertreatment support unit (ASU), replacing
254-065 1.00 Air pump flow, checking
254-125 1.75 Exhaust aftertreatment fuel injector, replacing
26 COOLING SYSTEM

EC340D L

replacing all belts
29 Miscellaneous
293-003 4.00 EGR Venturi tube, checking
293-007 0.40 EGR pressure sensor, replacing

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC340D L

ECU


386-044 0.40 Auto idling sensor, replacing
replacing
39 MISCELLANEOUS
ECU
ECU
43 GEARBOX,

EC340D L

49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME


EC340D L

replacing

ANYWHERE




EC340D L


replacing
911-034 2.50 Oil cooler fan motor, replacing
replacing

EC340D L
97 UNIT, DIGGING
replacing
99 MISCELLANEOUS
activation

EC350E L

17 SERVICE
173-303 0.30 Lubrication, every 50 hours

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge

EC350E L
23 FUEL SYSTEM

non-programmed
pre-programmed
254-101 1.25 AdBlue®/DEF pump, replacing
254-109 0.20 Aftertreatment fuel nozzle, cleaning
254-111 1.50 Muffler, replacing
26 COOLING SYSTEM

EC350E L
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC350E L


39 MISCELLANEOUS
43 GEARBOX,

EC350E L
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC350E L



replacing

EC350E L

replacing
97 UNIT, DIGGING
replacing

EC35C

17 SERVICE
19 GENERAL

21 ENGINE
221-014 3.50 Oil pump, replacing 3538 - 4104
23 FUEL SYSTEM

EC35C


26 COOLING SYSTEM
adjusting tension
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
333-002 0.60 Glow plug, removal 4105 - 9999
333-003 0.60 Glow plug, installation 4105 - 9999
35 LIGHTING

EC35C


39 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME


EC35C

ANYWHERE

852-011 0.40 Seat retention cable, replacement 3538 - 5935

90 GENERAL
ECU


EC35C

replacing seals
replacing seals
pressure
913-067 0.50 LR pressure relief valve, checking and adjusting

EC35C

914-104 0.50 Travel valve (pedal), removing 5936 - 9999
914-105 0.60 Travel valve (pedal), installing 5936 - 9999
97 UNIT, DIGGING
974-013 1.50 Boom, removal 3538 - 4705
974-013 1.50 Boom, removal 4706 - 9999

EC380D HR

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC380D HR


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM

EC380D HR

replacing all belts
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC380D HR

ECU


replacing
387-019 0.30 Rear view camera, replacing
387-031 0.50 Total moment indicator (TMI), replacing
39 MISCELLANEOUS
ECU
43 GEARBOX,

EC380D HR
49 MISCELLANEOUS
492-027 0.50 Swing limitation sensor, adjusting

WHEEL/TRACK UNIT
71 FRAME

replacing

EC380D HR

ANYWHERE



867-000 0.90 Falling object guard, removal
867-001 1.25 Falling object guard, installation


EC380D HR


replacing
replacing

EC380D HR


944-005 2.50 Middle dipper arm cylinder, replacing
945-057 1.75 Cab tilting cylinder, replacing
97 UNIT, DIGGING
replacing
975-072 3.50 Bucket cylinder bushing on dipper arm, changing 210389 - 230000
975-073 3.50 Bucket cylinder bushing lever-link, replacing 210389 - 230000
975-085 3.00 Demolition dipper arm cylinder, replacing

EC380D L

17 SERVICE
Programme
230001 - 270000
260001 - 270000
230001 - 270000
260001 - 270000
230001 - 270000
260001 - 270000
230001 - 270000
260001 - 270000
230001 - 270000
260001 - 270000
230001 - 270000
260001 - 270000
230001 - 270000
260001 - 270000
230001 - 270000
260001 - 270000
230001 - 270000
260001 - 270000

EC380D L


20 GENERAL
200-009 0.30 VCADS Pro, MID 128, programming E-ECU 270001 - 310000
230001 - 270000
260001 - 270000
ECU 230001 - 270000
260001 - 270000
ECU
230001 - 270000
260001 - 270000
21 ENGINE
210-070 6.50 Engine, removing 210001 - 230000
210-070 6.00 Engine, removing 270001 - 310000
230001 - 270000
260001 - 270000
230001 - 270000
260001 - 270000
230001 - 270000
260001 - 270000
214-092 9.50 Rocker arms, replacing 210001 - 230000
215-042 6.50 Camshaft, replacing 210001 - 230000
230001 - 270000
260001 - 270000
gauge

EC380D L
23 FUEL SYSTEM
230-002 0.90 Air in fuel system, checking 210001 - 230000
230001 - 270000
260001 - 270000

254-021 3.00 Atomization unit, replacing 210001 - 230000
non-programmed
pre-programmed
254-034 1.25 Compressor, replacing 210001 - 230000
254-048 0.40 Spark plug cable, replacing 210001 - 230000
254-061 3.50 Exhaust aftertreatment system, fuel pump, 210001 - 230000
replacing
254-063 2.50 Aftertreatment support unit (ASU), replacing 210001 - 230000
254-064 0.50 High pressure air system, pressure, checking 210001 - 230000
254-065 1.00 Air pump flow, checking 210001 - 230000
254-069 0.70 Exhaust aftertreatment system fuel flow, checking210001 - 230000
254-125 1.75 Exhaust aftertreatment fuel injector, replacing 210001 - 230000
255-003 1.75 Actuator, variable turbocharger, replacing 210001 - 230000
230001 - 270000
260001 - 270000
230001 - 270000

EC380D L
260001 - 270000
230001 - 270000
260001 - 270000
26 COOLING SYSTEM
260001 - 270000
replacing all belts
29 Miscellaneous
293-003 4.00 EGR Venturi tube, checking 210001 - 230000
293-007 0.40 EGR pressure sensor, replacing 210001 - 230000

30 GENERAL
31 BATTERY
230001 - 270000


EC380D L
33 STARTING SYSTEM
230001 - 270000
260001 - 270000
35 LIGHTING

ECU

230001 - 270000
260001 - 270000
280001 - 310000
230001 - 270000
372-002 0.50 Electrical distribution box, circuit board replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000

383-001 0.30 Hour meter, replacing 210001 - 230000
270001 - 280000
230001 - 260000

EC380D L
280001 - 310000
260001 - 270000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
230001 - 270000
260001 - 270000
280001 - 310000
386-011 0.30 Fuel level sender, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
386-017 0.50 Hydraulic oil temperature sensor, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
386-044 0.40 Auto idling sensor, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
replacing 270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
387-019 0.30 Rear view camera, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
39 MISCELLANEOUS
393-001 0.50 Voltage converter, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
393-021 0.60 Radio, replacing 210001 - 230000
270001 - 280000

EC380D L
230001 - 260000
280001 - 310000
260001 - 270000
395-021 0.70 Antenna, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
395-031 0.40 Speaker, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
398-001 0.60 CareTrack antenna, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
230001 - 270000
260001 - 270000
280001 - 310000
ECU 230001 - 270000
260001 - 270000
280001 - 310000
ECU
398-004 0.50 CareTrack battery, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
43 GEARBOX,

EC380D L
49 MISCELLANEOUS
210001 - 210479
270001 - 270282
280001 - 280107
270283 - 280000
280108 - 310000
230113 - 260000
210001 - 210479
270001 - 270282
280001 - 280107
270283 - 280000
280108 - 310000
230113 - 260000

WHEEL/TRACK UNIT
71 FRAME


EC380D L

replacing

ANYWHERE
810-001 1.75 Cab, removing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
810-002 2.50 Cab, installing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000

821-005 0.90 Engine hood, replacing 270001 - 310000
230001 - 270000
260001 - 270000
280001 - 310000
827-091 1.75 Tool box assembly, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000

841-061 0.30 Rear-view mirror, changing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
843-002 1.50 Windscreen, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000

EC380D L
260001 - 270000
843-012 4.00 Rear window, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
843-013 4.50 Side window, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
843-048 0.70 Door window, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
852-008 1.25 Seat, replacing 210001 - 230000
852-008 1.75 Seat, replacing 270001 - 310000
230001 - 270000
260001 - 270000
280001 - 310000
852-012 1.75 Longitudinal adjustment cable, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
852-013 0.60 Longitudinal suspension cable, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
852-089 0.30 Seat cushion, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
852-090 0.60 Backrest, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
852-091 2.50 Seat support, replacing 210001 - 230000
230001 - 270000
260001 - 270000
280001 - 310000


EC380D L
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
870-010 0.70 ECC, MID 146, changing pre-programmed ECU 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
870-011 1.00 ECC, MID 146, changing non-programmed ECU 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
872-001 0.50 Cab filter, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
873-004 3.00 Heater core, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
873-006 0.80 Fan motor, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
873-011 0.70 Air mix door actuator, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
270001 - 280000

EC380D L
230001 - 260000
280001 - 310000
260001 - 270000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
874-016 0.30 Compressor, replacing magnetic clutch 210001 - 230000
(compressor removed) 270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
874-094 0.60 Vent actuator, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
874-095 0.60 Mode (foot) actuator, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
874-096 0.60 Intake actuator, replacing 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
881-003 1.00 Instrument panel, replacing (left) 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000
881-005 1.25 Instrument panel, replacing (right) 210001 - 230000
270001 - 280000
230001 - 260000
280001 - 310000
260001 - 270000


EC380D L

replacing
replacing
97 UNIT, DIGGING

EC380D L

replacing

EC380D NL

17 SERVICE

20 GENERAL
ECU
21 ENGINE
210-070 6.50 Engine, removing 210001 - 230000
gauge
23 FUEL SYSTEM

EC380D NL


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM

EC380D NL

replacing all belts
29 Miscellaneous

30 GENERAL
31 BATTERY
230001 - 270000

33 STARTING SYSTEM
230001 - 270000
280001 - 310000
260001 - 270000
230001 - 270000
260001 - 270000
280001 - 310000

EC380D NL
35 LIGHTING

ECU

230001 - 270000

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 210001 - 230000
ECU

EC380D NL
43 GEARBOX,
49 MISCELLANEOUS
210001 - 210479
270001 - 270282
280001 - 280107
270283 - 280000
280108 - 310000
230113 - 260000
210001 - 210479
270001 - 270282
280001 - 280107
270283 - 280000
280108 - 310000
230113 - 260000

EC380D NL

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
810-001 1.75 Cab, removing 210001 - 230000
810-002 2.50 Cab, installing 210001 - 230000


852-008 1.25 Seat, replacing 210001 - 230000

EC380D NL



replacing

EC380D NL

replacing
97 UNIT, DIGGING
replacing

EC380D NL


EC380E HR

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge

EC380E HR
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

EC380E HR
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC380E HR


39 MISCELLANEOUS
43 GEARBOX,

EC380E HR

49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

EC380E HR

replacing




EC380E HR

replacing
912-177 1.75 Demolition control valve, replacing
replacing

97 UNIT, DIGGING

EC380E HR

replacing

EC380E L

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge

EC380E L
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

EC380E L
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC380E L


39 MISCELLANEOUS
43 GEARBOX,

EC380E L
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC380E L



replacing

EC380E L

replacing
97 UNIT, DIGGING
replacing

EC380E LD

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge

EC380E LD
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

EC380E LD
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC380E LD


39 MISCELLANEOUS
43 GEARBOX,

EC380E LD
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

EC380E LD

replacing




EC380E LD

replacing
replacing
97 UNIT, DIGGING

EC380E LD

replacing

EC380E LR

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge

EC380E LR
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

EC380E LR
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC380E LR


39 MISCELLANEOUS
43 GEARBOX,

EC380E LR
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC380E LR



replacing

EC380E LR

replacing
97 UNIT, DIGGING
replacing

EC380E NL

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge

EC380E NL
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

EC380E NL
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC380E NL


39 MISCELLANEOUS
43 GEARBOX,

EC380E NL
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC380E NL



replacing

EC380E NL

replacing
97 UNIT, DIGGING
replacing

EC380E NLD

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge

EC380E NLD
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

EC380E NLD
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC380E NLD


39 MISCELLANEOUS
43 GEARBOX,

EC380E NLD
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE
replacing



EC380E NLD



replacing

EC380E NLD

replacing
97 UNIT, DIGGING
replacing

EC480D HR

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC480D HR


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM

EC480D HR

replacing all belts
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC480D HR

ECU


replacing
387-019 0.30 Rear view camera, replacing
39 MISCELLANEOUS
ECU
43 GEARBOX,
431-036 3.50 Pump gearbox flange, replacing

EC480D HR
431-111 6.00 Track gearbox, replacing

49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME
716-006 1.75 Removable counterweight, removing
716-007 2.00 Removable counterweight, installing
718-002 2.50 Retractable track, removing
718-003 3.00 Retractable track, installing


EC480D HR

replacing

ANYWHERE





EC480D HR


replacing
replacing

EC480D HR

944-004 2.00 Base boom modular joint cylinder, replacing
944-006 1.25 Base boom modular joint cylinder pin, replacing
97 UNIT, DIGGING
replacing

EC480D L

17 SERVICE
171-001 1.00 Arrival Inspection, according to Inspection
Programme
Programme
260001 - 270000
260001 - 270000
260001 - 270000
260001 - 270000
260001 - 270000
260001 - 270000
260001 - 270000
260001 - 270000
260001 - 270000

EC480D L

20 GENERAL
260001 - 270000
ECU 260001 - 270000
ECU
260001 - 270000
21 ENGINE
210-070 6.50 Engine, removing 210001 - 260000
210-070 6.00 Engine, removing 270001 - 310000
260001 - 270000
260001 - 270000
260001 - 270000
260001 - 270000
gauge
23 FUEL SYSTEM
260001 - 270000

EC480D L


non-programmed
pre-programmed
replacing
260001 - 270000
260001 - 270000
260001 - 270000
26 COOLING SYSTEM

EC480D L
replacing all belts
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
260001 - 270000
280001 - 310000
260001 - 270000
35 LIGHTING


EC480D L

ECU

280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000

270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000

EC480D L
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
replacing 270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
39 MISCELLANEOUS
270001 - 280000
280001 - 310000
260001 - 270000
393-021 0.60 Radio, replacing 210001 - 260000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
280001 - 310000
260001 - 270000
ECU 280001 - 310000
260001 - 270000
ECU
270001 - 280000
280001 - 310000
260001 - 270000

EC480D L
43 GEARBOX,
431-111 6.00 Track gearbox, replacing
271750 - 280000
280119 - 310000
280001 - 280118
270001 - 270001
441-111 3.50 Track motor, replacing 210124 - 270000
270001 - 310000
260001 - 270000
280001 - 310000
270001 - 310000
260001 - 270000
280001 - 310000
49 MISCELLANEOUS
280001 - 280113
280001 - 280113
280114 - 310000

EC480D L

WHEEL/TRACK UNIT
71 FRAME
716-006 1.25 Removable counterweight, removing 210001 - 270000
716-007 1.50 Removable counterweight, installing 210001 - 270000
718-002 2.50 Retractable track, removing 210001 - 270000
718-003 3.00 Retractable track, installing 210001 - 270000

replacing

ANYWHERE
810-001 1.75 Cab, removing 210001 - 260000
270001 - 280000
280001 - 310000
260001 - 270000
810-002 2.50 Cab, installing 210001 - 260000
270001 - 280000
280001 - 310000
260001 - 270000

280001 - 310000
260001 - 270000

EC480D L

270001 - 280000
280001 - 310000
260001 - 270000

270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
852-008 1.25 Seat, replacing 210001 - 260000
852-008 1.75 Seat, replacing 270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000

EC480D L

280001 - 310000
260001 - 270000

270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000

EC480D L
280001 - 310000
260001 - 270000
(compressor removed) 270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000
270001 - 280000
280001 - 310000
260001 - 270000

replacing
911-038 3.50 Hydraulic oil tank, replacing 270001 - 310000
260001 - 270000
912-001 8.50 Control valve, replacing 270001 - 310000
260001 - 270000

EC480D L
912-001 8.50 Control valve, replacing 210001 - 260000

260001 - 270000
replacing
914-060 2.00 Servo pump, replacing 270001 - 310000
260001 - 270000
97 UNIT, DIGGING
974-013 6.00 Boom, removal 210001 - 260000
974-013 6.00 Boom, removal 270001 - 310000
260001 - 270000
974-014 6.50 Boom, installation 210001 - 260000
260001 - 270000
974-025 6.00 Boom cylinder, repacking in machine

EC480D L

replacing
975-043 6.00 Dipper arm cylinder, repacking in machine 270001 - 310000
975-063 6.00 Bucket cylinder, repacking in machine 270001 - 310000

EC480E L

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge

EC480E L
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

EC480E L
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC480E L


39 MISCELLANEOUS
43 GEARBOX,
431-111 6.00 Track gearbox, replacing 310001 - 310010

EC480E L
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

EC480E L

replacing




EC480E L

replacing
replacing
97 UNIT, DIGGING

EC480E L

replacing

EC480E LD

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge

EC480E LD
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

EC480E LD
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC480E LD


39 MISCELLANEOUS
43 GEARBOX,

EC480E LD
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

EC480E LD

ANYWHERE
replacing




EC480E LD

replacing
replacing
97 UNIT, DIGGING

EC480E LD

replacing

EC480E LR

17 SERVICE

20 GENERAL
programmed
programmed
21 ENGINE
replacing
replacing
gauge

EC480E LR
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

EC480E LR
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC480E LR


39 MISCELLANEOUS
43 GEARBOX,

EC480E LR
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

EC480E LR

replacing




EC480E LR

replacing
replacing
97 UNIT, DIGGING

EC480E LR

replacing

EC55C

17 SERVICE
Programme
Programme
173-077 0.20 Hydraulic oil tank, changing breather filter

20 GENERAL
ECU
21 ENGINE

EC55C
gauge
23 FUEL SYSTEM
233-002 0.40 Feed pump, replacing
234-010 2.50 Fuel tank, replacing
236-073 2.75 Injection pump, replacing incl setting injection
timing
237-004 1.75 Injector, replacing one

26 COOLING SYSTEM
adjusting tension
replacing all belts

EC55C

30 GENERAL
300-072 1.25 I-ECU, MID 140, changing non-programmed ECU120001 - 210000
300-074 0.80 I-ECU, MID 140, changing pre-programmed ECU120001 - 210000
31 BATTERY
311-003 1.25 Main switch, replacing 120001 - 210000

33 STARTING SYSTEM
334-011 0.90 Starter switch (engine start switch), replacing 120001 - 210000
35 LIGHTING
356-056 0.60 Work lighting, replacing one head lamp assy 120001 - 210000

362-051 0.40 Travel alarm, replacing 120001 - 210000
363-002 0.80 Windscreen wiper front, replacing motor 120001 - 210000
ECU
367-052 0.40 V-ECU, replacing 110001 - 120000
367-056 0.30 I-ECU, replacing 110001 - 120000

39 MISCELLANEOUS
393-021 0.50 Radio, replacing 120001 - 210000

EC55C

43 GEARBOX,
441-032 0.80 Swing motor pressure, checking and adjusting
441-115 1.50 Track motor removed, replacing seal
replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME


EC55C

775-032 0.30 Track shoe, replacing one
775-033 3.50 Track shoe, replacing each side
replacing

ANYWHERE
810-001 1.50 Cab, removing 120001 - 210000
810-001 1.50 Cab, removing 110001 - 120000
810-002 2.00 Cab, installing 120001 - 210000
810-002 2.00 Cab, installing 110001 - 120000


852-003 0.70 Operator's seat, removing 120001 - 210000
852-004 0.80 Operator's seat, installing 120001 - 210000
852-008 1.50 Seat, replacing 120001 - 210000

870-003 3.00 Cooler and Heater assembly, removal 120001 - 210000
870-004 4.00 Cooler and Heater assembly, installation 120001 - 210000
873-014 0.90 Water valve, replacing 120001 - 210000

EC55C
111836 - 120000
874-021 5.00 Defroster actuator, replacing 120001 - 210000

911-025 1.00 Pipe and hose (valve - cylinder), replacing
911-026 1.00 Pipe and hose (valve - swing motor), replacing
911-031 1.00 Oil cooler line pipe and hose, replacing
912-070 0.80 Check valve, replacing
912-074 0.50 Rupture valve hose or pipe, replacing (boom
cylinder)
912-136 1.25 Main relief valve, adjusting
914-036 1.25 Servo pump block seal, replacing
914-086 1.00 Remote control valve hose, replacing

EC55C
914-099 2.50 Remote control valve (pedal), disassembly

914-100 2.00 Remote control valve (pedal), assembly
924-003 0.80 Quickfit solenoid valve, replacing
97 UNIT, DIGGING
970-008 0.50 Bushing general, replacing
974-017 1.00 Boom, replacing pin
974-022 1.50 Boom cylinder removed, repacking
974-024 0.50 Boom cylinder removed, replacing bearings
and/or bushes
975-026 1.50 Dipper arm cylinder removed, repacking
975-043 1.50 Dipper arm cylinder, repacking in machine
975-044 0.50 Dipper arm cylinder removed, replacing bearings
and/or bushes
975-063 1.50 Bucket cylinder, repacking in machine
975-069 1.50 Bucket cylinder removed, repacking
975-070 0.50 Bucket cylinder removed, replacing bushing

981-080 1.25 Dozer blade cylinder, replacing

EC60C

17 SERVICE

21 ENGINE
23 FUEL SYSTEM
timing

26 COOLING SYSTEM

EC60C

adjusting tension

31 BATTERY

43 GEARBOX,
replacing
replacing

WHEEL/TRACK UNIT

EC60C

replacing

ANYWHERE


EC60C
97 UNIT, DIGGING


EC80D

17 SERVICE

20 GENERAL
21 ENGINE
gauge
23 FUEL SYSTEM


EC80D
26 COOLING SYSTEM

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING




EC80D
39 MISCELLANEOUS
ECU
43 GEARBOX,

WHEEL/TRACK UNIT
71 FRAME

replacing
775-082 3.00 Recoil spring cylinder seal kit, replacing

EC80D

ANYWHERE



870-003 3.00 Cooler and Heater assembly, removal
870-004 4.00 Cooler and Heater assembly, installation
873-014 0.90 Water valve, replacing

replacing

EC80D

913-005 1.75 Hydraulic pump, flow control
97 UNIT, DIGGING

981-081 0.30 Blade lift cylinder, removing

EC80D
981-086 0.80 Blade lift cylinder, installing

ECR25D

17 SERVICE

21 ENGINE
211-081 2.50 Cylinder head, fitting
217-003 1.50 Oil sump, replacing
23 FUEL SYSTEM
236-080 3.00 Injection pump, checking
237-011 2.00 Unit injectors, checking

251-002 0.70 Induction manifold, replacing gasket
251-009 2.00 Exhaust manifold, replacing

ECR25D

26 COOLING SYSTEM
262-097 0.60 Thermostat, checking
adjusting tension
27 ENGINE CONTROL

31 BATTERY
311-011 0.30 Battery, removing
311-012 0.30 Battery, installing

33 STARTING SYSTEM
35 LIGHTING

ECR25D


39 MISCELLANEOUS
ECU
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME


ECR25D


ANYWHERE
810-065 0.80 Cab, position 1
810-067 0.60 Cab, position 1, restoring


90 GENERAL
ECU

912-036 0.40 Hose rupture valve, removal
912-037 0.30 Hose rupture valve, installation

ECR25D
912-142 0.90 Directional valve, dozer blade, disassembling

912-143 0.90 Load check valve, replacing
912-167 0.80 Directional valve, hydraulically operated,
912-168 3.50 Compensator valve, replacing
pressure
916-106 0.50 Control pattern selector valve, removal
916-107 0.50 Control pattern selector valve, installation
97 UNIT, DIGGING

ECR25D


ECR38

17 SERVICE
Programme
Programme
173-074 1.00 Hydraulic oil tank, changing oil and filter
173-076 0.50 Hydraulic oil tank, return oil filter change
173-088 0.20 Fuel filter, replacing
19 GENERAL

21 ENGINE
218-008 0.70 Engine mounts, removing
23 FUEL SYSTEM

ECR38

timing
237-018 0.25 Delivery pipe, replacing one

26 COOLING SYSTEM
260-002 2.50 Cooling system, flushing
adjusting tension
27 ENGINE CONTROL

ECR38

31 BATTERY
311-003 0.50 Main switch, replacing
311-008 2.25 Starter motor lead to battery, replacing

33 STARTING SYSTEM
35 LIGHTING

364-052 0.50 Battery relay, replacing

379-011 0.75 Boom wire harness, replacing


ECR38
441-011 3.00 Travel motor, replacing one
441-033 0.90 Swing motor, replacing counterbalance valve

WHEEL/TRACK UNIT
71 FRAME

775-024 0.30 Removing the guide sprocket

ANYWHERE
810-003 3.25 Operator cab, replacing

ECR38


831-051 0.50 Cab door, changing door catch



911-001 0.50 Oil return filter, replacing

ECR38

cylinder)
912-100 1.25 Hydraulic swivel joint, removing
912-101 1.50 Hydraulic swivel joint, installing
913-013 3.75 Hydraulic pump, replacing seal for input shaft
916-044 0.50 Boom, replacing hose (boom cylinder)
916-045 0.50 Boom, replacing pipe (dipper arm cylinder)
916-046 0.50 Boom, replacing hose (dipper arm cylinder)
916-047 0.75 Boom, replacing pipe (bucket cylinder)
916-048 0.50 Dipper arm, replacing hose (bucket cylinder)
916-049 0.50 Dipper arm, replacing pipe (bucket cylinder)
97 UNIT, DIGGING
and/or bushes

ECR50D

17 SERVICE

21 ENGINE
211-081 1.50 Cylinder head, fitting
gauge
23 FUEL SYSTEM

ECR50D

236-072 1.00 Injection pump, fitting incl setting injection timing
237-011 1.75 Unit injectors, checking

252-023 0.30 Exhaust pipe, replacing
26 COOLING SYSTEM
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECR50D


39 MISCELLANEOUS
ECU

WHEEL/TRACK UNIT
71 FRAME


ECR50D

ANYWHERE
810-065 0.70 Cab, position 1



ECR50D

97 UNIT, DIGGING

ECR58D

17 SERVICE

20 GENERAL
21 ENGINE
216-014 3.50 Crankshaft, replacing front oil seal 210001 - 280000
216-018 4.00 Crankshaft, replacing rear oil seal 210001 - 280000
216-018 4.00 Crankshaft, replacing rear oil seal 280001 - 310000

ECR58D
gauge
23 FUEL SYSTEM
236-044 0.90 Injection timing, checking 280001 - 310000
236-080 1.25 Injection pump, checking 280001 - 310000
237-125 1.50 Fuel pump unit, replacing 210001 - 280000
237-125 1.25 Fuel pump unit, replacing 280001 - 310000

254-059 0.80 Inlet throttle, replacing 210001 - 280000
254-060 2.00 Diesel oxidation catalyst, replacing 210001 - 280000
255-002 0.70 Turbocharger, inspection 280001 - 310000
256-003 0.20 Air cleaner, primary filter replacing 210001 - 280000
256-004 0.20 Air cleaner, secondary filter replacing 210001 - 280000
26 COOLING SYSTEM
262-002 1.50 Coolant pump, replacing 210001 - 280000

ECR58D
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM

ECU


replacing
39 MISCELLANEOUS

ECR58D

ECU
43 GEARBOX,

WHEEL/TRACK UNIT
71 FRAME

replacing

ECR58D

ANYWHERE




874-021 0.50 Defroster actuator, replacing

replacing

ECR58D

280001 - 280363
280364 - 310000
replacing
97 UNIT, DIGGING
971-089 1.50 Boom swing cylinder, replacing


ECR88D

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM
237-040 0.30 Overflow pipe, checking for leakage
237-125 1.50 Fuel pump unit, replacing

ECR88D

26 COOLING SYSTEM
29 Miscellaneous

31 BATTERY

33 STARTING SYSTEM

ECU

ECR88D


replacing
387-003 0.60 Key pad, replacing
39 MISCELLANEOUS
ECU
43 GEARBOX,

WHEEL/TRACK UNIT
71 FRAME


ECR88D

replacing

ANYWHERE





ECR88D


replacing
replacing

ECR88D
97 UNIT, DIGGING
971-089 2.50 Boom swing cylinder, replacing


EW140D

17 SERVICE

20 GENERAL
ECU
21 ENGINE
210-090 0.30 Camshaft and flywheel signals, checking with
VCADS Pro and oscilloscope
218-002 1.75 Engine mount front, changing
gauge
23 FUEL SYSTEM

EW140D

233-015 0.50 Fuel filter extra, replacing
233-020 0.10 Fuel filter, checking
235-003 0.30 Fuel return pressure, checking
237-036 1.50 Pressure relief valve (PRV), checking
237-037 1.50 Fuel rail pressure, checking
237-038 1.25 Fuel control valve (FCV), checking

non-programmed
pre-programmed
254-032 1.00 Burner, checking
26 COOLING SYSTEM

EW140D

replacing all belts
263-050 1.25 Cooling fan clutch, replacing
29 Miscellaneous

30 GENERAL
301-016 0.40 Tiltrotator control system, software updating
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EW140D

364-001 0.80 Electric center passage, replacing
ECU


386-016 0.60 Temperature sensor cooling system, replacing
386-018 0.50 Boost pressure / charge-air temperature sensor,
replacing
replacing
39 MISCELLANEOUS
ECU
424-002 0.20 Transmission mode, function check
43 GEARBOX,
431-012 2.00 Travel gearbox, removal
431-013 2.50 Travel gearbox, installation
431-020 0.40 Travel gearbox, bleeding
441-009 1.75 Travel motor, removing
441-010 2.00 Travel motor, installing
441-016 0.20 Travel motor removed, replacing seal
441-017 0.50 Travel motor pressure, checking and adjusting
441-018 0.90 Retardation valve, replacing

EW140D
441-020 0.80 Travel motor (electric proportional control)

pressure, checking and adjusting
441-027 2.50 Swing motor brake discs, replacing (motor
removed)
441-119 0.70 Travel motor regulation start, checking and
adjusting
441-120 0.80 Travel motor, calibrating
443-033 0.90 Center passage, disassembly and assembly
45 PROPELLER SHAFT

461-045 2.50 Drive shaft seal, replacing
461-070 8.50 King pin and bushing, replacing
49 MISCELLANEOUS
492-025 0.40 Swing ring, measuring axial clearance
5 BRAKE
51 WHEEL BRAKE

520-005 0.70 Brake system, check and adjusting pressure in
circuit

EW140D
527-014 0.50 Brake accumulator charging pressure, adjusting
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

WHEEL/TRACK UNIT
71 FRAME
76 SHOCK ABSORBER; AXLE LOCKING; ANTI ROLL BAR; LEVEL /

SIDE CONTROL
763-001 0.40 Pivot axle lock cylinder, removing
763-002 0.50 Pivot axle lock cylinder, installing
763-003 0.70 Pivot axle lock cylinder, changing seals
763-004 0.20 Pivot axle lock cylinder, releasing for towing
763-006 0.30 Pivot axle lock, function check


ANYWHERE

831-052 0.60 Cab door, removing door catch

EW140D
831-053 0.90 Cab door, installing door catch

852-088 0.30 Seat belt, replacing


90 GENERAL
900-001 0.30 Hydraulic system, warming up

EW140D

911-018 0.70 Cooling fan speed, checking and adjusting with
VCADS Pro
912-018 1.25 Back-up valve, checking and adjusting
912-162 1.00 Line rupture valve pressure, checking and
adjusting
912-210 0.70 Rupture valve, replacing (2pcs boom tilt cylinder)
914-031 0.40 Servo pump, removal
914-032 0.50 Servo pump, installation
914-103 0.20 Control lockout lever, function check
adjusting
916-061 0.50 Calibration of X1 hydraulic with pressure control
916-062 1.25 X1 pressure relief valve, adjusting
916-071 1.50 Boom suspension system, changing accumulator
916-110 0.90 X3 pressure and flow, adjusting
916-112 0.20 X1, function check
924-007 0.50 Cylinder for hydraulic quickfit S1, removal
924-008 0.50 Cylinder for hydraulic quickfit S1, installation

EW140D
924-011 0.50 Hydraulic quickfit cylinder, removal

924-012 0.70 Hydraulic quickfit cylinder, installation
924-017 0.40 Cylinder for hydraulic quickfit Universal, removal
924-018 0.40 Cylinder for hydraulic quickfit Universal,
installation
924-046 0.10 Quickfit, function check 220010 - 220442
97 UNIT, DIGGING

EW160D

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EW160D


non-programmed
pre-programmed
26 COOLING SYSTEM

EW160D

replacing all belts
29 Miscellaneous
293-006 0.20 EGR temperature sensor, replacing

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

EW160D

ECU


replacing
replacing
39 MISCELLANEOUS
ECU
43 GEARBOX,

EW160D
removed)
adjusting
45 PROPELLER SHAFT

49 MISCELLANEOUS
5 BRAKE
51 WHEEL BRAKE

EW160D

circuit
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL


EW160D

ANYWHERE




EW160D

90 GENERAL

VCADS Pro
adjusting
912-169 0.60 Unload valve, checking and adjusting
912-170 1.00 Unload valve, replacing
adjusting
916-111 0.90 X3 shock and refilling valves, adjusting

EW160D
installation
97 UNIT, DIGGING
99 MISCELLANEOUS
996-001 1.50 Cab elevating cylinder, replacing

EW180D

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EW180D


non-programmed
pre-programmed
26 COOLING SYSTEM

EW180D

replacing all belts
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

EW180D

ECU


replacing
replacing
39 MISCELLANEOUS
ECU
43 GEARBOX,

EW180D

adjusting
45 PROPELLER SHAFT

49 MISCELLANEOUS
5 BRAKE
51 WHEEL BRAKE

circuit

EW180D

55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL


ANYWHERE

EW180D




90 GENERAL

EW180D


VCADS Pro
adjusting
adjusting

EW180D

installation
97 UNIT, DIGGING

EW205D

17 SERVICE
173-300 0.40 Test running and checking
173-308 0.30 Brake disc wear, measuring
173-336 0.10 Cab door, covers, hinges, joints and locks,
lubricating
173-338 0.20 Tyre wear and air pressure, checking
173-340 0.20 Fan/alternator belt, checking
173-341 0.20 Air conditioner compressor belt, checking
173-344 0.10 Swing gearbox oil level, checking
173-345 0.10 Swing ring gear bearing, lubricating
173-346 0.20 Cab prefilter, cleaning
173-347 0.40 Radiator and hydraulic oil cooler, cleaning
173-348 0.10 Swing bath grease, checking
173-349 0.30 Hydraulic oil suction strainer, cleaning
173-356 0.20 Hydraulic oil level, checking
173-377 0.20 Drive axles and hubs oil level, checking
173-381 0.30 Wheel nuts torque, checking
173-403 0.10 Engine air cleaner primary filter, replacing
173-404 0.10 Engine air cleaner secondary filter, replacing
173-405 0.10 Cab prefilter, replacing
173-409 0.20 Fuel tank breather filter, replacing
173-420 0.20 Brake system pressure oil filter, replacing
173-421 0.40 Water separator filter, replacing
173-422 0.20 Hydraulic oil drain filter, replacing
173-423 0.20 Hydraulic oil servo filter, replacing

EW205D

173-453 0.80 Drive axles and hubs oil, changing
173-463 0.80 Swing gearbox oil, changing
173-464 0.20 Travel gearbox oil, changing
173-504 0.20 Oil-bath air cleaner reservoir oil, checking
173-521 0.30 Extra water separator filter element, replacing
173-639 0.10 Travel gearbox oil level, checking

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

26 COOLING SYSTEM

EW205D

replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EW205D

ECU


replacing
39 MISCELLANEOUS
ECU
43 GEARBOX,
431-009 1.50 Travel gearbox, disassembly
431-010 2.00 Travel gearbox, assembly

EW205D

45 PROPELLER SHAFT

461-040 3.00 Hub reduction gear, replacing
49 MISCELLANEOUS
5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING
640-001 0.50 Steering system, adjustment

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL

EW205D


ANYWHERE
replacing




EW205D


replacing
replacing
915-007 1.25 Control lever (dozer blade), replacing
927-001 1.00 Dozer blade, replacing

EW205D
97 UNIT, DIGGING
972-010 1.25 Stabilizer cylinder, replacing
replacing


EW210D

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EW210D


non-programmed
pre-programmed
26 COOLING SYSTEM

EW210D

replacing all belts
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

EW210D

ECU


replacing
replacing
39 MISCELLANEOUS
ECU
43 GEARBOX,

EW210D

adjusting
45 PROPELLER SHAFT

49 MISCELLANEOUS
5 BRAKE
51 WHEEL BRAKE

circuit

EW210D

55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL


ANYWHERE

EW210D




90 GENERAL

EW210D


VCADS Pro
adjusting
adjusting

EW210D

installation
97 UNIT, DIGGING
99 MISCELLANEOUS

EW230C

17 SERVICE

20 GENERAL
ECU
21 ENGINE
215-032 9.00 Timing gear case, fitting new gasket in machine
gauge
23 FUEL SYSTEM

EW230C

233-015 0.50 Fuel filter extra, replacing 120028 - 999999

251-004 1.50 Exhaust manifold, replacing gasket
26 COOLING SYSTEM
replacing all belts

EW230C

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU
367-058 0.70 W-ECU, MID 142, replacing



EW230C

replacing
replacing
39 MISCELLANEOUS
43 GEARBOX,
45 PROPELLER SHAFT


EW230C
49 MISCELLANEOUS
5 BRAKE
51 WHEEL BRAKE

circuit
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL

EW230C



ANYWHERE



873-019 0.90 ECC control unit, replacing

EW230C


90 GENERAL

VCADS Pro
911-044 0.90 Oil cooler fan motor, removal
911-046 0.90 Cooling fan pump, removal
911-047 1.75 Cooling fan pump, installation
912-019 0.40 Shock valve removed, checking
adjusting

EW230C

913-071 0.80 Swing pump, removing
913-072 2.50 Swing pump, installing
913-073 0.30 Swash plate angle sensor, replacing
913-074 3.50 Swing pump pressure, checking and adjusting
914-065 0.70 Servo valve, installation 120026 - 999999
914-067 0.60 Pressure relief valve, checking and adjusting
916-059 0.70 Calibration of cruise control
installation
924-046 0.10 Quickfit, function check
97 UNIT, DIGGING
972-012 0.90 Stabilisers, installation

EW60C

17 SERVICE
173-070 1.50 Axles, changing oil

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM
timing


EW60C
26 COOLING SYSTEM
adjusting tension
replacing all belts

30 GENERAL
31 BATTERY
33 STARTING SYSTEM
35 LIGHTING
350-001 0.60 Combination switch, replacing

364-025 1.25 Rotational connector, replacing
ECU

EW60C


39 MISCELLANEOUS
43 GEARBOX,
431-011 4.50 Travel gearbox, replacing
45 PROPELLER SHAFT

461-043 1.50 Hub, replacing seal
463-005 1.50 Drive shaft, replacing one side

EW60C
5 BRAKE
55 PARKING BRAKE
550-018 0.40 Parking brake assembly, removing
550-022 0.40 Parking Brake - Installation
6 STEERING
64 STEERING

WHEEL/TRACK UNIT
SIDE CONTROL
763-005 2.50 Front axle pivot pin and bushing, replacing


ANYWHERE

EW60C




replacing

EW60C

97 UNIT, DIGGING

G930
0 GENERAL
05 TRANSPORT INSTRUCTION.; STORAGE INSTRUCTION;
OPERATING INSTRUCTION
050-001 10.00 Removing and assembly of machine from shipping
container

17 SERVICE
170-005 0.20 Start of VCADS Pro computer and reading
machine data
501000 - 502837
173-061 2.50 Transmission, changing oil and filter
incl.cleaning tank
173-080 1.50 Master cylinder, changing oil 39300 - 526000
173-465 0.60 Rear axle oil, changing
173-466 2.50 Tandem oil, changing

20 GENERAL
21 ENGINE
212-070 0.40 Crankcase ventilation, changing
214-021 0.40 Valve cover, fitting new gasket each

G930

23 FUEL SYSTEM

255-070 0.40 Turbocharger, removing
255-072 0.40 Turbocharger, installing
26 COOLING SYSTEM
adjusting tension
263-016 0.50 Maximum fan speed, checking
263-019 0.80 Low fan speed, checking
263-052 0.40 Fan pump flow, checking
263-062 3.00 Cooling fan motor, replacing
263-071 0.40 Fan control valve, removing
263-072 0.30 Fan control valve, seal replacement
263-073 0.60 Fan control valve, installing

G930

30 GENERAL
300-007 1.00 VCADS Pro, MID 142, programming W-ECU
300-008 0.80 VCADS Pro, MID 140, programming I-ECU
31 BATTERY
313-001 0.30 Battery box, removing
313-002 0.30 Battery box, installing

33 STARTING SYSTEM
35 LIGHTING

361-018 0.40 Direction indicator switch, replacing
363-001 0.60 Windscreen wiper rear, replacing motor
363-005 0.70 Lower window wiper, replacing
363-006 1.75 Windscreen wiper, replacing pivot linkage
363-007 1.00 Windscreen wiper, install and adjust
366-007 0.80 VCADS Pro, MID187, programming V-ECU

386-004 1.00 Transmission temperature sensor, replacing
386-005 0.60 Transmission, revolution sensor, replacing
386-009 0.70 Transmission sensor and connection, checking
386-032 1.25 Sensor unit (differential lock), replacing
386-061 0.50 Revolution sensor (hydraulic cooling fan),
replacing
387-008 0.30 Display unit, replacing

G930
39 MISCELLANEOUS
393-022 0.30 Radio, removal
393-023 0.20 Radio, installation
413-018 0.50 Inching pedal, replacing
413-019 0.20 Inching pedal, function check

421-026 1.00 Transmission pressure sensor, replacing
421-027 0.80 Transmission oil filter restriction sensor, replacing
421-047 0.60 Gear selector, replacing
426-001 1.00 Rubber cushion, changing
442-011 1.50 Transmission pump, removing
442-012 2.50 Transmission pump, installing
442-041 1.75 Pump drive, removing
442-042 3.50 Pump drive, installing
442-043 3.00 Pump Drive, reconditioning
442-044 5.00 Spring coupling, changing
442-047 1.50 Charge pump, replacing
442-054 0.80 Control neutral adjustment for EDC controls
45 PROPELLER SHAFT
451-002 1.50 Support or intermediate bearing, replacing
451-031 0.60 Drive shaft, removing
451-032 0.60 Drive shaft, installing
451-033 1.25 Universal joint, replacing
451-034 1.25 Drive shaft, repair

G930

463-053 0.80 Tandem inspection
463-056 2.00 Tandem, removing
463-058 1.50 Tandem drive chain, removing
463-059 1.75 Tandem drive chain, installing
463-060 1.75 Tandem drive sprocket, removing
463-061 1.75 Tandem drive sprocket, installing
463-062 3.50 Tandem, installing
463-063 6.00 Four point bearing, replacing
463-064 2.00 Final drive axle seal, removal
463-065 3.00 Final drive axle seal, installation
5 BRAKE
51 WHEEL BRAKE
510-006 0.20 Service brakes warning system, checking 39300 - 526000
517-071 1.00 Oil disc brake assembly, removing
517-072 0.80 Oil disc brakes, disassembling
517-074 0.50 Brake Housing Pre - Assembly
517-076 0.70 Oil disc brakes , assembling
517-078 1.25 Oil disc brake, installing

520-001 0.70 Brake system, checking function, hydraulic 526001 - 526999
520-007 0.40 Brake pedal switch, replacing 39300 - 526000
520-037 0.70 Brake system, bleeding 526001 - 526999
520-112 0.40 Brake pedal stop, adjusting 526001 - 526999
521-009 1.50 Brake master cylinder, installing 39300 - 526000
521-011 0.50 Brake Master Cylinder and Power Booster - 39300 - 526000
Removal

G930
Removal
521-012 0.20 Power booster, disassembling 39300 - 526000
521-013 0.20 Power booster, assembling 39300 - 526000
521-014 0.50 Brake master cylinder, disassembling 39300 - 526000
521-015 0.50 Brake master cylinder, assembling 39300 - 526000
525-005 0.70 Foot brake valve, removal 526001 - 526999
525-006 1.50 Foot brake valve, installation 502838 - 502999
525-017 0.20 Brake pedal angle, adjusting 502838 - 502999
527-001 0.10 Accumulator removed, checking charging 502838 - 502999
pressure
pressure
527-012 0.40 Accumulator, removal 502838 - 502999
527-013 0.80 Accumulator, installation 502838 - 502999
55 PARKING BRAKE
550-056 1.75 Parking brake assembly, installing
6 STEERING
60 GENERAL
62 STEERING AXLE
622-052 0.70 Wheel Hub - Removal
622-054 0.30 Drag link, removing
622-058 0.50 Tie bar, removing
622-059 2.00 Knuckle, removing
622-060 0.90 Front axle frame, removing
622-061 1.50 Front axle frame, installing

G930
622-062 2.00 Knuckle, installing

622-063 0.40 Tie bar, installing
622-067 0.90 Drag link, installing
622-069 1.25 Wheel Hub - Installation
622-071 0.70 Toe - in, adjustment
622-081 9.50 Front axle, overhaul
622-087 4.00 Front wheel bearing, repacking
64 STEERING
641-022 0.60 Steering column, disassembling
641-024 0.70 Steering column, assembling
641-025 0.90 Pedestal gas shock, replacing
645-008 0.50 Shock valve, testing
645-028 0.70 Steering system, checking and adjusting working
pressure
647-089 0.40 Secondary steering relief valve, adjusting
647-099 0.10 Secondary steering function, checking
648-001 0.50 Wheel lean cylinder, removing
648-002 0.40 Wheel lean cylinder, installing

WHEEL/TRACK UNIT
71 FRAME
715-011 0.20 Transmission guard, removing
715-012 0.20 Transmission guard, installing
715-031 0.50 Neck and nose cover, removing
715-032 0.50 Neck and nose cover, installing
74 FRAME LINK
741-002 7.00 Frame joint, assembly of separated machine
742-054 0.60 Articulation Indicator - Setup and Adjustment
742-055 0.60 Articulation indicator cable, removing
742-056 0.90 Articulation indicator cable, installing
742-081 0.70 Articulation cylinder, removing
742-082 0.80 Articulation cylinder, installing

771-001 0.80 Wheel, removing and fitting one

G930

ANYWHERE

827-001 0.50 Cab ladder, replacing
851-001 0.60 Rear headliner, removing
851-002 0.70 Rear headliner, installing
851-003 0.50 Front headliner, removing
851-004 0.60 Front headliner, installing
851-005 2.00 Cab interior covers, replacing
851-006 0.90 Side console covers, replacing
851-007 0.90 Floor mats, replacing

872-022 1.25 Defroster fan, replacing
873-012 3.00 Stepless motor drive, replacing
873-013 2.50 Heater unit relays, replacing
874-092 0.60 HVAC control switch, replacing

G930

90 GENERAL
900-051 1.75 Joystick control, replacing
900-052 0.20 Rear option controller, replacing

911-002 0.30 Ventilation filter, replacing
replacing
912-102 0.60 Hydraulic swivel joint, disassembly
912-103 0.60 Hydraulic swivel joint, assembly
912-104 0.30 Circle Turn Valve Overhaul Procedure
912-106 0.30 Circle turn valve, disassembly
912-107 0.30 Circle turn valve, assembly
912-108 0.40 Circle turn valve, installing
912-109 0.40 Circle Timing
912-110 0.90 Accumulator precharge pressure, checking
912-111 0.60 Accumulator -Charging
912-112 0.20 Hydraulic Cylinder Overhaul Procedure
912-113 0.50 Hydraulic Cylinder - Disassembly
912-114 0.40 Hydraulic Cylinder - Assembly
912-130 2.00 Directional control valve, removing
912-131 2.00 Directional control valve, installing
912-132 7.00 Directional control valve, reconditioning
912-133 0.60 Directional control valve, reconditioning (1 valve
section)
912-137 0.40 Priority flow valve, removing
912-138 0.60 Priority flow valve, installing
912-139 0.30 Priority flow valve, disassembly and inspection
912-140 0.20 Priority flow valve, assembly
912-229 0.80 Directional control valve solenoid, replacing

G930

pressure and working pressure
913-041 0.30 Test procedure for external load sense relief valve
913-045 0.40 Steering and implement pump controller,
removing
913-046 0.40 Steering and implement pump controller, installing
inspection and cleaning
913-048 1.25 Steering and implement pump, performance test
915-003 0.70 Control lever, adjusting
915-006 1.75 Control lever, overhaul and adjustment
916-116 0.90 Power supply unit, replacing
916-117 0.90 Relay, replacing
916-118 0.90 Counter balance steering valve, replacing
916-119 0.90 Steering valve solenoid, replacing
916-120 0.30 Articulation sensor, replacing
916-121 0.10 Articulation sensor, calibrating
916-122 0.90 J-ECU controller, replacing
916-123 0.20 Rear auxiliary valve solenoid, replacing
916-124 0.90 Steering pressure sensor, replacing
916-127 0.30 Left side controller, replacing
926-081 1.50 Ripper, removal
926-082 3.00 Ripper, installation
926-088 0.40 Support arch, removal
926-089 1.25 Support arch, installation

981-011 1.25 Mouldboard lower slide tube bearing, replacing
981-012 0.70 Mouldboard upper slide wear plate, replacing
981-013 1.25 Mouldboard cutting edge, replacing
981-021 1.25 Blade tilt cylinder, replacing
981-031 1.75 Blade lift stirrup bearing, replacement
981-041 1.00 Blade slide cylinder, replacing
981-051 0.70 Circle crank arm, removing
981-052 0.70 Circle crank arm, installing
981-053 1.25 Circle, checking
981-061 0.80 Blade lift system lock cylinder, removing
981-062 0.20 Blade lift system lock cylinder, disassembly

G930
981-063 0.20 Blade lift cylinder lock cylinder seal, replacing

981-064 0.70 Blade lift system lock cylinder, installing
981-071 2.00 Circle and Drawbar - Removal and Disassembly
981-072 3.50 Circle and Drawbar - Assembly and Installation
981-076 0.60 Drawbar ball stud, disassembly
981-077 1.00 Drawbar ball stud, assembly
981-079 1.00 Drawbar Ball Stud – Adjusting
981-082 1.25 Blade lift stirrup, removing
981-085 0.90 Blade lift stirrup, installing

G930C

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
21 ENGINE
23 FUEL SYSTEM

non-programmed
pre-programmed
254-130 0.80 AdBlue®/DEF pump unit, flushing
26 COOLING SYSTEM

G930C

30 GENERAL

ECU
programmed ECU
programmed ECU


WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

90 GENERAL

G930C

916-128 0.30 Front option controller, replacing
916-129 0.20 Joysticks, calibrating

G940
0 GENERAL
container

17 SERVICE
machine data
502000 - 503596
incl.cleaning tank

20 GENERAL
21 ENGINE

G940

23 FUEL SYSTEM

26 COOLING SYSTEM
adjusting tension

G940

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


replacing

G940
39 MISCELLANEOUS

45 PROPELLER SHAFT

G940

5 BRAKE
51 WHEEL BRAKE

Removal

G940
Removal
pressure
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
62 STEERING AXLE

G940

64 STEERING
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


G940

ANYWHERE



G940

90 GENERAL

replacing
section)

G940

removing


G940


G940C

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
21 ENGINE
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

G940C

30 GENERAL

ECU
programmed ECU
programmed ECU


WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

90 GENERAL

G940C


G946
0 GENERAL
container

17 SERVICE
machine data
504000 - 504114
incl.cleaning tank
173-095 1.00 AWD hydraulic filter, replacing

20 GENERAL
21 ENGINE

G946

23 FUEL SYSTEM

26 COOLING SYSTEM
adjusting tension

G946

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


replacing

G946
39 MISCELLANEOUS

441-042 4.50 Wheel motor seal, disassembly
441-043 2.50 Wheel motor seal, assembly
441-051 2.00 All wheel drive motor, replacing
441-052 0.70 Freewheeling solenoid cartridge, replacing
441-053 1.75 Freewheeling valve, replacing
441-058 0.40 AWD speed sensor, replacing
441-059 0.80 AWD bypass switch, replacing
442-050 3.00 All Wheel Drive pumps, replacing
442-055 1.75 EDC control module, housing removal and
installation

G946

installation
45 PROPELLER SHAFT

5 BRAKE
51 WHEEL BRAKE


G946

Removal
Removal
pressure
pressure
55 PARKING BRAKE

G946
6 STEERING
60 GENERAL
62 STEERING AXLE
64 STEERING
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK

G946



ANYWHERE



G946


90 GENERAL

replacing

G946

section)
removing


G946


G946C

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
21 ENGINE
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

G946C

30 GENERAL

ECU
programmed ECU
programmed ECU


WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

90 GENERAL

G946C


G960
0 GENERAL
container

17 SERVICE
machine data
505000 - 505154
incl.cleaning tank

20 GENERAL
21 ENGINE

G960

23 FUEL SYSTEM

26 COOLING SYSTEM
adjusting tension

G960

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


replacing

G960
39 MISCELLANEOUS

45 PROPELLER SHAFT

G960

5 BRAKE
51 WHEEL BRAKE

Removal

G960
Removal
pressure
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
62 STEERING AXLE

G960

64 STEERING
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


G960

ANYWHERE



G960

90 GENERAL

replacing
section)

G960

removing


G960


G960C

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
21 ENGINE
23 FUEL SYSTEM

non-programmed
pre-programmed
26 COOLING SYSTEM

G960C

30 GENERAL

ECU
programmed ECU
programmed ECU


WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

90 GENERAL

G960C


G970
0 GENERAL
container

17 SERVICE
machine data
506000 - 506052
incl.cleaning tank

20 GENERAL
21 ENGINE

G970

23 FUEL SYSTEM

26 COOLING SYSTEM
262-007 0.60 Coolant pump belt, replacing

G970

30 GENERAL
31 BATTERY

321-007 0.80 Alternator, changing belt
33 STARTING SYSTEM
35 LIGHTING


replacing

G970
39 MISCELLANEOUS

45 PROPELLER SHAFT

G970

5 BRAKE
51 WHEEL BRAKE

Removal

G970
Removal
pressure
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
62 STEERING AXLE

G970

64 STEERING
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


G970

ANYWHERE



G970

90 GENERAL

replacing
section)

G970

removing


G970


G976
0 GENERAL
container

17 SERVICE
machine data
507000 - 507052
incl.cleaning tank
173-095 1.00 AWD hydraulic filter, replacing

20 GENERAL
21 ENGINE

G976

23 FUEL SYSTEM

26 COOLING SYSTEM

G976

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


replacing

G976
39 MISCELLANEOUS

441-042 4.50 Wheel motor seal, disassembly
441-043 2.50 Wheel motor seal, assembly
441-052 0.70 Freewheeling solenoid cartridge, replacing
441-053 1.75 Freewheeling valve, replacing
441-058 0.40 AWD speed sensor, replacing
441-059 0.80 AWD bypass switch, replacing
442-050 3.00 All Wheel Drive pumps, replacing

G976

installation
installation
45 PROPELLER SHAFT

5 BRAKE
51 WHEEL BRAKE


G976

Removal
Removal
pressure
pressure
55 PARKING BRAKE

G976
6 STEERING
60 GENERAL
62 STEERING AXLE
64 STEERING
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK

G976



ANYWHERE



G976


90 GENERAL

replacing

G976

section)
removing


G976


G990
0 GENERAL
container

17 SERVICE
machine data
508000 - 508109
incl.cleaning tank

20 GENERAL
21 ENGINE

G990

23 FUEL SYSTEM

26 COOLING SYSTEM

G990

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


replacing

G990
39 MISCELLANEOUS

45 PROPELLER SHAFT

G990

5 BRAKE
51 WHEEL BRAKE

Removal

G990
Removal
pressure
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
62 STEERING AXLE

G990

64 STEERING
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


G990

ANYWHERE



G990

90 GENERAL

replacing
section)

G990

removing


G990


L110H

17 SERVICE
173-506 3.00 Fire suppression system, checking
176-001 0.80 Mechanical release of parking brake
19 GENERAL

20 GENERAL
programmed
programmed
21 ENGINE
gauge
23 FUEL SYSTEM

L110H


non-programmed
pre-programmed
254-131 0.50 AdBlue®/DEF pump unit, inlet nipple, replacing
26 COOLING SYSTEM
260-003 0.60 Cooling system, pressure control
263-081 0.60 Hydraulic pump P3, removal
263-082 1.25 Hydraulic pump P3, installation

L110H
29 Miscellaneous

30 GENERAL
300-077 0.60 CCM, replacing
31 BATTERY

39 MISCELLANEOUS
421-048 0.90 Gear selector valve, replacing one solenoid
421-052 2.00 Seal for front output shaft, replacing
421-091 1.50 Lock up valve, replacing
421-099 0.70 Transmission, calibration
421-100 0.30 Transmission, function check

L110H

463-037 5.50 Axle suspension, replacing bushes and seals
468-006 0.20 Differential lock, function check
468-051 1.25 Differential lock, adjusting
5 BRAKE
51 WHEEL BRAKE
510-003 0.40 Brake discs, measuring wear
516-050 2.50 Brake piston, replacing seals

520-002 0.20 Brake system, checking function, retardation
circuit
520-036 0.80 Brake system charging, checking
520-111 0.20 Automatic brake, function check
pressure
527-003 0.50 Accumulators, checking in machine
55 PARKING BRAKE
550-006 4.00 Parking brake, replacing discs and seals
6 STEERING
60 GENERAL

L110H
64 STEERING
645-011 0.90 Left steering cylinder, removal
645-012 1.75 Left steering cylinder, installation
645-013 0.80 Right steering cylinder, removal
645-014 1.75 Right steering cylinder, installation
pressure
645-037 0.20 Steering accumulator removed, checking
645-113 0.40 Steering accumulator, removing
645-114 0.40 Steering accumulator, installing
647-091 0.70 Secondary steering pump, checking and adjusting
working pressure
66 LEVER STEERING
660-006 1.50 Comfort drive control (CDC), angle sensor,
changing
660-007 1.25 Comfort drive control (CDC), solenoid valve,
changing
660-011 0.20 Lever steering (CDC), functional check
660-012 0.40 Comfort Drive Control, servo pressure, checking

WHEEL/TRACK UNIT
74 FRAME LINK
741-036 12.00 Frame joint, replacing bearings


ANYWHERE
821-010 0.60 Actuator, replacing

831-054 0.30 Electric door opener, control unit, replacing
831-055 0.30 Electric door opener, locking motor, replacing
831-056 0.20 Electric door opener, rotor switch, replacing

L110H
831-057 0.30 Electric door opener, opening support motor,

replacing
834-013 0.30 Door lock cylinder, replacing

852-010 0.50 Operator's seat, securing

870-012 1.00 Climate unit, removing
870-013 1.25 Climate unit, installing
874-009 0.50 Cooling unit, leak detection
874-022 3.50 Drying filter, replacing
874-023 4.00 Condenser, replacing
874-024 4.50 Evaporator, replacing
874-025 4.00 Expansion valve, replacing

90 GENERAL

912-021 0.60 Shock valve, tilt function, checking
912-023 0.60 Shock valve lift function, checking
912-121 1.50 Lift, solenoid valve, changing
912-122 1.50 Lower, solenoid valve, changing
912-123 1.50 Tilt in, solenoid valve, changing
912-124 1.50 Tilt out, solenoid valve, changing
912-125 0.70 Lift/lower, angle sensor, changing
912-126 2.50 Tilt in/out, angle sensor, changing

L110H
912-127 0.20 Tilt, functional check

912-226 0.20 Lift/lower function, checking
912-227 0.60 Pressure back-up valve, replacing
913-059 1.50 Hydraulic pump P3, checking function
914-049 0.40 Accumulator removed, checking
914-063 0.60 Servo pressure, checking at the spool in control
valve
916-001 0.30 Boom suspension system, functional check
916-003 0.60 Boom suspension accumulator, reconditioning
916-006 1.00 Boom suspension system, pressure reduction,
safety valve, checking and adjusting
916-008 1.00 Boom suspension system, right accumulator,
removal
installation
916-010 1.00 Boom suspension system, left accumulator,
removal
installation
916-017 0.50 3rd/4th hydraulic function, shock valve, checking
916-018 0.60 3rd/4th hydraulic function, solenoid valve,
changing
916-020 0.30 3rd/4th hydraulic function, checking and adjusting
pressure
916-070 0.50 Boom suspension system, hydraulic oil pressure
in accumulators, depressurizing
916-072 0.20 Accumulator, boom suspension system,
discarding
924-036 0.10 Attachment locking, functional check

945-005 4.50 Lift cylinder, repacking in machine
945-009 2.00 Tilt cylinder, repacking in machine
99 MISCELLANEOUS

L110H

activation

L120H

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
21 ENGINE
gauge
23 FUEL SYSTEM

L120H


non-programmed
pre-programmed
254-131 0.50 AdBlue®/DEF pump unit, inlet nipple, replacing
26 COOLING SYSTEM

L120H
29 Miscellaneous

30 GENERAL
31 BATTERY

39 MISCELLANEOUS

L120H

5 BRAKE
51 WHEEL BRAKE

circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL

L120H
64 STEERING
pressure
working pressure
66 LEVER STEERING
changing
changing

WHEEL/TRACK UNIT
74 FRAME LINK


ANYWHERE


L120H

replacing



90 GENERAL


L120H

valve
removal
installation
removal
installation
changing
pressure
discarding

99 MISCELLANEOUS

L120H

activation

L150H

17 SERVICE
19 GENERAL

20 GENERAL
programmed
200-067 1.50 ECM (Engine control module), replacing non- 9001 - 14000
programmed
programmed
21 ENGINE
210-070 6.00 Engine, removing 9001 - 14000
210-070 7.00 Engine, removing 4001 - 9000
replacing
replacing

L150H

214-100 3.00 EGR valve (internal), replacing 9001 - 14000
215-043 5.00 Camshaft setting, checking 9001 - 14000
218-001 5.50 Rubber cushion, replacing 9001 - 14000
gauge
223-007 0.50 Oil cooler, leakage check
23 FUEL SYSTEM
237-017 8.50 Injector sleeves, replacing 4001 - 9000

252-017 0.90 Silencer, removing 9001 - 14000
252-018 1.25 Silencer, installing 9001 - 14000
non-programmed
non-programmed

L150H
254-102 0.50 AdBlue®/DEF nozzle, replacing 4001 - 9000
254-103 3.00 AdBlue®/DEF tank, tank armature, replacing 4001 - 9000
254-104 0.20 Aftertreatment fuel nozzle, replacing 4001 - 9000
254-107 1.25 AdBlue®/DEF pump unit, replacing 4001 - 9000
254-108 0.70 Aftertreatment fuel dosing unit, replacing 4001 - 9000
254-109 0.20 Aftertreatment fuel nozzle, cleaning 4001 - 9000
254-114 1.75 AdBlue®/DEF, draining 4001 - 9000
254-117 1.25 AdBlue®/DEF pump unit, components, replacing 4001 - 9000
254-118 0.50 SCR system, dosing test 4001 - 9000
254-121 0.50 AdBlue®/DEF quality, checking 4001 - 9000
254-128 2.50 Muffler with console, installing 4001 - 9000
254-129 1.50 Muffler with console, removing 4001 - 9000
26 COOLING SYSTEM
29 Miscellaneous
293-010 0.60 EGR Venturi tube, replacing 4001 - 9000
293-013 1.75 EGR venturi tube, cleaning 4001 - 9000

30 GENERAL
31 BATTERY
33 STARTING SYSTEM

L150H

39 MISCELLANEOUS

5 BRAKE
51 WHEEL BRAKE

L150H


circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING
pressure
working pressure
66 LEVER STEERING
changing
changing

L150H

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


ANYWHERE
810-065 1.00 Cab, position 1
810-066 1.75 Cab, position 2
810-069 1.75 Cab, tilt cylinder, replacing


replacing



L150H


90 GENERAL


L150H

valve
removal
installation
removal
installation
changing
pressure
discarding

99 MISCELLANEOUS
activation

L180H

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
programmed
21 ENGINE
210-070 6.00 Engine, removing 8001 - 13000
210-070 7.00 Engine, removing 3001 - 8000
replacing
replacing

L180H

gauge
23 FUEL SYSTEM

non-programmed
non-programmed

L180H
26 COOLING SYSTEM
29 Miscellaneous

30 GENERAL
31 BATTERY
33 STARTING SYSTEM

L180H

39 MISCELLANEOUS

5 BRAKE
51 WHEEL BRAKE

L180H


circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING
pressure
working pressure
66 LEVER STEERING
changing
changing

L180H

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


ANYWHERE
810-065 1.00 Cab, position 1
810-066 1.75 Cab, position 2


replacing



L180H


90 GENERAL


L180H

valve
removal
installation
removal
installation
changing
pressure
discarding

99 MISCELLANEOUS
activation

L180H HL

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
programmed
21 ENGINE
210-070 6.00 Engine, removing 2001 - 10000
210-070 7.00 Engine, removing 1001 - 2000
replacing
replacing

L180H HL

gauge
23 FUEL SYSTEM

non-programmed
non-programmed

L180H HL
26 COOLING SYSTEM
29 Miscellaneous

30 GENERAL
31 BATTERY
33 STARTING SYSTEM

L180H HL

39 MISCELLANEOUS

5 BRAKE
51 WHEEL BRAKE

L180H HL


circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING
pressure
working pressure
66 LEVER STEERING
changing
changing

L180H HL

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE
810-065 1.00 Cab, position 1
810-066 1.75 Cab, position 2


replacing



L180H HL


90 GENERAL

912-159 0.70 Shock valve removed (Control valve 2), checking
912-164 0.20 Shock valves grapple tilt (Control valve 2),
checking
912-278 0.20 Log mover, function checking
912-279 0.30 Grapple, function checking
912-280 0.20 Rotator, function checking
912-281 0.20 Rotator, checking and adjusting
912-282 0.70 Rotator pin, replacing

L180H HL

valve
valve 2
adjusting
discarding
926-035 1.25 Grapple complete, removal at cross member
926-036 2.00 Grapple complete, installing at cross member
99 MISCELLANEOUS
activation

L20F

17 SERVICE
176-004 0.30 Towing a disabled machine
19 GENERAL

21 ENGINE
215-010 2.50 Belt, changing
23 FUEL SYSTEM
234-016 0.50 Fuel tank level sensor, replacing

251-006 0.80 EGR (exhaust gas recirculation) sensor, replacing1705001 - 1706300

L20F
26 COOLING SYSTEM

33 STARTING SYSTEM

421-061 0.30 Induction sensor for output shaft, changing
441-002 2.50 Hydraulic motor, replacing
442-016 0.10 Hydrostatic pump charge pressure, check and
adjust
442-017 0.70 Start hydraulic pump control, check and adjust
442-018 0.40 Hydrostatic pump cut off valve, check and adjust
442-020 0.30 Hydrostatic pump mechanical zero position, check
and adjust

5 BRAKE
51 WHEEL BRAKE
511-006 1.25 Brake pads, replacing
511-007 1.50 Brake cylinder, replacing

L20F

520-040 0.40 Inching and brake pedal, adjusting
6 STEERING
64 STEERING
pressure

WHEEL/TRACK UNIT
74 FRAME LINK
741-022 0.80 Frame joint, Replacing the front pivot bearing with
machine separated
741-023 0.70 Frame joint, replacing the rear pivot bearing with
machine separated

ANYWHERE



L20F

90 GENERAL

912-172 0.40 Secondary pressure limiting valve, checking and
adjusting
912-173 0.40 Primary pressure limiting valve, checking and
adjusting

945-004 1.00 Lift cylinder, replacing
945-008 0.90 Tilt cylinder, replacing
945-056 1.50 Implement attachment, repacking removed
hydraulic cylinder

L220H

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
programmed
21 ENGINE
210-070 7.00 Engine, removing 2001 - 7000
210-070 6.00 Engine, removing 7001 - 12000
replacing

L220H

replacing
gauge
23 FUEL SYSTEM

non-programmed
non-programmed

L220H

26 COOLING SYSTEM
29 Miscellaneous

30 GENERAL
31 BATTERY
33 STARTING SYSTEM

L220H

39 MISCELLANEOUS

5 BRAKE
51 WHEEL BRAKE

L220H


circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING
pressure
working pressure
66 LEVER STEERING
changing
changing

L220H

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


ANYWHERE
810-065 1.00 Cab, position 1
810-066 1.75 Cab, position 2


replacing



L220H


90 GENERAL


L220H

valve
removal
installation
removal
installation
changing
pressure
discarding

99 MISCELLANEOUS
activation

L250H

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
programmed
21 ENGINE
210-070 7.00 Engine, removing 1001 - 6000
210-070 6.00 Engine, removing 6001 - 11000
replacing

L250H

replacing
gauge
23 FUEL SYSTEM

non-programmed
non-programmed

L250H
26 COOLING SYSTEM
29 Miscellaneous

30 GENERAL
31 BATTERY
33 STARTING SYSTEM

L250H

39 MISCELLANEOUS

5 BRAKE
51 WHEEL BRAKE

L250H


circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING
pressure
working pressure
66 LEVER STEERING
changing
changing

L250H

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


ANYWHERE
810-065 1.00 Cab, position 1
810-066 1.75 Cab, position 2


replacing



L250H


90 GENERAL


L250H

valve
removal
installation
removal
installation
changing
pressure
discarding

99 MISCELLANEOUS
activation

L25F

17 SERVICE
19 GENERAL

21 ENGINE
23 FUEL SYSTEM

251-006 0.80 EGR (exhaust gas recirculation) sensor, replacing1755001 - 1756300

L25F
26 COOLING SYSTEM

33 STARTING SYSTEM

adjust
and adjust

5 BRAKE
51 WHEEL BRAKE

L25F

6 STEERING
64 STEERING
pressure

WHEEL/TRACK UNIT
74 FRAME LINK
machine separated
machine separated

ANYWHERE



L25F

90 GENERAL

adjusting
adjusting
adjusting

hydraulic cylinder

L30G

17 SERVICE
19 GENERAL

20 GENERAL
21 ENGINE
221-006 0.60 Oil pressure relief valve, replacing
221-021 0.40 Lubrication oil pressure, checking
23 FUEL SYSTEM


L30G
26 COOLING SYSTEM
263-001 1.50 Fan motor, removing
263-003 1.75 Fan motor, installing
442-016 0.10 Hydrostatic pump charge pressure, check and 120001 - 129999
adjust
adjust
442-019 0.30 Hydrostatic pump high pressure valve, check and120001 - 129999
adjust
adjust
and adjust

5 BRAKE
6 STEERING
64 STEERING

L30G

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK

ANYWHERE



90 GENERAL

working pressure

L30G
924-031 1.50 Implemental attachment hydraulic cylinder,
replacing


L350F

17 SERVICE
170-006 0.30 VCADS Pro, central systems updating, replace
component
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
gauge
23 FUEL SYSTEM

L350F


255-010 0.60 Waste gate actuator, replacing
26 COOLING SYSTEM
263-010 0.50 Pump 3 (P3) standby pressure, checking
263-011 0.90 Pump 3 (P3) standby pressure, checking and
adjusting (LS-line removed)
263-021 0.70 Pump 3 (P3), max pressure and fan speed,
checking and adjusting
263-051 1.25 Cooling fan hydraulics, funktion check

30 GENERAL
31 BATTERY

ECU

386-016 1.00 Temperature sensor cooling system, replacing 1232 - 9999
39 MISCELLANEOUS

L350F
421-049 0.10 Transmission, functional check
421-068 7.50 Transmission, removing (upwards)
43 GEARBOX,
432-078 0.40 T-ECU, MID 130, changing pre-programmed ECU

5 BRAKE
51 WHEEL BRAKE

circuit
523-041 0.80 Axle oil cooler (front) replacing
523-042 1.00 Axle oil cooler (rear) replacing
525-009 0.50 Foot brake valve removed, reconditioning
pressure
pressure
55 PARKING BRAKE
550-017 1.25 Parking brake, checking wear

L350F
6 STEERING
60 GENERAL
64 STEERING
pressure
645-060 1.75 Steering cylinder, repacking in machine
645-091 1.25 Shift valve, removing
645-092 1.25 Shift valve, installing
645-101 0.90 EHPS valve, removing
645-102 1.50 EHPS valve, installing
645-103 0.40 EHPS valve, regulated pressure, checking
645-104 0.60 PVED valve, replacing
66 LEVER STEERING
changing
660-012 0.40 Comfort Drive Control, servo pressure, checking 1250 - 9999

WHEEL/TRACK UNIT
74 FRAME LINK

ANYWHERE
818-020 1.75 Viscous cab suspension, changing one unit



L350F

replacing
834-011 0.20 Door lock, changing


870-012 0.90 Climate unit, removing 1232 - 9999
870-013 1.25 Climate unit, installing 1232 - 9999
873-019 0.90 ECC control unit, replacing 1232 - 9999

90 GENERAL
ECU
ECU


L350F

912-007 0.40 Anti-cavitation valve, lowering function, checking
912-023 0.60 Shock valve lift function, checking 1561 - 9999
912-120 0.20 Lift, functional check
913-034 0.20 Lifting time, checking
913-044 1.25 Hydraulic pump P1 and P2, checking function
913-055 0.30 Hydraulic pump P1, standby pressure, checking
913-056 0.40 Hydraulic pump P1 and P2, working pressure,
checking
913-057 0.30 Hydraulic pump P2, regulated pressure, checking
valve
adjusting
removal
installation
removal

L350F

installation
916-014 0.40 3rd hydraulic function, shock valve, checking
916-015 0.60 3rd hydraulic function, solenoid valve, changing
discarding
925-014 1.50 Bucket, removal
925-015 4.50 Bucket, installation

945-002 6.50 Lift frame, replacing bearing in lower bucket- or
implement attachment
99 MISCELLANEOUS
993-025 2.50 Automatic lubrication pump unit, reconditioning 1436 - 9999

L35G

17 SERVICE
19 GENERAL

20 GENERAL
21 ENGINE
23 FUEL SYSTEM


L35G
26 COOLING SYSTEM
adjust
adjust
adjust
adjust
adjust
adjust
and adjust

5 BRAKE

L35G
6 STEERING
64 STEERING

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK

ANYWHERE



90 GENERAL


L35G
working pressure
replacing


L40B

17 SERVICE
Programme
Programme
173-068 1.00 Rear axle, changing oil
173-069 1.00 Front axle, changing oil
incl.cleaning tank

21 ENGINE
210-071 34.00 Engine removed, general overhaul
211-068 1.50 Cylinder heads all removed, decarbonizing and
grinding in valves
211-071 1.00 Cylinder head removed, pressure testing each
212-011 0.75 Cylinder, cylinder heads removed, measuring
wear in all cylinders
215-002 0.75 Timing gear cover, fitting new gasket in machine
217-002 1.00 Sump gasket, replacing incl cleaning oil strainer

L40B
23 FUEL SYSTEM
237-080 1.00 Injectors removed, reconditioning all

255-073 2.00 Turbocharger removed, reconditioning
256-002 0.50 Air cleaner, checking prssure drop indicator
26 COOLING SYSTEM
adjusting tension
replacing all belts
27 ENGINE CONTROL

31 BATTERY

L40B


321-025 1.00 Alternator, replacing carbon brush kit in machine
322-005 0.50 Charging regulator, replacing
33 STARTING SYSTEM
334-001 0.80 Starter lock, replacing
35 LIGHTING
incl. setting
353-016 0.50 Rear lamp, replacing one
353-018 0.25 Rear lamp, replacing glass or bulb
356-057 0.50 Work lighting, replacing one insert

360-001 0.80 Combination control (by steering wheel), changing
361-010 0.50 Flasher switch, replacing
361-017 0.25 Flasher lamp, replacing glass or bulb
364-008 0.25 Brake light switch, replacing
367-020 1.50 ECU, replacing

386-013 0.50 Hydrostatic system temperature sensor, replacing
386-014 0.50 Hydrostatic system oil pressure sensor, replacing
387-003 0.80 Key pad, replacing
387-005 1.00 Information display, replacing
387-021 0.90 Instrument panel (display unit), replacing

L40B
39 MISCELLANEOUS
43 GEARBOX,
434-016 4.00 Dropbox, oil pump, replacing
434-029 2.00 Dropbox removed, reconditioning
441-001 1.00 Hydrostatic system, checking oil pressure
45 PROPELLER SHAFT

461-001 3.00 Axle, replacing
461-013 2.00 Centre gear, axle removed, reconditioning
461-014 1.00 Pinion front, fitting new gasket
461-041 3.00 Hub reduction gear, removed, reconditioning
463-041 3.00 Hub reduction gear removed, reconditioning

L40B
5 BRAKE
51 WHEEL BRAKE
511-002 1.25 Brake disc, replacing one 1921001 - 1929999
511-002 0.80 Brake disc, replacing one 1911001 - 1919999
511-081 0.90 Brake calliper removed, reconditioning 1921001 - 1929999
511-081 0.90 Brake calliper removed, reconditioning
516-001 0.25 Brake linings, checking wear
516-004 1.00 Brake discs, replacing on both sides

520-004 0.50 Brake system, adjusting unloading pressure
circuit
520-038 0.50 Brake system, front, bleeding
55 PARKING BRAKE
6 STEERING
64 STEERING
pressure
replacing bearings
647-093 1.50 Auxiliary steering, replacing hydraulic pump

L40B

WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.50 Frame joint, checking clearance


ANYWHERE
818-015 2.50 Cab suspension, rubber element replacing


831-014 0.50 Door, replacing sealing strip


874-005 1.75 Refrigerant, filling excl vacuum pumping
874-007 0.75 Belt, replacing

L40B
874-015 1.00 Compressor, replacing shaft seal (compressor

removed)
874-017 1.00 Compressor, replacing magnetic clutch in
machine
874-019 0.50 Compressor, replacing valve plate (compressor
removed)

912-002 4.00 Control valve removed, reconditioning
912-009 1.00 Shock valve, tilt function, checking and adjusting
912-011 1.00 Shock valve lift function, adjusting
pressure
working pressure
914-054 0.50 Servo valve, adjusting control
adjusting
916-004 1.50 Boom suspension system, checking closing
pressure
916-005 1.00 Boom suspension system, checking opening
pressure

945-002 3.00 Lift frame, replacing bearing in lower bucket- or
implement attachment
945-006 1.50 Lift cylinder removed, repacking
945-011 1.50 Implemental attachment, replacing hydraulic
cylinder

L40B
945-012 1.00 Lift cylinder removed, replacing bearings "C-P"

945-016 6.00 Lift frame, replacing bearing in upper mounting "O"
945-024 1.00 Tilting cylinder, changing bearing 'E-F' in machine
945-054 3.00 Implement attachment, replacing
hydraulic cylinder
945-063 1.50 T-link upper removed, replacing bearings "HIJ"
945-064 1.00 T-link, lower, replacing "IB"
945-066 1.00 Tilt link, replacing "GH"
945-067 1.00 Tilt link removed, replacing bearings "GH"
945-069 1.00 Tilt arm, replacing "GDF"
945-070 1.00 Tilt arm removed, replacing bearing "GDF"

L45G

17 SERVICE
19 GENERAL

21 ENGINE
23 FUEL SYSTEM


L45G

non-programmed
pre-programmed
26 COOLING SYSTEM

30 GENERAL
33 STARTING SYSTEM

421-028 0.40 Transmission sensor, replacing
421-100 2.50 Transmission, function check 220001 - 229999
441-060 0.40 Start hydraulic motor control, check and adjust
adjust

L45G

442-019 0.30 Hydrostatic pump high pressure valve, check and
adjust
and adjust

5 BRAKE
51 WHEEL BRAKE
511-002 0.80 Brake disc, replacing one

pressure
527-009 0.40 Accumulator, check
6 STEERING
64 STEERING
pressure
66 LEVER STEERING
changing
changing
660-009 0.90 Comfort Drive Control (CDC), control valve,
removal
660-010 1.25 Comfort drive control (CDC), control valve,
installation

L45G

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK
75 AXLE SUSPENSION

ANYWHERE



90 GENERAL

pressure
working pressure

L45G
replacing
924-035 0.60 Attachment locking hydraulic cylinder (vision-
optimised bracket), replacing

L50G

17 SERVICE
19 GENERAL

21 ENGINE
23 FUEL SYSTEM


L50G

non-programmed
pre-programmed
26 COOLING SYSTEM

30 GENERAL
33 STARTING SYSTEM

421-028 0.40 Transmission sensor, replacing
421-100 2.50 Transmission, function check 420001 - 429999
441-060 0.40 Start hydraulic motor control, check and adjust
adjust

L50G

442-019 0.30 Hydrostatic pump high pressure valve, check and
adjust
and adjust

5 BRAKE
51 WHEEL BRAKE

pressure
527-009 0.40 Accumulator, check
6 STEERING
64 STEERING
pressure
66 LEVER STEERING
changing
changing
660-009 0.90 Comfort Drive Control (CDC), control valve,
removal
660-010 1.25 Comfort drive control (CDC), control valve,
installation

L50G

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK
75 AXLE SUSPENSION

ANYWHERE



90 GENERAL

pressure
working pressure

L50G
replacing
924-035 0.60 Attachment locking hydraulic cylinder (vision-
optimised bracket), replacing

L60H

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
programmed
21 ENGINE
gauge
23 FUEL SYSTEM

L60H


non-programmed
26 COOLING SYSTEM
29 Miscellaneous

L60H

30 GENERAL
31 BATTERY

39 MISCELLANEOUS


L60H
5 BRAKE
51 WHEEL BRAKE

circuit
pressure
55 PARKING BRAKE
550-019 0.50 Parking Brake - Disassembly
550-021 0.30 Parking Brake - Assembly
6 STEERING
60 GENERAL
64 STEERING
pressure
working pressure
66 LEVER STEERING

L60H

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

replacing



L60H


90 GENERAL

912-151 0.50 Back-up valve, replacing
912-932 0.20 Inductive sensor, lift, adjusting
912-933 0.30 Inductive sensor, tilt, adjusting
discarding
99 MISCELLANEOUS
activation

L70H

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
programmed
21 ENGINE
gauge
23 FUEL SYSTEM

L70H


non-programmed
26 COOLING SYSTEM
29 Miscellaneous

L70H

30 GENERAL
31 BATTERY

39 MISCELLANEOUS


L70H
5 BRAKE
51 WHEEL BRAKE

circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING
pressure
working pressure
66 LEVER STEERING

L70H

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

replacing



L70H


90 GENERAL

discarding
99 MISCELLANEOUS
activation

L90H

17 SERVICE
19 GENERAL

20 GENERAL
programmed
programmed
programmed
21 ENGINE
gauge
23 FUEL SYSTEM

L90H


non-programmed
26 COOLING SYSTEM
29 Miscellaneous

L90H

30 GENERAL
31 BATTERY

39 MISCELLANEOUS


L90H
5 BRAKE
51 WHEEL BRAKE

circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING
pressure
working pressure
66 LEVER STEERING

L90H

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

replacing



L90H


90 GENERAL

discarding
99 MISCELLANEOUS
activation

MC105C

17 SERVICE

23 FUEL SYSTEM

ANYWHERE
843-003 0.20 Window pane, removal
843-004 0.20 Window pane, installation

MC110C

17 SERVICE

21 ENGINE

ANYWHERE


915-008 0.80 Control lever, removing
915-009 0.80 Control lever, installing

MC115C

17 SERVICE

21 ENGINE

ANYWHERE



MC135C

17 SERVICE

21 ENGINE

ANYWHERE



MC155C

17 SERVICE

21 ENGINE

ANYWHERE



MC60C

17 SERVICE

23 FUEL SYSTEM

ANYWHERE

MC70C

17 SERVICE

23 FUEL SYSTEM

ANYWHERE

MC85C

17 SERVICE

23 FUEL SYSTEM

ANYWHERE

MC95C

17 SERVICE

23 FUEL SYSTEM

ANYWHERE

MCT110C

17 SERVICE

21 ENGINE

WHEEL/TRACK UNIT
775-112 1.00 Recoil unit, removing
775-113 1.00 Recoil unit, installing

ANYWHERE


MCT110C


MCT125C

17 SERVICE

21 ENGINE

WHEEL/TRACK UNIT

ANYWHERE


MCT125C


MCT135C

17 SERVICE

21 ENGINE

WHEEL/TRACK UNIT

ANYWHERE


MCT135C


MCT145C

17 SERVICE

21 ENGINE

WHEEL/TRACK UNIT

ANYWHERE


MCT145C


MCT85C

17 SERVICE

23 FUEL SYSTEM

ANYWHERE

MCT95C

17 SERVICE

23 FUEL SYSTEM

ANYWHERE

MT2000

17 SERVICE

21 ENGINE
210-070 13.00 Engine, removing 1 - 475018
210-070 13.00 Engine, removing 475019 - 479999

252-022 2.50 Exhaust pipe, changing pipe between silencer and1 - 475018
turbocharger
252-022 2.50 Exhaust pipe, changing pipe between silencer and475019 - 479999
turbocharger
256-022 0.60 Scavenge pipe, replacing 1 - 475018
256-022 0.60 Scavenge pipe, replacing 475019 - 479999
258-025 0.40 Charge air cooler pipe, removing 1 - 475018

MT2000
258-025 0.40 Charge air cooler pipe, removing 475019 - 479999

258-026 0.20 Charge air cooler pipe, installing 1 - 475018
258-026 0.20 Charge air cooler pipe, installing 475019 - 479999
26 COOLING SYSTEM
263-001 0.80 Fan motor, removing 1 - 475018
263-001 0.80 Fan motor, removing 475019 - 479999
263-003 0.50 Fan motor, installing 1 - 475018
263-003 0.50 Fan motor, installing 475019 - 479999
263-023 5.00 Fan pump, removing 1 - 475018
263-023 5.00 Fan pump, removing 475019 - 479999
263-024 1.50 Fan pump, installing 1 - 475018
263-024 1.50 Fan pump, installing 475019 - 479999
263-037 0.40 Fan louvre, removing 1 - 475018
263-037 0.40 Fan louvre, removing 475019 - 479999
263-038 0.30 Fan louvre, installing 1 - 475018
263-038 0.30 Fan louvre, installing 475019 - 479999
263-039 0.50 Cooling fan, removing 1 - 475018
263-039 0.50 Cooling fan, removing 475019 - 479999
263-040 0.40 Cooling fan, installing 1 - 475018
263-040 0.40 Cooling fan, installing 475019 - 479999
263-043 0.40 Cooling fan, manual speed overriding 1 - 475018
263-043 0.40 Cooling fan, manual speed overriding 475019 - 479999
263-044 0.40 Cooling fan pump solenoid, replacing 1 - 475018
263-044 0.40 Cooling fan pump solenoid, replacing 475019 - 479999
263-045 0.50 Cooling fan motor reversing solenoid, replacing 1 - 475018
263-045 0.50 Cooling fan motor reversing solenoid, replacing 475019 - 479999
263-087 0.60 Cooling fan motor reversing valve, replacing 1 - 475018
263-087 0.60 Cooling fan motor reversing valve, replacing 475019 - 479999
263-088 0.40 Cooling fan speed, checking 1 - 475018
263-088 0.40 Cooling fan speed, checking 475019 - 479999
263-089 0.40 Cooling fan system pressure, checking 1 - 475018
263-089 0.40 Cooling fan system pressure, checking 475019 - 479999

MT2000

31 BATTERY
311-009 0.40 Battery, disconnecting 1 - 475018
311-010 0.20 Battery, connecting 1 - 475018
313-001 0.40 Battery box, removing 1 - 475018
313-001 0.40 Battery box, removing 475019 - 479999
313-002 0.20 Battery box, installing 1 - 475018
313-002 0.20 Battery box, installing 475019 - 479999
35 LIGHTING
352-003 0.40 Strobe, replacing 1 - 475018
352-003 0.40 Strobe, replacing 475019 - 479999

366-003 0.40 Front I/O box, removing
366-004 0.40 Front I/O box, installing
366-005 0.10 Front I/O box assembly, repairing
366-084 0.70 Front RCE, replacing
366-085 0.70 Rear RCE, replacing
366-090 0.40 Grade sensor, removing
366-091 0.40 Grade sensor, installing
366-092 0.40 Ground panel, removing
366-093 0.40 Ground panel, installing
367-022 0.40 SMC panel, removing 1 - 475018
367-022 0.40 SMC panel, removing 475019 - 479999
367-023 0.40 SMC panel, installing 1 - 475018
367-023 0.40 SMC panel, installing 475019 - 479999

386-020 0.40 Object detection system sensor, adjusting 1 - 475018
386-020 0.40 Object detection system sensor, adjusting 475019 - 479999
387-021 1.25 Instrument panel (display unit), replacing 475019 - 479999
387-021 1.50 Instrument panel (display unit), replacing 1 - 475018
413-012 1.75 Clutch assembly, removing 1 - 475018

MT2000
413-012 1.75 Clutch assembly, removing 475019 - 479999

413-013 2.50 Clutch assembly, installing 1 - 475018
413-013 2.50 Clutch assembly, installing 475019 - 479999
43 GEARBOX,
431-113 2.00 Track gearbox, removing 1 - 475018
431-113 2.00 Track gearbox, removing 475019 - 479999
431-114 2.00 Track gearbox, installing 1 - 475018
431-114 2.00 Track gearbox, installing 475019 - 479999
441-110 0.30 Track drive motor solenoid, replacing 1 - 475018
441-110 0.30 Track drive motor solenoid, replacing 475019 - 479999
441-113 0.60 Track motor, removing 1 - 475018
441-113 0.60 Track motor, removing 475019 - 479999
441-114 0.40 Track motor, installing 1 - 475018
441-114 0.40 Track motor, installing 475019 - 479999
442-082 6.50 Propulsion pump, removing 1 - 475018
442-083 3.00 Propulsion pump, installing 1 - 475018
442-153 0.50 Propulsion pump charge pressure, checking 1 - 475018
442-153 0.50 Propulsion pump charge pressure, checking 475019 - 479999
442-154 1.25 Propulsion pump system pressure, checking 1 - 475018
442-154 1.25 Propulsion pump system pressure, checking 475019 - 479999
442-155 0.80 Right side propulsion pump EDC (Electronic 1 - 475018
Displacement Control), replacing
442-155 0.80 Right side propulsion pump EDC (Electronic 475019 - 479999
442-156 0.80 Left side propulsion pump EDC (Electronic 1 - 475018
442-156 0.80 Left side propulsion pump EDC (Electronic 475019 - 479999
442-157 0.50 Pilot permissive valve, replacing 1 - 475018
442-157 0.50 Pilot permissive valve, replacing 475019 - 479999
442-158 0.40 Propulsion pump high pressure relief valve, 1 - 475018
replacing
442-158 0.40 Propulsion pump high pressure relief valve, 475019 - 479999
replacing
442-159 0.40 Propel, calibrating 1 - 475018
442-159 0.40 Propel, calibrating 475019 - 479999

MT2000
5 BRAKE
55 PARKING BRAKE
550-055 0.80 Parking brake release valve, replacing 1 - 475018
6 STEERING
64 STEERING
640-002 0.40 Steering limit switch, replacing 1 - 475018
640-002 0.40 Steering limit switch, replacing 475019 - 479999
641-002 0.90 Steering wheel sensor, replacing 1 - 475018
641-002 0.80 Steering wheel sensor, replacing 475019 - 479999
645-004 0.50 Steering cylinder, removing 1 - 475018
645-004 0.50 Steering cylinder, removing 475019 - 479999
645-005 0.40 Steering cylinder, installing 1 - 475018
645-005 0.40 Steering cylinder, installing 475019 - 479999
645-018 0.50 Steering pressure, checking 1 - 475018
645-018 0.50 Steering pressure, checking 475019 - 479999
645-024 0.40 Steering valve solenoid, replacing 1 - 475018
645-024 0.40 Steering valve solenoid, replacing 475019 - 479999
645-082 0.50 Steering valve, replacing 1 - 475018
645-082 0.50 Steering valve, replacing 475019 - 479999
645-109 0.30 Steering valve solenoid, overriding 1 - 475018
645-109 0.30 Steering valve solenoid, overriding 475019 - 479999
645-111 0.50 Track steering calibration, adjusting 1 - 475018
645-111 0.50 Track steering calibration, adjusting 475019 - 479999

WHEEL/TRACK UNIT
71 FRAME
715-025 0.40 Silencer housing panel, removing 1 - 475018
715-025 0.40 Silencer housing panel, removing 475019 - 479999
715-026 0.40 Silencer housing panel, installing 1 - 475018
715-026 0.40 Silencer housing panel, installing 475019 - 479999
715-027 0.40 Belt guard door, removing 1 - 475018
715-027 0.40 Belt guard door, removing 475019 - 479999
715-028 0.50 Belt guard door, installing 1 - 475018
715-028 0.50 Belt guard door, installing 475019 - 479999

MT2000
715-029 0.60 Silencer housing, removing 1 - 475018

715-029 0.60 Silencer housing, removing 475019 - 479999
715-030 0.70 Silencer housing, installing 1 - 475018
715-030 0.70 Silencer housing, installing 475019 - 479999
715-033 0.50 Exhaust ejector guard, removing 1 - 475018
715-033 0.50 Exhaust ejector guard, removing 475019 - 479999
715-034 0.50 Exhaust ejector guard, installing 1 - 475018
715-034 0.50 Exhaust ejector guard, installing 475019 - 479999
715-035 0.70 Front wrapper, removing 1 - 475018
715-035 0.70 Front wrapper, removing 475019 - 479999
715-036 0.70 Front wrapper, installing 1 - 475018
715-036 0.70 Front wrapper, installing 475019 - 479999

775-062 1.00 Bottom roller, removing 1 - 475018
775-062 1.00 Bottom roller, removing 475019 - 479999
775-063 0.70 Bottom roller, installing 1 - 475018
775-063 0.70 Bottom roller, installing 475019 - 479999
775-074 0.30 Track pad, removing 1 - 475018
775-074 0.30 Track pad, removing 475019 - 479999
775-075 0.20 Track pad, installing 1 - 475018
775-075 0.20 Track pad, installing 475019 - 479999
775-076 0.40 Track grouser, removing 1 - 475018
775-076 0.40 Track grouser, removing 475019 - 479999
775-077 0.30 Track grouser, installing 1 - 475018
775-077 0.30 Track grouser, installing 475019 - 479999
775-078 1.75 Leg cylinder, removing 1 - 475018
775-079 1.75 Leg cylinder, installing 1 - 475018
775-083 3.00 Leg, removing 1 - 475018
775-083 3.00 Leg, removing 475019 - 479999
775-084 4.50 Leg, installing 1 - 475018
775-084 4.50 Leg, installing 475019 - 479999
775-085 1.25 Leg cylinder support, removing 1 - 475018

MT2000

775-086 2.50 Leg cylinder support, installing 1 - 475018
775-087 1.50 Chain tension unit, removing 1 - 475018
775-087 1.50 Chain tension unit, removing 475019 - 479999
775-088 1.50 Chain tension unit, installing 1 - 475018
775-088 1.50 Chain tension unit, installing 475019 - 479999
775-090 7.00 Steering collar bearing, replacing 1 - 475018
775-090 7.00 Steering collar bearing, replacing 475019 - 479999
775-091 7.00 Bearing sleeve, replacing 1 - 475018
775-091 7.00 Bearing sleeve, replacing 475019 - 479999
775-100 0.80 Track assembly, removing 1 - 475018
775-100 0.80 Track assembly, removing 475019 - 479999
775-101 1.00 Track assembly, installing 1 - 475018
775-101 1.00 Track assembly, installing 475019 - 479999
775-114 0.40 Speed sensor, replacing 1 - 475018
775-114 0.40 Speed sensor, replacing 475019 - 479999
775-115 0.40 Leg valve solenoid, replacing 1 - 475018
775-115 0.40 Leg valve solenoid, replacing 475019 - 479999
775-116 0.50 Leg valve, replacing 1 - 475018
775-116 0.50 Leg valve, replacing 475019 - 479999

ANYWHERE
821-031 0.70 Engine hood, changing gas spring 1 - 475018
827-001 1.75 Cab ladder, replacing 1 - 475018

MT2000

827-002 0.90 Engine access ladder, replacing 1 - 475018
827-002 0.90 Engine access ladder, replacing 475019 - 479999

831-040 0.30 Access panel, removing 1 - 475018
831-040 0.30 Access panel, removing 475019 - 479999
831-041 0.40 Access panel, installing 1 - 475018
831-041 0.40 Access panel, installing 475019 - 479999

841-001 0.30 Mirror, removing 1 - 475018
841-001 0.30 Mirror, removing 475019 - 479999
841-002 0.30 Mirror, installing 1 - 475018
841-002 0.30 Mirror, installing 475019 - 479999
852-022 1.25 Seat channel guide, replacing 1 - 475018
852-022 1.25 Seat channel guide, replacing 475019 - 479999



MT2000
911-036 7.00 Hydraulic oil tank, removing 1 - 475018

911-037 4.00 Hydraulic oil tank, installing 1 - 475018
911-041 7.00 Auxiliary hydraulic oil tank, replacing 1 - 475018
911-041 7.00 Auxiliary hydraulic oil tank, replacing 475019 - 479999
912-070 0.40 Check valve, replacing 1 - 475018
912-070 0.40 Check valve, replacing 475019 - 479999
912-180 0.90 Valve block, removing 1 - 475018
912-180 0.90 Valve block, removing 475019 - 479999
912-181 0.60 Valve block, installing 1 - 475018
912-181 0.60 Valve block, installing 475019 - 479999
912-200 0.50 General purpose distribution valve, removing 1 - 475018
912-200 0.50 General purpose distribution valve, removing 475019 - 479999
912-201 0.40 General purpose distribution valve, installing 1 - 475018
912-201 0.40 General purpose distribution valve, installing 475019 - 479999
913-052 0.80 Hydraulic pump, removing 1 - 475018
913-052 0.80 Hydraulic pump, removing 475019 - 479999
913-053 0.60 Hydraulic pump, installing 1 - 475018
913-053 0.60 Hydraulic pump, installing 475019 - 479999
913-076 5.00 General purpose pump, removing 1 - 475018
913-077 1.50 General purpose pump, installing 1 - 475018
913-078 0.50 General purpose pump system pressure, 1 - 475018
checking
913-078 0.50 General purpose pump system pressure, 475019 - 479999
checking
913-079 0.40 Left rear general purpose valve, overriding 1 - 475018
913-079 0.40 Left rear general purpose valve, overriding 475019 - 479999
913-080 0.50 General purpose system pressure valve, adjusting1 - 475018
913-080 0.50 General purpose system pressure valve, adjusting475019 - 479999

983-002 3.00 Gathering conveyor, removing 1 - 475018
983-002 3.00 Gathering conveyor, removing 475019 - 479999
983-003 2.00 Gathering conveyor, installing 1 - 475018
983-003 2.00 Gathering conveyor, installing 475019 - 479999
983-004 4.00 Gathering conveyor belt, removing 1 - 475018
983-004 4.00 Gathering conveyor belt, removing 475019 - 479999
983-005 3.00 Gathering conveyor belt, installing 1 - 475018
983-005 3.00 Gathering conveyor belt, installing 475019 - 479999
983-006 9.50 Conveyor slider rail, replacing 1 - 475018
983-006 9.50 Conveyor slider rail, replacing 475019 - 479999

MT2000
983-007 9.00 Rubber disc roller, replacing 1 - 475018

983-007 9.00 Rubber disc roller, replacing 475019 - 479999
983-008 0.40 Belt tension cylinder, removing 1 - 475018
983-009 0.40 Belt tension cylinder, installing 1 - 475018
983-010 0.50 Live shaft roller, removing 1 - 475018
983-010 0.50 Live shaft roller, removing 475019 - 479999
983-011 0.40 Live shaft roller, installing 1 - 475018
983-011 0.40 Live shaft roller, installing 475019 - 479999
983-012 2.00 Sideboard seal, replacing 1 - 475018
983-022 3.00 Gathering conveyor rubber flap, removing 1 - 475018
983-022 3.00 Gathering conveyor rubber flap, removing 475019 - 479999
983-023 2.50 Gathering conveyor rubber flap, installing 1 - 475018
983-023 2.50 Gathering conveyor rubber flap, installing 475019 - 479999
983-024 0.40 Hopper, removing 1 - 475018
983-024 0.40 Hopper, removing 475019 - 479999
983-025 0.40 Hopper, installing 1 - 475018
983-025 0.40 Hopper, installing 475019 - 479999
983-026 1.00 Hopper, replacing 1 - 475018
983-026 1.00 Hopper, replacing 475019 - 479999
983-027 1.75 Discharge conveyor, removing 1 - 475018
983-027 1.75 Discharge conveyor, removing 475019 - 479999
983-028 1.50 Discharge conveyor, installing 1 - 475018
983-028 1.50 Discharge conveyor, installing 475019 - 479999
983-029 0.30 Conveyor cover, removing 1 - 475018
983-030 0.50 Conveyor cover, installing 1 - 475018
983-031 0.50 Conveyor lift cylinder, removing 1 - 475018
983-031 0.50 Conveyor lift cylinder, removing 475019 - 479999
983-032 0.50 Conveyor lift cylinder, installing 1 - 475018
983-032 0.50 Conveyor lift cylinder, installing 475019 - 479999

MT2000
983-033 0.50 Safety cable, removing 1 - 475018

983-033 0.50 Safety cable, removing 475019 - 479999
983-034 0.20 Safety cable, installing 1 - 475018
983-034 0.20 Safety cable, installing 475019 - 479999
983-035 6.00 Discharge conveyor belt, removing 1 - 475018
983-035 6.00 Discharge conveyor belt, removing 475019 - 479999
983-036 6.50 Discharge conveyor belt, installing 1 - 475018
983-036 6.50 Discharge conveyor belt, installing 475019 - 479999
983-037 1.75 Discharge conveyor folding hinge link, removing 1 - 475018
983-037 1.75 Discharge conveyor folding hinge link, removing 475019 - 479999
983-038 2.00 Discharge conveyor folding hinge link, installing 1 - 475018
983-038 2.00 Discharge conveyor folding hinge link, installing 475019 - 479999
983-039 15.00 Throughing idler, replacing 1 - 475018
983-039 15.00 Throughing idler, replacing 475019 - 479999
983-040 1.75 Conveyor support, removing 1 - 475018
983-040 1.75 Conveyor support, removing 475019 - 479999
983-041 2.50 Conveyor support, installing 1 - 475018
983-041 2.50 Conveyor support, installing 475019 - 479999
983-048 0.50 Conveyor swing cylinder, removing 1 - 475018
983-048 0.50 Conveyor swing cylinder, removing 475019 - 479999
983-049 0.40 Conveyor swing cylinder, installing 1 - 475018
983-049 0.40 Conveyor swing cylinder, installing 475019 - 479999
983-050 2.50 Conveyor swing pin bearing, replacing 1 - 475018
983-050 2.50 Conveyor swing pin bearing, replacing 475019 - 479999
983-202 0.30 Discharge conveyor speed sensor, replacing 1 - 475018
983-202 0.30 Discharge conveyor speed sensor, replacing 475019 - 479999
983-203 0.30 Conveyor drive pressure transducer, replacing 1 - 475018
983-203 0.30 Conveyor drive pressure transducer, replacing 475019 - 479999
983-204 1.25 Conveyor valve, replacing 1 - 475018
983-204 1.25 Conveyor valve, replacing 475019 - 479999
983-205 0.40 Conveyor load sensing pressure, checking 1 - 475018
983-205 0.40 Conveyor load sensing pressure, checking 475019 - 479999
983-206 0.50 Conveyor relief pressure, checking 1 - 475018
983-206 0.50 Conveyor relief pressure, checking 475019 - 479999
983-207 0.60 Conveyor joystick, replacing 475019 - 479999
983-207 0.80 Conveyor joystick, replacing 1 - 475018
983-208 0.70 Conveyor control valve, replacing 1 - 475018
983-208 0.70 Conveyor control valve, replacing 475019 - 479999
983-209 0.70 Gathering conveyor motor, removing 1 - 475018
983-209 0.70 Gathering conveyor motor, removing 475019 - 479999
983-210 0.60 Gathering conveyor motor, installing 1 - 475018
983-210 0.60 Gathering conveyor motor, installing 475019 - 479999
983-211 1.00 Discharge conveyor motor, removing 1 - 475018
983-211 1.00 Discharge conveyor motor, removing 475019 - 479999

MT2000
983-212 0.90 Discharge conveyor motor, installing 1 - 475018

983-212 0.90 Discharge conveyor motor, installing 475019 - 479999
983-213 0.60 Conveyor load sensing pressure valve, adjusting 1 - 475018
983-213 0.60 Conveyor load sensing pressure valve, adjusting 475019 - 479999
983-214 0.80 Conveyor pressure compensator valve, adjusting 1 - 475018
983-214 0.80 Conveyor pressure compensator valve, adjusting 475019 - 479999
9833-001 5.50 Conveyor drive pump, removing 1 - 475018
9833-001 5.50 Conveyor drive pump, removing 475019 - 479999
9833-002 2.00 Conveyor drive pump, installing 1 - 475018
9833-002 2.00 Conveyor drive pump, installing 475019 - 479999
985-001 0.60 Water system assembly, removing 1 - 475018
985-001 0.60 Water system assembly, removing 475019 - 479999
985-002 0.50 Water system assembly, installing 1 - 475018
985-002 0.50 Water system assembly, installing 475019 - 479999
988-002 0.70 Cutting drum tooth, replacing 1 - 475018
988-002 0.70 Cutting drum tooth, replacing 475019 - 479999
988-007 11.00 Cutting drum housing, removing 1 - 475018
988-007 11.00 Cutting drum housing, removing 475019 - 479999
988-009 0.50 Rubber flap, replacing 1 - 475018
988-009 0.50 Rubber flap, replacing 475019 - 479999
988-013 0.40 Gradation beam cylinder, removing 1 - 475018
988-013 0.40 Gradation beam cylinder, removing 475019 - 479999
988-014 0.40 Gradation beam cylinder, installing 1 - 475018
988-014 0.40 Gradation beam cylinder, installing 475019 - 479999
988-017 5.50 Cutting drum housing, installing 1 - 475018
988-017 5.50 Cutting drum housing, installing 475019 - 479999
988-018 0.60 Cutting drum flanged bearing, removing 1 - 475018
988-018 0.60 Cutting drum flanged bearing, removing 475019 - 479999
988-019 0.60 Cutting drum flanged bearing, installing 1 - 475018
988-019 0.60 Cutting drum flanged bearing, installing 475019 - 479999
988-020 0.70 Mouldboard cylinder, replacing 1 - 475018
988-020 0.70 Mouldboard cylinder, replacing 475019 - 479999
988-030 0.40 Wearing strip on mouldboard, removing 1 - 475018
988-030 0.40 Wearing strip on mouldboard, removing 475019 - 479999
988-031 0.60 Wearing strip on mouldboard, installing 1 - 475018
988-031 0.60 Wearing strip on mouldboard, installing 475019 - 479999
988-036 11.00 Rear mouldboard, removing 1 - 475018
988-036 11.00 Rear mouldboard, removing 475019 - 479999
988-037 0.40 Rear mouldboard, installing 1 - 475018
988-037 0.40 Rear mouldboard, installing 475019 - 479999
988-039 4.00 Gradation beam, removing 1 - 475018
988-039 4.00 Gradation beam, removing 475019 - 479999
988-040 2.50 Gradation beam, installing 1 - 475018
988-040 2.50 Gradation beam, installing 475019 - 479999

MT2000
988-041 0.40 Window door, removing 1 - 475018

988-041 0.40 Window door, removing 475019 - 479999
988-042 0.40 Window door, installing 1 - 475018
988-042 0.40 Window door, installing 475019 - 479999
988-047 0.40 Sideskirt cylinder, removing 1 - 475018
988-047 0.40 Sideskirt cylinder, removing 475019 - 479999
988-048 0.40 Sideskirt cylinder, installing 1 - 475018
988-048 0.40 Sideskirt cylinder, installing 475019 - 479999
988-049 0.80 Left side sideskirt, removing 1 - 475018
988-049 0.80 Left side sideskirt, removing 475019 - 479999
988-050 0.90 Left side sideskirt, installing 1 - 475018
988-050 0.90 Left side sideskirt, installing 475019 - 479999
988-051 0.70 Right side sideskirt, removing 1 - 475018
988-051 0.70 Right side sideskirt, removing 475019 - 479999
988-052 0.80 Right side sideskirt, installing 1 - 475018
988-052 0.80 Right side sideskirt, installing 475019 - 479999
988-053 0.70 Sideskirt ski, replacing 1 - 475018
988-053 0.70 Sideskirt ski, replacing 475019 - 479999
988-060 1.50 Baseplate, replacing 1 - 475018
988-060 1.50 Baseplate, replacing 475019 - 479999
988-070 0.60 Milling sheave, removing 1 - 475018
988-071 0.50 Milling sheave, installing 1 - 475018
988-072 0.50 Milling sheave idler removing 1 - 475018
988-072 0.50 Milling sheave idler removing 475019 - 479999
988-073 0.40 Milling sheave idler, installing 1 - 475018
988-073 0.40 Milling sheave idler, installing 475019 - 479999
988-074 0.80 Milling sheave idler bearing and pin, replacing 1 - 475018
988-074 0.80 Milling sheave idler bearing and pin, replacing 475019 - 479999
988-087 14.00 Drum drive, removing 1 - 475018
988-088 8.00 Drum drive, installing 1 - 475018
988-089 11.00 Drum carrier spindle, removing 1 - 475018
988-089 11.00 Drum carrier spindle, removing 475019 - 479999
988-090 0.50 Drum carrier spindle, installing 1 - 475018
988-090 0.50 Drum carrier spindle, installing 475019 - 479999
988-092 0.70 Drum drive belt tension arm, removing 1 - 475018
988-092 0.70 Drum drive belt tension arm, removing 475019 - 479999

MT2000
988-093 0.80 Drum drive belt tension arm, installing 1 - 475018

988-093 0.80 Drum drive belt tension arm, installing 475019 - 479999
988-094 1.25 Drum drive belt tension arm bushing, replacing 1 - 475018
988-094 1.25 Drum drive belt tension arm bushing, replacing 475019 - 479999
988-096 0.40 Drum drive belt, removing 1 - 475018
988-096 0.40 Drum drive belt, removing 475019 - 479999
988-097 0.30 Drum drive belt, installing 1 - 475018
988-097 0.30 Drum drive belt, installing 475019 - 479999
988-100 0.90 Cutting drum sleeve, replacing 1 - 475018
988-100 0.90 Cutting drum sleeve, replacing 475019 - 479999
988-101 12.00 Cutting drum, removing 1 - 475018
988-101 12.00 Cutting drum, removing 475019 - 479999
988-102 6.50 Cutting drum, installing 1 - 475018
988-102 6.50 Cutting drum, installing 475019 - 479999
988-103 1.25 Cutting drum coolant, draining 1 - 475018
988-103 1.25 Cutting drum coolant, draining 475019 - 479999
988-104 0.80 Cutting drum coolant, filling 1 - 475018
988-104 0.80 Cutting drum coolant, filling 475019 - 479999
988-105 0.60 Cutting drum housing door cylinder, replacing 1 - 475018
988-105 0.60 Cutting drum housing door cylinder, replacing 475019 - 479999
988-106 11.00 Cutting drum housing door, removing 1 - 475018
988-106 11.00 Cutting drum housing door, removing 475019 - 479999
988-107 6.00 Cutting drum housing door, installing 1 - 475018
988-107 6.00 Cutting drum housing door, installing 475019 - 479999

MW500

17 SERVICE
173-001 1.50 Maintenance service, as required
173-050 0.10 Greasing, daily
19 GENERAL

21 ENGINE
23 FUEL SYSTEM

26 COOLING SYSTEM

MW500

30 GENERAL
301-002 0.50 Control unit, software update
301-005 0.70 Pre-programmed ECU, replacing
301-011 0.60 Wheel support sensor, Calibrating
413-012 2.50 Clutch assembly, removing
413-013 2.50 Clutch assembly, installing

6 STEERING
62 STEERING AXLE
64 STEERING

MW500

WHEEL/TRACK UNIT
71 FRAME

778-001 1.75 Support leg cylinder left, replacing
778-002 1.75 Support leg cylinder right, replacing
778-003 1.50 Front axle cylinder, replacing
778-004 1.25 Sliding plates, replacing

ANYWHERE
810-006 0.10 Ascent, removing
810-007 0.10 Ascent, installing



MW500

97 UNIT, DIGGING
971-094 4.50 Slewing cylinder, replacing

983-001 0.20 Conveyor belt tension, adjusting
983-013 0.90 Conveyor belt, removing
983-014 1.25 Conveyor belt, installing
983-015 0.20 Conveyor, removing
983-016 0.20 Conveyor, installing
983-017 1.25 Deflect pulley, replacing
983-018 0.60 Rubber stripes, replacing
983-019 0.50 Cover rubber, replacing
983-020 1.25 Conveyor head, removing
983-021 0.90 Conveyor head, installing
983-031 0.40 Conveyor lift cylinder, removing
983-032 0.70 Conveyor lift cylinder, installing
983-051 0.50 Conveyor drive pump belt, replacing
9833-001 0.80 Conveyor drive pump, removing
9833-002 0.80 Conveyor drive pump, installing
985-005 0.30 Sprinkling pipe, removing
985-006 0.20 Sprinkling pipe, installing
988-002 0.40 Cutting drum tooth, replacing
988-004 0.60 Scraper, replacing
988-009 0.80 Rubber flap, replacing
988-020 1.00 Mouldboard cylinder, replacing
988-021 0.90 Deflector cylinder, replacing
988-022 0.40 Deflector right, removing
988-023 0.40 Deflector right, installing
988-024 0.40 Deflector front, removing
988-025 0.40 Deflector front, installing
988-026 1.00 Intermidiate shaft, adjusting
988-027 1.75 Milling gearbox, removing
988-028 2.00 Milling gearbox, installing
988-030 0.40 Wearing strip on mouldboard, removing
988-031 0.40 Wearing strip on mouldboard, installing

MW500
988-032 1.75 Deflector left, removing

988-033 1.75 Deflector left, installing
988-034 2.50 Intermediate shaft, removing
988-035 3.00 Intermediate shaft, installing
988-036 1.25 Rear mouldboard, removing
988-037 1.25 Rear mouldboard, installing
988-043 0.50 Sliding device mouldboard, removing
988-044 0.50 Sliding device mouldboard, installing
988-098 0.70 Drum drive belt top, replacing
988-099 2.50 Drum drive belt down, replacing
988-101 0.70 Cutting drum, removing
988-102 0.60 Cutting drum, installing
988-106 0.20 Cutting drum housing door, removing
988-107 0.20 Cutting drum housing door, installing

Omni 1000

17 SERVICE
19 GENERAL

WHEEL/TRACK UNIT

ANYWHERE
827-005 0.50 Walkway, removing
827-006 0.40 Walkway, installing
827-007 0.60 Deck platform, removing
827-008 0.50 Deck platform, installing

982-015 2.00 Extension cylinder, removing
982-016 3.00 Extension cylinder, installing

Omni 1000
982-019 1.75 Slope cylinder, removing

982-020 2.00 Slope cylinder, installing
982-026 0.40 End plate, replacing
982-030 1.75 Sliding bearing, replacing
982-050 2.50 Crown control cylinder, replacing
983-130 0.90 Vibration shaft, removing
983-131 0.80 Vibration shaft, installing
983-132 1.50 Vibration bearing, removing
983-133 1.25 Vibration bearing, installing
986-005 0.70 Heater bar, removing
986-006 1.75 Heater bar, installing
987-017 0.50 Edger guide, removing
987-018 0.60 Edger guide, installing
987-024 15.00 Screed plate, replacing
987-030 0.70 Extension height gear motor, removing
987-031 0.40 Extension height gear motor, installing
987-032 0.70 Outer height assembly, removing
987-033 0.60 Outer height assembly, installing
987-050 0.50 Deflector, removing
987-051 0.60 Deflector, installing

Omni 318

17 SERVICE

982-007 0.60 Strike off plate, removing
982-008 0.70 Strike off plate, installing
982-009 4.50 Saddle assembly, removing
982-010 5.50 Saddle assembly,installing
982-011 2.00 Inner support tube, removing
982-012 2.50 Inner support tube, installing
982-013 2.50 Outer support tube, removing
982-014 2.50 Outer support tube, installing
982-021 1.25 Pre-Strike off, removing
982-022 1.50 Pre-Strike off, installing
982-023 11.00 Saddle bushing, replacing
982-024 5.00 Saddle, removing
982-025 6.00 Saddle, installing
982-502 0.90 Extension height adjustment chain, removing
982-503 0.90 Extension height adjustment chain, installing

Omni 318

983-136 1.25 Vibration drive belt, replacing
987-008 0.60 Power crown motor, removing
987-009 0.60 Power crown motor, installing
987-010 1.50 Power crown, removing
987-011 2.00 Power crown, installing
987-012 4.50 Power crown, disassembly and assembly
987-013 1.75 Main screed strike off, removing
987-014 2.00 Main screed strike off, installing
987-015 4.00 Screed extension, removing
987-016 4.50 Screed extension, installing
987-019 0.50 Depth crank, removing
987-020 0.40 Depth crank, installing
987-021 0.80 Depth crank, disassembly and assembly
987-022 0.70 Side arm, removing
987-023 0.60 Side arm, installing
987-034 2.50 Outer height screw assembly, disassembling/
assembling
987-035 0.80 Inner height assembly, removing
987-036 0.90 Inner height assembly, installing
987-037 2.50 Inner height screw assembly, disassembling/
assembling
987-040 0.80 Edger guide bracket, removing
987-041 0.90 Edger guide bracket, installing
987-042 0.40 Edger guide jack, removing
987-043 0.40 Edger guide jack, installing
987-044 1.75 Edger plate, removing
987-045 1.50 Edger plate, installing
987-046 0.30 Edger shoe, removing
987-047 0.30 Edger shoe, installing

P4370B

17 SERVICE
19 GENERAL

21 ENGINE

P5770C ABG

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

P5770C ABG

239-002 0.60 Fuel cooler, removing
239-003 0.40 Fuel cooler, installing

non-programmed
pre-programmed
254-068 1.25 Muffler, adjusting
26 COOLING SYSTEM
263-090 3.00 Fan, installing
263-091 2.50 Fan, removing

P5770C ABG
29 Miscellaneous

30 GENERAL
301-014 0.60 Trimming (offset adjustment)
31 BATTERY
33 STARTING SYSTEM

43 GEARBOX,
440-024 3.00 Travel drive, calibrating
440-025 1.00 Gear shift valve pressure limiting valve, adjusting

P5770C ABG
442-088 1.25 Propulsion pump pressure cut off valve, checking

and adjusting
442-167 2.50 Propulsion pump mechanical zero position,
6 STEERING
64 STEERING
643-025 0.30 Steering angle sensor, adjusting

WHEEL/TRACK UNIT
71 FRAME
715-039 1.25 Noise-absorbing mats, replacing


ANYWHERE


P5770C ABG

912-274 0.70 Screed assist, pressure regulating valve,
replacing
912-275 0.30 Screed assist, pressure regulating valve, adjusting
912-276 0.70 Screed tensioning device, pressure regulating
valve, replacing
valve, adjusting
912-286 1.00 Cylinder valve block flow divider, adjusting
913-083 1.25 Auger drive pump max. working pressure,
913-084 0.90 Auger drive pump standby pressure, checking and
adjusting

982-029 0.30 Levelling scales, adjusting
982-055 1.25 Screed spacer blocks, removing
982-056 1.25 Screed spacer blocks, installing
983-054 2.00 Conveyor drive shaft, dissassembly and assembly
assembly
983-140 1.25 Front apron plate, removing
983-141 1.00 Front apron plate, installing

P5770C ABG

99 MISCELLANEOUS
993-022 0.20 Automatic lubrication pump, removing
993-023 0.60 Automatic lubrication pump, installing

P5870C ABG

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

P5870C ABG


non-programmed
pre-programmed
26 COOLING SYSTEM

P5870C ABG
29 Miscellaneous

30 GENERAL
31 BATTERY
33 STARTING SYSTEM

43 GEARBOX,

P5870C ABG

and adjusting
6 STEERING
64 STEERING

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE


P5870C ABG

replacing
valve, replacing
valve, adjusting
adjusting

983-096 0.60 Auger bearing protector, replacing
assembly

P5870C ABG

99 MISCELLANEOUS

P6820C ABG

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
210-093 0.40 Engine rotation speed sensor (crank shaft), 715030 - 999999
replacing
replacing
gauge

P6820C ABG
23 FUEL SYSTEM
234-011 1.25 Fuel tank, removing 51 - 715029
234-012 1.50 Fuel tank, installing 51 - 715029

251-007 0.60 Air intake hose, replacing
non-programmed
pre-programmed
254-038 0.70 DPF inlet temperature sensor, replacing 715030 - 999999
254-045 1.25 Glow plug, checking
254-052 0.70 Air pump safety valve, replacing

P6820C ABG
254-053 0.70 Glow plug control unit, replacing

255-070 1.25 Turbocharger, removing 51 - 715029
255-070 1.00 Turbocharger, removing 715030 - 999999
255-072 1.25 Turbocharger, installing 51 - 715029
255-072 1.25 Turbocharger, installing 715030 - 999999
26 COOLING SYSTEM
29 Miscellaneous

P6820C ABG

30 GENERAL
301-015 0.30 Calibrate travel potentiometer and steering
potentiometer
33 STARTING SYSTEM
331-016 1.75 Starter motor, removing 51 - 715029
331-017 1.00 Starter motor, installing 51 - 715029


387-043 1.00 Steering potentiometer, installing
387-044 0.80 Steering potentiometer, removing
387-045 1.00 Speed potentiometer, installing
387-046 0.80 Speed potentiometer, removing
387-047 0.50 Drive lever, installing
387-048 0.80 Drive lever, removing
43 GEARBOX,

P6820C ABG


WHEEL/TRACK UNIT
71 FRAME


ANYWHERE


P6820C ABG

912-244 0.80 Valve block, tamper, removing
912-245 0.80 Valve block, tamper, installing
912-248 0.50 Valve block, rinsing valves, removing
912-249 0.50 Valve block, rinsing valves, installing
removing
installing
912-270 0.80 Valve block, auger, height adjustment, removing
912-271 0.80 Valve block, auger, height adjustment, installing

P6820C ABG

982-035 0.40 Screed assist, adjusting
983-081 0.60 Push roller, removing
983-082 0.60 Push roller, installing
983-086 1.75 Hopper flap, replacing
983-106 1.25 Auger drive pump, removing
983-107 1.50 Auger drive pump, installing
assembly

P6820C ABG

983-184 0.60 Conveyor pump, removing
983-185 0.60 Conveyor pump, installing
983-215 0.80 Conveyor pump right side/ tamper pump,
removing
983-216 0.70 Conveyor pump right side/tamper pump, installing
986-003 1.50 Generator, removing
986-004 4.00 Generator, installing
986-009 2.00 Generator, adjusting

P6870C ABG

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

P6870C ABG


non-programmed
pre-programmed
26 COOLING SYSTEM

P6870C ABG
29 Miscellaneous

30 GENERAL
31 BATTERY
33 STARTING SYSTEM

43 GEARBOX,

P6870C ABG

and adjusting
6 STEERING
64 STEERING

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE


P6870C ABG

replacing
valve, replacing
valve, adjusting
adjusting

assembly

P6870C ABG

99 MISCELLANEOUS

P7110

17 SERVICE
19 GENERAL

20 GENERAL
ECU
200-201 0.20 Engine belt, removing
200-202 0.10 Engine belt, installing
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

P7110


non-programmed
pre-programmed
254-049 0.50 Throttle, replacing
replacing
26 COOLING SYSTEM
263-023 1.50 Fan pump, removing
263-024 1.50 Fan pump, installing
263-060 7.50 Fan speed sensor, replacing
29 Miscellaneous

P7110

31 BATTERY
311-009 0.20 Battery, disconnecting
311-010 0.10 Battery, connecting



413-021 2.50 Pump decoupler, removing
413-022 2.50 Pump decoupler, installing
413-023 0.50 Pump decoupler valve, removing
413-024 0.40 Pump decoupler valve, installing

441-040 2.50 Hydraulic motor speed sensor, replacing
441-080 4.00 Propulsion motor, removing
441-081 5.00 Propulsion motor, installing
441-082 4.00 Propulsion planetary, removing
441-083 5.00 Propulsion planetary, installing
441-117 0.30 Positraction valve, removing
441-118 0.20 Positraction valve, installing
442-076 3.50 Propulsion pump, removing, right side
442-077 3.00 Propulsion pump, installing, right side
442-078 2.00 Propulsion pump, removing, left side

P7110
442-079 1.75 Propulsion pump, installing, left side

442-087 0.30 Propulsion pump, multi function valve, replacing
442-168 0.40 Planetary shift valve, replacing
442-169 0.40 Drive motor shift valve, replacing
5 BRAKE
525-012 0.60 Brake shift valve, replacing
55 PARKING BRAKE
550-055 0.40 Parking brake release valve, replacing

WHEEL/TRACK UNIT
775-040 0.60 Rubber track, aligning
775-100 3.50 Track assembly, removing
775-101 5.00 Track assembly, installing
775-102 2.50 Bogie wheel assembly, removing
775-103 3.50 Bogie wheel assembly, installing
775-104 2.00 Track drive wheel, removing
775-105 2.50 Track drive wheel, installing

ANYWHERE

P7110

913-076 2.00 General purpose pump, removing
913-077 1.75 General purpose pump, installing

983-061 0.80 Conveyor motor assembly, removing
983-062 1.25 Conveyor motor assembly, installing
983-098 2.50 Generator pump, removing
983-099 2.00 Generator pump, installing
985-021 3.50 Fumes fan motor, replacing
986-001 0.40 Generator motor, removing
986-002 0.40 Generator motor, installing

P7170

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

P7170


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM
263-060 7.50 Fan speed sensor, replacing
29 Miscellaneous

P7170



413-023 0.50 Pump decoupler valve, removing
413-024 0.40 Pump decoupler valve, installing

441-040 3.50 Hydraulic motor speed sensor, replacing
441-080 3.00 Propulsion motor, removing
441-081 3.50 Propulsion motor, installing
441-082 3.00 Propulsion planetary, removing
441-083 3.50 Propulsion planetary, installing
441-117 0.30 Positraction valve, removing
441-118 0.20 Positraction valve, installing
442-078 2.00 Propulsion pump, removing, left side
442-079 1.75 Propulsion pump, installing, left side

P7170

442-168 0.40 Planetary shift valve, replacing
442-169 0.40 Drive motor shift valve, replacing
442-170 0.50 Front wheel assist valve, replacing
5 BRAKE
525-012 0.60 Brake shift valve, replacing
55 PARKING BRAKE
6 STEERING
62 STEERING AXLE
622-090 1.50 Bogie assembly, removing
622-091 1.75 Bogie assembly, installing

WHEEL/TRACK UNIT
72 SUSPENSION
725-014 0.50 Bogie lift cylinders, filling


ANYWHERE

913-076 2.00 General purpose pump, removing

P7170
913-077 1.75 General purpose pump, installing

983-061 2.00 Conveyor motor assembly, removing
983-062 3.00 Conveyor motor assembly, installing
983-098 2.50 Generator pump, removing
983-099 2.00 Generator pump, installing
985-021 3.50 Fumes fan motor, replacing
986-001 0.40 Generator motor, removing
986-002 0.40 Generator motor, installing

P7820C ABG

17 SERVICE
19 GENERAL

20 GENERAL
ECU
ECU
21 ENGINE

P7820C ABG
gauge
23 FUEL SYSTEM

non-programmed
pre-programmed

P7820C ABG

26 COOLING SYSTEM
261-020 1.25 Expansion tank, removing 51 - 999999
261-021 0.90 Expansion tank, installing 51 - 999999
261-022 3.50 Cooling package, removing 51 - 999999
261-023 3.00 Cooling package, installing 51 - 999999
29 Miscellaneous

30 GENERAL
potentiometer
33 STARTING SYSTEM

P7820C ABG



43 GEARBOX,

WHEEL/TRACK UNIT
71 FRAME


P7820C ABG


ANYWHERE


912-244 0.70 Valve block, tamper, removing
912-245 0.70 Valve block, tamper, installing

P7820C ABG
912-248 0.50 Valve block, rinsing valves, removing

912-249 0.50 Valve block, rinsing valves, installing
removing
installing


P7820C ABG

assembly
983-148 1.25 Tamper pump, removing
983-149 1.50 Tamper pump, installing

P7820C ABG


P8820C ABG

17 SERVICE
19 GENERAL

20 GENERAL
ECU
ECU
21 ENGINE

P8820C ABG
gauge
23 FUEL SYSTEM

non-programmed
pre-programmed

P8820C ABG

26 COOLING SYSTEM
261-020 1.25 Expansion tank, removing 51 - 999999
261-021 0.90 Expansion tank, installing 51 - 999999
29 Miscellaneous

30 GENERAL
potentiometer
33 STARTING SYSTEM

P8820C ABG



43 GEARBOX,

WHEEL/TRACK UNIT
71 FRAME


P8820C ABG


ANYWHERE



P8820C ABG

removing
installing


P8820C ABG

assembly

P8820C ABG

PF2181

21 ENGINE
210-070 3.00 Engine, removing 200987 - 499999
26 COOLING SYSTEM

31 BATTERY
311-011 0.30 Battery, removing 200987 - 499999
311-012 0.30 Battery, installing 200987 - 499999

364-100 0.30 SW3703, replacing 200987 - 499999

372-053 0.20 RE3706, replacing 200987 - 499999
413-012 3.00 Clutch assembly, removing
413-013 4.00 Clutch assembly, installing

424-050 0.30 SW4233, replacing 200987 - 499999
424-051 0.30 SW4234, replacing 200987 - 499999
440-060 0.30 Propulsion system pressure, checking 200987 - 499999
440-065 0.30 High/low valve, replacing 200987 - 499999
440-067 0.40 Propulsion motor case drain flow, checking 200987 - 499999
441-082 1.75 Propulsion planetary, removing 200987 - 499999
441-083 2.00 Propulsion planetary, installing 200987 - 499999
442-070 0.30 Charge pressure relief valve, replacing 200987 - 499999
442-072 0.20 Charge pressure relief valve, adjusting 200987 - 499999

PF2181

442-078 0.80 Propulsion pump, removing, left side 200987 - 499999
442-079 0.90 Propulsion pump, installing, left side 200987 - 499999
442-087 0.30 Propulsion pump, multi function valve, replacing 200987 - 499999
442-097 0.30 Servo shunt valve spool, replacing 200987 - 499999
442-099 0.20 Propulsion pump, charge pressure checking 200987 - 499999
442-150 0.20 MA4206, replacing 200987 - 499999
442-151 0.20 MA4412, replacing 200987 - 499999
442-152 0.20 MA4413, replacing 200987 - 499999
45 PROPELLER SHAFT
5 BRAKE
524-002 0.20 RE5501, replacing 200987 - 499999
524-002 0.20 RE5501, replacing 200987 - 499999
525-012 0.30 Brake shift valve, replacing 200987 - 499999
525-013 0.20 Pressure at brake shift valve, checking 200987 - 499999
55 PARKING BRAKE
550-050 0.20 MA5501, replacing 200987 - 499999
550-052 0.30 SW5501, replacing 200987 - 499999
550-053 0.20 SE5501, replacing 200987 - 499999

WHEEL/TRACK UNIT

ANYWHERE

PF2181

911-053 0.60 Hydraulic oil tank relief valve, removing 200987 - 499999
911-054 0.60 Hydraulic oil tank relief valve, installing 200987 - 499999
911-060 1.00 Hydraulic oil system, priming
912-206 0.20 General purpose hydraulic system pressure, 200987 - 499999
checking
912-207 0.30 General purpose hydraulic system flow, checking200987 - 499999
912-223 1.25 Main distribution valve, removing 200987 - 499999
912-224 1.25 Main distribution valve, installing 200987 - 499999

982-003 0.60 Screed, removing 200987 - 499999
982-004 0.60 Screed, installing 200987 - 499999
983-098 0.90 Generator pump, removing 200987 - 499999
983-099 0.80 Generator pump, installing 200987 - 499999
983-160 0.50 Hopper cylinder pressure, checking 200987 - 499999
983-165 0.40 Auger lift cylinder pressure, checking 200987 - 499999
983-166 0.30 Auger/conveyor system pressure, checking 200987 - 499999
983-167 0.20 Auger/conveyor servo activation pressure, 200987 - 499999
checking
983-168 0.40 Auger/conveyor pump case drain, checking 200987 - 499999
983-169 0.40 Auger/conveyor motor case drain, checking 200987 - 499999
983-170 0.40 Auger/conveyor hydraulic system flow, checking 200987 - 499999
983-175 1.00 Auger/conveyor pump, removing 200987 - 499999
983-176 1.25 Auger/conveyor pump, installing 200987 - 499999
983-178 0.40 Auger/conveyor pump force motor, adjusting 200987 - 499999
983-179 0.70 Auger/conveyor motor, removing 200987 - 499999
983-181 1.75 Auger/conveyor planetary, removing 200987 - 499999
983-200 0.40 MA9470, replacing 200987 - 499999
983-201 0.40 MA9471, replacing 200987 - 499999
986-007 0.20 Generator hydraulic system pressure, checking 200987 - 499999
986-008 0.20 Generator hydraulic system flow, checking 200987 - 499999

PF4410

21 ENGINE
26 COOLING SYSTEM

31 BATTERY

372-053 0.20 RE3706, replacing 375009 - 499999
424-050 0.30 SW4233, replacing 375009 - 499999
424-051 0.30 SW4234, replacing 375009 - 499999
440-060 0.30 Propulsion system pressure, checking 375009 - 499999
440-065 0.40 High/low valve, replacing 375009 - 499999
440-067 0.20 Propulsion motor case drain flow, checking 375009 - 499999
441-080 1.25 Propulsion motor, removing 375009 - 499999
441-082 1.00 Propulsion planetary, removing 375009 - 499999
441-083 0.90 Propulsion planetary, installing 375009 - 499999
442-070 0.30 Charge pressure relief valve, replacing 375009 - 499999
442-072 0.20 Charge pressure relief valve, adjusting 375009 - 499999
442-078 2.00 Propulsion pump, removing, left side 375009 - 499999
442-079 1.25 Propulsion pump, installing, left side 375009 - 499999
442-087 0.30 Propulsion pump, multi function valve, replacing 375009 - 499999
442-097 0.30 Servo shunt valve spool, replacing 375009 - 499999
442-099 0.20 Propulsion pump, charge pressure checking 375009 - 499999
442-150 0.30 MA4206, replacing 375009 - 499999
442-151 0.20 MA4412, replacing 375009 - 499999
442-152 0.20 MA4413, replacing 375009 - 499999

PF4410
5 BRAKE
524-002 0.20 RE5501, replacing 375009 - 499999
525-012 0.20 Brake shift valve, replacing 375009 - 499999
525-013 0.20 Pressure at brake shift valve, checking 375009 - 499999
55 PARKING BRAKE
550-040 0.20 Parking brake, release pressure, checking 375009 - 499999
550-050 0.20 MA5501, replacing 375009 - 499999
550-052 0.30 SW5501, replacing 375009 - 499999
550-053 0.10 SE5501, replacing 375009 - 499999

WHEEL/TRACK UNIT
775-041 1.25 Rubber track, removing 375009 - 499999
775-042 1.75 Rubber track, installing 375009 - 499999
775-089 0.40 Track tension system relief pressure, checking

ANYWHERE
881-001 0.50 Instrument console, removing 375009 - 499999
881-009 0.20 Instrument console lock pin, replacing 375009 - 499999

911-060 1.25 Hydraulic oil system, priming
912-206 0.20 General purpose hydraulic system pressure, 375009 - 499999
checking

PF4410
912-207 0.20 General purpose hydraulic system flow, checking375009 - 499999

912-223 0.50 Main distribution valve, removing 375009 - 499999
912-224 0.70 Main distribution valve, installing 375009 - 499999

982-003 0.60 Screed, removing 375009 - 499999
982-004 0.60 Screed, installing 375009 - 499999
983-098 0.70 Generator pump, removing 375009 - 499999
983-099 0.50 Generator pump, installing 375009 - 499999
983-160 0.50 Hopper cylinder pressure, checking 375009 - 499999
983-165 0.40 Auger lift cylinder pressure, checking 375009 - 499999
983-166 0.30 Auger/conveyor system pressure, checking 375009 - 499999
983-167 0.20 Auger/conveyor servo activation pressure, 375009 - 499999
checking
983-168 0.10 Auger/conveyor pump case drain, checking 375009 - 499999
983-169 0.20 Auger/conveyor motor case drain, checking 375009 - 499999
983-170 0.30 Auger/conveyor hydraulic system flow, checking 375009 - 499999
983-171 0.90 Auger/conveyor pump, removing, right side 375009 - 499999
983-173 1.00 Auger/conveyor pump, removing, left side 375009 - 499999
983-178 0.40 Auger/conveyor pump force motor, adjusting 375009 - 499999
983-179 0.70 Auger/conveyor motor, removing 375009 - 499999
983-183 0.30 Impulse converter, replacing 375009 - 499999
983-200 0.40 MA9470, replacing
983-201 0.40 MA9471, replacing

PT125

23 FUEL SYSTEM

27 ENGINE CONTROL
271-002 0.30 Throttle control cable, removal
271-003 0.30 Throttle control cable, installation
275-012 0.80 Engine speed control, mechanical basic setting

31 BATTERY
441-037 3.00 Drive motor center mount, replacing
6 STEERING
62 STEERING AXLE
622-056 0.80 Spindle - Removal and Disassembly

PT125
622-065 0.80 Spindle - Assembly and Installation

622-095 2.00 Spindle center mount, replacing
622-096 3.00 Steering bolster center mount, replacing
622-097 3.00 Steering bearing, replacing
64 STEERING
645-072 0.40 Hydraulic pump, installing.

WHEEL/TRACK UNIT
75 AXLE SUSPENSION
753-001 1.75 Suspension, removing
753-002 2.00 Suspension, installing

ANYWHERE



PT125


PT220

17 SERVICE
19 GENERAL

21 ENGINE
23 FUEL SYSTEM
234-017 0.50 Fuel tank lid,cover plate gasket, replacing
234-018 0.30 Fuel tank breather cap, replacing
234-019 0.50 Fuel tank sight gauge, replacing

252-024 0.80 Flexible pipe, replacing
252-024 0.70 Flexible pipe, replacing
256-013 0.60 Air duct rubber ring, replacing
256-014 0.70 Air duct, replacing
256-015 0.40 Air hose, air duct, elbow, replacing

PT220
256-017 0.40 Air filter clog sensor, replacing

256-020 0.30 Pre-cleaner, replacing
258-020 0.70 Charge air cooler, inlet pipe, replacing
258-021 0.40 Charge air cooler, outlet pipe, replacing
26 COOLING SYSTEM
adjusting tension
263-086 1.50 Fan guard, replacing
27 ENGINE CONTROL
272-019 0.70 Throttle control lever, replacing
272-022 1.00 Throttle control cable, replacing
272-023 0.80 Throttle control assembly, replacing

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
352-009 0.40 Head lamp, replacing

PT220
353-050 0.40 Licence plate lamp, replacing


362-052 0.50 Dual function alarm, replacing
362-053 0.50 Back up alarm, replacing
364-005 0.40 Control box limit switch, replacing
364-011 0.50 Reverse alarm switch, replacing
364-012 0.50 Control box limit switch, checking
364-013 0.60 Emergency stop switch, replacing
364-015 0.50 Indicator lamp High beam , replacing

371-032 2.00 Rear wire harness, replacing
371-037 1.50 Front wire harness, replacing
371-040 0.80 Battery cable negative, replacing
371-091 1.50 Platform wire harness, replacing
372-011 0.40 Fuse box, changing
372-025 0.60 Power relay, replacing
372-027 0.40 Resistor, replacing
372-052 0.60 Light relay, replacing

387-021 0.50 Instrument panel (display unit), replacing

PT220
424-017 1.25 Propulsion rod, pipe, removing
424-018 0.90 Propulsion rod, pipe, installing
424-019 0.80 Propulsion control lever clamp attachment,
replacing
424-019 0.60 Propulsion control lever clamp attachment,
replacing
441-044 2.50 Hydraulic motor, removing
441-045 2.50 Hydraulic motor, installing
442-100 2.00 Propulsion pump manifold, replacing
442-163 2.50 Propulsion pump coupling, removing
442-164 3.00 Propulsion pump coupling, installing
5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING
641-010 0.40 Control console wheel, replacing
641-011 2.50 Control panel, replacing
641-012 2.00 Flexible hose, replacing
641-013 1.25 Control panel rail, guide, replacing
641-014 0.40 Control panel stop plate, replacing
641-015 0.90 Control panel lock pin, replacing
641-016 0.40 Control panel lock pin spring, replacing
641-017 0.30 Control panel lock plate, replacing

PT220
643-015 1.50 Steering arm, removing

643-016 2.00 Steering arm, installing
643-020 2.00 Pivot, removing
643-021 2.50 Pivot, installing
643-022 4.00 Pivot bushing, replacing
643-023 0.70 Track rods, removing
643-024 0.90 Track rods, installing

WHEEL/TRACK UNIT
71 FRAME
711-003 0.50 Cap support, replacing
711-040 0.80 Hydraulic oil level gauge, replacing
711-041 0.60 Hydraulic tank lid, cover plate gasket, replacing
711-042 0.50 Hydraulic tank breather cap, replacing
711-043 1.75 Cover plates gasket, replacing
72 SUSPENSION
725-011 2.50 Suspension cylinder connecting tube, replacing
75 AXLE SUSPENSION


PT220

ANYWHERE
821-003 0.50 Engine hood latch, replacing
821-029 0.70 Engine hood hinge, replacing
821-034 0.40 Engine hood sealing, replacing

837-007 1.50 Deck plates, replacing

89 MISCELLANEOUS
891-001 0.60 Unloading valve,replacing
891-002 0.40 Tyre inflation components, replacing

912-213 3.50 Hydraulic manifold block LH, replacing
912-214 3.00 Hydraulic manifold block RH, replacing
912-283 1.75 Combination valve, replacing
912-284 0.50 Solenoid coil, replacing


PT220

985-015 0.30 Cocoa mats, replacing
985-017 0.50 Water strainer, replacing
985-018 0.50 Ball valve, replacing

SD105

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

252-022 2.50 Exhaust pipe, changing pipe between silencer and
turbocharger
258-022 0.50 Charge air cooler connection (hose, tube),
replacing
26 COOLING SYSTEM
adjusting tension

31 BATTERY

SD105

33 STARTING SYSTEM


421-089 1.25 Pump de-stroke valve solenoid and cartridge,
replacing
442-069 1.00 Loop flushing valve cartridge, replacing
442-081 0.40 Rear axle motor speed sensor, replacing
442-091 1.50 Traction valve, solenoid and cartridge, replacing

SD105

5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING

WHEEL/TRACK UNIT
74 FRAME LINK
machine separated
machine separated


SD105

777-020 5.00 Drum bolt-on shell option, installing
777-022 1.25 Padfoot drum scrapers, replacing

ANYWHERE
818-023 2.50 Viscous cab suspension, changing all units

821-030 2.50 Engine hood, changing spring


SD105


SD110

17 SERVICE
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
173-089 0.80 Drum carrier, changing oil 51936 - 99999
58001 - 99999
550001 - 999999
173-382 0.40 Transmission oil level, checking 51936 - 99999
58001 - 99999
550001 - 999999

SD110

173-451 2.00 Hydraulic oil, changing 51936 - 99999
58001 - 99999
550001 - 999999
173-459 0.80 Transmission oil, changing 51936 - 99999
58001 - 99999
550001 - 999999
173-465 1.25 Rear axle oil, changing 51936 - 99999
58001 - 99999
550001 - 999999
176-004 0.30 Towing a disabled machine 51936 - 99999
58001 - 99999
550001 - 999999
19 GENERAL
58001 - 99999
550001 - 999999

21 ENGINE
210-070 4.50 Engine, removing 51936 - 52331
210-070 6.00 Engine, removing 52332 - 99999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
23 FUEL SYSTEM
58001 - 99999
550001 - 999999
233-008 2.50 Fuel pump, replacing 52332 - 99999
58001 - 99999
550001 - 999999
234-017 0.40 Fuel tank lid,cover plate gasket, replacing 58001 - 99999

SD110
52332 - 99999
550001 - 999999
234-018 0.40 Fuel tank breather cap, replacing 58359 - 99999
234-018 0.40 Fuel tank breather cap, replacing 51936 - 52331
235-005 0.50 Fuel lines, replacing 52592 - 99999
58091 - 99999
550534 - 999999
58001 - 58090
550001 - 550533
236-076 1.50 Injection pump, one changing 52332 - 99999
58001 - 99999
550001 - 999999

251-008 2.00 Inlet manifold, replacing 52332 - 99999
58001 - 99999
550001 - 999999
251-009 1.75 Exhaust manifold, replacing 52332 - 99999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
550001 - 550721
52332 - 52944
550722 - 999999
52945 - 99999
252-024 0.90 Flexible pipe, replacing 52332 - 52944
58001 - 58243
550001 - 550721
252-024 0.90 Flexible pipe, replacing 51936 - 52331
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999

SD110

58001 - 99999
550001 - 999999
256-020 0.30 Pre-cleaner, replacing 51936 - 99999
58001 - 99999
550001 - 999999
256-023 0.50 Air cleaner, inlet hose, replacing 51936 - 52331
256-023 0.40 Air cleaner, inlet hose, replacing 58001 - 99999
550001 - 999999
52332 - 99999
256-024 0.40 Air cleaner, outlet hose, replacing 52332 - 99999
58001 - 99999
550001 - 999999
258-020 1.50 Charge air cooler, inlet pipe, replacing 52332 - 99999
58001 - 99999
550001 - 999999
258-021 0.40 Charge air cooler, outlet pipe, replacing 52332 - 99999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
52332 - 99999
550001 - 999999
26 COOLING SYSTEM
52332 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999

SD110
adjusting tension 58001 - 99999
550001 - 999999
adjusting tension
263-041 4.50 Cooling fan, replacing 58001 - 99999
52332 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
27 ENGINE CONTROL
272-019 0.60 Throttle control lever, replacing 52332 - 99999
58001 - 99999
550001 - 999999
272-019 0.70 Throttle control lever, replacing 51936 - 52331
272-022 0.90 Throttle control cable, replacing 51936 - 52331
272-022 0.90 Throttle control cable, replacing 52332 - 99999
58001 - 99999
550001 - 999999

31 BATTERY
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999

321-003 0.50 Alternator, removing 52332 - 99999
58001 - 99999
550001 - 999999
321-004 0.60 Alternator, installing 52332 - 99999
58001 - 99999
550001 - 999999
321-075 0.40 Alternator, test 51936 - 52331
321-075 0.40 Alternator, test 52332 - 99999
58001 - 99999
550001 - 999999

SD110
33 STARTING SYSTEM
58001 - 99999
550001 - 999999
331-021 0.70 Starter motor, tests 51936 - 52331
35 LIGHTING
352-009 0.40 Head lamp, replacing 51936 - 99999
58001 - 99999
353-050 0.40 Licence plate lamp, replacing 51936 - 52331
353-050 0.40 Licence plate lamp, replacing 52332 - 99999
58001 - 99999
353-051 0.50 Tail lamp, replacing 52332 - 99999
58001 - 99999
353-051 0.40 Tail lamp, replacing 51936 - 52331

361-002 0.40 Flasher unit, replacing relay 51936 - 99999
58001 - 99999
550001 - 999999
362-002 0.40 Horn, replacing 52332 - 99999
58001 - 99999
550001 - 999999
362-002 0.50 Horn, replacing 51936 - 52331
362-016 0.50 Horn switch, replacing 52332 - 99999
58001 - 99999
550001 - 999999
362-016 0.50 Horn switch, replacing 51936 - 52331
362-053 0.40 Back up alarm, replacing 51936 - 99999
58001 - 99999
550001 - 999999
364-004 0.50 Switch, replacing 51936 - 52331
58001 - 99999
550001 - 999999
364-011 1.25 Reverse alarm switch, replacing 51936 - 52331
364-011 0.70 Reverse alarm switch, replacing 52332 - 99999
58001 - 99999
550001 - 999999
364-013 0.50 Emergency stop switch, replacing 52332 - 99999
58001 - 99999
550001 - 999999
364-013 0.60 Emergency stop switch, replacing 51936 - 52331
364-014 0.40 Ignition switch, replacing 52332 - 99999
58001 - 99999
550001 - 999999

SD110
364-014 0.50 Ignition switch, replacing 51936 - 52331

364-050 0.40 Relay (general), replacing 52332 - 99999
58001 - 99999
364-050 0.50 Relay (general), replacing 51936 - 52331
366-100 0.50 Seat switch timer, replacing 51936 - 99999
58001 - 99999
550001 - 999999

371-011 3.50 Main wire harness, replacing 52332 - 99999
58001 - 99999
371-021 0.90 Instrument wire harness, replacing 51936 - 52331
371-021 0.90 Instrument wire harness, replacing 51936 - 52331
371-032 0.90 Rear wire harness, replacing 51936 - 52331
371-040 0.60 Battery cable negative, replacing 52332 - 99999
58001 - 99999
550001 - 999999
371-040 0.50 Battery cable negative, replacing 51936 - 52331
371-041 0.70 Battery cable +, replacing 52332 - 99999
58001 - 99999
550001 - 999999
58001 - 99999
58001 - 99999
550001 - 999999
371-049 5.50 Console wiring harness, replacing 58001 - 99999
52332 - 99999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
372-020 0.60 Fuse (general), replacing 51936 - 52331
372-020 0.40 Fuse (general), replacing 52332 - 99999
58001 - 99999
372-052 0.60 Light relay, replacing

58001 - 99999
58001 - 99999

SD110
550001 - 999999
58001 - 99999
386-016 0.40 Temperature sensor cooling system, replacing 52332 - 99999
58001 - 99999
550001 - 999999
387-006 0.50 Engine temperature gauge, replacing 51936 - 52331
387-011 0.50 Fuel level gauge, replacing 52332 - 99999
58001 - 99999
550001 - 999999
387-011 0.50 Fuel level gauge, replacing 51936 - 52331
387-020 0.50 Tachometer, replacing 51936 - 52331
387-029 0.50 Instrument panel indicator/s, replacing 52332 - 99999
58001 - 99999
550001 - 999999
387-041 0.50 Engine oil pressure gauge, replacing 51936 - 52331
387-042 1.75 Control box, replacing 52332 - 99999
58001 - 99999
550001 - 999999
421-096 0.70 Two speed solenoid valve, replacing 51936 - 99999
58001 - 99999
550001 - 999999
424-003 1.50 Propulsion control cable, replacing 51936 - 52331
424-003 1.25 Propulsion control cable, replacing 52332 - 99999
58001 - 99999
550001 - 999999
424-005 1.50 Neutral safety switch, replacing 51936 - 52331
424-005 1.25 Neutral safety switch, replacing 52332 - 99999
58001 - 99999
550001 - 999999
424-020 0.30 Propulsion control cable mounting bracket, 51936 - 52331
replacing
424-021 1.50 Control group assembly, replacing 52332 - 99999
58001 - 99999
550001 - 999999
424-021 1.50 Control group assembly, replacing 51936 - 52331
441-047 0.60 Rear axle drive motor, removing 51936 - 99999
441-047 0.70 Rear axle drive motor, removing 58001 - 99999
550001 - 999999
441-048 0.60 Rear axle drive motor, installing 51936 - 99999
441-048 0.80 Rear axle drive motor, installing 58001 - 99999

SD110
550001 - 999999
441-061 1.00 Thermal bypass valve, replacing 51936 - 99999
58001 - 99999
550001 - 999999
52332 - 99999
550001 - 999999
550001 - 999999
52332 - 99999
442-163 2.50 Propulsion pump coupling, removing 52332 - 99999
58001 - 99999
550001 - 999999
442-163 3.00 Propulsion pump coupling, removing 51936 - 52331
442-164 2.50 Propulsion pump coupling, installing 52332 - 99999
58001 - 99999
550001 - 999999
442-164 2.00 Propulsion pump coupling, installing 51936 - 52331

463-002 2.50 Axle, removing 51936 - 99999
58001 - 99999
550001 - 999999
463-003 3.00 Axle, installing 51936 - 99999
58001 - 99999
550001 - 999999
5 BRAKE
55 PARKING BRAKE
550-015 0.50 Parking brake, manually releasing 51936 - 99999
550001 - 999999
550-015 0.40 Parking brake, manually releasing 58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
551-012 0.70 Parking brake pressure switch, replacing 52332 - 99999
58001 - 99999
550001 - 999999

SD110
6 STEERING
62 STEERING AXLE
622-097 0.80 Steering bearing, replacing
64 STEERING
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
645-016 0.50 Steering pump, removing 51936 - 52331
645-017 0.60 Steering pump, installing 51936 - 52331
645-022 0.60 Steering valve, removal 52332 - 99999
58001 - 99999
550001 - 999999
645-022 0.60 Steering valve, removal 51936 - 52331
645-023 0.50 Steering valve, installation 52332 - 99999
58001 - 99999
550001 - 999999
645-023 0.70 Steering valve, installation 51936 - 52331

WHEEL/TRACK UNIT
71 FRAME
711-041 0.40 Hydraulic tank lid, cover plate gasket, replacing 58001 - 99999
52332 - 99999
550001 - 999999
711-042 0.40 Hydraulic tank breather cap, replacing 52981 - 99999
58359 - 99999
711-042 0.40 Hydraulic tank breather cap, replacing 51936 - 52331

771-001 2.00 Wheel, removing and fitting one 51936 - 99999

SD110
58001 - 99999
550001 - 999999
777-001 5.50 Drum, removing 51936 - 99999
58001 - 99999
550001 - 999999
777-002 5.00 Drum, installing 51936 - 99999
58001 - 99999
550001 - 999999
777-003 1.50 Vibration pump, removing 52332 - 99999
58001 - 99999
550001 - 999999
777-003 1.50 Vibration pump, removing 51936 - 52331
777-004 1.75 Vibration pump, installing 51936 - 52331
777-004 1.75 Vibration pump, installing 52332 - 99999
58001 - 99999
550001 - 999999
777-005 0.40 Vibration motor, removing 51936 - 99999
58001 - 99999
550001 - 999999
777-006 0.50 Vibration motor, installing 51936 - 99999
58001 - 99999
550001 - 999999
777-007 4.00 Eccentric weight, removing 51936 - 99999
58001 - 99999
550001 - 999999
777-008 3.50 Eccentric weight, installing 51936 - 99999
58001 - 99999
550001 - 999999
777-009 4.00 Drum shock mount, replacing 51936 - 99999
58001 - 99999
550001 - 999999
777-009 4.50 Drum shock mount, replacing 51936 - 99999
58001 - 99999
550001 - 999999
777-011 3.00 Torque hub, removing 51936 - 99999
777-012 3.50 Torque hub, installing 51936 - 99999
777-013 11.00 Eccentric weight bearings, replacing 51936 - 99999
58001 - 99999
550001 - 999999
777-014 9.50 Carrier bearings, replacing 51936 - 99999
58001 - 99999
550001 - 999999
777-015 8.50 Eccentric weight, overhaul 51936 - 99999
58001 - 99999
550001 - 999999
777-018 5.50 Drum drive motor, replacing 58001 - 99999
51936 - 99999
550001 - 999999
777-029 1.75 Drum assembly, removing 51936 - 99999

SD110
58001 - 99999
550001 - 999999
777-030 1.50 Drum assembly, installing 51936 - 99999
58001 - 99999
550001 - 999999
777-073 9.50 Carrier V-ring seal, replacing 51936 - 99999
58001 - 99999
550001 - 999999
777-081 0.50 Drum shock mount (single), replacing 51936 - 99999
58001 - 99999
550001 - 999999
777-092 1.25 Vibration control cable, replacing 52332 - 99999
58001 - 99999
550001 - 999999
777-092 1.25 Vibration control cable, replacing 51936 - 52331

ANYWHERE
58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999
821-003 0.40 Engine hood latch, replacing 58001 - 99999
51936 - 99999
550001 - 999999
821-028 0.50 Retractor strap assembly, replacing 51936 - 99999
58001 - 99999
550001 - 999999
821-029 1.25 Engine hood hinge, replacing 52332 - 99999
58001 - 99999
550001 - 999999
821-034 0.40 Engine hood sealing, replacing 51936 - 99999
58001 - 99999
550001 - 999999
852-008 0.60 Seat, replacing 51936 - 99999
58001 - 99999
550001 - 999999

SD110

867-002 0.90 ROPS (Roll Over Protection), removing 52332 - 99999
58001 - 99999
867-003 1.25 ROPS (Roll Over Protection), installing 52332 - 99999
58001 - 99999
881-012 0.80 Instrument panel, replacing (Center) 52332 - 99999
884-001 0.30 Seat safety belt, replacing 51936 - 99999
58001 - 99999
550001 - 999999

58001 - 99999
550001 - 999999
911-015 0.90 Oil level gauge, replacing 51936 - 52331
58001 - 99999
550001 - 999999

58001 - 99999
550001 - 999999
58001 - 99999
550001 - 999999

SD115

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
replacing
replacing
gauge
23 FUEL SYSTEM

SD115


non-programmed
pre-programmed
254-039 0.60 DPF outlet temperature sensor, replacing 235001 - 236999
254-043 0.50 Spark plug control unit, replacing 245001 - 246999
254-050 1.75 Fuel metering unit A, replacing 245001 - 246999
254-051 2.50 Fuel metering unit B, replacing 235001 - 236999
26 COOLING SYSTEM

SD115

29 Miscellaneous
293-008 3.00 EGR Actuator, replacing 245001 - 246999

30 GENERAL

ECU

441-047 1.00 Rear axle drive motor, removing
441-048 0.70 Rear axle drive motor, installing
442-070 0.40 Charge pressure relief valve, replacing

SD115

442-113 0.30 Hi/low drum drive motor valve solenoid, replacing
442-114 0.30 Hi/low drum drive motor valve, replacing
442-115 0.90 ASC (Anti-spin control) solenoid, replacing
442-116 0.30 Traction control module, replacing
442-117 0.30 Drive enable valve solenoid, replacing
442-118 0.30 Drive enable valve, replacing
5 BRAKE
55 PARKING BRAKE
554-001 0.30 Brake release valve solenoid, replacing
6 STEERING
64 STEERING

WHEEL/TRACK UNIT
71 FRAME
711-030 2.50 Drum frame, removing
711-031 3.00 Drum frame, installing
711-035 3.50 Swivel, removing
711-036 3.50 Swivel, installing
74 FRAME LINK


SD115

777-088 0.30 Vibration control module, replacing
adjusting
replacing
replacing

ANYWHERE
810-010 0.50 Operator's platform, raising
810-011 0.40 Operator's platform, lowering

821-011 0.20 Engine hood, operating
821-012 0.20 Engine hood, manually operating

SD130

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

252-022 2.50 Exhaust pipe, changing pipe between silencer and
turbocharger
replacing
26 COOLING SYSTEM
adjusting tension

31 BATTERY

SD130

33 STARTING SYSTEM


replacing

SD130

5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING

WHEEL/TRACK UNIT
74 FRAME LINK
machine separated
machine separated


SD130


ANYWHERE

821-030 2.50 Engine hood, changing spring


SD130


SD135

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM


SD135

non-programmed
pre-programmed
26 COOLING SYSTEM
29 Miscellaneous

30 GENERAL

ECU


SD135
5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING

SD135

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK

adjusting
replacing
replacing

SD135

ANYWHERE


SD160

SD200

23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

31 BATTERY
33 STARTING SYSTEM


replacing

SD200

5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

ANYWHERE


SD200



SD45

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

26 COOLING SYSTEM
adjusting tension
263-039 0.60 Cooling fan, removing
263-040 0.90 Cooling fan, installing
27 ENGINE CONTROL
272-022 1.50 Throttle control cable, replacing
272-023 0.50 Throttle control assembly, replacing
275-012 1.25 Engine speed control, mechanical basic setting

31 BATTERY

SD45

33 STARTING SYSTEM
334-020 0.40 Neutral start diode, replacing

372-025 0.50 Power relay, replacing

424-006 0.40 Neutral safety switch, adjusting
440-005 0.20 Drum drive motor, case drain flow measuring
440-015 0.70 Charge relief pressure, test
440-030 0.80 Propel system relief pressure, check
442-030 0.40 Anti cavatation valve, replacing
442-071 0.40 Traction valve flow divider, replacing
442-084 0.60 Propulsion pump function valve, replacing
442-085 0.20 Propulsion pump bypass valve, replacing
442-086 0.70 Propulsion pump, case drain flow measuring
442-092 0.50 Traction relief pressure valve, replacing
442-096 0.20 Servo shunt valve solenoid, replacing
442-097 0.20 Servo shunt valve spool, replacing
4422-001 0.50 Traction valve, removing
4422-002 0.50 Traction valve, installing


SD45
5 BRAKE
524-001 0.50 Brake latching relay, replacing
55 PARKING BRAKE
550-034 0.60 Brake manifold, brake release pressure check
550-035 0.40 Axle drive motor, brake release pressure check
554-002 0.30 Brake release valve spool, replacing
6 STEERING
64 STEERING

WHEEL/TRACK UNIT
71 FRAME

771-006 0.30 Tyres, checking pressure

SD45

777-016 0.20 Vibration control valve solenoid, replacing
777-017 0.20 Vibration control valve spool, replacing
777-051 0.40 Vibration system pressure, measuring
777-052 0.40 Vibration pump function valve, replacing

ANYWHERE


912-204 0.40 Brake shunt two speed manifold, removing
912-205 0.40 Brake shunt two speed manifold, installing

SD70

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

26 COOLING SYSTEM

SD70

31 BATTERY

33 STARTING SYSTEM


421-087 0.40 Multi function brake valve solenoid and cartridge,
replacing


SD70
5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

SD70

ANYWHERE


SD75

17 SERVICE

20 GENERAL
ECU
21 ENGINE
212-072 0.30 Crankcase ventilation separator, checking
gauge
23 FUEL SYSTEM
237-040 0.40 Overflow pipe, checking for leakage

SD75

26 COOLING SYSTEM
29 Miscellaneous


ECU

380-007 0.40 Instrument cluster, replacing

SD75
442-112 1.25 Traction control valve, replacing
442-119 0.30 Hi/low axle motor valve solenoid, replacing
442-120 0.40 Hi/low axle motor valve, replacing
5 BRAKE
55 PARKING BRAKE
6 STEERING
64 STEERING

SD75


WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK

adjusting
replacing
replacing

SD75

ANYWHERE


Ultimat 200

17 SERVICE

ANYWHERE

837-003 0.40 Left side vibration cover, removing
837-004 0.40 Left side vibration cover, installing
837-005 0.50 Right side vibration cover, removing
837-006 0.60 Right side vibration cover, installing

982-027 4.50 Horizontal guide tube, removing
982-028 4.50 Horizontal guide tube, installing
982-051 5.50 Secondary guide tube bearings, replacing
982-052 5.00 Vertical guide tube bushings, replacing
982-053 9.00 Horizontal guide tube bushings, replacing

Ultimat 200

983-136 0.90 Vibration drive belt, replacing
987-003 0.50 Power crown torque converter, removing
987-004 0.60 Power crown torque converter, installing
987-005 0.60 Power crown chain, replacing
987-010 1.00 Power crown, removing
987-011 1.75 Power crown, installing
987-012 3.50 Power crown, disassembly and assembly
987-013 2.00 Main screed strike off, removing
987-014 3.50 Main screed strike off, installing
987-021 0.90 Depth crank, disassembly and assembly
987-022 0.70 Side arm, removing
987-023 0.70 Side arm, installing
987-029 5.00 Height assembly, disassembling/assembling
987-029 5.50 Height assembly, disassembling/assembling
987-035 2.50 Inner height assembly, removing
987-036 2.50 Inner height assembly, installing
987-040 0.50 Edger guide bracket, removing
987-041 0.30 Edger guide bracket, installing

Ultimat 200
987-042 0.30 Edger guide jack, removing

987-043 0.10 Edger guide jack, installing
987-046 0.40 Edger shoe, removing
987-047 0.20 Edger shoe, installing
987-048 2.00 Screed plate, removing
987-048 1.25 Screed plate, removing
987-049 3.00 Screed plate, installing
987-049 1.50 Screed plate, installing
987-052 0.60 Extension strike off plate, removing
987-053 0.60 Extension strike off plate, installing

VB78 ETC

17 SERVICE
19 GENERAL

WHEEL/TRACK UNIT

ANYWHERE


VB78 ETC

983-150 1.50 Tamper, adjusting
983-151 0.70 Tamper bar, removing
983-152 0.90 Tamper bar, installing
983-153 1.50 Tamper shaft, removing
983-154 1.75 Tamper shaft, installing
983-155 3.00 Tamper bearing, removing
983-156 2.00 Tamper bearing, installing
983-157 0.70 Tamper motor, removing
983-158 0.50 Tamper motor, installing

VB78 GTC

17 SERVICE
19 GENERAL

WHEEL/TRACK UNIT

ANYWHERE


VB78 GTC


VB88 ETC

17 SERVICE
19 GENERAL

WHEEL/TRACK UNIT

ANYWHERE


VB88 ETC


VB88 GTC

17 SERVICE
19 GENERAL

WHEEL/TRACK UNIT

ANYWHERE


VB88 GTC


VDT-V78 ETC

17 SERVICE
19 GENERAL

WHEEL/TRACK UNIT

ANYWHERE


VDT-V78 ETC


VDT-V78 GTC

17 SERVICE
19 GENERAL

WHEEL/TRACK UNIT

ANYWHERE


VDT-V78 GTC


VDT-V88 ETC

17 SERVICE
19 GENERAL

WHEEL/TRACK UNIT

ANYWHERE


VDT-V88 ETC


VDT-V88 GTC

17 SERVICE
19 GENERAL

WHEEL/TRACK UNIT

ANYWHERE


VDT-V88 GTC


Foreword
The following applies to the use of Volvo Construction Equipment guideline times
Listed times indicate guideline times for maintenance and repairs of machines manufactured by Volvo
CE (Volvo Construction Equipment AB).
Guideline time is the time that the mechanic normally needs to perform an operation according to
the instructions normally found in each machine's service manual or component manual, and that is
performed according to the conditions listed below.
Feedback address for Time Guide: servicemanuals@volvo.com
Applicability
The time for performing an operation varies with a number of parameters, e.g., environment (where
the work is done), training and equipment. Guideline times are developed with the following
conditions:
• Workshop in an indoor environment with a solid and level concrete floor.

• Workshop equipped with lifting device that has lifting capacity and lifting height adapted to a
majority of operations (except lifting complete machine units/machine frames) performed on
machines handled by the workshop.
• Use of approved support and lifting equipment, in addition to the equipment indicated in each
machine's service manual.
• Workshop equipped with compressed air, electricity and lighting.
• Use of indicated Volvo CE special tools.
• Tools stored in easily accessed location, in the immediate vicinity of the workplace.
• Where applicable, oils/fluids are handled in an environmentally correct manner.
For guideline times to apply it is required, in addition to the above conditions, that the mechanic has
the training and experience required for the machine and the work that is being done (e.g., Basic
Course Electricity and hydraulics as well as machine course step 1 Volvo CE Service school).
Guideline times apply when one person performs the operation. However, in the operations actions
may be performed that require help from another person. In these cases, the time for that step which
requires two persons has been doubled. The guideline times do not apply if more than one mechanic
performs the entire operation.
Actions not included in guideline times are:
• Transport of machine to and from workshop site.

• Troubleshooting not described as a separate operation.
• Retrieval of spare parts, consumables and tools that are not stored in easily accessed location.
• Washing of the whole or parts of the machine before repair/maintenance.
• Actions that due to deformation, corrosion or external damage increase the repair time.
• Additional work that due to retrofitted equipment reduces access, unless these work steps are
mentioned in the method description in each service manual.
Other
For every operation there is an operation number, heading and guideline time. The description for
how the work is done is normally found in the service manual for each machine under the
corresponding operation number.

Foreword
New format of operation number
In the time guide, each operation number has a heading with a three-digit function group number
(see function group below) as well as a three-digit running number.
Example: Op no. 210-070 Engine removing
210- 070
Function group Running number (Sequential number)
Example of discontinued op. no. is 21070 alt. 21070-1 (Engine removing).
Function group:
According to Volvo Construction Equipment function group index, where the first digit indicates
section and is divided in the following functions, which follows the same design as other service
information:
1. Standard parts, service

2. Engine with mounting and equipment
3. Elec.system; Warning system; Information system; Instrumentsl
4. Power transmission
5. Brakes
6. Steering
7. Frame; Springs; Damping; Axle suspension; Wheel/track unit
8. Machinery house; Cab; Exterior trim parts anywhere
9. Hydraulic system; Digging/handling/grading equipment; Misc. Equip. hydraulics
The second and third digit (10) indicate sub-group, which in turn divides the functions within the group,
also this follows the same design as other service information.
Running number:
Running number or sequential number 001 to 899 (in the example 070) is a number to identify each
operation.
Other
Equipment:
Running number 901 to 999 are reserved for installation times for equipment (installation
instructions).
Earlier (discontinued) format of operation numbers:

From 2005-03-08, only the new format for operation numbers shall be used, with the exception of
operations for VCADS Pro. Already published service information makes use of the earlier format for
operation numbers.
VCADS Pro:
For the time being, VCADS Pro operations will adhere to the same design as before, XXXXX-X, and
will have a code digit (-3) for test procedures.

Contents
Foreword ......................................................................................................................................... 1
A25F (SN –99999) ........................................................................................................................... 7
A30F (SN –99999) ......................................................................................................................... 17
A35F (SN –99999) ......................................................................................................................... 27
A35F FS (SN –99999) ................................................................................................................... 37
A40F (SN –99999) ......................................................................................................................... 47
A40F FS (SN –99999) ................................................................................................................... 57
ABG5770 ....................................................................................................................................... 67
ABG5870 ....................................................................................................................................... 69
ABG6820 ....................................................................................................................................... 71
ABG6870 ....................................................................................................................................... 75
BL60 .............................................................................................................................................. 77
BL61 .............................................................................................................................................. 83
BL61 PLUS .................................................................................................................................... 89
BL70 .............................................................................................................................................. 93
BL71 .............................................................................................................................................. 99
BL71 PLUS .................................................................................................................................. 105
DD112HF ..................................................................................................................................... 111
DD118HF ..................................................................................................................................... 115
DD118HFA .................................................................................................................................. 119
DD132HF ..................................................................................................................................... 123
DD138HF ..................................................................................................................................... 127
DD138HFA .................................................................................................................................. 131
DD25 ........................................................................................................................................... 135
DD25W ........................................................................................................................................ 139
EC13 XR ...................................................................................................................................... 141
EC13 XTV .................................................................................................................................... 143
EC140C ....................................................................................................................................... 145
EC140C L .................................................................................................................................... 155
EC140C LM ................................................................................................................................. 163
EC15B XR ................................................................................................................................... 171
EC15B XT .................................................................................................................................... 173
EC15B XTV ................................................................................................................................. 175
EC160C L .................................................................................................................................... 177
EC160C NL ................................................................................................................................. 185
EC180C L .................................................................................................................................... 193
EC20B XT .................................................................................................................................... 201
EC20B XTV ................................................................................................................................. 203
EC210C L .................................................................................................................................... 205
EC210C LR ................................................................................................................................. 215
EC210C N ................................................................................................................................... 223
EC210C NL ................................................................................................................................. 231
EC235C NL ................................................................................................................................. 239
EC240C L .................................................................................................................................... 247
EC240C LR ................................................................................................................................. 257
EC240C NL ................................................................................................................................. 265
EC25 ............................................................................................................................................ 273
EC290C L .................................................................................................................................... 275
EC290C LR ................................................................................................................................. 283
EC290C NL ................................................................................................................................. 291
EC30 ............................................................................................................................................ 299
EC330C L .................................................................................................................................... 301
EC35 ............................................................................................................................................ 311
EC360C HR ................................................................................................................................. 315

Contents
EC360C L .................................................................................................................................... 321

EC360C NL ................................................................................................................................. 331
EC45 ............................................................................................................................................ 339
EC460C HR ................................................................................................................................. 343
EC460C L .................................................................................................................................... 349
EC55B ......................................................................................................................................... 359
EC700C L .................................................................................................................................... 367
ECR145C L ................................................................................................................................. 375
ECR235C L ................................................................................................................................. 383
ECR28 ......................................................................................................................................... 393
ECR305C L ................................................................................................................................. 399
ECR48C ...................................................................................................................................... 407
ECR58 ......................................................................................................................................... 413
ECR88 ......................................................................................................................................... 421
EW140C ...................................................................................................................................... 429
EW145B ...................................................................................................................................... 439
EW160C ...................................................................................................................................... 449
EW180C ...................................................................................................................................... 459
EW210C ...................................................................................................................................... 469
EW55B ........................................................................................................................................ 479
FC2121C ..................................................................................................................................... 487
FC2421C ..................................................................................................................................... 495
FC2924C ..................................................................................................................................... 503
FC3329C ..................................................................................................................................... 511
G930B ......................................................................................................................................... 519
G940B ......................................................................................................................................... 529
G946B ......................................................................................................................................... 539
G960B ......................................................................................................................................... 549
L110G .......................................................................................................................................... 559
L120G .......................................................................................................................................... 567
L150G .......................................................................................................................................... 575
L180G .......................................................................................................................................... 585
L180G HL .................................................................................................................................... 595
L20B ............................................................................................................................................ 603
L220G .......................................................................................................................................... 611
L250G .......................................................................................................................................... 621
L25B ............................................................................................................................................ 631
L30B ............................................................................................................................................ 639
L35B ............................................................................................................................................ 647
L45F ............................................................................................................................................ 655
L50F ............................................................................................................................................ 659
L60G ............................................................................................................................................ 663
L70G ............................................................................................................................................ 671
L90G ............................................................................................................................................ 679
MC110B ....................................................................................................................................... 687
MC60B ......................................................................................................................................... 693
MC70B ......................................................................................................................................... 699
MC80B ......................................................................................................................................... 705
MC90B ......................................................................................................................................... 711
PF6110 ........................................................................................................................................ 717
PF6160 ........................................................................................................................................ 723
PF6170 ........................................................................................................................................ 729
SD100D ....................................................................................................................................... 735
SD100F ....................................................................................................................................... 741

Contents
SD116DX ..................................................................................................................................... 747

SD116F ....................................................................................................................................... 753
SD160DX ..................................................................................................................................... 759
SD160F ....................................................................................................................................... 761
SD200DX ..................................................................................................................................... 763
SD200F ....................................................................................................................................... 767
SD45D ......................................................................................................................................... 771
SD45F ......................................................................................................................................... 775
SD70D ......................................................................................................................................... 779
SD70F ......................................................................................................................................... 783
SD77F ......................................................................................................................................... 787

A25F (SN –99999)
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A25F (SN –99999)

gauge
23 FUEL SYSTEM
237-016 12.00 Injectors, replacing copper sleeve in machine
237-123 0.70 Injector shut off, manual

254-010 0.70 DPF flame sensor, replacing
non-programmed
pre-programmed
replacing
258-015 1.50 Fan pump, installation

A25F (SN –99999)

low rpm
high rpm
26 COOLING SYSTEM
adjusting tension
low rpm
high rpm
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

A25F (SN –99999)

39 MISCELLANEOUS
ECU
421-001 0.70 Checking of main, torque converter and lubricating
oil pressure
421-058 2.00 Retarder valve, replacing
43 GEARBOX,
unit
45 PROPELLER SHAFT
451-006 6.50 Intermediate shaft and/or bearing, replacing (in
frame joint)

461-006 8.50 Spindle, replacing one side

A25F (SN –99999)

replacing
48 POWER TAKE OFF

482-004 8.50 Power take-off, between engine and gearbox,
reconditioning
5 BRAKE
51 WHEEL BRAKE
511-005 1.75 Brake pads, replacing (one wheel, front axle)
511-045 4.00 Brake calliper, replacing one
512-005 1.75 Brake pads, replacing (one wheel, first boggie
axle)
512-045 4.00 Brake caliper, replacing one
513-005 1.75 Brake pads, replacing (one wheel, 2:d boggie axle)

pressure
55 PARKING BRAKE
550-012 3.00 Parking brake , replacing brake caliper
and adjusting
553-003 0.40 Load and dump brake, servo accumulator,
checking

A25F (SN –99999)
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting
replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
replacing

A25F (SN –99999)

725-013 0.40 Suspension cylinder (GHS), function check
74 FRAME LINK
separated)
75 AXLE SUSPENSION
(front)
removed beam


ANYWHERE

A25F (SN –99999)





A25F (SN –99999)

90 GENERAL
ECU
ECU

pressure
working pressure
working pressure
95 LOAD CARRIER
adjusting

A25F (SN –99999)
99 MISCELLANEOUS

A30F (SN –99999)
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A30F (SN –99999)

gauge
23 FUEL SYSTEM

non-programmed
pre-programmed
replacing

A30F (SN –99999)

low rpm
high rpm
26 COOLING SYSTEM
adjusting tension
low rpm
high rpm
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

A30F (SN –99999)

39 MISCELLANEOUS
ECU
oil pressure
421-058 2.00 Retarder valve, replacing
43 GEARBOX,
unit
45 PROPELLER SHAFT
451-006 6.50 Intermediate shaft and/or bearing, replacing (in
frame joint)


A30F (SN –99999)

replacing
48 POWER TAKE OFF

reconditioning
5 BRAKE
51 WHEEL BRAKE
511-005 1.75 Brake pads, replacing (one wheel, front axle)
511-045 4.00 Brake calliper, replacing one
512-005 1.75 Brake pads, replacing (one wheel, first boggie
axle)
513-005 1.75 Brake pads, replacing (one wheel, 2:d boggie axle)

pressure
55 PARKING BRAKE
and adjusting
checking

A30F (SN –99999)
59 MISCELLANEOUS
6 STEERING
64 STEERING
adjusting
replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
replacing

A30F (SN –99999)

725-013 0.40 Suspension cylinder (GHS), function check
74 FRAME LINK
separated)
75 AXLE SUSPENSION
(front)
removed beam


ANYWHERE


A30F (SN –99999)





90 GENERAL

A30F (SN –99999)

ECU
ECU

pressure
working pressure
working pressure
95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A35F (SN –99999)
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A35F (SN –99999)

23 FUEL SYSTEM

non-programmed
pre-programmed
replacing

A35F (SN –99999)

low rpm
high rpm
26 COOLING SYSTEM
adjusting tension
low rpm
high rpm
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

A35F (SN –99999)

39 MISCELLANEOUS
ECU
oil pressure
43 GEARBOX,
unit

replacing

A35F (SN –99999)

48 POWER TAKE OFF

reconditioning
5 BRAKE
51 WHEEL BRAKE
516-010 5.00 Wheel brake, replacing

pressure
55 PARKING BRAKE
and adjusting
checking
59 MISCELLANEOUS

A35F (SN –99999)
6 STEERING
64 STEERING
adjusting
replacing bearings
647-095 1.00 Auxiliary steering, adjusting working- and stand-by10001 - 16999
pressure

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
727-002 2.50 Rubber element, replacing
74 FRAME LINK
separated)

A35F (SN –99999)
75 AXLE SUSPENSION
removed beam


ANYWHERE




A35F (SN –99999)


90 GENERAL
ECU
ECU

pressure
working pressure
working pressure

A35F (SN –99999)


95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A35F FS (SN –99999)
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A35F FS (SN –99999)

23 FUEL SYSTEM

non-programmed
pre-programmed
replacing

A35F FS (SN –99999)

low rpm
high rpm
26 COOLING SYSTEM
adjusting tension
low rpm
high rpm
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

A35F FS (SN –99999)

39 MISCELLANEOUS
ECU
oil pressure
43 GEARBOX,
unit

replacing

A35F FS (SN –99999)

48 POWER TAKE OFF

reconditioning
5 BRAKE
51 WHEEL BRAKE

pressure
55 PARKING BRAKE
and adjusting
checking
59 MISCELLANEOUS

A35F FS (SN –99999)
6 STEERING
64 STEERING
adjusting
replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
replacing
replacing

A35F FS (SN –99999)

adjusting
adjusting
adjusting
74 FRAME LINK
75 AXLE SUSPENSION


A35F FS (SN –99999)

ANYWHERE





A35F FS (SN –99999)

90 GENERAL
ECU
ECU

pressure
working pressure
working pressure
95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A40F (SN –99999)
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A40F (SN –99999)

23 FUEL SYSTEM

non-programmed
pre-programmed
replacing

A40F (SN –99999)

low rpm
high rpm
26 COOLING SYSTEM
adjusting tension
low rpm
high rpm
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

A40F (SN –99999)

39 MISCELLANEOUS
ECU
oil pressure
43 GEARBOX,
unit

replacing

A40F (SN –99999)

48 POWER TAKE OFF

reconditioning
5 BRAKE
51 WHEEL BRAKE

pressure
55 PARKING BRAKE
and adjusting
checking
59 MISCELLANEOUS

A40F (SN –99999)
6 STEERING
64 STEERING
adjusting
replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
727-002 2.50 Rubber element, replacing
74 FRAME LINK
separated)

A40F (SN –99999)
75 AXLE SUSPENSION
removed beam


ANYWHERE




A40F (SN –99999)


90 GENERAL
ECU
ECU

pressure
working pressure
working pressure

A40F (SN –99999)


95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

A40F FS (SN –99999)
0 GENERAL
09 MISCELLANEOUS

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing

A40F FS (SN –99999)

23 FUEL SYSTEM

non-programmed
pre-programmed
replacing

A40F FS (SN –99999)

low rpm
high rpm
26 COOLING SYSTEM
adjusting tension
low rpm
high rpm
29 Miscellaneous

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

A40F FS (SN –99999)

39 MISCELLANEOUS
ECU
oil pressure
43 GEARBOX,
unit

replacing

A40F FS (SN –99999)

48 POWER TAKE OFF

reconditioning
5 BRAKE
51 WHEEL BRAKE

pressure
55 PARKING BRAKE
and adjusting
checking
59 MISCELLANEOUS

A40F FS (SN –99999)
6 STEERING
64 STEERING
adjusting
replacing bearings
pressure

WHEEL/TRACK UNIT
71 FRAME
72 SUSPENSION
replacing
replacing

A40F FS (SN –99999)

adjusting
adjusting
adjusting
74 FRAME LINK
separated)
75 AXLE SUSPENSION


A40F FS (SN –99999)

ANYWHERE





A40F FS (SN –99999)

90 GENERAL
ECU
ECU

pressure
working pressure
working pressure
95 LOAD CARRIER
adjusting
99 MISCELLANEOUS

ABG5770

17 SERVICE
19 GENERAL

30 GENERAL
43 GEARBOX,

ABG5770
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

983-118 0.90 Conveyor drive chain, removing 22092 - 999999
983-119 0.70 Conveyor drive chain, installing 22092 - 999999
assembly
983-143 0.10 Auger flight, installing 22092 - 999999

ABG5870

17 SERVICE
19 GENERAL

30 GENERAL
43 GEARBOX,

ABG5870
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

assembly

ABG6820

17 SERVICE
19 GENERAL

30 GENERAL

387-032 1.50 Main control unit memory battery, replacing 17958 - 999999

ABG6820

WHEEL/TRACK UNIT

ANYWHERE


ABG6820

assembly

ABG6870

17 SERVICE
19 GENERAL

30 GENERAL
43 GEARBOX,

ABG6870
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

assembly

BL60

17 SERVICE
173-059 0.50 Engine, changing oil and filter 10939 - 11314
173-063 0.50 Transmission, oil filter, changing

21 ENGINE
210-070 6.00 Engine, removing 11315 - 99999
23 FUEL SYSTEM

26 COOLING SYSTEM

BL60

263-085 1.25 Fan shroud, additional sheet, installing 11315 - 99999
27 ENGINE CONTROL
272-010 4.00 Accelerator control cable, changing 11315 - 99999

30 GENERAL
302-130 0.50 Loader lever, electrical measuring 11315 - 99999
31 BATTERY

39 MISCELLANEOUS
421-002 0.80 Transmission oil pressure, checking 10939 - 99999
421-025 0.50 Transmission solenoid, replacing 10939 - 99999

5 BRAKE

BL60
55 PARKING BRAKE
550-002 0.30 Parking brake, adjusting 10939 - 19999
6 STEERING
62 STEERING AXLE
64 STEERING
643-011 0.40 Steering angle, adjustment

WHEEL/TRACK UNIT
71 FRAME
716-004 0.30 Additional counterweight, removing 11315 - 99999
716-005 0.50 Additional counterweight, installing 10001 - 11314


BL60

ANYWHERE
851-008 0.70 Headliner, installing 10939 - 99999
851-009 0.80 Headliner, removing 10939 - 99999

90 GENERAL
900-005 0.20 Vacuum pump, connection 10001 - 10938
900-006 0.10 Vacuum pump, disconnection 10939 - 11314

910-004 1.50 Hydraulic pressure, adjusting
912-047 2.00 Main valve block, backhoe, removal 11315 - 99999
912-048 2.00 Main valve block, backhoe, installation 11315 - 99999
912-054 1.00 Pressure regulating valve, replacing
adjusting

BL60

97 UNIT, DIGGING
974-083 1.00 Boom lock cylinder, reconditioning

BL61

17 SERVICE

21 ENGINE
210-070 6.00 Engine, removing 11459 - 99999
23 FUEL SYSTEM

26 COOLING SYSTEM

BL61

27 ENGINE CONTROL

30 GENERAL
31 BATTERY

39 MISCELLANEOUS

5 BRAKE

BL61
55 PARKING BRAKE
6 STEERING
62 STEERING AXLE
64 STEERING

WHEEL/TRACK UNIT
71 FRAME


BL61

ANYWHERE

90 GENERAL

adjusting

BL61

97 UNIT, DIGGING
972-005 0.70 Stabilizer cylinder, removal
972-006 0.60 Stabilizer cylinder, installation

BL61 PLUS

17 SERVICE

21 ENGINE
210-070 6.00 Engine, removing 10287 - 99999
23 FUEL SYSTEM

26 COOLING SYSTEM

BL61 PLUS

27 ENGINE CONTROL

30 GENERAL
31 BATTERY
39 MISCELLANEOUS

5 BRAKE
55 PARKING BRAKE

BL61 PLUS
6 STEERING
62 STEERING AXLE
64 STEERING

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

BL61 PLUS

90 GENERAL

adjusting

97 UNIT, DIGGING

BL70

17 SERVICE
173-062 0.40 Transmission, changing oil 10001 - 11144

21 ENGINE
210-070 6.00 Engine, removing 11489 - 99999
23 FUEL SYSTEM

26 COOLING SYSTEM

BL70

27 ENGINE CONTROL

30 GENERAL
31 BATTERY

39 MISCELLANEOUS


BL70
5 BRAKE
55 PARKING BRAKE
6 STEERING
62 STEERING AXLE
64 STEERING

WHEEL/TRACK UNIT
71 FRAME


BL70

ANYWHERE

90 GENERAL

910-004 2.00 Hydraulic pressure, adjusting 10658 - 99999
912-041 2.50 Main valve block, removal 11489 - 99999
912-042 3.00 Main valve block, installation 11489 - 99999

BL70

adjusting

97 UNIT, DIGGING

BL71

17 SERVICE
173-062 0.40 Transmission, changing oil 10001 - 14669

21 ENGINE
210-070 6.00 Engine, removing 16827 - 99999
211-080 0.50 Cylinder heads all, removing
211-082 1.50 Cylinder heads all, fitting
218-003 2.00 Engine mount, right rear, changing
23 FUEL SYSTEM

BL71


26 COOLING SYSTEM
27 ENGINE CONTROL

30 GENERAL
31 BATTERY

39 MISCELLANEOUS

BL71


5 BRAKE
55 PARKING BRAKE
6 STEERING
62 STEERING AXLE
64 STEERING

WHEEL/TRACK UNIT
71 FRAME

BL71


ANYWHERE

90 GENERAL

910-004 2.00 Hydraulic pressure, adjusting 11702 - 99999

BL71

adjusting

97 UNIT, DIGGING
972-013 0.30 Stabilisers, adjusting wearpads 10001 - 16826
972-013 0.30 Stabilisers, adjusting wearpads 16827 - 99999
972-090 0.50 Stabiliser wear pads, replacing 10001 - 16826
972-090 0.50 Stabiliser wear pads, replacing 16827 - 99999

BL71 PLUS

17 SERVICE

21 ENGINE
210-070 6.00 Engine, removing 10495 - 99999
23 FUEL SYSTEM

26 COOLING SYSTEM

BL71 PLUS
27 ENGINE CONTROL

30 GENERAL
31 BATTERY
39 MISCELLANEOUS

5 BRAKE
55 PARKING BRAKE

BL71 PLUS
6 STEERING
62 STEERING AXLE
64 STEERING

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

BL71 PLUS

90 GENERAL

adjusting

97 UNIT, DIGGING

BL71 PLUS


DD112HF

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

26 COOLING SYSTEM

DD112HF

31 BATTERY

33 STARTING SYSTEM


5 BRAKE
55 PARKING BRAKE

DD112HF
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

ANYWHERE


DD112HF




DD118HF

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

26 COOLING SYSTEM

DD118HF

31 BATTERY

33 STARTING SYSTEM


5 BRAKE
55 PARKING BRAKE

DD118HF
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

ANYWHERE


DD118HF




DD118HFA

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

26 COOLING SYSTEM

DD118HFA

31 BATTERY

33 STARTING SYSTEM


5 BRAKE
55 PARKING BRAKE

DD118HFA
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

ANYWHERE


DD118HFA




DD132HF

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

26 COOLING SYSTEM

DD132HF

31 BATTERY

33 STARTING SYSTEM


5 BRAKE
55 PARKING BRAKE

DD132HF
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

ANYWHERE


DD132HF




DD138HF

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

26 COOLING SYSTEM

DD138HF

31 BATTERY

33 STARTING SYSTEM


5 BRAKE
55 PARKING BRAKE

DD138HF
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

ANYWHERE


DD138HF




DD138HFA

17 SERVICE

21 ENGINE
23 FUEL SYSTEM

26 COOLING SYSTEM

DD138HFA

31 BATTERY

33 STARTING SYSTEM


5 BRAKE
55 PARKING BRAKE

DD138HFA
6 STEERING
64 STEERING

WHEEL/TRACK UNIT

ANYWHERE


DD138HFA




DD25

17 SERVICE
19 GENERAL

21 ENGINE
23 FUEL SYSTEM
235-004 3.00 Fuel pipes, replacing

26 COOLING SYSTEM
27 ENGINE CONTROL
272-011 1.25 Accelerator lever throttle cable, removing
272-012 1.25 Accelerator lever throttle cable, installing

31 BATTERY

DD25

33 STARTING SYSTEM
35 LIGHTING


371-045 0.20 Battery disconnector, installation
442-160 1.00 Travel lever throttle cable, removing
442-161 1.25 Travel lever throttle cable, installing
442-162 0.60 Travel lever throttle cable, adjusting
5 BRAKE
55 PARKING BRAKE
550-026 0.30 Parking brake, activate manually
550-027 0.40 Parking brake, deactivate manually
6 STEERING
64 STEERING

DD25

WHEEL/TRACK UNIT
74 FRAME LINK
740-001 2.00 Articulation hinge, disassembly
740-002 2.50 Articulation hinge, assembly

777-034 0.50 Scraper strip, replacing
777-035 0.40 Scraper set, removing
777-036 0.30 Scraper set, installing
777-039 0.50 Offset drum, adjusting
777-040 0.70 Drum drive, removing
777-042 5.00 Eccentric shaft, removing
777-043 5.50 Eccentric shaft, installing
777-044 1.50 Travel bearings, removing
777-045 1.75 Travel bearings, installing

ANYWHERE


DD25



DD25W

EC13 XR

17 SERVICE
Programme
Programme

21 ENGINE
210-076 8.00 Engine, replacing
216-003 3.00 Main bearing shells, replacing, removed sump
216-015 4.00 Crankshaft engine removed, replacing
222-011 0.25 Oil filter, replacing
23 FUEL SYSTEM
233-041 0.25 Fuel strainer, changing
timing


EC13 XR
26 COOLING SYSTEM
replacing all belts
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting

362-092 0.50 Melody horn (buzzer), replacing

EC13 XTV

17 SERVICE
Programme
Programme

21 ENGINE
23 FUEL SYSTEM
timing


EC13 XTV
26 COOLING SYSTEM
replacing all belts
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting

362-092 0.50 Melody horn (buzzer), replacing

EC140C

17 SERVICE
machine data
Programme
Programme

20 GENERAL
ECU
21 ENGINE
gauge

EC140C
23 FUEL SYSTEM
233-016 0.70 Fuel filter housing, replacing
233-017 0.70 Water separator housing, replacing

replacing
258-030 1.50 Charge air system, inspection
26 COOLING SYSTEM
adjusting tension
replacing all belts

EC140C

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU



EC140C

386-043 0.50 Travel speed sensor or alarm sensor, replacing
replacing
39 MISCELLANEOUS
390-903 3.00 CareTrack standard cab, installing new
390-904 3.00 CareTrack optional cab, installing new
393-021 0.60 Radio, replacing 110013 - 310000
393-021 0.60 Radio, replacing 110001 - 110012
43 GEARBOX,

EC140C

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

EC140C






EC140C

911-017 1.50 Suction cover, replacing
replacing
working pressure
914-037 1.00 Servo pump shaft seal, replacing
replacing
924-001 1.00 Quickfit pump (gear pump), replacing
924-021 2.00 Quickfit hydraulic cylinder bracket (body),
replacing

EC140C
97 UNIT, DIGGING
and/or bushes
974-026 3.00 Boom cylinder rod, replacing
975-029 3.50 Dipper arm cylinder rod, replacing
replacing
and/or bushes

EC140C
975-076 3.00 Bucket cylinder rod, replacing

EC140C L

17 SERVICE

20 GENERAL
ECU
21 ENGINE
23 FUEL SYSTEM


EC140C L
26 COOLING SYSTEM

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

EC140C L

39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110013 - 310000
393-021 0.60 Radio, replacing 110001 - 110012
43 GEARBOX,
replacing
replacing
49 MISCELLANEOUS

EC140C L

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE



EC140C L


replacing

EC140C L

97 UNIT, DIGGING
replacing

EC140C L

EC140C LM

17 SERVICE

20 GENERAL
ECU
21 ENGINE
23 FUEL SYSTEM


EC140C LM
26 COOLING SYSTEM

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

EC140C LM

39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110013 - 310000
393-021 0.60 Radio, replacing 110001 - 110012
43 GEARBOX,
replacing
replacing
49 MISCELLANEOUS

EC140C LM

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE



EC140C LM


replacing

EC140C LM

97 UNIT, DIGGING
replacing

EC140C LM

EC15B XR

17 SERVICE
Programme

21 ENGINE
23 FUEL SYSTEM
timing


EC15B XR
26 COOLING SYSTEM
replacing all belts
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting


EC15B XT

17 SERVICE
Programme

21 ENGINE
23 FUEL SYSTEM
timing

26 COOLING SYSTEM

EC15B XT

replacing all belts
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting


EC15B XTV

17 SERVICE
Programme

21 ENGINE
23 FUEL SYSTEM
timing

26 COOLING SYSTEM

EC15B XTV

replacing all belts
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting


EC160C L

17 SERVICE
machine data
Programme
Programme
173-030 0.30 Maintenance service, according to display
message

20 GENERAL
ECU
21 ENGINE

EC160C L

gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

EC160C L

adjusting tension
replacing all belts

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

EC160C L

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 120001 - 120512
140001 - 140010
393-021 0.60 Radio, replacing 120513 - 320000
140011 - 340000
43 GEARBOX,

EC160C L

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE


EC160C L





EC160C L

911-032 1.50 Oil cooler line pipe coupling, replacing
replacing
working pressure
replacing
replacing
97 UNIT, DIGGING

EC160C L

and/or bushes
and/or bushes

EC160C NL

17 SERVICE
message

20 GENERAL
ECU
21 ENGINE
23 FUEL SYSTEM

EC160C NL


replacing
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM

EC160C NL

35 LIGHTING

ECU

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 120513 - 320000
140011 - 340000
393-021 0.60 Radio, replacing 120001 - 120512
140001 - 140010
43 GEARBOX,

EC160C NL

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

EC160C NL





EC160C NL

replacing
97 UNIT, DIGGING

EC160C NL


EC180C L

17 SERVICE
machine data
Programme
Programme
message

20 GENERAL
ECU
21 ENGINE

EC180C L

gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

EC180C L

adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC180C L

ECU

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 120144 - 320000
393-021 0.60 Radio, replacing 120001 - 120143
43 GEARBOX,

EC180C L

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

EC180C L






EC180C L

replacing
working pressure
replacing
replacing

EC180C L
97 UNIT, DIGGING
and/or bushes
and/or bushes

EC20B XT

17 SERVICE
Programme

21 ENGINE
23 FUEL SYSTEM
timing

26 COOLING SYSTEM

EC20B XT

replacing all belts
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting


EC20B XTV

17 SERVICE
Programme

21 ENGINE
23 FUEL SYSTEM
timing

26 COOLING SYSTEM

EC20B XTV

replacing all belts
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting


EC210C L

17 SERVICE
machine data
Programme
Programme
message

20 GENERAL
ECU
ECU
21 ENGINE

EC210C L

gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

EC210C L

adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC210C L

ECU
ECU


replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 111025 - 310000
140018 - 340000
120533 - 310000
393-021 0.60 Radio, replacing 110001 - 111024
140001 - 140017
120001 - 120532
43 GEARBOX,

EC210C L

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

EC210C L

replacing

ANYWHERE





EC210C L


replacing
working pressure

EC210C L

replacing
replacing
97 UNIT, DIGGING
and/or bushes

EC210C L

replacing
and/or bushes
99 MISCELLANEOUS

EC210C LR

17 SERVICE
message

20 GENERAL
ECU
ECU
21 ENGINE
23 FUEL SYSTEM

EC210C LR


replacing
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

EC210C LR


33 STARTING SYSTEM
35 LIGHTING

ECU
ECU


replacing
39 MISCELLANEOUS

EC210C LR
393-021 0.60 Radio, replacing 111025 - 140000

140018 - 340000
120533 - 310000
393-021 0.60 Radio, replacing 110001 - 111024
140001 - 140017
120001 - 120532
43 GEARBOX,
replacing
replacing
49 MISCELLANEOUS

EC210C LR

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE



EC210C LR


replacing

EC210C LR

97 UNIT, DIGGING
99 MISCELLANEOUS

EC210C N

17 SERVICE
message

20 GENERAL
ECU
ECU
21 ENGINE
23 FUEL SYSTEM

EC210C N


replacing
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

EC210C N


33 STARTING SYSTEM
35 LIGHTING

ECU
ECU


replacing
39 MISCELLANEOUS

EC210C N
393-021 0.60 Radio, replacing 111025 - 140000

140018 - 340000
120533 - 310000
393-021 0.60 Radio, replacing 110001 - 111024
140001 - 140017
120001 - 120532
43 GEARBOX,
replacing
replacing
49 MISCELLANEOUS

EC210C N

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE



EC210C N


replacing

EC210C N

97 UNIT, DIGGING
99 MISCELLANEOUS

EC210C NL

17 SERVICE
message

20 GENERAL
ECU
ECU
21 ENGINE
23 FUEL SYSTEM

EC210C NL


replacing
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

EC210C NL


33 STARTING SYSTEM
35 LIGHTING

ECU
ECU


replacing
39 MISCELLANEOUS

EC210C NL
393-021 0.60 Radio, replacing 111025 - 140000

140018 - 340000
120533 - 310000
393-021 0.60 Radio, replacing 110001 - 111024
140001 - 140017
120001 - 120532
43 GEARBOX,
replacing
replacing
49 MISCELLANEOUS

EC210C NL

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE



EC210C NL


replacing

EC210C NL

97 UNIT, DIGGING
99 MISCELLANEOUS

EC235C NL

17 SERVICE
machine data
Programme
Programme
message

20 GENERAL
ECU
21 ENGINE

EC235C NL
gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM
adjusting tension

EC235C NL

replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

EC235C NL

replacing
39 MISCELLANEOUS
43 GEARBOX,

EC235C NL

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

EC235C NL






EC235C NL

replacing
replacing
replacing

EC235C NL
97 UNIT, DIGGING
and/or bushes

EC240C L

17 SERVICE
machine data
Programme
Programme

20 GENERAL
ECU
21 ENGINE

EC240C L
gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

EC240C L

adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC240C L

ECU

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110359 - 310000
120001 - 320000
393-021 0.60 Radio, replacing 110001 - 110358
120001 - 120001
43 GEARBOX,
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000

EC240C L

145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
443-039 1.00 Center passage hose (valve – center passage), 115001 - 120000
replacing 145001 - 310000
125001 - 140000
443-040 1.50 Center passage hose (center passage – motor), 115001 - 120000
replacing 145001 - 310000
125001 - 140000
49 MISCELLANEOUS
145001 - 310000
125001 - 140000

WHEEL/TRACK UNIT
71 FRAME

EC240C L

replacing

ANYWHERE





EC240C L


140001 - 210000
120001 - 140000
replacing
working pressure

EC240C L

replacing
replacing
97 UNIT, DIGGING
and/or bushes
974-047 0.50 Adapter, removal
974-048 0.60 Adapter, installation

EC240C L

and/or bushes
99 MISCELLANEOUS

EC240C LR

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC240C LR


replacing
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

EC240C LR


33 STARTING SYSTEM
35 LIGHTING

ECU

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110359 - 310000
120001 - 320000
393-021 0.60 Radio, replacing 110001 - 110358
120001 - 120001

EC240C LR
43 GEARBOX,
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
replacing 145001 - 310000
125001 - 140000
replacing 145001 - 310000
125001 - 140000
49 MISCELLANEOUS
145001 - 310000
125001 - 140000

EC240C LR

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE




EC240C LR


140001 - 210000
120001 - 140000
replacing
replacing

EC240C LR
97 UNIT, DIGGING
99 MISCELLANEOUS

EC240C NL

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC240C NL


replacing
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

EC240C NL


33 STARTING SYSTEM
35 LIGHTING

ECU

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110359 - 310000
120001 - 320000
393-021 0.60 Radio, replacing 110001 - 110358
120001 - 120001

EC240C NL
43 GEARBOX,
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
145001 - 310000
125001 - 140000
replacing 145001 - 310000
125001 - 140000
replacing 145001 - 310000
125001 - 140000
49 MISCELLANEOUS
145001 - 310000
125001 - 140000

EC240C NL

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE




EC240C NL


140001 - 210000
120001 - 140000
replacing
replacing

EC240C NL
97 UNIT, DIGGING
99 MISCELLANEOUS

EC25

EC290C L

17 SERVICE
machine data
Programme
Programme

20 GENERAL
ECU
21 ENGINE

EC290C L
gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

EC290C L

adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC290C L

ECU

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110339 - 310000
393-021 0.60 Radio, replacing 110001 - 110338
43 GEARBOX,

EC290C L

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

EC290C L

ANYWHERE





EC290C L

replacing
working pressure
913-029 0.40 Pump regulator, replacing 115001 - 310000
replacing

EC290C L
replacing
97 UNIT, DIGGING
and/or bushes
and/or bushes

EC290C LR

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC290C LR


replacing
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

EC290C LR


33 STARTING SYSTEM
35 LIGHTING

ECU

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110339 - 310000
393-021 0.60 Radio, replacing 110001 - 110338

EC290C LR
43 GEARBOX,
replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME


EC290C LR

replacing

ANYWHERE




EC290C LR

replacing
97 UNIT, DIGGING

EC290C LR


EC290C NL

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC290C NL


replacing
26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

EC290C NL


33 STARTING SYSTEM
35 LIGHTING

ECU

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110339 - 310000
393-021 0.60 Radio, replacing 110001 - 110338

EC290C NL
43 GEARBOX,
replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME


EC290C NL

replacing

ANYWHERE




EC290C NL

replacing
97 UNIT, DIGGING

EC290C NL


EC30

EC330C L

17 SERVICE
machine data
Programme
Programme
173-079 1.00 Swing motor gearbox, changing oil 110001 - 210000
140001 - 140051
173-101 0.50 Track motor gearbox, changing oil 110001 - 210000
140001 - 140051

20 GENERAL
ECU
21 ENGINE

EC330C L

gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

EC330C L

adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

EC330C L

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110001 - 310000
393-021 0.60 Radio, replacing 110001 - 140000
140001 - 310000
43 GEARBOX,
145001 - 210000

EC330C L
140001 - 145000
140001 - 145000
140001 - 145000
replacing 140001 - 145000
replacing 140001 - 145000
49 MISCELLANEOUS
140001 - 145000

WHEEL/TRACK UNIT
71 FRAME

replacing

EC330C L

ANYWHERE





EC330C L

replacing
working pressure
replacing

EC330C L

replacing
97 UNIT, DIGGING
and/or bushes
and/or bushes
99 MISCELLANEOUS

EC330C L

EC35

17 SERVICE
Programme
Programme
incl.cleaning tank

21 ENGINE
23 FUEL SYSTEM
timing
237-019 0.50 Fuel line, leak-off pipe, replacing

26 COOLING SYSTEM

EC35

adjusting tension
27 ENGINE CONTROL
272-010 1.50 Accelerator control cable, changing

33 STARTING SYSTEM
35 LIGHTING


371-042 0.75 Cables, changing battery ground lead

43 GEARBOX,

EC35
441-012 0.50 Travel motor relief valve, replacing
443-013 5.00 Turning joint, replacing

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

821-006 0.25 Engine hood, removing (on site)


844-052 2.00 Sliding window, changing

873-097 1.50 Heater hose, replacing

EC35

cylinder)
912-075 2.00 Rupture valve hose or pipe, replacing (dipper arm
cylinder)
914-071 2.50 Servo pipe and hose, replacing
915-001 0.50 Servo valve, solenoid replacing

EC360C HR

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EC360C HR


replacing
26 COOLING SYSTEM
replacing all belts

30 GENERAL


EC360C HR
33 STARTING SYSTEM
35 LIGHTING

ECU

replacing
39 MISCELLANEOUS
43 GEARBOX,

EC360C HR
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE



EC360C HR


replacing
replacing

EC360C HR

97 UNIT, DIGGING

EC360C L

17 SERVICE
machine data
Programme
Programme
140001 - 140082
145001 - 340000
140001 - 140082

20 GENERAL
ECU
21 ENGINE

EC360C L

gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

EC360C L

adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC360C L

ECU

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110001 - 110187
43 GEARBOX,
145001 - 210000
145001 - 210000

EC360C L

145001 - 210000
140001 - 145000
140001 - 145000
140001 - 145000
replacing 140001 - 145000
replacing 140001 - 145000
49 MISCELLANEOUS
145001 - 340000
140001 - 145000

WHEEL/TRACK UNIT
71 FRAME

EC360C L

replacing

ANYWHERE





EC360C L


replacing
working pressure

EC360C L

replacing
replacing
97 UNIT, DIGGING
and/or bushes

EC360C L

and/or bushes
99 MISCELLANEOUS

EC360C NL

17 SERVICE
140001 - 140082
145001 - 340000
140001 - 140082

20 GENERAL
ECU
21 ENGINE

EC360C NL
gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM
replacing all belts

EC360C NL

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU


EC360C NL

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110001 - 110187
393-021 0.60 Radio, replacing 110188 - 140000
140001 - 310000
43 GEARBOX,
145001 - 210000
145001 - 210000
145001 - 210000
140001 - 145000
140001 - 145000
140001 - 145000
replacing 140001 - 145000

EC360C NL
replacing 140001 - 145000
49 MISCELLANEOUS
145001 - 340000
140001 - 145000

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE

EC360C NL




replacing

EC360C NL

replacing
97 UNIT, DIGGING

EC360C NL

99 MISCELLANEOUS

EC45

17 SERVICE
Programme
Programme
incl.cleaning tank

21 ENGINE
23 FUEL SYSTEM
timing
237-019 0.50 Fuel line, leak-off pipe, replacing


EC45
26 COOLING SYSTEM
adjusting tension
27 ENGINE CONTROL
272-010 1.50 Accelerator control cable, changing

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
352-008 0.25 Headlamp reflector and/or glass, replacing one
incl adjusting


371-042 0.75 Cables, changing battery ground lead


EC45
43 GEARBOX,
443-013 5.00 Turning joint, replacing

WHEEL/TRACK UNIT
71 FRAME

775-031 2.50 Track chain assembly, replacing (incl. shoe fitting)

ANYWHERE

821-006 0.25 Engine hood, removing (on site)


EC45

844-052 2.00 Sliding window, changing


cylinder)
cylinder)
915-001 0.50 Servo valve, solenoid replacing

EC460C HR

17 SERVICE

20 GENERAL
ECU
21 ENGINE
23 FUEL SYSTEM

EC460C HR


replacing
26 COOLING SYSTEM
replacing all belts

30 GENERAL

33 STARTING SYSTEM
35 LIGHTING

EC460C HR

ECU

replacing
39 MISCELLANEOUS
replacing
replacing
49 MISCELLANEOUS

EC460C HR

WHEEL/TRACK UNIT

ANYWHERE





EC460C HR

replacing
replacing

940-006 2.00 Demolition equipment, removal
940-007 2.50 Demolition equipment, installation
944-004 2.00 Base boom modular joint cylinder, replacing
944-006 1.25 Base boom modular joint cylinder pin, replacing
97 UNIT, DIGGING

EC460C L

17 SERVICE
machine data
Programme
Programme

20 GENERAL
ECU
21 ENGINE

EC460C L
gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM
adjusting tension

EC460C L

replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

EC460C L

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110001 - 110128
393-021 0.60 Radio, replacing 110129 - 310000
43 GEARBOX,

EC460C L

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

EC460C L

ANYWHERE





EC460C L

replacing
working pressure
replacing

EC460C L

replacing
97 UNIT, DIGGING
and/or bushes
and/or bushes
99 MISCELLANEOUS

EC460C L

EC55B

17 SERVICE
Programme
Programme

21 ENGINE
23 FUEL SYSTEM
timing

EC55B

26 COOLING SYSTEM
adjusting tension
replacing all belts

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


EC55B


372-091 0.50 Slow blow fuse, replacing

39 MISCELLANEOUS
395-022 1.00 Antenna cable, replacing
43 GEARBOX,
431-125 1.75 Track unit, removal
431-126 1.75 Track unit, installation

EC55B
441-023 3.50 Swing motor, replacing cylinder block

441-028 0.75 Swing motor brake valve, replacing
replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

EC55B

ANYWHERE



872-011 1.00 Duct, replacing
872-021 1.00 Defroster hose, replacing
874-081 1.50 Liquid hose, replacing incl. draining and filling
874-082 1.25 Discharge hose, replacing incl. draining and filling
874-083 1.25 Suction hose, replacing incl. draining and filling
874-091 1.00 Switch and controller, replacing

911-004 0.50 Suction strainer, replacing

EC55B

replacing
911-043 0.25 Servo system filter, replacing
cylinder)
cylinder)
916-091 0.50 Hammer and shear pipe, replacing (for boom)
916-092 0.50 Hammer and shear hose, replacing (for boom)
916-093 0.50 Hammer and shear pipe, replacing (for dipper arm)
916-094 0.50 Hammer and shear hose, replacing (for dipper
arm)
916-095 0.50 Hammer and shear hose and pipe, replacing
(MCV - 3 way valve)

EC55B
924-002 1.00 Quickfit valve, replacing
924-004 0.50 Quickfit control switch, replacing
924-041 0.50 Quickfit hydraulic hose, replacing (for boom)
924-042 0.50 Quickfit hydraulic pipe, replacing (for boom)
924-043 0.25 Quickfit hydraulic hose, replacing (for dipper arm)
924-044 0.50 Quickfit hydraulic pipe, replacing (for dipper arm)
924-045 0.50 Quickfit hydraulic cylinder hose, replacing (dipper
arm cylinder)
97 UNIT, DIGGING
974-018 0.30 Boom grease pipe or hose, replacing
and/or bushes
and/or bushes

EC55B


EC700C L

17 SERVICE
machine data
Programme
Programme

20 GENERAL
ECU
21 ENGINE

EC700C L
gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM
adjusting tension
replacing all belts

EC700C L

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU


EC700C L

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110001 - 110011
393-021 0.60 Radio, replacing 110012 - 310000
43 GEARBOX,
431-113 4.00 Track gearbox, removing
431-114 3.50 Track gearbox, installing

EC700C L

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

EC700C L






EC700C L

replacing
working pressure
replacing
replacing

EC700C L
97 UNIT, DIGGING
and/or bushes
and/or bushes

ECR145C L

17 SERVICE
machine data
Programme
Programme
message

20 GENERAL
ECU
21 ENGINE

ECR145C L
gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

ECR145C L

adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


ECR145C L

ECU

replacing
39 MISCELLANEOUS
43 GEARBOX,

ECR145C L

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ECR145C L

ANYWHERE





ECR145C L

replacing
working pressure
replacing

ECR145C L

replacing
97 UNIT, DIGGING
and/or bushes
and/or bushes


ECR235C L

17 SERVICE
machine data
Programme
Programme
message

20 GENERAL
ECU
21 ENGINE

ECR235C L
gauge
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

ECR235C L

adjusting tension

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

ECR235C L

replacing
39 MISCELLANEOUS
43 GEARBOX,

ECR235C L

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ECR235C L

ANYWHERE





ECR235C L

replacing
working pressure
replacing

ECR235C L
replacing
97 UNIT, DIGGING
and/or bushes
and/or bushes

ECR235C L


ECR28

17 SERVICE
Programme
Programme
19 GENERAL

21 ENGINE
218-008 0.70 Engine mounts, removing
23 FUEL SYSTEM

ECR28

timing

26 COOLING SYSTEM
adjusting tension
27 ENGINE CONTROL

ECR28

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING




ECR28

WHEEL/TRACK UNIT
71 FRAME

775-024 0.30 Removing the guide sprocket

ANYWHERE


ECR28


831-051 0.50 Cab door, changing door catch



cylinder)

ECR28

97 UNIT, DIGGING
and/or bushes

ECR305C L

17 SERVICE
machine data
Programme
Programme

20 GENERAL
ECU
21 ENGINE
23 FUEL SYSTEM

ECR305C L

26 COOLING SYSTEM
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM


ECR305C L

ECU
39 MISCELLANEOUS
43 GEARBOX,
replacing
replacing

ECR305C L
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE


ECR305C L


replacing

ECR305C L

working pressure
replacing
97 UNIT, DIGGING

ECR305C L


ECR48C

17 SERVICE
19 GENERAL

21 ENGINE
23 FUEL SYSTEM

ECR48C


26 COOLING SYSTEM
adjusting tension
27 ENGINE CONTROL

31 BATTERY

33 STARTING SYSTEM
333-002 0.60 Glow plug, removal 5176 - 9999
333-003 0.60 Glow plug, installation 5176 - 9999
35 LIGHTING

ECR48C


39 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME


ECR48C

ANYWHERE

852-011 0.40 Seat retention cable, replacement

90 GENERAL
ECU


ECR48C
replacing seals
replacing seals
pressure
913-067 0.50 LR pressure relief valve, checking and adjusting

ECR48C
97 UNIT, DIGGING
974-013 1.50 Boom, removal 4838 - 5499
974-013 1.50 Boom, removal 5500 - 9999

ECR58

17 SERVICE
Programme
Programme

21 ENGINE
23 FUEL SYSTEM
timing

ECR58

26 COOLING SYSTEM
adjusting tension
replacing all belts

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING


ECR58



39 MISCELLANEOUS
43 GEARBOX,

ECR58

replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE


ECR58



replacing

ECR58

cylinder)
cylinder)
arm)
(MCV - 3 way valve)
arm cylinder)

ECR58

97 UNIT, DIGGING
and/or bushes
and/or bushes

ECR88

17 SERVICE
Programme
Programme

21 ENGINE
23 FUEL SYSTEM

ECR88

timing

26 COOLING SYSTEM
adjusting tension
replacing all belts

31 BATTERY

33 STARTING SYSTEM

ECR88
35 LIGHTING



39 MISCELLANEOUS
ECU
43 GEARBOX,

ECR88

replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ECR88

ANYWHERE





ECR88

replacing
cylinder)
cylinder)
arm)
(MCV - 3 way valve)

ECR88
arm cylinder)
97 UNIT, DIGGING
and/or bushes

ECR88

and/or bushes


EW140C

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EW140C


26 COOLING SYSTEM
replacing all belts

EW140C

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

364-001 0.80 Electric center passage, replacing 120760 - 999999
ECU

replacing
39 MISCELLANEOUS

EW140C
43 GEARBOX,
441-019 0.90 Travel motor speed, checking and adjusting
removed)
441-029 2.50 Swing motor, brake kit, upgrade 120861 - 999999
45 PROPELLER SHAFT

49 MISCELLANEOUS

EW140C
5 BRAKE
51 WHEEL BRAKE

circuit
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL


EW140C

ANYWHERE




EW140C

90 GENERAL

911-010 0.40 Cooling fan speed, checking and adjusting
911-045 1.25 Oil cooler fan motor, installation
912-118 1.00 Safety relief valve, replacing
adjusting
pressure

EW140C

installation
97 UNIT, DIGGING
974-006 7.50 2-piece boom, removal
974-007 6.50 2-piece boom, installation
974-008 1.25 Tilt cylinder 2-piece boom, removal
974-009 1.25 Tilt cylinder 2-piece boom, installation
974-040 0.40 Tilt cylinder 2-piece boom, rear bushing, replacing
974-041 0.40 Tilt cylinder 2-piece boom, front bushing, replacing
974-042 1.25 Boom foot bushing, replacing
replacing
975-045 0.70 Dipper arm bushing-boom, replacing
975-048 0.70 Dipper arm bushing-bucket, replacing
975-049 0.60 Dipper arm bushing-lever, replacing

EW140C

975-074 0.50 Lever bushing-bucket, replacing
975-075 0.40 Lever link bushing-bucket cylinder, replacing

EW145B

17 SERVICE
machine data
Programme
Programme

20 GENERAL
ECU
ECU
21 ENGINE
23 FUEL SYSTEM

EW145B

237-037 0.70 Fuel rail pressure, checking 15001 - 210000

replacing
26 COOLING SYSTEM
261-072 0.25 Coolant filter, changing
adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

EW145B

311-003 0.70 Main switch, replacing 15001 - 210000
311-008 2.50 Starter motor lead to battery, replacing 15001 - 210000

33 STARTING SYSTEM
35 LIGHTING
incl. setting

361-002 0.50 Flasher unit, replacing relay
ECU


EW145B

replacing
39 MISCELLANEOUS
ECU
43 GEARBOX,

EW145B

replacing
replacing
45 PROPELLER SHAFT

461-015 6.50 Diff wheel axle, replacing
461-040 1.75 Hub reduction gear, replacing 15001 - 210000
461-043 3.00 Hub, replacing seal 15001 - 210000
49 MISCELLANEOUS
5 BRAKE
51 WHEEL BRAKE
517-005 2.50 Brake disc, replacing 15001 - 210000
517-050 3.00 Brake piston, replacing seals 15001 - 210000

circuit

EW145B
6 STEERING
64 STEERING
pressure
645-072 1.00 Hydraulic pump, installing.

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL
761-001 2.00 Shock absorber front, replacing all

ANYWHERE




EW145B


873-020 1.00 Heat control valve actuator, replacing
874-093 1.00 Power transistor (ceramic resister), replacing
874-097 1.00 Shutter assembly, replacing
874-098 1.00 Valve (mix) actuator, replacing


EW145B

replacing
911-042 0.25 Oil drain filter, replacing
cylinder)
cylinder)
replacing
915-007 1.50 Control lever (dozer blade), replacing
916-043 1.00 Boom, replacing pipe (boom cylinder)

EW145B

arm)
(MCV - 3 way valve)
916-097 0.75 Hammer and shear 3-way valve, replacing
916-098 0.75 Hammer and shear pipe and hose, replacing (for
2nd pump flow)
916-099 0.50 Hammer and shear ball valve, replacing
replacing
arm cylinder)
927-001 1.75 Dozer blade, replacing 15001 - 210000
97 UNIT, DIGGING

EW145B

and/or bushes
975-023 0.25 Dipper arm pipe or hose, replacing
and/or bushes

981-081 0.80 Blade lift cylinder, removing 15001 - 210000
981-086 1.25 Blade lift cylinder, installing 15001 - 210000

EW160C

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EW160C


26 COOLING SYSTEM
replacing all belts

EW160C

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

replacing
replacing

EW160C

replacing
39 MISCELLANEOUS
43 GEARBOX,
441-019 0.90 Travel motor speed, checking and adjusting
removed)
441-029 2.50 Swing motor, brake kit, upgrade 121464 - 999999
45 PROPELLER SHAFT


EW160C
49 MISCELLANEOUS
5 BRAKE
51 WHEEL BRAKE

circuit
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL

EW160C


ANYWHERE




EW160C


90 GENERAL

adjusting
pressure

EW160C

installation
97 UNIT, DIGGING

EW160C

replacing
99 MISCELLANEOUS

EW180C

17 SERVICE

20 GENERAL
ECU
21 ENGINE

EW180C
gauge
23 FUEL SYSTEM
234-010 2.00 Fuel tank, replacing 122001 - 999999
234-010 3.50 Fuel tank, replacing 120010 - 120777
234-041 0.40 Fuel filling pump, removing 122001 - 999999
234-041 0.60 Fuel filling pump, removing 120010 - 120777

26 COOLING SYSTEM

EW180C

replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

362-002 0.50 Horn, replacing 122001 - 999999
362-002 0.30 Horn, replacing 120010 - 120777
363-091 0.50 Windscreen wiper, replacing controller 122001 - 999999
363-091 0.50 Windscreen wiper, replacing controller 120010 - 120777

EW180C

ECU

replacing
replacing
replacing
39 MISCELLANEOUS
43 GEARBOX,
441-009 1.75 Travel motor, removing 122501 - 999999
441-010 2.00 Travel motor, installing 122501 - 999999
441-019 0.90 Travel motor speed, checking and adjusting 122139 - 122499

EW180C
441-032 0.40 Swing motor pressure, checking and adjusting 122501 - 999999
441-032 0.40 Swing motor pressure, checking and adjusting 120010 - 122499
45 PROPELLER SHAFT

461-002 2.50 Axle, removing 122501 - 999999
461-002 4.00 Axle, removing 120010 - 122499
461-003 4.00 Axle, installing 120010 - 122499
461-003 3.00 Axle, installing 122501 - 999999
463-002 2.50 Axle, removing 120010 - 122499
463-002 1.50 Axle, removing 122501 - 999999
463-003 2.50 Axle, installing 122501 - 999999
463-003 2.50 Axle, installing 120010 - 122499
49 MISCELLANEOUS
492-025 0.40 Swing ring, measuring axial clearance 122501 - 999999
5 BRAKE
51 WHEEL BRAKE

circuit
55 PARKING BRAKE

EW180C
6 STEERING
60 GENERAL
64 STEERING
645-003 0.30 Steering system working pressure, checking 120010 - 122499
645-003 0.30 Steering system working pressure, checking 122501 - 999999

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL
763-001 0.40 Pivot axle lock cylinder, removing 122501 - 999999
763-001 0.40 Pivot axle lock cylinder, removing 120010 - 122499
763-002 0.50 Pivot axle lock cylinder, installing 120010 - 122499
763-002 0.50 Pivot axle lock cylinder, installing 122501 - 999999
763-004 0.20 Pivot axle lock cylinder, releasing for towing 122501 - 999999
763-004 0.20 Pivot axle lock cylinder, releasing for towing 120010 - 122499


ANYWHERE


EW180C



90 GENERAL

EW180C

912-018 1.25 Back-up valve, checking and adjusting 122501 - 999999
912-018 1.25 Back-up valve, checking and adjusting 120010 - 122499
912-071 1.00 Rupture valve, replacing (boom cylinder) 122139 - 999999
912-118 1.00 Safety relief valve, replacing 122001 - 999999
adjusting
912-169 0.60 Unload valve, checking and adjusting 122139 - 999999
912-170 1.00 Unload valve, replacing 122139 - 999999
913-003 0.30 Hydraulic pump, checking and adjusting standby 120010 - 122138
pressure

EW180C

installation
97 UNIT, DIGGING
974-013 4.00 Boom, removal 120010 - 120777
974-013 4.00 Boom, removal 122001 - 999999
974-032 2.50 Boom cylinder, installation 120010 - 120777

EW180C

replacing

EW210C

17 SERVICE

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

EW210C


26 COOLING SYSTEM
replacing all belts

EW210C

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU



EW210C

replacing
replacing
39 MISCELLANEOUS
43 GEARBOX,
45 PROPELLER SHAFT


EW210C

49 MISCELLANEOUS
5 BRAKE
51 WHEEL BRAKE

circuit
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL

EW210C



ANYWHERE




EW210C


90 GENERAL

912-071 1.00 Rupture valve, replacing (boom cylinder) 120102 - 999999
adjusting

EW210C

913-003 0.30 Hydraulic pump, checking and adjusting standby 120010 - 120101
pressure
installation
97 UNIT, DIGGING

EW210C


EW55B

17 SERVICE
Programme
Programme

21 ENGINE
23 FUEL SYSTEM
timing

EW55B

26 COOLING SYSTEM
adjusting tension
replacing all belts

31 BATTERY

33 STARTING SYSTEM
35 LIGHTING
incl. setting

EW55B

361-002 0.50 Flasher unit, replacing relay


39 MISCELLANEOUS
43 GEARBOX,

EW55B

replacing
replacing
45 PROPELLER SHAFT

49 MISCELLANEOUS

EW55B
5 BRAKE
51 WHEEL BRAKE

circuit
6 STEERING
64 STEERING
pressure

WHEEL/TRACK UNIT
71 FRAME

SIDE CONTROL
761-001 2.00 Shock absorber front, replacing all

ANYWHERE

EW55B





EW55B

replacing
cylinder)
cylinder)
arm)
(MCV - 3 way valve)

EW55B

arm cylinder)
97 UNIT, DIGGING
and/or bushes
and/or bushes

FC2121C

17 SERVICE
machine data
Programme
Programme
message

20 GENERAL
ECU
21 ENGINE
gauge

FC2121C
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

FC2121C

adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

FC2121C

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110004 - 999999
393-021 0.60 Radio, replacing 110001 - 110003
43 GEARBOX,

FC2121C

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

FC2121C






FC2121C

replacing
replacing
replacing
97 UNIT, DIGGING

FC2121C

and/or bushes
and/or bushes

FC2421C

17 SERVICE
machine data
Programme
Programme
message

20 GENERAL
ECU
21 ENGINE
gauge

FC2421C
23 FUEL SYSTEM

replacing
26 COOLING SYSTEM

FC2421C

adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

FC2421C

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110006 - 999999
393-021 0.60 Radio, replacing 110001 - 110005
43 GEARBOX,

FC2421C

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME

replacing

ANYWHERE

FC2421C

821-065 0.50 Gull wing power pack, replacing
821-066 0.50 Gull wing cylinder, replacing




FC2421C

replacing
replacing
replacing

FC2421C

97 UNIT, DIGGING
and/or bushes
and/or bushes

FC2924C

17 SERVICE
machine data
Programme
Programme
Programme
message

20 GENERAL
ECU
21 ENGINE
gauge

FC2924C
23 FUEL SYSTEM
234-014 2.00 Additional fuel tank, removal
234-015 1.75 Additional fuel tank, installation

replacing
26 COOLING SYSTEM

FC2924C

adjusting tension
replacing all belts

30 GENERAL
31 BATTERY

33 STARTING SYSTEM
35 LIGHTING

ECU

FC2924C

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110002 - 999999
43 GEARBOX,

FC2924C

replacing
replacing
49 MISCELLANEOUS

WHEEL/TRACK UNIT
71 FRAME
710-003 14.00 Leveler structure, removing
710-004 15.00 Leveler structure, installing
710-005 6.00 Leveler structure, disassembling
710-006 12.00 Leveler structure, assembling

replacing

FC2924C

ANYWHERE




FC2924C

replacing
working pressure
replacing

FC2924C

replacing
97 UNIT, DIGGING
and/or bushes
and/or bushes

FC3329C

17 SERVICE
machine data
Programme
message

20 GENERAL
ECU
21 ENGINE
gauge
23 FUEL SYSTEM

FC3329C

234-014 2.00 Additional fuel tank, removal
234-015 1.75 Additional fuel tank, installation

replacing
26 COOLING SYSTEM
adjusting tension

FC3329C

replacing all belts

30 GENERAL

33 STARTING SYSTEM
35 LIGHTING

ECU


FC3329C

replacing
39 MISCELLANEOUS
393-021 0.60 Radio, replacing 110003 - 999999
393-021 0.60 Radio, replacing 110001 - 110002
43 GEARBOX,
replacing
replacing
49 MISCELLANEOUS

FC3329C


WHEEL/TRACK UNIT
71 FRAME
710-003 14.00 Leveler structure, removing
710-004 15.00 Leveler structure, installing
710-005 6.00 Leveler structure, disassembling
710-006 12.00 Leveler structure, assembling

replacing

ANYWHERE

FC3329C





FC3329C

replacing
working pressure
replacing
replacing
97 UNIT, DIGGING

FC3329C

and/or bushes
and/or bushes

G930B

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

G930B


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM

G930B

29 Miscellaneous

30 GENERAL
31 BATTERY
35 LIGHTING

ECU

replacing
39 MISCELLANEOUS

G930B

45 PROPELLER SHAFT
451-009 1.50 Intermediate bearing, replacing


G930B
49 MISCELLANEOUS
491-007 0.30 Transmission oil cooler, removing
491-008 0.20 Transmission oil cooler, installing
5 BRAKE
51 WHEEL BRAKE

521-008 0.50 Brake master cylinder, removing 575001 - 576048
pressure
55 PARKING BRAKE

G930B
6 STEERING
60 GENERAL
62 STEERING AXLE
64 STEERING
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


G930B

ANYWHERE



90 GENERAL

G930B

912-105 0.40 Circle turn valve, removing
removing
913-081 3.00 Steering and implement pump, removing
913-082 3.50 Steering and implement pump, installing
914-096 1.75 Control levers, replacing

G930B

981-083 0.40 Blade lift arm, removing
981-084 0.40 Blade lift arm, installing
981-087 2.00 Circle and drawbar, removing
981-088 3.00 Circle and drawbar, installing

G940B

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

G940B


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM

G940B

29 Miscellaneous

30 GENERAL
31 BATTERY
35 LIGHTING

ECU

replacing

G940B
39 MISCELLANEOUS

45 PROPELLER SHAFT


G940B
49 MISCELLANEOUS
5 BRAKE
51 WHEEL BRAKE


G940B

pressure
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
62 STEERING AXLE
64 STEERING
pressure

G940B

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


ANYWHERE



G940B


90 GENERAL

removing

G940B



G946B

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

G946B


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM

G946B

29 Miscellaneous

30 GENERAL
31 BATTERY
35 LIGHTING

ECU

replacing
39 MISCELLANEOUS

G946B

45 PROPELLER SHAFT


G946B
49 MISCELLANEOUS
5 BRAKE
51 WHEEL BRAKE

pressure
55 PARKING BRAKE

G946B
6 STEERING
60 GENERAL
62 STEERING AXLE
64 STEERING
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


G946B

ANYWHERE



90 GENERAL

G946B

removing


G946B


G960B

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

G960B


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM

G960B

29 Miscellaneous

30 GENERAL
31 BATTERY
35 LIGHTING

ECU

replacing
39 MISCELLANEOUS

G960B

45 PROPELLER SHAFT


G960B
49 MISCELLANEOUS
5 BRAKE
51 WHEEL BRAKE

pressure
55 PARKING BRAKE

G960B
6 STEERING
60 GENERAL
62 STEERING AXLE
64 STEERING
pressure

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


G960B

ANYWHERE



90 GENERAL

G960B

removing

G960B


L110G

17 SERVICE
173-150 1.75 Maintenance service, fire suppression system
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

L110G


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM

L110G

29 Miscellaneous
293-011 0.40 EGR reed valve, checking

30 GENERAL
31 BATTERY


ECU
39 MISCELLANEOUS

L110G


5 BRAKE
51 WHEEL BRAKE
510-004 0.10 Wheel brakes, functional check

circuit
pressure

L110G

55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING
pressure
645-055 2.00 Left steering cylinder, replacing bearings
645-056 1.25 Right steering cylinder, replacing bearings
645-063 0.60 Steering cylinder, repacking
replacing bearings
working pressure
66 LEVER STEERING
changing
changing
660-013 0.90 Comfort Drive Control (CDC), joystick, changing

WHEEL/TRACK UNIT
71 FRAME

L110G
74 FRAME LINK


ANYWHERE


replacing


870-014 0.90 Pause heater, replacing

L110G


90 GENERAL

valve
914-905 0.90 Single lever control electric servo, replacing

L110G

916-008 0.70 Boom suspension system, right accumulator, 1000 - 8373
removal
removal
installation
installation
916-010 1.00 Boom suspension system, left accumulator, 8374 - 99999
removal
removal
installation
installation
changing
pressure
discarding

99 MISCELLANEOUS
activation

L120G

17 SERVICE
19 GENERAL

20 GENERAL
ECU
21 ENGINE
replacing
replacing
gauge
23 FUEL SYSTEM

L120G


non-programmed
pre-programmed
replacing
26 COOLING SYSTEM

L120G

29 Miscellaneous
293-011 0.40 EGR reed valve, checking

30 GENERAL
31 BATTERY


ECU
39 MISCELLANEOUS

L120G


5 BRAKE
51 WHEEL BRAKE

circuit
pressure

L120G

55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING
pressure
645-055 2.00 Left steering cylinder, replacing bearings
645-056 1.25 Right steering cylinder, replacing bearings
645-063 0.60 Steering cylinder, repacking
replacing bearings
working pressure
66 LEVER STEERING
changing
changing

WHEEL/TRACK UNIT
71 FRAME

L120G
74 FRAME LINK


ANYWHERE


replacing



L120G


90 GENERAL


L120G

valve
removal
removal
installation
installation
removal
removal
installation
installation
changing
pressure
discarding

99 MISCELLANEOUS
activation

L150G

17 SERVICE
18928 - 22000
23295 - 99999
23295 - 99999
18928 - 22000
23295 - 99999
19 GENERAL

20 GENERAL
18928 - 22000
23295 - 99999
ECU
21 ENGINE

L150G

replacing
23295 - 99999
18928 - 22000
23295 - 99999
gauge
23 FUEL SYSTEM
18928 - 22000
23295 - 99999

23295 - 99999
23295 - 99999
23295 - 99999
23295 - 99999
23295 - 99999
254-042 0.60 Air purge tank, replacing 22001 - 23294
23295 - 99999

L150G

23295 - 99999
23295 - 99999
23295 - 99999
replacing 23295 - 99999
23295 - 99999
23295 - 99999
23295 - 99999
23295 - 99999
23295 - 99999
18928 - 22000
23295 - 99999
23295 - 99999
26 COOLING SYSTEM
29 Miscellaneous
23295 - 99999
23295 - 99999
23295 - 99999
23295 - 99999
23295 - 99999
23295 - 99999
293-006 0.20 EGR temperature sensor, replacing 22001 - 23294
23295 - 99999
23295 - 99999

L150G

30 GENERAL
31 BATTERY
33 STARTING SYSTEM

ECU

39 MISCELLANEOUS


L150G

5 BRAKE
51 WHEEL BRAKE

circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

L150G

pressure
working pressure
66 LEVER STEERING
changing
changing

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


ANYWHERE
810-001 3.00 Cab, removing 22001 - 23294
810-002 4.50 Cab, installing 22001 - 23294
810-065 1.00 Cab, position 1 23295 - 99999
810-066 1.75 Cab, position 2 23295 - 99999
810-067 0.80 Cab, position 1, restoring 23295 - 99999


L150G


replacing


874-022 0.30 Drying filter, replacing 22001 - 23294
23295 - 99999

90 GENERAL

L150G

valve
removal
installation
removal
installation

L150G

changing
pressure
discarding
99 MISCELLANEOUS
activation

L180G

17 SERVICE
16302 - 19000
19001 - 22034
19001 - 22034
16302 - 19000
19001 - 22034
19 GENERAL

20 GENERAL
16302 - 19000
22035 - 99999
ECU
21 ENGINE

L180G

replacing
22035 - 99999
16302 - 19000
19001 - 22034
gauge
23 FUEL SYSTEM
16302 - 19000
22035 - 99999

19001 - 22034
22035 - 99999
22035 - 99999
22035 - 99999
22035 - 99999
22035 - 99999

L180G

22035 - 99999
22035 - 99999
19001 - 22034
replacing 22035 - 99999
22035 - 99999
22035 - 99999
22035 - 99999
22035 - 99999
22035 - 99999
16302 - 19000
22035 - 99999
26 COOLING SYSTEM
29 Miscellaneous
22035 - 99999
22035 - 99999
22035 - 99999
19001 - 22034
22035 - 99999
22035 - 99999
22035 - 99999
22035 - 99999

L180G

30 GENERAL
31 BATTERY
33 STARTING SYSTEM

ECU

39 MISCELLANEOUS


L180G

5 BRAKE
51 WHEEL BRAKE

circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

L180G

pressure
working pressure
66 LEVER STEERING
changing
changing

WHEEL/TRACK UNIT
71 FRAME
74 FRAME LINK


ANYWHERE
810-001 3.00 Cab, removing 19001 - 22034
810-002 4.50 Cab, installing 19001 - 22034
810-065 1.00 Cab, position 1 22035 - 99999
810-066 1.75 Cab, position 2 22035 - 99999


L180G


replacing


22035 - 99999

90 GENERAL

L180G

valve
removal
installation
removal
installation

L180G

changing
pressure
discarding
99 MISCELLANEOUS
activation

L180G HL

17 SERVICE
21011 - 99999
20002 - 20059
20002 - 20059
21011 - 99999
20002 - 20059
21011 - 99999
19 GENERAL

20 GENERAL
21011 - 99999
20060 - 21000
ECU
21 ENGINE

L180G HL

replacing
20060 - 21000
21011 - 99999
20002 - 20059
gauge
23 FUEL SYSTEM
21011 - 99999
20060 - 21000

20002 - 20059
20060 - 21000
20060 - 21000
20060 - 21000
20060 - 21000
20060 - 21000

L180G HL

20060 - 21000
20060 - 21000
20002 - 20059
replacing 20060 - 21000
20060 - 21000
20060 - 21000
20060 - 21000
20060 - 21000
20060 - 21000
21011 - 99999
20060 - 21000
26 COOLING SYSTEM
29 Miscellaneous
20060 - 21000
20060 - 21000
20060 - 21000
20002 - 20059
20060 - 21000
20060 - 21000
20060 - 21000
20060 - 21000

L180G HL

30 GENERAL
31 BATTERY
33 STARTING SYSTEM

ECU

39 MISCELLANEOUS


L180G HL

5 BRAKE
51 WHEEL BRAKE

circuit
pressure
55 PARKING BRAKE
6 STEERING
60 GENERAL
64 STEERING

L180G HL

pressure
working pressure
66 LEVER STEERING
changing
changing

WHEEL/TRACK UNIT
71 FRAME


ANYWHERE
810-065 1.00 Cab, position 1 20060 - 99999
810-066 1.75 Cab, position 2 20060 - 99999



L180G HL

replacing


20060 - 21000

90 GENERAL

912-159 0.70 Shock valve removed (Control valve 2), checking

L180G HL
912-164 0.20 Shock valves grapple tilt (Control valve 2),

checking
912-278 0.20 Log mover, function checking
912-279 0.30 Grapple, function checking
912-280 0.20 Rotator, function checking
912-281 0.20 Rotator, checking and adjusting
912-282 0.70 Rotator pin, replacing
valve
valve 2
adjusting
discarding
926-035 1.25 Grapple complete, removal at cross member
926-036 2.00 Grapple complete, installing at cross member
99 MISCELLANEOUS
activation

L20B

17 SERVICE
Programme
Programme
incl.cleaning tank
19 GENERAL

21 ENGINE
211-068 2.00 Cylinder heads all removed, decarbonizing and
grinding in valves
211-071 1.00 Cylinder head removed, pressure testing each
212-011 1.00 Cylinder, cylinder heads removed, measuring
wear in all cylinders

L20B

23 FUEL SYSTEM
237-080 1.50 Injectors removed, reconditioning all

251-006 0.80 EGR (exhaust gas recirculation) sensor, replacing
255-073 1.50 Turbocharger removed, reconditioning
256-002 0.25 Air cleaner, checking prssure drop indicator
26 COOLING SYSTEM
adjusting tension
replacing all belts

L20B
27 ENGINE CONTROL

31 BATTERY

321-025 1.00 Alternator, replacing carbon brush kit in machine
33 STARTING SYSTEM
35 LIGHTING
incl. setting
353-018 0.25 Rear lamp, replacing glass or bulb
356-057 0.50 Work lighting, replacing one insert


L20B

386-013 0.50 Hydrostatic system temperature sensor, replacing
39 MISCELLANEOUS
43 GEARBOX,
434-029 2.00 Dropbox removed, reconditioning
441-001 1.00 Hydrostatic system, checking oil pressure
adjust
and adjust
45 PROPELLER SHAFT

461-014 1.50 Pinion front, fitting new gasket
461-042 2.00 Hub reduction gear, reconditioning one side

L20B

463-014 1.00 Pinion rear, fitting new gasket
463-042 2.00 Hub reduction gear, reconditioning one side
5 BRAKE
51 WHEEL BRAKE

55 PARKING BRAKE
6 STEERING
64 STEERING
pressure
replacing bearings
647-093 1.50 Auxiliary steering, replacing hydraulic pump

WHEEL/TRACK UNIT
74 FRAME LINK
741-005 0.50 Frame joint, checking clearance

L20B


ANYWHERE





90 GENERAL

912-002 2.50 Control valve removed, reconditioning
912-009 1.00 Shock valve, tilt function, checking and adjusting
912-011 1.00 Shock valve lift function, adjusting
adjusting

L20B

adjusting
working pressure
913-011 2.00 Hydraulic pump removed, reconditioning

945-006 1.50 Lift cylinder removed, repacking
945-011 2.00 Implemental attachment, replacing hydraulic
cylinder
945-012 1.00 Lift cylinder removed, replacing bearings "C-P"
945-016 6.00 Lift frame, replacing bearing in upper mounting "O"
945-054 3.00 Implement attachment, replacing
hydraulic cylinder
945-066 1.00 Tilt link, replacing "GH"
945-067 0.50 Tilt link removed, replacing bearings "GH"
945-069 1.00 Tilt arm, replacing "GDF"
945-070 0.50 Tilt arm removed, replacing bearing "GDF"

L220G

17 SERVICE
12001 - 12852
9375 - 12000
12001 - 12852
9375 - 12000
12001 - 12852
19 GENERAL

20 GENERAL
9375 - 12000
12853 - 99999
ECU
21 ENGINE

L220G

replacing
12853 - 99999
9375 - 12000
12001 - 12852
gauge
23 FUEL SYSTEM
9375 - 12000
12853 - 99999

12001 - 12852
12853 - 99999
12853 - 99999
12853 - 99999
12853 - 99999

L220G

12853 - 99999
12853 - 99999
12853 - 99999
12001 - 12852
replacing 12853 - 99999
12853 - 99999
12853 - 99999
12853 - 99999
12853 - 99999
12853 - 99999
9375 - 12000
12853 - 99999
26 COOLING SYSTEM
29 Miscellaneous
12853 - 99999
12853 - 99999
12853 - 99999
12001 - 12852
12853 - 99999
12853 - 99999
12853 - 99999
12853 - 99999
12/14/2014 Volvo Construction Equipment

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Available Formats

L60H, L70H, L90H

VOLVO WHEEL LOADERS 13.0-18.3 t / 24,250-38,140 lb 165-184 hp

Helping you to do more

The major R&D center and manufacturing plant in the Americas

We’re on your side

We have a passion for performance.

A strong, dedicated, capable dealer network.

HMI – New display and controls

Heating, ventilation and air conditioning Industry leading air-filtration

Double sealed joints

Roll back angle Parallel movement

New General Purpose (GP) bucket

Material handling arm Light Material (LM) bucket

Counter shaft transmission

Differential lock Intelligent hydraulic system

Service access 95% of the machine is recyclable

Human Machine Interface

Attachment offer Eco pedal

Hydraulic cooling fan

Intelligent hydraulic system

Low Emissions Level

* In markets where CareTrack is available

Max torque at r/s (r/min) 23.3 (1,400) 95 70 600

Max torque at r/s (r/min) 23.3 (1,400) 95 70 600

Max torque at r/s (r/min) 23.3 (1,400) 95 70 600

Tires 20.5 R25 L3

Tires 20.5R25 XHA2 L3

1.9 m³ 2.1 m³ 2.1 m³ 2.3 m³ 2.3 m³ 1.7 m³

t/m lb/yd m3 yd3 m3 yd3

~ 1.75 ~ 2,950 1.9 2.5 1.9 2.5

Supplemental Operating Data

Tires 20.5R25 XHA2 L3

2.1 m³ 2.3 m³ 2.3 m³ 2.4 m³ 2.4 m³ 2.2 m³

t/m lb/yd m3 yd3 m3 yd3

~ 1.75 ~ 2,950 2.5 3.3 2.5 3.3

Supplemental Operating Data

Tires 20.5R25 XHA2 L3

2.3 m³ 2.5 m³ 2.5 m³ 2.6 m³ 2.8 m³ 2.8 m³

t/m lb/yd m3 yd3 m3 yd3

~ 1.75 ~ 2,950 2.5 3.3 2.5 3.3

Supplemental Operating Data

Selection of Volvo optional equipment

Rear view camera Reversible fan Fire suppression system

1. Main control valve

For description of components, see:

 3rd, or 3rd/4th hydraulic function, description

Green Pressureless oil

Green Pressureless oil

Green Pressureless oil

Parameter (code) Setting

 Braking system, description

 3rd/4th hydraulic, functional check

Pin Component Function Wiring diagram

Part Tightening torques

Part Tightening torques

Automatic differential brake

B Thrust plates slide outward.

1. Crown wheel 6. Half shaft

 helps the engine to brake the machine on downhill grades

For more information, see

 Cooling fan, description

 Cooling fan rpm, specifications

 Batteries must only be charged using battery charger.

1. Gas valve screw