Volvo BL61B Backhoe Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo BL61B Backhoe Loaders, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo Constructions BL61B Backhoe Loaders workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 2,303 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo BL61B Backhoe Loaders Service Repair Manual.pdf
MAIN SECTIONS
0 - Foreword....2
0 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Description_{09-57-37}....5
Description_{09-58-06}....7
03 - SPECIFICATIONS....9
Conversion tables....10
Tightening torques....14
07 - STANDARD TIME....23
Operation numbers for additional work....24
08 - TOOL....26
E 1708, Checking point....27
E-5001....29
E-5002....30
E-5003....32
E1820....34
1 - STANDARD PARTS, SERVICE....36
16 - LUBRICANT; FUEL; OTHER FLUID....37
Alternative fuels....38
Coolant....41
Fuel_{09-47-18}....42
Fuel_{09-47-44}....43
Recommended lubricants, oils_{09-48-53}....44
Recommended lubricants, oils_{09-49-54}....48
17 - SERVICE....51
Accumulator, check pre-charging pressure....56
Air cleaner dust valve, cleaning....59
Axle hubs, changing oil....60
Axle hubs, checking oil level....62
Axles, changing oil....64
Axles, checking oil level....66
Battery, current capacity, electrolyte level, cables and connections, especially connections at starter motor, check....68
Bolted joints, check tightening torque_{08-34-34}....70
Bolted joints, check tightening torque_{08-34-59}....71
Boom lock functions, check....72
Brake test_{08-12-48}....74
Brake test_{08-13-16}....77
Cab filter, replace (clean when necessary)....79
Check coolant anti-freeze concentration (or yearly before winter season)....81
Coolant level, checking....83
Coolant, changing_{09-22-58}....84
Coolant, changing_{09-23-26}....87
Crankcase ventilation separator, checking_{08-05-18}....90
Crankcase ventilation separator, replacing_{08-01-07}....92
Diesel particulate filter, checking and cleaning_{08-11-19}....94
EGR cooler, pressure test_{08-00-01}....108
EGR valve, cleaning_{07-58-55}....115
Engine air cleaner primary filter, cleaning....121
Engine air cleaner primary filter, replacing_{09-15-29}....124
Engine air cleaner primary filter, replacing_{09-15-58}....127
Engine air cleaner secondary filter, replacing....130
Engine belt tension, adjusting_{08-06-24}....131
Engine oil level, checking_{08-14-22}....133
Engine oil level, checking_{08-14-50}....135
Engine radiator, oil cooler and condensor (if installed), clean_{09-18-31}....137
Engine radiator, oil cooler and condensor (if installed), clean_{09-19-00}....139
Engine speed_{08-18-35}....141
Engine speed_{08-19-03}....142
Engine, changing oil and filter_{08-29-24}....143
Engine, changing oil and filter_{08-29-52}....146
Engine, pipes and hoses, checking_{07-56-42}....150
Extendible dipper (if installed) wear pads, check....156
Fan belt and belt tension, check_{08-07-31}....157
Fan belt, checking_{08-08-33}....159
Front and rear axle breather, clean....160
Fuel filters, primary and secondary filter, replace_{08-42-31}....162
Fuel filters, primary and secondary filter, replace_{08-42-59}....164
Fuel system, bleeding_{08-41-21}....166
Fuel system, bleeding_{08-41-49}....168
Fuel system, water trap, check_drain_{08-40-10}....170
Fuel system, water trap, check_drain_{08-40-38}....172
Fuel tank breather filter, replacing....174
Fuel, coolant and oil leakage, check....175
Gas springs, doors, rear window, check function....176
Hydraulic cylinders, check for oil leakage....177
Hydraulic locking cylinders for sideshift mechanism, check (BL61B, BL71B)....178
Hydraulic oil filter, changing....180
Hydraulic oil level, checking_{08-24-18}....182
Hydraulic oil level, checking_{08-24-48}....184
Hydraulic oil tank breather filter, replace....186
Hydraulic oil, changing_{08-26-15}....187
Hydraulic oil, changing_{08-26-43}....190
Hydraulic pressure, checking ....193
Hydraulic system, pressure release ....198
Injectors, checking_{08-03-36}....199
MATRIS, reading, export reading_{07-54-56}....212
Maintenance service, daily....214
Maintenance service, every 1000 hours_{09-32-13}....216
Maintenance service, every 1000 hours_{09-32-42}....222
Maintenance service, every 1000 hours_{09-33-10}....228
Maintenance service, every 1500 hours_{09-31-29}....234
Maintenance service, every 2000 hours_{09-30-01}....236
Maintenance service, every 2000 hours_{09-30-25}....238
Maintenance service, every 250 hours_{09-35-03}....240
Maintenance service, every 250 hours_{09-35-33}....243
Maintenance service, every 3000 hours....246
Maintenance service, every 50 hours_{09-36-16}....248
Maintenance service, every 50 hours_{09-36-44}....250
Maintenance service, every 500 hours_{09-33-53}....252
Maintenance service, every 500 hours_{09-34-21}....256
Maintenance service, every 6000 hours_{09-28-34}....260
Maintenance service, every 6000 hours_{09-28-58}....262
Maintenance service, first 100 hours_{09-39-25}....263
Maintenance service, first 100 hours_{09-39-53}....267
Maintenance service, first 1000 hours_{09-38-13}....271
Maintenance service, first 1000 hours_{09-38-43}....276
Overflow pipe, inspecting_{08-02-14}....278
Pipes, couplings and hoses, check....281
Powershift Transmission (option), oil pressures, checking_{08-19-58}....282
Powershift Transmission (option), oil pressures, checking_{08-20-35}....290
Propeller shaft, lubrication....298
Safety when servicing....299
Seat belt, replace....300
Service brake, checking pressure....302
Service journal (included in Operator's manual), fill in....305
Service points....306
Service position 1 ....308
Service position 2 ....310
Service position 3 ....312
Service_{09-41-51}....314
Service_{09-42-16}....315
Stabiliser legs, check wear pads (BL61B, BL71B)....316
Stabilisers, loader, backhoe, front axle oscillation pivot and front axle steering pivots, lubricate....317
Test-run and check....318
This information is not valid for serial number range_{07-54-28}....320
This information is not valid for serial number range_{07-56-08}....321
This information is not valid for serial number range_{07-57-20}....322
This information is not valid for serial number range_{07-58-27}....323
This information is not valid for serial number range_{07-59-33}....324
This information is not valid for serial number range_{08-00-39}....325
This information is not valid for serial number range_{08-01-46}....326
This information is not valid for serial number range_{08-03-00}....327
This information is not valid for serial number range_{08-04-50}....328
This information is not valid for serial number range_{08-05-56}....329
This information is not valid for serial number range_{08-07-03}....330
This information is not valid for serial number range_{08-08-09}....331
This information is not valid for serial number range_{08-09-11}....332
This information is not valid for serial number range_{09-25-05}....333
This information is not valid for serial number range_{09-31-04}....334
Transmission 2WD, oil pressures, checking_{08-22-57}....335
Transmission 2WD, oil pressures, checking_{08-23-34}....341
Transmission 4WD, oil pressures, checking_{08-21-34}....346
Transmission 4WD, oil pressures, checking_{08-22-11}....352
Transmission breather filter, replacing....357
Transmission oil filter, replacing_{08-31-35}....358
Transmission oil filter, replacing_{08-32-03}....359
Transmission oil level, checking_{09-27-25}....361
Transmission oil level, checking_{09-27-55}....363
Transmission oil, changing....365
Transmission suction filter, replacing....367
Turbocharger inclusive inlet and exhaust systems, leakage, check_{09-24-40}....369
Turbocharger, checking_{07-57-48}....371
Tyres, wear and air pressure, checking....374
Valve clearance, checking and adjusting_{09-21-22}....375
Valve clearance, checking and adjusting_{09-22-07}....388
Wheel nuts, torque, check....401
19 - GENERAL....402
Backhoe, boom lock....403
CE-marking, EMC-directive_{07-52-12}....405
Checklist after a fire or heat exposure....407
Declaration of Conformity_{07-52-35}....408
FOPS and ROPS....410
Health hazards with paint, plastics and rubber....411
Loader boom, safety strut....413
Pressure setting and leak detection....416
Rules when handling tyres....417
Safety concerns everybody!....419
Safety during electric welding....423
Safety for work on hydraulic systems....424
Safety rules when servicing....426
Safety when handling oils and fuel....429
Safety when lifting and supporting the machine....430
Safety when working with air conditioning refrigerant....431
Safety when working with batteries....433
Service position 1....435
Service position 2....437
Service position 3....439
Starting with booster batteries....441
Working on the electrical system of the machine....442
Working under raised loader arm....443
2 - ENGINE WITH MOUNTING AND EQUIPMENT....444
20 - GENERAL....445
E-ECU MID 128 non-programmed, replacing_{07-28-06}....446
E-ECU MID 128 pre-programmed, replacing_{07-29-12}....449
E-ECU, replacing_{07-26-59}....452
Engine protection plates, tightening torques_{07-31-18}....453
Engine, capacities_{07-33-06}....454
Engine, capacities_{07-33-30}....455
Engine, component locations_{07-35-39}....456
Engine, description_{07-36-26}....460
Engine, description_{07-36-54}....463
Engine, tightening torque_{07-32-04}....467
Engine, tightening torque_{07-32-27}....468
Engine, weights_{07-34-08}....469
Engine, weights_{07-34-33}....470
Tech Tool, operations_{07-30-15}....471
This information is not valid for serial number range_{07-26-35}....472
This information is not valid for serial number range_{07-27-38}....473
This information is not valid for serial number range_{07-28-44}....474
This information is not valid for serial number range_{07-29-51}....475
This information is not valid for serial number range_{07-30-53}....476
This information is not valid for serial number range_{07-35-11}....477
21 - ENGINE....478
Crankcase ventilation separator, replacing_{07-18-37}....479
Engine mounts, replacing_{06-44-53}....481
Engine protection plates, removing and installing_{07-19-49}....485
Engine, installing_{07-20-54}....488
Engine, installing_{07-21-46}....498
Engine, removing_{07-22-52}....513
Engine, removing_{07-23-56}....523
Engine, specifications_{07-24-35}....538
Engine, specifications_{07-24-59}....539
Engine, specifications_{07-25-23}....540
Engine, specifications_{07-25-47}....541
This information is not valid for serial number range_{06-45-17}....542
This information is not valid for serial number range_{07-15-43}....543
This information is not valid for serial number range_{07-18-09}....544
This information is not valid for serial number range_{07-19-20}....545
Valve system, specifications_{07-16-07}....546
Valves, adjusting_{06-48-17}....547
Valves, adjusting_{07-14-49}....560
Valves, description_{07-16-50}....573
Valves, description_{07-17-18}....575
22 - LUBRICATING SYSTEM....577
Lubricating system, description_{06-43-49}....578
Lubrication oil pressure, checking_{06-39-28}....582
Lubrication system, component locations_{06-41-04}....584
Lubrication system, description_{06-42-58}....586
Lubrication system, specification_{06-41-50}....589
Lubrication system, specification_{06-42-14}....590
This information is not valid for serial number range_{06-39-52}....591
This information is not valid for serial number range_{06-40-35}....592
23 - FUEL SYSTEM....593
Feed pump, replacing_{06-30-59}....594
Fuel cooler, replacing....596
Fuel filters, replacing_{06-28-15}....600
Fuel filters, replacing_{06-28-43}....603
Fuel pump, installing_{06-31-41}....606
Fuel pump, removing_{06-32-47}....609
Fuel system, bleeding_{06-29-25}....613
Fuel system, bleeding_{06-29-53}....615
Fuel system, description_{06-37-12}....617
Fuel system, description_{06-38-18}....619
Fuel system, specifications_{06-35-04}....624
Fuel system, specifications_{06-35-28}....625
Fuel system, specifications_{06-36-30}....626
Fuel system, tightening torques_{06-33-58}....627
Fuel system, tightening torques_{06-34-26}....628
Fuel tank, installing....630
Fuel tank, removing....632
Injection pump, replacing_{05-41-51}....635
Injectors, replacing_{05-40-02}....643
Overflow pipe, inspecting_{05-38-40}....657
This information is not valid for serial number range_{05-38-12}....660
This information is not valid for serial number range_{05-39-18}....661
This information is not valid for serial number range_{05-40-45}....662
This information is not valid for serial number range_{06-30-31}....663
This information is not valid for serial number range_{06-32-05}....664
This information is not valid for serial number range_{06-33-11}....665
This information is not valid for serial number range_{06-36-07}....666
25 - INLET & EXHAUST SYSTEM....667
Air cleaner, installing_{05-19-06}....669
Air cleaner, installing_{05-19-34}....671
Air cleaner, removing_{05-20-16}....675
Air cleaner, removing_{05-20-44}....678
Charge air cooler, installing_{07-00-53}....682
Charge air cooler, removing_{05-18-20}....687
DPF (Diesel particulate filter), checking and cleaning_{05-23-22}....693
Exhaust Aftertreatment System, description_{05-26-45}....707
Exhaust aftertreatment system_{05-27-21}....711
Exhaust pipe flexible tube, replacing_{05-29-25}....715
Exhaust pipe, replacing_{05-28-43}....717
Exhaust system, description_{05-32-05}....722
Inlet and exhaust system, component location_{05-35-24}....723
Inlet and exhaust system, description_{05-36-35}....726
Inlet and exhaust system, specification_{05-33-54}....730
Inlet and exhaust system, specification_{05-34-18}....731
Inlet and exhaust system, tightening torques_{05-32-48}....732
Inlet and exhaust system, tightening torques_{05-33-16}....733
Perform a regeneration_{05-25-31}....735
Regeneration process, description_{05-24-29}....739
Silencer, replacing_{05-30-39}....741
This information is not valid for serial number range_{05-17-44}....745
This information is not valid for serial number range_{05-22-42}....746
This information is not valid for serial number range_{05-24-01}....747
This information is not valid for serial number range_{05-26-17}....748
This information is not valid for serial number range_{05-28-04}....749
This information is not valid for serial number range_{05-29-49}....750
This information is not valid for serial number range_{05-31-03}....751
This information is not valid for serial number range_{05-31-41}....752
This information is not valid for serial number range_{05-34-56}....753
This information is not valid for serial number range_{05-36-02}....754
This information is not valid for serial number range_{06-59-32}....755
This information is not valid for serial number range_{07-01-32}....756
Turbocharger, description_{05-21-31}....757
Turbocharger, description_{05-21-59}....759
26 - COOLING SYSTEM....761
Belt tension, specifications_{06-47-17}....762
Cooling system, component location_{06-57-31}....763
Cooling system, description_{06-58-14}....765
Cooling system, description_{06-58-44}....767
Cooling system, specifications_{06-54-48}....771
Cooling system, specifications_{06-55-12}....772
Cooling system, tightening torques_{06-55-50}....773
Cooling system, tightening torques_{06-56-19}....774
Expansion tank, replacing_{06-53-36}....777
Expansion tank, replacing_{06-54-05}....780
Fan belt and_or alternator belt, checking and adjusting tension_{06-42-21}....784
Fan belt and_or alternator belt, replacing_{06-43-27}....787
Fan belt and_or alternator belt, replacing_{06-45-51}....790
Fan shroud, replacing_{06-44-20}....795
Fan shroud, replacing_{06-45-08}....802
Radiator hose upper, replacing_{06-52-10}....811
Radiator hose upper, replacing_{06-52-38}....813
Radiator hoses lower, replacing_{06-51-01}....815
Radiator hoses lower, replacing_{06-51-28}....817
Radiator, installing_{06-48-04}....819
Radiator, installing_{06-48-40}....823
Radiator, removing_{06-49-30}....829
Radiator, removing_{06-50-18}....833
This information is not valid for serial number range_{06-42-59}....840
This information is not valid for serial number range_{06-46-15}....841
This information is not valid for serial number range_{06-46-54}....842
This information is not valid for serial number range_{06-56-58}....843
27 - ENGINE CONTROL....844
Throttle control cable, installing_{06-40-40}....845
Throttle control cable, removing_{06-40-09}....849
29 - MISCELLANEOUS....853
EGR cooler pressure, testing_{06-38-04}....854
Exhaust Gas Recirculation (EGR), description_{06-39-17}....855
This information is not valid for serial number range_{06-37-36}....859
This information is not valid for serial number range_{06-38-49}....860
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....861
30 - GENERAL....862
AL3201, description and measuring....867
Air filter clogged....869
Boom suspension system_{06-15-26}....870
Boom suspension system_{06-15-54}....872
Code lock (option)....874
Collection of basic data....875
Communication with data buses....877
Differential lock_{06-11-37}....879
Differential lock_{06-12-05}....880
Direction indicators....881
Electrical system, description_{06-35-52}....882
Electrical system, description_{06-36-20}....884
Electrical system, specifications....887
Electrical system, work instructions....888
Electrical troubleshooting, Powershift transmission ....889
Electronic control system, description_{06-34-27}....890
Electronic control system, description_{06-34-54}....892
Engine coolant temperature_{06-27-22}....894
Engine coolant temperature_{06-27-50}....897
Engine speed_{06-26-17}....900
Engine speed_{06-26-40}....901
Error codes, build-up_{05-52-12}....902
FU20, description and measuring....905
FX1016, description and measuring....907
FX1052, description and measuring....910
FX1053, description and measuring....913
FX1054, description and measuring....915
FX1093, description and measuring....917
Fault code list....919
Forward _ Reverse _ Neutral_{06-22-20}....924
Forward _ Reverse _ Neutral_{06-22-48}....929
Fourwheel drive_{06-18-00}....934
Fourwheel drive_{06-18-27}....936
Fuel shut-off....938
Gear selector switch, testing....939
Hazard lights....941
Hour meter_{06-23-53}....942
Hour meter_{06-24-21}....943
Hydraulic attachment bracket, backhoe (option)....944
Hydraulic attachment bracket, loader (option)....946
Hydraulic oil temperature_{06-19-39}....948
Hydraulic oil temperature_{06-20-07}....950
I-ECU inputs and Outputs_{05-55-41}....953
I-ECU inputs and Outputs_{05-56-04}....955
Information display, electrical system (Electrical system)....957
Information display, engine (Engine)....967
Information display, general....971
Information display, hydraulics (Hydraulic)....976
Information display, vehicle information (Vehicle information)....980
Lead and connector checks....990
Limp-home operation....994
Loader lever lock....995
MA2301-MA2304, description and measuring....996
MA2310, description and measuring....998
MA4220, description and measuring....1000
MA4221, description and measuring....1002
MA4409, description and measuring....1004
MA4601, description and measuring....1006
MA8701, description and measuring....1008
MA9136, description and measuring....1010
PWM9123, description and measuring....1012
PWM9124, description and measuring....1014
PWM9133, description and measuring....1016
PWM9145, description and measuring....1018
PWM9146, description and measuring....1020
Parking brake....1022
Power derating-[5340]....1023
Power derating....1024
RE2501, description and measuring....1025
RE3601, description and measuring....1027
RE9102, description and measuring....1029
SAE J1939_CAN1 Control link, description and measuring....1031
SE2206, description and measuring....1034
SE2302, description and measuring....1036
SE2303, description and measuring....1038
SE2306, description and measuring....1040
SE2309, description and measuring....1042
SE2502, description and measuring....1044
SE2507, description and measuring....1046
SE2508, description and measuring....1048
SE2510, description and measuring....1050
SE2519, description and measuring....1052
SE2521, description and measuring....1054
SE2522, description and measuring....1056
SE2606, description and measuring....1058
SE2702, description and measuring....1060
SE2708, description and measuring....1062
SE2709, description and measuring....1064
SE2710, description and measuring....1066
SE4202, description and measuring_{04-50-33}....1068
SE4202, description and measuring_{04-51-23}....1070
SE4307, description and measuring_{04-48-38}....1072
SE4307, description and measuring_{04-49-24}....1074
SE6406, description and measuring....1077
SE9105, description and measuring....1079
SE9106, description and measuring....1082
SW4202, description and measuring....1084
SW9111, description and measuring....1085
SW9113, description and measuring....1087
SW9114, description and measuring....1089
SW9161, description and measuring....1091
Seat belt....1093
Service light....1094
Service mode, description....1095
Software parameters, description_{06-09-32}....1097
Software parameters, description_{06-09-56}....1098
Software versions and ECUs_part number, checking_{06-30-23}....1104
Software versions and ECUs_part number, checking_{06-30-46}....1105
Software versions and ECUs_part number, general....1106
Software versions and ECUs_part number, general_{05-48-19}....1107
Software versions and ECUs_part number, general_{05-49-20}....1108
Software versions and ECUs_part number, general_{05-51-44}....1109
Software versions and ECUs_part number, general_{05-54-15}....1110
Software versions and ECUs_part number, general_{06-31-24}....1111
Software versions and ECUs_part number, general_{06-31-48}....1112
Software_{06-32-26}....1113
Software_{06-32-50}....1114
Solenoid valves, specification....1115
Solenoids, checking resistance-[3630]....1116
Solenoids, checking resistance-[3702]....1118
Solenoids, checking resistance....1120
Special tools for troubleshooting....1123
Stabilisers_{06-14-16}....1124
Stabilisers_{06-14-44}....1126
Starter motor engagement_{06-12-42}....1128
Starter motor engagement_{06-13-06}....1130
T-ECU, Inputs and outputs ....1132
Tech Tool operation, 17034-3 - Vehicle information, test_{05-54-39}....1134
Tech Tool, operations_{05-48-42}....1135
Transmission oil temperature_{06-16-36}....1136
Transmission oil temperature_{06-17-03}....1138
Troubleshooting, general....1140
V-ECU inputs and outputs_{05-56-42}....1141
V-ECU inputs and outputs_{05-57-06}....1144
V-ECU, software functions....1148
VCADS Pro service tool_{05-49-48}....1149
Wires, testing....1153
Working lights....1157
31 - BATTERY....1159
Batteries, replacing....1160
Battery, charging....1162
Battery, checking electrolyte....1163
Battery, description_{04-32-56}....1165
Battery, description_{04-33-23}....1167
Battery, specifications_{04-31-36}....1169
Battery, specifications_{04-31-59}....1170
Battery, storage....1171
32 - ALTERNATOR; CHARGE REGULATOR....1172
Alternator, description....1173
Alternator, specifications_{04-28-52}....1175
Alternator, specifications_{04-29-16}....1176
Alternator, tightening torques....1177
33 - STARTING SYSTEM....1178
Preheating, description....1179
Preheating, specifications....1180
Starter motor, description....1181
Starter motor, specifications....1182
35 - LIGHTING....1183
Lighting, description....1184
Lighting, specifications....1186
36 - OTHER ELECTRICAL EQUIPMENT....1187
Engine control unit E-ECU, description_{04-24-07}....1188
I-ECU, replacing-[2055]....1189
I-ECU, replacing....1192
Instrument control unit I-ECU, description....1195
Software versions and ECUs_part number, general_{04-23-40}....1197
This information is not valid for serial number range_{04-16-43}....1198
This information is not valid for serial number range_{04-18-03}....1199
Transmission control unit T-ECU, description ....1200
V-ECU MID 187 non-programmed, replacing_{04-18-30}....1202
V-ECU MID 187 pre-programmed, replacing_{04-17-18}....1208
V-ECU, replacing_{04-19-16}....1214
V-ECU, replacing_{04-19-39}....1220
Vehicle control unit V-ECU, description_{04-21-34}....1221
Vehicle control unit V-ECU, description_{04-22-01}....1223
37 - CABLE; FUSE; RELAY....1225
Cables, description....1228
Component list, Alternator, batteries, code lock, radio_{04-14-58}....1230
Component list, Alternator, batteries, code lock, radio_{04-15-26}....1232
Component list, Antennas (Care Track)....1234
Component list, Diodes....1235
Component list, Distribution boxes and control units_{04-12-57}....1236
Component list, Distribution boxes and control units_{04-13-24}....1239
Component list, Heating coils....1243
Component list, Solenoid valves_{04-03-04}....1244
Component list, Solenoid valves_{04-03-33}....1251
Component list, Sounders_{04-01-47}....1259
Component list, Sounders_{04-02-14}....1260
Component list, Switches_{04-00-07}....1261
Component list, Switches_{04-00-36}....1267
Component list, Switches_{04-01-04}....1274
Component list, fuses_{04-11-46}....1281
Component list, fuses_{04-12-15}....1287
Component list, instruments_{04-10-05}....1293
Component list, instruments_{04-10-32}....1296
Component list, lights_{04-08-55}....1299
Component list, lights_{04-09-23}....1302
Component list, motors_{04-07-45}....1305
Component list, motors_{04-08-13}....1307
Component list, relays_{04-06-34}....1309
Component list, relays_{04-07-03}....1314
Component list, resistors_{04-05-29}....1319
Component list, resistors_{04-05-53}....1320
Component list, sensors_{04-04-16}....1321
Component list, sensors_{04-04-49}....1329
Fuses, specifications_{03-29-03}....1340
Fuses, specifications_{03-29-26}....1342
T-ECU, Inputs and outputs....1344
This information is not valid for serial number range_{03-30-03}....1346
This information is not valid for serial number range_{03-31-08}....1347
This information is not valid for serial number range_{03-32-20}....1348
This information is not valid for serial number range_{03-33-25}....1349
V-ECU inputs and outputs_{03-58-22}....1350
V-ECU inputs and outputs_{03-58-46}....1353
Wiring diagram SCH01, overview_{03-57-21}....1357
Wiring diagram SCH01, overview_{03-57-45}....1358
Wiring diagram SCH02_{03-56-15}....1359
Wiring diagram SCH02_{03-56-43}....1362
Wiring diagram SCH03_{03-55-05}....1365
Wiring diagram SCH03_{03-55-33}....1368
Wiring diagram SCH04_{03-53-55}....1371
Wiring diagram SCH04_{03-54-23}....1374
Wiring diagram SCH05_{03-52-45}....1377
Wiring diagram SCH05_{03-53-13}....1380
Wiring diagram SCH06_{03-51-35}....1383
Wiring diagram SCH06_{03-52-03}....1386
Wiring diagram SCH07_{03-50-25}....1389
Wiring diagram SCH07_{03-50-53}....1392
Wiring diagram SCH08_{03-49-16}....1395
Wiring diagram SCH08_{03-49-43}....1398
Wiring diagram SCH09_{03-48-06}....1401
Wiring diagram SCH09_{03-48-34}....1404
Wiring diagram SCH10_{03-46-57}....1407
Wiring diagram SCH10_{03-47-24}....1410
Wiring diagram SCH11_{03-45-47}....1413
Wiring diagram SCH11_{03-46-15}....1416
Wiring diagram SCH12_{03-44-38}....1419
Wiring diagram SCH12_{03-45-05}....1422
Wiring diagram SCH13_{03-43-20}....1425
Wiring diagram SCH13_{03-43-48}....1429
Wiring diagram SCH14_{03-42-10}....1433
Wiring diagram SCH14_{03-42-38}....1436
Wiring diagram SCH15_{03-40-17}....1440
Wiring diagram SCH15_{03-40-45}....1443
Wiring diagram SCH15_{03-41-13}....1446
Wiring diagram SCH16_{03-39-07}....1449
Wiring diagram SCH16_{03-39-35}....1452
Wiring diagram SCH17_{03-37-58}....1455
Wiring diagram SCH17_{03-38-25}....1458
Wiring diagram SCH18_{03-36-49}....1461
Wiring diagram SCH18_{03-37-16}....1464
Wiring diagram SCH19_{03-35-40}....1467
Wiring diagram SCH19_{03-36-07}....1470
Wiring diagram SCH20_{03-34-34}....1473
Wiring diagram SCH20_{03-34-58}....1476
Wiring diagram SCH21_{03-33-53}....1479
Wiring diagram SCH22_{03-32-48}....1482
Wiring diagram SCH23_{03-31-35}....1485
Wiring diagram SCH24_{03-30-31}....1488
39 - MISCELLANEOUS....1491
CareTrack W-ECU, description....1492
4 - POWER TRANSMISSION....1493
40 - GENERAL....1494
Power transmission, description....1495
Power transmission, troubleshooting....1497
41 - CLUTCH; TORQUE CONVERTER....1500
Torque converter, description....1501
Torque converter, installing....1503
Torque converter, removing....1504
Torque converter, specifications....1505
42 - TRANSMISSION; HYDRAULIC CONTROL....1506
Electrical troubleshooting, Powershift transmission....1507
Hydraulic control valve, reconditioning....1508
Oil filler pipe, replacing_{03-13-51}....1513
Oil filler pipe, replacing_{03-14-18}....1516
Powershift Transmission (option), oil pressures, checking_{03-16-44}....1521
Powershift Transmission (option), oil pressures, checking_{03-17-12}....1530
Powershift transmission, description....1539
Powershift transmission, specifications....1541
Solenoid valves, description-[2339]....1543
Transmission control unit T-ECU, description....1545
Transmission solenoid, replacing-[1453]....1547
Transmission solenoid, replacing-[1526]....1549
Transmission, capacities-[2219]....1552
Transmission, installing_{03-17-53}....1553
Transmission, installing_{03-18-20}....1559
Transmission, removing_{03-19-10}....1565
Transmission, removing_{03-19-49}....1573
Transmission, tightening torques_{03-21-28}....1582
Transmission, tightening torques_{03-21-51}....1584
Transmission, weights-[2245]....1586
43 - GEARBOX....1587
4WD control valve, reconditioning....1588
Gearbox 2WD, specifications....1593
Gearbox 4WD, description....1594
Gearbox 4WD, specifications....1598
Gearbox, installing_{03-07-14}....1599
Gearbox, installing_{03-07-41}....1605
Gearbox, removing_{03-08-31}....1612
Gearbox, removing_{03-09-11}....1621
Oil filler pipe, replacing....1631
Solenoid valves, description....1632
T-ECU, replacing....1634
Transmission 2WD, oil pressures, checking_{03-06-05}....1638
Transmission 2WD, oil pressures, checking_{03-06-33}....1645
Transmission 4WD, oil pressures, checking_{03-04-57}....1651
Transmission 4WD, oil pressures, checking_{03-05-24}....1658
Transmission mounts, changing_{03-00-31}....1664
Transmission mounts, changing_{03-00-59}....1667
Transmission mounts, tightening torque_{03-01-36}....1671
Transmission mounts, tightening torque_{03-02-00}....1672
Transmission solenoid, replacing....1673
Transmission, capacities....1674
Transmission, tightening torques_{03-09-54}....1675
Transmission, tightening torques_{03-10-17}....1677
Transmission, weights....1679
45 - PROPELLER SHAFT....1680
Propeller shaft front, replacing....1681
Propeller shaft rear, replacing....1684
Propeller shaft, tightening torque....1687
46 - FRONT AXLE; REAR AXLE....1688
Axle suspension, adjusting axial clearance-[5751]....1689
Axle suspension, adjusting axial clearance....1692
Axle, installing_{02-52-03}....1693
Axle, removing_{02-51-36}....1697
Axles to frame, tightening torques....1700
Front axle, capacities....1701
Front axle, installing....1702
Front axle, removing....1705
Front axle, specification....1709
Front axle, tightening torque....1710
Front axle, weight....1711
Rear axle, capacities....1712
Rear axle, specification....1713
Rear axle, tightening torque....1714
Rear axle, weight....1715
49 - MISCELLANEOUS....1716
Hydraulic diagram, Powershift transmission....1717
Hydraulic diagram, gearbox 2WD....1720
Hydraulic diagram, gearbox 4WD....1722
Transmission oil cooler....1724
5 - BRAKE....1725
51 - WHEEL BRAKE....1726
Brake disc, replacing both sides....1727
Brake discs, checking wear....1732
General description....1733
Parking brake, description....1735
Service brake, description....1738
Service brake, specification....1742
Service brakes function, checking....1744
Service brakes, tightening torques....1745
52 - HYDRAULIC BRAKE SYSTEM....1746
Brake pedals, adjusting....1747
Brake system, bleeding....1749
Foot brake valve, installing....1751
Foot brake valve, removing....1755
Service brake pressure, checking....1758
55 - PARKING BRAKE....1760
Parking brake cable, adjusting....1761
Parking brake function, checking_{11-17-47}....1763
Parking brake function, checking_{11-18-16}....1766
Parking brake, replacing control cable....1768
6 - STEERING....1776
60 - GENERAL....1777
Steering system function, checking....1778
Steering, description....1780
Steering, hydraulic equipment, specifications....1786
Steering, specifications....1787
Steering, tightening torques....1788
Steering, troubleshooting....1789
62 - STEERING AXLE....1790
Steering axle and swivel-joint, description....1791
Toe - in, checking and adjusting....1794
64 - STEERING....1797
Priority valve, description....1798
Steering angle, checking and adjusting....1800
Steering column, installing_{02-41-13}....1803
Steering column, installing_{02-41-40}....1807
Steering column, removing_{02-42-22}....1811
Steering column, removing_{02-42-49}....1815
Steering cylinder removed, reconditioning incl replacing bearings....1819
Steering cylinder, installing....1822
Steering cylinder, removing....1825
Steering system working pressure, checking....1829
Steering valve, description....1831
Steering valve, installing....1835
Steering valve, removing....1837
Steering wheel, replacing....1839
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....1841
70 - GENERAL....1842
Frame, description....1843
Frame, tightening torque....1845
71 - FRAME....1846
Additional counterweight, installing....1847
Additional counterweight, removing....1849
Counterweight, description....1851
Counterweight, installing_{02-32-08}....1852
Counterweight, installing_{02-32-43}....1855
Counterweight, removing_{02-33-24}....1861
Counterweight, removing_{02-33-51}....1865
Counterweight, specifications....1871
Counterweight, tightening torques....1872
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....1873
Front wheel, installing....1874
Front wheel, removing....1877
Rear wheel, installing....1880
Rear wheel, removing....1883
Wheels, tightening torques....1886
Wheels, weights....1887
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....1888
80 - GENERAL....1889
Cab, description....1890
Cab, tightening torques....1891
Cab, weights....1892
Canopy, weights....1893
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....1894
Engine hood, installing_{02-23-25}....1895
Engine hood, installing_{02-23-51}....1897
Engine hood, removing_{02-24-33}....1899
Engine hood, removing_{02-25-00}....1902
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....1905
Rear window bearing, adjusting....1906
Window panes, glued, replacing....1908
Windows, general....1915
85 - CAB INTERIOR; UPHOLSTERY....1917
Front console, installing_{02-19-04}....1918
Front console, installing_{02-19-31}....1922
Front console, removing_{02-20-13}....1926
Front console, removing_{02-20-40}....1930
Operator's seat, installing....1934
Operator's seat, removing....1935
87 - AIR CONDITIONING UNIT....1937
Air conditioning, specifications....1938
Air conditioning, tightening torques....1939
Belt, replacing....1940
Cab filter box, assembling....1943
Climate control system, description....1948
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....1955
90 - GENERAL....1956
Cleanliness when working on hydraulic components....1957
Hydraulic components, storing and transporting....1958
Hydraulic oil, description....1959
Hydraulic oil, storage and handling....1960
Hydraulic system, bleeding air....1961
Hydraulic system, repair of hydraulic components in workshop....1964
This information is not valid for serial number range_{02-09-04}....1965
This information is not valid for serial number range_{02-10-08}....1966
V2-ECU, MID 249, changing non-programmed ECU_{02-09-31}....1967
V2-ECU, MID 249, changing pre-programmed ECU_{02-10-43}....1971
Vacuum pump, connection....1975
Vacuum pump, disconnection....1977
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....1978
Accumulator, specification....1980
Boom Suspension System, description....1981
Boom suspension accumulator, checking and adjusting....1983
Control lever, changing....1986
Hose rupture valve (safety valve) for boom cylinder, description....1994
Hose rupture valve (safety valve) for dipper arm cylinder, description....1997
Hose rupture valve, checking....2000
Hose rupture valves (safety valves) for loader, description....2001
Hose rupture valves (safety valves), specification....2005
Hose rupture valves....2006
Hydraulic cylinders, cleaning....2009
Hydraulic oil cooler, description....2010
Hydraulic oil cooler, installing_{02-02-01}....2012
Hydraulic oil cooler, removing_{02-03-10}....2017
Hydraulic oil tank, description....2023
Hydraulic pressure, checking....2026
Hydraulic pump, description....2031
Hydraulic pump, replacing....2033
Hydraulic pump, specification....2037
Hydraulic pump, suction hose, replacing....2038
Hydraulic pump, tightening torque....2042
Hydraulic system, capacities....2043
Hydraulic system, component location....2044
Hydraulic system, description....2050
Hydraulic system, pressure release....2051
Hydraulic system, specification....2052
Hydraulic system, weights_{02-06-15}....2053
Hydraulic system, weights_{02-06-38}....2054
Lowering of backhoe with hose rupture valves (safety valves)....2055
Main control valve leakage....2057
Main control valve, changing spool seal....2058
Main valve block, backhoe, installing....2065
Main valve block, backhoe, removing....2070
Main valve block, loader, installing....2075
Main valve block, loader, removing....2079
Radiator, installing_{02-01-27}....2083
Radiator, removing_{02-02-43}....2087
This information is not valid for serial number range....2091
Valve block, backhoe, description_{01-59-46}....2092
Valve block, backhoe, specification_{01-58-15}....2096
Valve block, loader, description_{01-59-19}....2097
Valve block, loader, specification_{01-57-53}....2100
Valve block, specification_{01-58-38}....2101
Valve block, tightening torques....2102
Working hydraulics, description....2103
92 - MECHANICAL EQUIPMENT_ATTACHMENT....2105
Bucket assembly, replacing....2106
Hammer, connection....2117
Hammer, disconnection....2119
Multi-purpose bucket cylinder, reconditioning....2121
Multi-purpose bucket cylinder, replacing....2127
94 - UNIT, LOAD HANDLING....2132
Cylinders loader unit, description....2133
Cylinders loader unit, specification....2139
Hydraulic cylinders, tightening torques ....2140
Lift cylinder, installing....2141
Lift cylinder, reconditioning....2144
Lift cylinder, removing....2150
Multi-purpose bucket cylinder....2154
Self level function, description....2155
Tilt cylinder, installing....2158
Tilt cylinder, reconditioning....2161
Tilt cylinder, removing....2167
97 - UNIT, DIGGING....2170
Boom bushing, changing....2171
Boom cylinder, installing....2176
Boom cylinder, removing....2181
Boom cylinder, renovation....2185
Boom lock, description....2191
Boom swing cylinder, installing....2193
Boom swing cylinder, removing....2200
Bucket cylinder, installing....2206
Bucket cylinder, removing....2210
Bucket cylinder, renovation....2214
Cylinders backhoe unit, description....2221
Cylinders backhoe unit, specification....2223
Dipper arm cylinder, installing....2225
Dipper arm cylinder, removing....2231
Dipper arm cylinder, renovation....2235
Extendible dipper arm cylinder, installing....2242
Extendible dipper arm cylinder, removing....2246
Extendible dipper arm cylinder, renovation....2250
Hydraulic cylinders, tightening torques....2256
Stabiliser detection switches, function check....2258
Stabiliser legs, cleaning....2261
Stabiliser wear pads, replacing....2263
Stabilisers wearpads, adjusting....2265
Stabilisers, description....2267
Stabilisers, hydraulic cylinder, installing....2270
Stabilisers, hydraulic cylinder, removing....2276
Stabilisers, reconditioning hydraulic cylinder....2282
Swing cylinder, renovation....2289
99 - MISCELLANEOUS....2295
Hydraulic diagram_{01-16-22} Image....2296
Hydraulic diagram_{01-16-22}....2297
Hydraulic diagram_{01-16-50} Image....2300
Hydraulic diagram_{01-16-50}....2301
