Volvo L150G Wheel Loader Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo L150G Wheel Loaders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions L150G Wheel 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: 2,721 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo L150G Wheel Loaders Service Repair Manual.pdf
TABLE OF CONTENTS
0 - GENERAL...2
03 - SPECIFICATIONS...3
Tightening torques...4
Tightening torque; cylinder head...15
Lubrication system; specifications ...17
Oil cooler; tightening torques ...19
Tightening torques; unit injector_{20-27}...21
Tightening torques; unit injector_{20-08}...23
Exhaust aftertreatment system; specifications ...25
Compressed-air system; specifications ...28
Turbocharger; specifications_{18-59}...30
Turbocharger; specifications_{18-40}...32
Thermostat; specifications ...34
Rocker arm shaft; tightening torques_...35
Valve cover; tightening torques_...37
Exhaust manifold; tightening torques_{16-45}...38
Exhaust manifold; tightening torques_{16-23}...40
EGR system; tightening torques ...42
Cooling fan rpm; specifications ...43
Conversion tables...46
Fuel system; specifications ...50
Engine; specifications ...51
07 - STANDARD TIME...53
Operation numbers for additional work...54
08 - TOOL...56
E1680; Holder...57
E 1708; Checking point...59
E1711...61
E-2000...63
E-2001...65
E-2005...67
E-2007...69
E-2015...71
E-2017...73
E-2018...74
E-2020...76
E-2028...77
Infrared Thermometer...79
Leak detector 951 1207; description...83
88830557 User Instruction...87
1 - STANDARD PARTS; SERVICE...97
16 - LUBRICANT; FUEL; OTHER FLUID...98
Coolant...99
Recommended lubricants...101
Alternative fuels...104
17 - SERVICE...107
Service...111
Electric welding ...114
Arrival Inspection; according to Inspection Programme...116
Delivery Inspection; according to Inspection Programme...117
Maintenance of Stored Machines; according to Inspection Programme...118
Maintenance service; first 1000 hours...119
Maintenance service; every 50 hours...120
Maintenance service; every 250 hours...121
Maintenance service; every 500 hours...122
Maintenance service; every 1000 hours...124
Maintenance service; every 2000 hours_{58-45}...126
Maintenance service; every 2000 hours_{58-27}...129
Maintenance service; every 4000 hours_{57-58}...132
Maintenance service; every 4000 hours_{57-40}...135
Maintenance service; every 4500 hours...138
Maintenance service; every 6000 hours...140
Maintenance service; every 8000 hours...141
Maintenance service; every 12000 hours...142
Brake discs; measuring wear...144
Wheel brakes function; checking...147
Service position 2_{55-12}...148
Service position 1_{54-44}...150
Wheel brake; specification...152
Drive axles; oil; draining...153
Front axle; breather filter; replacing...156
Axle oil cooler; front axle; filter; replacing...158
Rear axle bearing; oil; draining...160
Hydraulic oil tank; draining...162
Transmission oil; draining...164
Engine oil; changing...166
Engine oil; draining...167
EGR venturi tube; checking ...169
Spark plug cable; replacing ...172
Spark plug; replacing ...174
Valves; adjusting_{48-43}...179
Valves; adjusting_{48-17}...185
Oil plugs; installing...191
Take the hose away from the draining point of engine oil and replace the cap...192
Water separator; draining...193
Fuel filters; primary and secondary filter; replace...195
Engine oil filter; removing...197
Fuel tank breather filter; replacing...198
Axle oil cooler; rear axle; filter; replacing...199
Engine air cleaner; replacing...200
Transmission oil filter; replacing...203
Transmission suction strainer; cleaning...205
Automatic central lubrication; filter; cleaning_replacing...207
Cab; extra prefilter; replacing...209
Air pump; oil level; checking...211
Air drier; drier cartridge; replace...213
Transmission breather filter; replacing...215
Rear axle; breather filter; replace...216
Alternator; filter; replace...217
Engine oil filter; installing...219
Engine oil; filling...220
Drive belts; check_{39-20}...221
Drive belts; check_{38-59}...223
Hydraulic tank breather filter; changing...225
Hydraulic oil tank; return oil filter; replace; and magnetic rod; clean...226
Hydraulic oil; filling...228
Transmission oil; filling...230
Rear axle bearing; oil; filling...232
Drive axles; oil; filling...234
Cab; prefilter; replace when required...236
Cab filter; replacing...238
Restore operating condition after all test and adjustment work...241
Warming up machine...242
Transmission oil; checking level...244
Hydraulic oil level; checking...246
Engine oil level; checking...248
Coolant level; checking...249
Brake system charging; checking...251
Steering system working pressure; checking and adjusting...255
Boom suspension accumulator; checking and adjusting...258
Hydraulic pump; standby pressure and working pressure; checking and adjusting...262
Oil-bath air cleaner's reservoir (optional equipment); oil; check...267
Oil-bath air cleaner's reservoir (optional equipment); clean; and oil; change...270
Oil bath air cleaner oil; changing...273
Battery; cables and connections; check...276
Engine radiator; oil cooler and condensor (if installed); clean...278
Hinge; lubricating...281
Restore the machine to original condition...286
Coolant's freezing point; check...287
Tyres; wear and air pressure; checking...289
Air pump; oil; changing...290
DPF (Diesel particulate filter); checking and cleaning ...292
Lubrication; 50 hours maintenance interval...296
Lubrication; 250 hours maintenance interval...299
Lubrication; 500 hours maintenance interval...302
Lubrication; 1000 hours maintenance interval...306
Lubrication; 2000 hours maintenance interval...310
Lubrication; 4000 hours maintenance interval...314
Maintenance service; fire suppression system...318
Hydraulic oil tank; sediment drain...335
Coolant; changing...337
Rear axle pivot bearing; greasing...340
Parking brake; manually releasing...342
Towing...344
Electric welding...346
19 - GENERAL...347
Working on the electrical system of the machine...348
CE-marking; EMC-directive...350
Safety concerns everybody!...354
Checking function...358
Safety when handling the machine...359
Safety rules when servicing...364
Service position 2_{13-25}...367
Service position 1_{12-59}...369
Working under raised boom...371
Fire prevention measures...373
Some simple rules regarding tyre handling...377
Safety when lifting and supporting complete machine...379
Starting with booster batteries...383
Safety when handling oils and fuel...386
Safety when handling accumulators...388
Safety when working on hydraulic systems...390
Checklist after a fire or heat exposure...392
Health hazards with paint; plastics and rubber...395
Environmental handling for the future...398
Waste handling...401
Environmentally safe handling...405
Environmentally hazardous fluids...408
Safety when working with air conditioning refrigerant...411
Working in environmentally contaminated areas...414
Decontamination...417
2 - ENGINE WITH MOUNTING AND EQUIPMENT...421
20 - GENERAL...422
Engine; description_{02-06}...423
Engine; description_{01-45}...428
Component locations_{01-14}...433
Component locations_{00-53}...436
Tech Tool; operations_{00-23}...439
Tech Tool; operations_{00-04}...442
Engine; capacities...444
E-ECU MID 128 pre-programmed; replacing_{59-14}...445
E-ECU MID 128 pre-programmed; replacing_{58-53}...448
21 - ENGINE...451
Engine; specifications...453
Cylinder block; tightening torques_{56-52}...455
Cylinder block; tightening torques_{56-30}...460
Engine rotation speed sensor (crank shaft); replacing...466
Engine rotation speed sensor (camshaft); replacing...469
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope...472
Engine; removing_{53-03}...478
Engine; removing_{52-31}...489
VCADS Pro; MID 128; programming E-ECU_{51-48}...499
VCADS Pro; MID 128; programming E-ECU_{51-30}...501
Engine; installing_{51-01}...503
Engine; installing_{50-34}...513
Cylinder compression; testing_{49-59}...522
Cylinder compression; testing_{49-13}...538
Valve cover; tightening torques_48-24...551
Valve cover; tightening torques...552
Cylinder head; tightening torques...553
Cylinder block; specifications...555
Crankcase ventilation; description_{46-37}...556
Crankcase ventilation; description_{46-14}...561
Crankcase ventilation separator; replacing...564
Valve mechanism; tightening torques...566
Valve system; specifications...567
Rocker arms; replacing...570
Rocker arm shaft; tightening torques...572
Valves; adjusting_{43-13}...574
Valves; adjusting_{42-49}...580
Valve cover; removing...586
Valve cover; installing...589
Engine transmission; tightening torque...594
Engine transmission; specification...599
Camshaft setting; checking_{39-31}...602
Camshaft setting; checking_{39-10}...610
Camshaft; replacing_{38-22}...618
Camshaft; replacing_{37-47}...644
Crank mechanism; specifications...665
Crankshaft; tightening torques...668
Flywheel; tightening torques...669
Belt pulley_vibration damper; tightening torques...670
Oil sump; tightening torque...671
22 - LUBRICATING SYSTEM...672
Lubrication system; description...673
Lubrication system; specifications...680
Lubrication oil consumption; checking...682
Lubrication system; component locations_{32-46}...686
Lubrication system; component locations_{32-25}...690
Lubrication system; tightening torques...693
Lubrication oil pressure; checking with pressure gauge...695
Oil cooler; tightening torques...697
23 - FUEL SYSTEM...699
Fuel system; description_{29-45}...700
Fuel system; description_{29-21}...706
Fuel system; specifications...712
Fuel system; tightening torques...713
Air in fuel system; checking...721
Carbon dioxide in fuel system; checking...725
Fuel system; component location...731
Fuel system hand pump; replacing...733
Feed pump pressure; checking...737
Feed pump; replacing...739
Fuel system; bleeding_{23-22}...741
Fuel system; bleeding_{23-02}...743
Feed pump removed; reconditioning...745
Stall speed; checking...750
Unit injector pretension; adjusting...752
Injectors; checking...755
Yoke; injector; checking...766
Injectors; replacing_{18-54}...771
Injectors; replacing_{18-19}...786
Overflow valve; replacing...798
Injector sleeves; replacing_{17-05}...801
Injector sleeves; replacing_{16-25}...810
25 - INLET & EXHAUST SYSTEM...817
Inlet and exhaust system; description_{14-49}...819
Inlet and exhaust system; description_{14-24}...824
Inlet and exhaust system; component location_{13-45}...829
Inlet and exhaust system; component location_{13-24}...832
Inlet and exhaust system; tightening torques...835
Exhaust manifold; tightening torques_{11-32}...838
Exhaust manifold; tightening torques_{11-12}...840
Exhaust pipe flexible tube; replacing...842
Auxiliary brake (engine braking); description...846
Exhaust Aftertreatment System; description...848
Exhaust Aftertreatment System; component location...856
Regeneration process; description...859
Exhaust aftertreatment system; specifications...862
Perform a service regeneration...865
DPF (Diesel particulate filter); checking and cleaning...868
Exhaust aftertreatment system; tightening torques...872
ACM (Aftertreatment control module) non-programmed; replacing...877
ACM (Aftertreatment control module) pre-programmed; replacing...879
Atomization unit; replacing...881
Drying filter; replacing...886
Spark plug; inspecting...889
Spark plug; replacing...894
Spark plug cable; replacing...899
Air purge tank; replacing...901
Air pump flow; checking...903
Air pump; replacing...905
Burner; replacing...908
Compressor; replacing...914
Exhaust aftertreatment system fuel pump; replacing...919
ASU (Aftertreatment support unit); replacing...927
High pressure air system pressure; checking...931
Compressed-air system; specifications...935
Exhaust aftertreatment system fuel flow; checking...937
Exhaust aftertreatment fuel injector; replacing...942
Turbocharger; description_{57-01}...947
Turbocharger; description_{56-40}...953
Turbocharger; specifications_{56-06}...955
Turbocharger; specifications_{55-47}...957
Turbocharger; inspecting_{55-19}...959
Turbocharger; inspecting_{54-59}...962
Turbocharger; replacing_{54-29}...965
Turbocharger; replacing_{54-08}...972
Wastegate; checking...979
Variable turbocharger actuator; replacing...981
Preheating; specifications...986
26 - COOLING SYSTEM...987
Cooling system; description...988
Carbon dioxide in coolant system; checking...993
Cooling system; component location...999
Cooling system; capacity...1001
Cooling system pressure; checking...1002
Radiator; replacing...1004
Thermostat; specifications...1016
Cooling fan; component location...1017
Cooling fan; description...1020
Reversible cooling fan; description...1024
Cooling fan motor; description...1028
Cooling fan; tightening torques...1030
Temperature limits for cooling fan speed; specifications...1032
Cooling fan rpm; specifications...1033
Fan control valve; seal replacing...1036
Drive belts; check...1039
27 - ENGINE CONTROL...1040
ECO - accelerator pedal...1041
29 - MISCELLANEOUS...1043
Exhaust Gas Recirculation (EGR); description...1044
Exhaust gas recirculation (EGR); component location...1051
EGR system; tightening torques...1053
EGR cooler; replacing...1054
EGR cooler pressure; testing_{40-30}...1063
EGR cooler pressure; testing_{40-10}...1068
EGR temperature sensor; replacing...1072
EGR pressure sensor; replacing...1075
EGR valve; replacing...1078
EGR venturi tube; checking...1084
EGR actuator; specification...1087
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...1088
30 - GENERAL...1089
Electrical system; work instructions...1095
Electrical system; description...1097
Software; description...1099
Electronic control system; description...1100
Communication with data buses...1109
VCADS Pro; Operations...1111
Electrical system; specifications...1113
Software parameters; description...1114
General fault diagnosis information...1128
Troubleshooting strategy...1130
Collection of basic data...1132
Information display; check...1135
Error codes; showing...1137
SAE error codes; translation to error messages; general...1140
Bus communication supervision...1143
Conditions when checking...1145
Lead and connector checks...1148
Troubleshooting tools...1153
Special tools for troubleshooting...1155
VCADS Pro; Error codes...1157
VCADS Pro service tool...1160
CU3605; description and measuring...1164
CU6601; description and measuring...1166
CU9901; description and measuring...1171
E-ECU PID158; description and measuring...1174
FX1005; description and measuring...1175
FX1006; description and measuring...1177
FX1007; description and measuring...1180
FX1008; description and measuring...1183
FX1009; description and measuring...1186
FX1024; description and measuring...1189
FX1025; description and measuring...1193
FX1032; description and measuring...1196
HE2501; description and measuring...1198
IG2501; description and measuring...1200
MA2301-MA2306; description and measuring...1202
MA2506; description and measuring...1205
MA2507; description and measuring...1207
MA2601; description and measuring...1209
MA2602; description and measuring...1211
MA4603; description and measuring...1213
MA5501; description and measuring...1215
MA5503; description and measuring...1218
MA9103; description and measuring...1220
MA9104; description and measuring...1223
MA9106; description and measuring...1226
MA9114; description and measuring...1228
MA9127; description and measuring...1231
MO2501; description and measuring...1233
MO2504; description and measuring...1235
MO3301; description and measuring...1237
MO3612; description and measuring...1239
MO3613; description and measuring...1241
MO6401; description and measuring...1243
MO8707; description and measuring...1245
MO8711; description and measuring...1247
Power supply; ACM (Aftertreatment Control Module); description and measuring...1249
Power supply ECC; description and measuring...1251
Power supply E-ECU; description and measuring...1253
5 V Power supply E-ECU; description and measuring...1255
Power supply I-ECU; description and measuring...1257
Power supply V-ECU; description and measuring...1259
Power supply V2-ECU; description and measuring...1261
Power supply W-ECU; description and measuring...1263
PWM2503; description and measuring...1265
PWM2602; description and measuring...1267
PWM4203; description and measuring...1269
PWM4213 - PWM4218; description and measuring...1271
PWM5202; description and measuring...1274
PWM6601; description and measuring...1276
PWM6602; description and measuring...1278
PWM9101; description and measuring...1280
PWM9102; description and measuring...1282
PWM9103; description and measuring...1284
PWM9104; description and measuring...1286
PWM9105; description and measuring...1288
PWM9106; description and measuring...1290
PWM9107; description and measuring...1292
PWM9108; description and measuring...1294
R2701; description and measuring...1296
RE02; description and measuring...1298
RE06; description and measuring...1300
RE08; description and measuring...1302
RE09; description and measuring...1304
RE10; description and measuring...1306
RE15; description and measuring...1308
RE2501; description and measuring...1310
RE6401; description and measuring...1312
RE8712; description and measuring...1314
SAE J1708_1587 Information link; description and measuring...1316
SAE J1939_CAN1 Control link; description and measuring...1319
SAE J1939_CAN2 Control link; description and measuring...1322
SAE J1939-1 SubNet 1; description and measuring...1325
SE2203; description and measuring...1328
SE2301; description and measuring...1330
SE2303; description and measuring_{19-23}...1332
SE2303; description and measuring_{18-53}...1335
SE2509; description and measuring...1338
SE2510; description and measuring...1340
SE2512; description and measuring...1343
SE2514; description and measuring...1345
SE2515; description and measuring...1347
SE2516; description and measuring...1349
SE2519; description and measuring...1351
SE2521; description and measuring...1354
SE2522; description and measuring...1357
SE2525; description and measuring...1360
SE2527; description and measuring...1363
SE2528; description and measuring...1366
SE2603; description and measuring...1369
SE2604; description and measuring...1371
SE2606; description and measuring...1373
SE2701; description and measuring...1375
SE2702; description and measuring...1377
SE2703; description and measuring...1380
SE2704; description and measuring...1382
SE4202; description and measuring...1384
SE4203; description and measuring...1386
SE4209; description and measuring...1388
SE4213; description and measuring...1390
SE4218; description and measuring...1392
SE4219; description and measuring...1394
SE4226; description and measuring...1396
SE4307; description and measuring...1398
SE4312; description and measuring...1400
SE4609; description and measuring...1402
SE5201; description and measuring...1404
SE5203; description and measuring...1407
SE5222; description and measuring...1410
SE5223; description and measuring...1412
SE5501; description and measuring...1414
SE6404; description and measuring...1416
SE6407; description and measuring...1418
SE6411; description and measuring...1420
SE8702; description and measuring...1423
SE8705; description and measuring...1425
SE8706; description and measuring...1427
SE8708; description and measuring...1429
SE8709; description and measuring...1431
SE9116; description and measuring...1434
SE9117; description and measuring...1437
SE9119; description and measuring...1440
SE9147; description and measuring...1442
SE9148; description and measuring...1445
SW2506; description and measuring...1448
SW3630; description and measuring...1450
SW3801; description and measuring...1452
SW4205_SW4206; description and measuring...1455
SW4208; description and measuring...1458
SW4209; description and measuring...1460
SW4211; description and measuring...1462
SW4212; description and measuring...1464
SW4217; description and measuring...1467
SW4219; description and measuring...1469
SW4220; description and measuring...1471
SW5501; description and measuring...1473
SW8701; description and measuring...1475
SW9143; description and measuring...1477
SW9148; description and measuring...1479
SW9149; description and measuring...1481
VCADS Pro socket; measuring...1484
VCADS Pro; connecting problems...1487
31 - BATTERY...1490
System voltage...1491
Key feed...1493
Battery; description...1495
Battery; weight...1496
Battery; specifications...1497
Battery condition; checking...1498
Battery; charging...1501
Batteries; replacing...1503
32 - ALTERNATOR; CHARGE REGULATOR...1505
Alternator 80 A; specification...1506
Alternator; description...1507
Alternator 80 A; description...1513
33 - STARTING SYSTEM...1514
Starter motor; specifications...1515
Starter motor; tightening torques...1516
Booting sequence...1519
Starter motor; replacing...1521
Preheating; specifications...1523
Preheating; description...1524
Starter lock; replacing...1527
35 - LIGHTING...1529
Lighting; specifications...1530
Lighting; description...1531
36 - OTHER ELECTRICAL EQUIPMENT...1534
Intermittent wiper and washer...1535
Connectors; position...1537
Connectors; overview...1548
Vehicle control unit V2-ECU; description...1552
I-ECU MID 140 non-programmed; replacing...1554
I-ECU MID 140 pre-programmed; replacing...1556
V-ECU MID 187 non-programmed; replacing...1558
V-ECU MID 187 pre-programmed; replacing...1560
Hood opening...1562
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...1564
Instrument panels...1565
Middle instrument panel with warning lights...1567
Information display; general...1569
Information display; start lockout...1572
Information display; operating display...1574
Information display; engine...1576
Information display; transmission...1579
Information display; hydraulics...1581
Information display; axles _ brakes...1584
Information display; electrical system...1586
Information display; vehicle info...1588
Information display; vehicle messages...1591
Information display; service...1592
Information display; service mode...1595
Information display; settings...1599
Information display; check...1601
Alarm; description_{42-25}...1603
Alarm; description_{42-07}...1605
Central warning...1607
39 - MISCELLANEOUS...1608
CareTrack W-ECU; description...1609
CareTrack battery; replacing...1613
4 - POWER TRANSMISSION...1616
40 - GENERAL...1617
Drivetrain; component location...1618
VCADS Pro; Operations ...1620
Error codes when calibrating ...1622
42 - TRANSMISSION; HYDRAULIC CONTROL...1623
Transmission; component location...1624
Transmission; specifications ...1629
Hydraulic transmission; capacity...1631
Transmission; tightening torques...1632
Hydraulic transmission; description...1634
Transmission; specifications...1644
Transmission; removing_{33-49}...1646
Transmission; removing_{33-28}...1656
Transmission; installing_{32-53}...1666
Transmission; installing_{32-31}...1674
Hydraulic diagram transmission...1682
Lock up valve; replacing...1685
Transmission oil pressure; checking...1691
Gear selector valve; replacing one solenoid...1696
Seal for front output shaft; replacing...1700
Seal for rear output shaft; replacing...1703
Transmission; function check...1706
Transmission; calibration...1707
45 - PROPELLER SHAFT...1709
Propeller shaft; tightening torque...1710
Propeller shaft; component description...1711
46 - FRONT AXLE; REAR AXLE...1713
Drive axles; description...1714
Front and rear axles; tightening torque...1716
Front and rear axles; specifications...1718
Front axle; component description...1719
Rear axle; component description...1722
Rear axle mounting; component description...1726
Front and rear axles; volume...1729
Automatic differential brake; Limited Slip; description...1730
Rear axle mounting; volume...1733
Hub seal; replacing 2...1734
Hub reduction; removing ...1750
Axle; removing...1753
Axle suspension bushes and seals; replacing...1756
Axle suspension; tightening torque...1765
Axle; installing...1766
Hub reduction; removing...1769
Hub reduction; installing...1772
Hub seal; replacing...1775
Differential lock; description...1792
Differential lock; adjusting...1794
Differential lock; function check...1798
49 - MISCELLANEOUS...1800
Oil cooler; component description...1801
Heat exchanger; replacing...1802
5 - BRAKE...1807
50 - GENERAL...1808
VCADS Pro; Operations ...1809
Tech Tool; operations...1810
51 - WHEEL BRAKE...1811
Wheel brake; specification...1812
Brake discs; measuring wear...1813
Wheel brakes function; checking...1816
Brake discs; replacing...1817
Brake piston seals; replacing ...1823
Brake disc; replacing...1827
Brake piston seals; replacing...1833
52 - HYDRAULIC BRAKE SYSTEM...1837
Brake system; component location...1838
Braking system; description...1840
Brake system; specifications...1845
Brake system circuit pressure; checking and adjusting...1846
Brake system; bleeding...1849
Brake system retardation function; checking...1851
Automatic brake function; checking...1852
Brake system charging; checking...1854
Axle oil cooler; component location...1858
Axle oil cooler; description...1860
Foot brake valve; description...1863
Automatic brake valve; description...1865
Brake accumulator; description...1867
Brake accumulator; specifications...1869
Accumulator (removed) charging pressure; checking...1870
Accumulator; removing...1872
Accumulator; installing...1874
Accumulators; checking in machine...1875
Accumulator; discarding ...1877
55 - PARKING BRAKE...1880
Parking brake; specifications...1881
Parking brake; component location...1882
Parking brake; component description...1885
Parking brake; function description...1887
Parking brake discs and seals; replacing...1893
Parking brake function; checking...1899
6 - STEERING...1901
60 - GENERAL...1902
Steering system; component location...1903
Steering system; description...1906
Steering system function; checking...1914
VCADS Pro; Operations ...1916
Lever steering CDC; tightening torques...1917
64 - STEERING...1919
Steering; specifications...1920
Steering cylinder; description...1921
Steering valve; description...1923
Steering cylinder; tightening torque...1925
Shift valve; description ...1927
Steering system working pressure; checking and adjusting...1930
Steering cylinder; repacking in machine...1933
Left steering cylinder; removing...1941
Right steering cylinder; removing...1947
Left steering cylinder; installing...1953
Right steering cylinder; installing...1956
Accumulator; discarding ...1960
Secondary steering pump; specifications...1962
Secondary steering; component location...1963
Secondary steering; description...1965
Pressure monitor; description ...1969
Secondary steering pump working pressure; checking and adjusting...1971
66 - LEVEL STEERING...1974
Comfort Drive Control (CDC); description...1975
CDC valve; lever steering; description...1980
Lever steering (CDC); specifications...1983
Comfort Drive Control (CDC); component location...1984
Comfort drive control (CDC) angle sensor; changing...1986
Comfort Drive Control; servo pressure; checking...1990
Error codes when calibrating_41-51...1992
Comfort Drive Control (CDC) joystick; changing...1995
Comfort drive control (CDC) solenoid valve; changing...2000
Lever steering (CDC) function; checking...2002
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...2005
70 - GENERAL...2006
Frame; description...2007
71 - FRAME...2010
Counterweight; tightening torques...2011
Counterweight; weight...2012
Counterweight; removing...2014
Counterweight; installing...2017
74 - FRAME LINK...2019
Frame joint; tightening torques...2020
Frame joint; description...2021
Frame joint; replacing bearings...2023
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...2045
Wheels; tightening torques...2046
Rear wheel; removing...2047
Rear wheel; installing...2051
Front wheel; removing...2054
Front wheel; installing...2057
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...2060
80 - GENERAL...2061
Cab; description_{32-13}...2062
Cab; description_{31-53}...2064
81 - CAB; NAKED; CANOPY...2067
Cab; position 1...2068
Cab; position 1; restoring...2072
Cab; position 2...2075
Cab; position 2; restoring...2081
Cab; removing...2087
Cab; installing...2099
Cabin; tightening torques_{26-20}...2112
Cabin; tightening torques_{25-59}...2113
Viscous cab suspension; description...2114
82 - ENGINE HOOD; MUDGUARD; FOOT STEP...2116
Plastic hood; repairing...2117
Engine hood; raising and securing...2122
Engine hood; removing...2124
Engine hood; installing...2128
Actuator; replacing...2132
Engine hood; manually operating...2137
83 - DOORS; HATCH; COVER PLATE; (all)...2140
Electric door opener; description...2141
Electric door opener; control unit; replacing...2145
Electric door opener; locking motor; replacing...2147
Electric door opener; rotor switch; replacing...2149
Electric door opener; opening support motor; replacing...2151
Door lock cylinder; replacing_{18-37}...2154
Door lock cylinder; replacing_{18-17}...2162
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...2170
Windows; general...2171
Side window; replacing_{16-23}...2173
Windscreen; replacing_{16-01}...2183
Window pane; installing...2193
Windows; general; gluing...2198
85 - CAB INTERIOR; UPHOLSTERY...2201
Operator's seat; securing...2202
87 - AIR CONDITIONING UNIT...2204
Climate control system; description...2205
ECC MID 146 non-programmed ECU; replacing...2210
ECC MID 146 pre-programmed ECU; replacing...2213
Troubleshooting; air conditioning unit (AC)...2216
Climate unit; removing...2220
Climate unit; installing...2228
Pause heater; description...2234
Pause heater; replacing...2236
Fan motor; replacing...2239
Air mix door actuator; replacing...2242
Heater core; replacing...2248
Heat control valve; replacing...2251
Air conditioning; tightening torques...2255
Air conditioning; specifications...2256
Air conditioning; refrigerant; weight_{06-30}...2258
Air conditioning; refrigerant; weight_{06-12}...2259
Air conditioning; refrigerant; weight_{05-54}...2260
Air conditioning; checking performance...2261
Drying filter; replacing...2263
Condenser; replacing...2267
Compressor; replacing...2271
Evaporator; replacing...2278
Expansion valve; replacing...2286
Refrigerant; draining...2297
Refrigerant; filling incl vacuum pumping...2300
88 - INTERIOR EQUIPMENT...2304
Accelerator pedal; replace...2305
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...2307
90 - GENERAL...2308
Hydraulic diagram; complete - Image...2309
Hydraulic diagram; basic machine - Image...2310
Explanations to hydraulic diagram...2311
Hydraulic components; cleanliness when handling...2320
Hydraulic diagram; complete...2323
Hydraulic diagram; basic machine...2326
VCADS Pro; Operations...2329
Hydraulic system; volume...2331
Hydraulic system; bleeding...2332
V2-ECU; MID 249; changing non-programmed ECU...2335
V2-ECU; MID 249; changing pre-programmed ECU...2337
Hydraulic system; warming up...2339
Control valve; tightening torques...2341
3rd_4th hydraulic function; tightening torques...2342
Accumulator; discarding...2343
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...2346
Error codes when calibrating...2349
Hydraulic oil tank; description...2353
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump...2354
Hydraulic connections; tightening torques...2356
Hydraulic couplings...2358
Working hydraulic system; component location_51-44...2362
Working hydraulic system; component location...2364
Working hydraulic system; description...2366
Control valve; description...2374
Central valve; description...2378
Control valve; specifications...2380
Back-up valve; checking and adjusting...2381
Shock valve lift function; checking...2384
Shock valve; tilt function; checking...2387
Back-up valve; replacing...2390
Lift; solenoid valve; changing...2393
Lower; solenoid valve; changing...2395
Tilt in; solenoid valve; changing...2397
Tilt out; solenoid valve; changing...2399
Lift_lower; angle sensor; changing_{45-50}...2401
Lift_lower; angle sensor; changing_{45-32}...2404
Tilt in_out; angle sensor; changing_{45-03}...2409
Tilt in_out; angle sensor; changing_{44-42}...2416
Tilt; checking...2427
Lift_lower function; checking...2429
Hydraulic pumps; description...2433
Hydraulic pump flow regulation; description...2438
Hydraulic pump (P1); specifications...2442
Hydraulic pump (P2); specifications...2443
Hydraulic pump (P3); specifications...2444
Function times; specifications...2445
Hydraulic pumps; tightening torques...2446
Lifting time; checking...2447
Hydraulic pump; standby pressure and working pressure; checking and adjusting...2448
LS (load sense) pressure; checking...2453
Hydraulic pump P1; removing...2456
Hydraulic pump P1; installing...2460
Hydraulic pump P2; removing...2463
Hydraulic pump P2; installing...2466
Hydraulic pump P3; removing...2470
Hydraulic pump P3; installing...2473
Hydraulic pump P3; checking...2476
Servo system; specifications...2479
Single lever control electric servo; replacing...2480
Servo pressure; checking and adjusting...2491
Servo pressure; at the spool in control valve; checking...2494
Accumulator removed; checking...2496
Servo accumulator; removing...2498
Servo accumulator; installing...2500
Accumulator; discarding...2502
Boom suspension system; component location...2504
Boom Suspension System; component description...2506
Boom Suspension System; description...2509
3rd; or 3rd_4th hydraulic function; description...2514
Boom Suspension System; specifications...2519
Boom Suspension System; tightening torques...2520
3rd_4th hydraulic function; specifications...2522
Boom suspension accumulator; checking and adjusting...2523
Boom suspension system; right accumulator; removing...2527
Boom suspension system; right accumulator; installing...2531
Boom suspension system; left accumulator; removing...2534
Boom suspension system; left accumulator; installing...2538
Boom suspension system; hydraulic oil pressure in accumulators; depressurizing...2541
Boom suspension system; pressure reduction; safety valve; checking and adjusting...2544
Accumulator; boom suspension system; discarding...2546
Boom suspension accumulator; reconditioning...2548
3rd_4th hydraulic function; pressure; checking and adjusting...2551
3rd_4th hydraulic function; solenoid valve; replacing...2554
3rd_4th hydraulic function; shock valve; checking...2557
Boom suspension system; checking...2560
3rd_4th hydraulic; functional check...2565
3rd; or 3rd_4th hydraulic function; component location...2568
92 - MECHANICAL EQUIPMENT_ATTACHMENT...2570
Hydraulic attachment bracket; description...2571
Attachment locking; checking...2576
94 - UNIT; LOAD HANDLING...2578
Hydraulic cylinder; piston's lock brace; installing...2579
Lift cylinder; tightening torques...2581
Tilt cylinder; tightening torques_{22-11}...2583
Tilt cylinder; tightening torques_{21-54}...2584
Lift cylinder; repacking in machine...2586
Tilt cylinder; repacking in machine...2594
99 - MISCELLANEOUS...2602
System test...2603
Fire suppression system; specification...2605
Fire suppression system; component location...2606
Fire suppression system; functional description...2608
Fire suppression system; component description...2612
Fire suppression system; actions after manual activation...2619
Fire suppression system; actions after activation...2637
Central lubrication system; description...2654
Pump unit; description...2659
Shift valve; description...2662
Pressure monitor; description...2664
Dosage valves; description...2666
Automatic lubrication system; specifications...2670
Recommended lubricants...2671
Grease Locations...2673
TP-Linkage's bearing points...2677
Diagnostic tools; description...2679
Parameter settings...2681
Software; parameter settings and read-outs...2683
Automatic lubrication pump unit; reconditioning...2690
Filling lubricant...2712
Bleeding air ...2714
Change of lubrication interval...2720
Bleeding air...2722
Volvo L150G Wheel Loader Repair Service Manual
