Volvo L150F Wheel Loader Service and Repair Manual PDF

Volvo L150F Wheel Loader Service and Repair Manual PDF

Size: 129.85 MB
Language: English
Make: Volvo
Machine: Wheel Loader
Document: Service and Repair Manual, Hydraulic and Electrical Diagram
Model: Volvo L150F
Page: 5716 Pages

Detail Contents:
START
Descriptions

• Accelerator Pedal
  Air cleaner, description
  Air conditioning, description
  Alternator 80 A, description
  Automatic brake valve, description
  Automatic differential brake, Limited Slip, description
  Auxiliary brake (engine braking), description
  Basic checks
  Battery disconnector switch, description
  Battery, charging
  Battery, description
  Boom Suspension System, component description
  Boom suspension system, component location
  Boom Suspension System, description
  Booting sequence
  Brake accumulator, description
  Brake system, component location
  Braking system with RBB, description
  Braking system, description 1
  Braking system, description
  Cab and air conditioning
  Cable and component designations
  Cable and component marking explanations 1
  Cable and component marking explanations
  CareTrack W-ECU, description
  CDC valve, lever steering, description
  Central lubrication system, description
  Central valve, description
  Change of lubrication interval
  Charging of batteries
  Chassis connection
  Cleanliness, brake and hydraulic systems
  Climate control unit ECC, description
  Comfort Drive Control (CDC), description
  Component list Alternator, batteries, capacitors, electronic units, voltage outlet
  Component list Heating coils, instruments, service socket
  Component list Fuses
  Component list Lights
  Component list Motors, resistors, monitoring system
  Component list PWM valves
  Component list Relays
  Component list Sensors
  Component list Signals, shift solenoids
  Component list Solenoid valves
  Component list Switches
  Component list, Diodes
  Connectors, overview
  Control valve, description 2
  Control valve, description 3
  Control valve, description
  Cooling fan motor, description
  Cooling fan, description
  Cooling system, description
  Differential lock, description 1
  Differential lock, description
  Dosage valves, description
  Drive axles, description 1
  Drive axles, description
  ECC, IO list
  E-ECU, IO list
  Electric welding
  Electrical symbols and designations
  Electrical system, description
  Electrical system, work instructions
  Electronic control system, description
  Engine control unit E-ECU, description
  Engine, description
  Filling lubricant
  Fire suppression system, component description
  Fire suppression system, functional description
  Floating position, description
  Foot brake valve, description
  Frame joint, description
  Frame, description
  Fuel consumption
  Fuel filter, description
  Fuel system, description
  Hand Throttle
  Hydraulic attachment bracket, description
  Hydraulic oil tank, description
  Hydraulic pump flow regulation, description
  Hydraulic pumps, description
  Hydraulic system and component positions
  Hydraulic system, description
  Hydraulic transmission, description
  I-ECU, IO list
  Information display, engine
  Information display, general
  Information display, operating display
  Information display, start lockout
  Infrared Thermometer
  Instructions for working with electronic fuel injection
  Instrument control unit I-ECU, description
  Instrument panels
  Intake and exhaust system, description
  Intercooler, description
  Intermittent wiper and washer
  Internal Exhaust Gas Recirculation (IEGR), description
  Interruption in computer communication
  Key feed
  Lift function, description 1
  Lift function, description
  Lighting, description
  Limp Home
  Lock up, description
  Lubrication system, description
  Machine hours
  Maintenance service, fire suppression system
  Middle instrument panel with warning lights
  Parking brake, description 1
  Parking brake, description
  Pause heater, description 1
  Pause heater, description
  Preheating, description 1
  Preheating, description
  Pressure monitor, description
  RBB, description
  Reduced computer communication
  Repairing hydraulic system
  Reversible cooling fan, description
  Secondary steering, description
  Shift valve, description
  Software parameters, description
  Steering system, component location
  Steering system, description
  Steering valve, description
  System voltage
  Theft protection
  Tilt function, description
  TP-Linkage’s bearing points
  Transmission, component position
  Travelling speed
  Troubleshooting, air conditioning unit (AC)
  Turbocharger, description
  Unit injector, Delphi, description
  V2-ECU, IO list
  V-ECU, IO list
  Vehicle control unit V2-ECU, description
  Vehicle control unit V-ECU, description
  Viscous cab suspension, description
  Washer fluid level
  Windows, general
  Working on the electrical system of the machine

Installation Instructions

• 3rd 4th hydraulic function, installing new
  3rd 4th hydraulic funktion, electric-hydraulic, installing new
  3rd hydraulic function, electric-hydraulic, installing new
  3rd hydraulic function, installing new
  Attachment locking, installing new
  Attachment work light, installing new
  Automatic lift arm lowering (Return to dig), installing new
  Axle oil cooler and reversilble fan, installing new
  Boom suspension system, installing new
  Filtered alternator, installing new
  Forward view camera, installing new
  Front view mirror, installing new
  Fuel filter extra, installing new
  Hand throttle, instaling new
  Lever steering (CDC), electric, installing new 1
  Lever steering (CDC), electric, installing new
  Lever steering (CDC), hydraulic, installing new
  Protection for lighting, front, installing new
  Protection for lighting, rear, installing new
  Radiator grill guard, installaing new
  Rear view camera, installing new
  Rotating beacon, installing new
  Single lever control, installing new
  Swing out fender, installing new
  Work light extra front, installing new
  Work light front, installing new
  Work light rear, installing new

Repair

• 3rd 4th hydraulic function, checking and adjusting pressure
  3rd 4th hydraulic function, shock valve, checking
  3rd 4th hydraulic function, solenoid valve, replacing
  Accumulator removed, checking charging pressure
  Accumulator removed, checking
  Accumulator, boom suspension system, discarding
  Accumulator, check
  Accumulator, checking (pressure back-up for servo circuit)
  Accumulator, discarding 1
  Accumulator, discarding
  Air mix door actuator, replacing
  Attachment locking, functional check
  Automatic brake, function check
  Axle suspension, replacing bushes and seals
  Axle, installing
  Axle, removing
  Back-up valve, checking and adjusting
  Batteries, replacing
  Battery condition, check 1
  Battery condition, check
  Bleeding air hydraulic system
  Boom suspension accumulator, check and adjusting 1
  Boom suspension accumulator, check and adjusting
  Boom suspension accumulator, reconditioning
  Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
  Boom suspension system, left accumulator, installation
  Boom suspension system, left accumulator, removal
  Boom suspension system, pressure reduction, safety valve, checking and adjusting
  Boom suspension system, right accumulator, installation
  Boom suspension system, right accumulator, removal
  Brake disc, replacing 1
  Brake disc, replacing rear wheel 1
  Brake disc, replacing rear wheel
  Brake disc, replacing
  Brake discs, measuring wear 1
  Brake discs, measuring wear 2
  Brake discs, measuring wear
  Brake pedal, adjusting angle
  Brake piston, replacing seals 1
  Brake piston, replacing seals rear 1
  Brake piston, replacing seals rear
  Brake piston, replacing seals
  Brake system, bleeding
  Brake system, check and adjusting pressure in circuit
  Brake system, checking function, hydraulic
  Brake system, checking function, retardation
  Cab, installing 1
  Cab, installing 2
  Cab, installing
  Cab, removing 1
  Cab, removing 2
  Cab, removing
  Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope
  Camshaft, checking wear
  Carbon dioxide in coolant system, checking
  Carbon dioxide in fuel system, check
  Central valve, installation
  Central valve, removal
  Charge air system, inspection
  Climate unit, installing
  Climate unit, removing
  Comfort drive control (CDC), angle sensor, changing
  Comfort drive control (CDC), control valve, installation
  Comfort Drive Control (CDC), control valve, removal
  Comfort drive control (CDC), solenoid valve, changing
  Comfort Drive Control, servo pressure, checking
  Compression test 1
  Compression test
  Compressor, replacing incl draining and filling
  Condenser, replacing incl draining and filling
  Cooling fan hydraulics, funktion check
  Cooling fan motor, replacing
  Differential lock, adjusting
  Differential lock, function check
  Door lock cylinder, replacing
  Door lock, changing
  ECC control unit, replacing 1
  ECC control unit, replacing
  ECC, MID 146, changing non-programmed ECU
  ECC, MID 146, changing pre-programmed ECU
  E-ECU, MID 128, changing non-programmed ECU
  E-ECU, MID 128, changing pre-programmed ECU
  Engine hood, installing
  Engine hood, removing
  Engine oil filter, replacing
  Engine oil level, checking
  Engine rotation speed sensor (camshaft), replacing
  Engine rotation speed sensor, replacing
  Engine, installing 1
  Engine, installing
  Engine, removing 1
  Engine, removing
  Error codes when calibrating 1
  Error codes when calibrating steering
  Error codes when calibrating
  Evaporator, replacing incl draining and filling 1
  Evaporator, replacing incl draining and filling
  Expansion valve, replacing incl draining and filling
  Fan control valve, installing
  Fan control valve, removing
  Fan control valve, seal replacement
  Fan motor, replacing
  Feed pump, checking feed pressure
  Fire suppression system, actions after activation 1
  Fire suppression system, actions after activation
  Fire suppression system, actions after manual activation
  Fire suppression system, component location
  Foot brake valve removed, reconditioning
  Foot brake valve, installation
  Foot brake valve, removal
  Frame joint, changing bearings and pins
  Frame joint, checking clearance
  Front wheel, installation
  Front wheel, removal
  Fuel pump (valves), inspection
  Fuel pump, inspection
  Fuel system, bleeding
  Heat control valve, replacing
  Heater core, replacing 1
  Heater core, replacing
  Hub reduction, installing 1
  Hub reduction, installing 2
  Hub reduction, installing
  Hub reduction, removing 1
  Hub reduction, removing
  Hub, replacing seal
  Hydraulic oil level, checking
  Hydraulic oil return filter, replacing
  Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
  Hydraulic oil, changing
  Hydraulic pump P1, installation
  Hydraulic pump P1, removal
  Hydraulic pump P2, installation
  Hydraulic pump P2, removal
  Hydraulic pump P3, installation
  Hydraulic pump P3, removal
  Hydraulic pump, checking and adjusting max working pressure 1
  Hydraulic pump, checking and adjusting max working pressure 2
  Hydraulic pump, checking and adjusting max working pressure
  Hydraulic pump, checking and adjusting stand-by pressure (LS-line removed)
  Hydraulic pump, checking and adjusting standby pressure
  Hydraulic system, bleeding
  I-ECU, MID 140, changing non-programmed ECU
  I-ECU, MID 140, changing pre-programmed ECU
  Lever steering (CDC), functional check
  Lift lower, angle sensor, changing 1
  Lift lower, angle sensor, changing
  Lift, functional check
  Lift, solenoid valve, changing
  Lifting time, checking 1
  Lifting time, checking
  Lock up valve, replacing
  Lock up, function check
  Lock up, solenoid valve, replacing
  Lower, solenoid valve, changing
  LS (load sense) pressure, checking
  Lubrication oil pressure, checking with pressure gauge
  Main pressure valve, replacing
  Maintenance service, daily
  Maintenance service, every 50 hours
  Maintenance service, every 250 hours
  Maintenance service, every 500 hours
  Maintenance service, every 1000 hours
  Maintenance service, every 2000 hours
  Maintenance service, every 4000 hours
  Maintenance service, every 6000 hours
  Mechanical release of parking brake
  Operator’s seat, securing
  Parking brake, component location
  Parking brake, function checking
  Parking brake, replacing discs and seals
  Pump 3 (P3) standby pressure, checking and adjusting (LS-line removed)
  Pump 3 (P3), max pressure and fan speed, checking and adjusting
  Radiator, replacing
  Rear wheel, installing
  Rear wheel, removing
  Receiver, replacing incl draining and filling
  Receiver, replacing incl draining and fillingReceiver, replacing incl draining and filling
  Rocker arm mechanism removed, reconditioning
  Seal for front output shaft, replacing
  Seal for rear output shaft, replacing
  Secondary steering pump, checking and adjusting working pressure
  Servo accumulator, installation
  Servo accumulator, removal
  Servo pressure, checking and adjusting
  Servo pressure, checking at the spool in control valve
  Servo valve, adjusting control
  Servo valve, installation
  Servo valve, removal
  Shift valve, installing
  Shift valve, removing
  Shock valve lift function, checking 1
  Shock valve lift function, checking
  Side window, replacing fig 1
  Side window, replacing
  Stall speed, checking
  Steering system, checking and adjusting working pressure 1
  Steering system, checking and adjusting working pressure
  Steering system, function check
  Steering valve, replacing
  Temperature sensor cooling system, replacing
  Tilt in out, angle sensor, changing
  Tilt in, solenoid valve, changing
  Tilt out, solenoid valve, changing
  Tilt, functional check
  Towing
  Transmission oil pressure, checking 1
  Transmission oil pressure, checking
  Transmission pressure sensor, replacing
  Transmission solenoid, replacing
  Transmission, calibration
  Transmission, functional check
  Transmission, installing
  Transmission, removing
  Unit injector, replacing 1
  Unit injector, replacing
  Update of automatic lubrication system
  V2-ECU, MID 249, changing non-programmed ECU
  V2-ECU, MID 249, changing pre-programmed ECU
  Valves, adjusting 1
  Valves, adjusting
  VCADS Pro, Operations
  V-ECU, MID 187, changing non-programmed ECU
  V-ECU, MID 187, changing pre-programmed ECU
  Viscous cab suspension, changing one unit
  Warranty inspection 100 hours
  Warranty inspection 1000 hours

Service Bulletins

• AC compressor, fill with oil
  Air bleeding of the central lubrication system
  Alternative lubricants for axles with wet brakes
  Automatic greasing systems of foreign manufacture
  Automatic shifting (APS)
  Automatic transmission lubricants
  Battery and alternator test procedure
  Broken exhaust valve stem
  Cab suspension 1
  Cab suspension 2
  Cab suspension
  CareTrack, new software update 2008.3.0, including new Conversion kit part numbers for E series haulers and F series loaders
  CDC function, disengaging
  Central lubrication 1
  Central lubrication, oxide on pins
  Central lubrication
  Central valve, replacing priority spool
  Changes in option secondary steering
  Check method on engine oil consumption
  Cleaning of the machine
  Connector protection for axle oil temperature sensor
  Control measurement for electric servo lever and tilt lift angle sensor
  Cracks in cross tube
  D- arm cracks
  D9B and D12D Stage 3, valve adjustment, camshaft marking
  Diesel fuels – quality and function
  Discontinued recommendation for usage of anti-corrosion agent in cooling system
  ECU improvements
  ECU, functional check
  Engine labelling
  Engine oil diluted by fuel
  Erroneous signal from accelerator pedal
  Error code, check
  Fire suppression system
  Fork arms, information warranty matters, altered procedures
  Front propeller shaft support bearing alignment
  Fuel sampling, method
  Gearshifting
  Ghost codes for F-series wheel loaders
  Greasing of hydraulic pump drive shaft
  Guide pins D12D
  Heater element
  Heater unit, external leakage
  Heating core for cab heating
  Hydraulic oil cooler
  Improved climate control system
  Improved fuel filling capacity
  Improved hour recorder
  Improved wiper motor
  Incorrect symbol on lever carrier casing
  Incorrectly assembled back-up ring in compensator
  Inoperative audible reverse alarms
  Instructions for crack in lifting frame
  Instructions for drilling in ROPS structure
  Instructions for shielded metal arc welding
  Introduction of new climate unit, HVAC II
  Leaking cab heating element
  Limitation, TP-linkage
  Locking set screw installation on the double rocker arm
  Loctite added on plugs and cartridges on BSS-valve
  Loose seat base
  Moved brake pressure sensor
  New AC compressor
  New accelerator pedal with gold plated terminals
  New air breather filter to the hydraulic oil tank
  New angle sensor installation, lift and tilt function
  New angle sensor kit introduced
  New cab heater element
  New CareTrack W-ECU2
  New coolant pump connecting pipe
  New drive gear set
  New engine rubber cushion
  New equipment, OptiShift
  New front and rear axles introduced
  New fuel filter housing
  New fuel tank gasket
  New gas strut for cab door
  New gear lever combi-switch
  New hydraulic pump
  New installation for silencer
  New main fuel filter, D9, D12 and D16
  New reverse alarm
  New sealing method for oil sump
  New sensor and new sensor installation
  New software release V2015.2.0
  New software release V2015.3.1
  New software update 2011.3.0 for CareTrack
  New software version 2008.6.0 and 2008.6.1
  New software version V2011.4.1
  New system design to meet revised ISO 15998
  New temperature sensor
  New transmission
  New turbocharger for the D12 engine
  New axle oils
  New V-ECU and V2-ECU
  New wiper arm and wiper motor
  Non – VCE buckets and attachments
  Oil analyses
  Oil jet nozzle eliminated from the D12D exhaust double rocker arm
  Oil leakage from the engine cable harness grommet
  Oil sampling, method
  Oil sump
  Operator adaptation of electric servo lever functions with VCADS Pro
  O-ring with improved fit between hydraulic pump and transmission
  Parameter changes in VCADS Pro
  Parking brake solenoid valve
  Parking brake switch
  Problems with leaking test port hoses
  Protective grating, radiator
  Quality of illustrations in technical reports
  Radio band setting
  Recommendations for Oil Sampling Intervals 1
  Recommendations for Oil Sampling Intervals
  Reinforcing the general purpose and rock buckets
  Repair instructions for attachments
  Repair report for central lubrication pumps
  Repair Report for Volvo transmissions
  Reporting of product misuse & near-miss report
  Reports
  Return to dig, lifting arms lowering positioner
  Seals
  Secondary steering pump adjustment
  Serial number location on machine components
  Service solution, separate belts
  Shaking or vibration in the working hydraulics
  Smoother steering with improved draining of shift valve
  Software parameters, description
  Software release summary WLO F-models
  Soot on silencer
  Sound from hydraulic transmission
  Springs and plugs for main control valve
  Transmission components
  Transmission, introduced actions
  Troubleshooting hydraulic pumps
  Turbo Hot Shutdown
  Tyres, various types
  Valve spring update, D9, D12 and D16
  Ventilation hose
  Volvo Product incident accident report & Interview Form
  Warning decals
  Windshield guard interferes with nipple

Special Tools

• General
  Index
  Hooks
  1. Enviroment and Safety equipment
  2. Measuring equipment
  3. Tightening and Loosening tools
  4. Lifting equipment
  5. Pullers and Pressing equipment
  6. Drifts
  7. Guide pins and Guide sleeves
  8. Pliers
  9. Fixtures
  10. Tech Tool
  11. Spare parts

Specifications

• 3rd 4th hydraulic function, specifications
  Air conditioning, refrigerant, weight
  Alternator 80 A, specification
  Automatic lubrication system, specifications
  Axle suspension, tightening torques
  Battery, specifications
  Battery, weight
  Boom Suspension System, specifications
  Boom Suspension System, tightening torques
  Brake accumulator, specifications
  Brake system, specifications
  Brake valve, tightening torques
  Cab, tightening torque
  Control valve, lever steering (CDC), specifications
  Control valve, specifications
  Conversion tables 1
  Conversion tables
  Cooling fan rpm, specifications
  Cooling system, volume
  Electrical system, specifications
  Engine management system
  Engine, capacities
  Engine, specification 1
  Engine, specification
  Engine, weight
  Fire suppression system, specification
  Frame joint, tightening torques
  Frame, tightening torque
  Front and rear axles, specifications
  Front and rear axles, tightening torque
  Front and rear axles, volume
  Fuel feed pump, specifications
  Hydraulic connections, tightening torques
  Hydraulic pump (P1), specifications
  Hydraulic pump (P2), specifications
  Hydraulic pump (P3), specifications
  Hydraulic pumps, tightening torques
  Hydraulic system, volume
  Hydraulic transmission, capacity
  Hydraulic transmission, specifications 1
  Hydraulic transmission, specifications 2
  Hydraulic transmission, specifications
  Hydraulic transmission, tightening torques
  Lever steering (CDC), specifications
  Lubrication system, specifications
  Parking brake, specifications
  Preheating, specifications
  Propeller shaft, tightening torque
  Rear axle mounting, volume
  Rocker arm shaft, tightening torques
  Secondary steering pump, specifications
  Service brakes, specifications 1
  Service brakes, specifications
  Servo system, specifications
  Starter motor, specifications
  Steering cylinder, tightening torque
  Steering, specifications
  Temperature limits for cooling fan speed, specifications.
  Thermostat, specifications
  Tightening torque, fuel system
  Tightening torques, cooling fan
  Valve cover, tightening torque
  Valve mechanism, double rocker arm
  Valve mechanism, tightening torques
  Valve system, specification
  Wheel brake, tightening torques
  Wheels, tightening torques

Time Guide Currrent generation
Time Guide Old generation
Time Guide Previous generation
Wiring

• Hydraulic diagram transmission
  Hydraulic diagram, complete 2 fig 1
  Hydraulic diagram, complete 2 fig 2
  Hydraulic diagram, complete 2 fig 3
  Hydraulic diagram, complete 2
  Hydraulic diagram, complete 3 fig 1
  Hydraulic diagram, complete 3 fig 2
  Hydraulic diagram, complete 3 fig 3
  Hydraulic diagram, complete 3
  Hydraulic diagram, complete 4 fig 1
  Hydraulic diagram, complete 4 fig 2
  Hydraulic diagram, complete 4 fig 3
  Hydraulic diagram, complete 4
  Hydraulic diagram, complete 5 fig 1
  Hydraulic diagram, complete 5 fig 2
  Hydraulic diagram, complete 5 fig 3
  Hydraulic diagram, complete 5
  Hydraulic diagram, complete 6 fig 1
  Hydraulic diagram, complete 6 fig 2
  Hydraulic diagram, complete 6 fig 3
  Hydraulic diagram, complete 6
  Hydraulic diagram, complete fig 1
  Hydraulic diagram, complete fig 2
  Hydraulic diagram, complete fig 3
  Hydraulic diagram, complete
  Table of contents, wiring diagrams
  Wiring diagram 201
  Wiring diagram 202
  Wiring diagram 203
  Wiring diagram 204
  Wiring diagram 205
  Wiring diagram 206
  Wiring diagram 207
  Wiring diagram 301
  Wiring diagram 301-1
  Wiring diagram 301-2
  Wiring diagram 302
  Wiring diagram 302-1
  Wiring diagram 302-2
  Wiring diagram 303
  Wiring diagram 304
  Wiring diagram 305
  Wiring diagram 306
  Wiring diagram 308
  Wiring diagram 309
  Wiring diagram 310
  Wiring diagram 311
  Wiring diagram 311-1`
  Wiring diagram 311-2
  Wiring diagram 311-3
  Wiring diagram 312
  Wiring diagram 313
  Wiring diagram 314
  Wiring diagram 314-1
  Wiring diagram 315
  Wiring diagram 315-1
  Wiring diagram 315-2
  Wiring diagram 316
  Wiring diagram 317
  Wiring diagram 319
  Wiring diagram 401
  Wiring diagram 401-1
  Wiring diagram 402
  Wiring diagram 403
  Wiring diagram 403-1
  Wiring diagram 404
  Wiring diagram 405
  Wiring diagram 407
  Wiring diagram 408
  Wiring diagram 408-1
  Wiring diagram 409
  Wiring diagram 501
  Wiring diagram 501-1
  Wiring diagram 501-2
  Wiring diagram 501-3
  Wiring diagram 601
  Wiring diagram 601-2
  Wiring diagram 602
  Wiring diagram 602-1
  Wiring diagram 604
  Wiring diagram 604-1
  Wiring diagram 801
  Wiring diagram 802
  Wiring diagram 804
  Wiring diagram 804-1
  Wiring diagram 806
  Wiring diagram 806-1
  Wiring diagram 807
  Wiring diagram 901
  Wiring diagram 901-1
  Wiring diagram 902
  Wiring diagram 902-1
  Wiring diagram 903
  Wiring diagram 904
  Wiring diagram 909
  Wiring diagram 910
  Wiring diagram 911
  Wiring diagram 911-1
  Wiring diagram 912
  Wiring diagram 912-1
  Wiring diagram 913
  Wiring diagram 915

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