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Volvo L150E Service Manual

Wheel loader

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L150E Wheel Loader

W E B E D I T I O N

Service Manual

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Page 1 L150E Wheel Loader W E B E D I T I O N Service Manual...
Page 2 Description The L150E is a four-wheel drive wheel loader with articulated frame steering. The L150E is equipped with a six cylinder, four-stroke, direct-injected turbocharged diesel engine of the type D9A alternatively D10B. The hydro-mechanical transmission, in which all gears are in constant mesh, has the type designation HTE210.
Page 3 Service Information Document Title: Function Group: Information Type: Date: E1711 Service Information 2014/4/24 Profile: WLO, L150E [GB] E1711 E1711 Figure 1 E1711...
Page 4 Information Type: Date: Section Power Service Information 2014/4/24 transmission, Brakes Profile: WLO, L150E [GB] Section 4.5 Power transmission, Brakes E 1234 Nipple Figure 1 E 1234 Nipple 999 3522 Standard pipe bushing, R1/4” - R1/8” Testing nipple, part no. 930032 Standard T-pipe, R 1/4”...
Page 6 The Operator's Manual must always be kept in the cab for easy reference. Volvo designs and manufactures machines with a high level of safety as well as effectiveness. All this work may be wasted if anyone who is about to perform service on any of our machines does not read the safety instructions, or does not follow them, e.g., does not replace guards, climbs on slippery machine parts instead of using a ladder, grabs a hold of hoses...
Page 7 As proof that the requirements are met, an EU Declaration of Conformity, issued by Volvo CE, is supplied with each separate machine. This EU declaration also covers attachments and equipment manufactured by Volvo CE. The documentation is a valuable document, which should be kept safe and retained for at least 10 years.
Page 8 If anyone in your company discovers that a certain machine has been modified in a non-approved manner, your company must notify the customer and manufacturer in writing regarding the applicable machine and how it was modified.
Page 9  no safety seals have been opened by an unauthorized person.  all modifications and repairs have been performed in the manner prescribed by Volvo.  only genuine Volvo parts/accessories, or attachments that fulfil Volvo's requirements have been used. WARNING Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating the machine.
Page 10 Figure 1 Entering/leaving the machine  Always wear a hard hat, protective goggles, gloves, work shoes and other safety items that your work requires.  Avoid standing in front of or behind the machine when the engine is running.  Always use a rubber window scraper or brush with a long handle when cleaning the outside of the windows in order to avoid unnecessary climbing on the machine.
Page 11 Figure 3 Use the seat belt during all operation  If the seatbelt needs washing: Use a mild soap solution when washing and let the belt dry while it's fully pulled out before it's rolled up. Make sure that the belt is installed correctly. ...
Page 12 Safety rules when servicing 191 Service Information 2014/4/24 Profile: WLO, L150E [GB] Safety rules when servicing This section covers general safety rules when checking and servicing. Other rules, information and warning texts are given in the Operator's manual. CE marking This machine is CE-marked.
Page 13 Engine off and ignition key removed. (Does not apply for special checks). Pressurized lines and pressure tanks shall be depressurized carefully so that the high pressure is released without  191 Safety when working on hydraulic systems risk. [ 1] Yellow-black warning flag should be attached to the steering wheel (USA - a red flag may be used instead) Frame joint lock connected.
Page 14  Never wear loose fitting clothing, for example, a scarf or jewellery, that can get caught and cause injury when working on the machine.  Always use a hard hat, safety glasses, gloves, protective work shoes and other protective items as required by the work situation.
Page 15 Service Information 2014/4/24 boom Profile: WLO, L150E [GB] Working under raised boom Always secure the loader linkage with Support 999 3831 (2 pcs. L330, L350) before starting to work. Position the support on an even and firm ground surface. Figure 1 Securing the boom (L330, L350) 999 3831 Support (2 pcs.)
Page 16 Figure 2 Securing the boom 999 3831 Support...
Page 17: Fire Prevention Measures
Fire prevention measures Service Information 2014/4/24 Profile: WLO, L150E [GB] Fire prevention measures General  There is always a risk of fire. Find out which type of fire extinguisher to use, where it is located and how to use it.
Page 18 NOTICE If a high-pressure washer is used when cleaning, work carefully since damage may be caused to electrical components and insulation of the electrical cabling even at relatively moderate water pressure and temperature. Protect electrical cabling in a suitable manner. ...
Page 19 Service Information 2014/4/24 regarding tyre handling Profile: WLO, L150E [GB] Some simple rules regarding tyre handling WARNING Tires installed on a split rim may explode and cause very severe injuries. Inflating  Never stand to the side of the tyre while inflating which is fitted on a split rim. Use a self-locking outlet with a hose long enough to allow you to stand outside of the hazard zone during inflation, see the illustration.
Page 20 2014/4/24 supporting complete machine Profile: WLO, L150E [GB] Safety when lifting and supporting complete machine 191 Safety rules when servicing Place the machine in service position, see Always use jacks and support equipment with sufficient capacity. It is important to support the front and/or rear axle in a safe way before doing other work.
Page 21 Figure 2 E-models 11668007 Stand jack Support point Recommended method for rear axle Prevent the rear axle from oscillating by locking it with jacks or wooden blocks between the frame and axle on both sides. NOTE! Do not forget to remove the oscillation lock before lowering the machine. The machine must be secured with axle stands or stand jacks with sufficient capacity, 5–15 tons.
Page 22 Figure 4 V1031966 On smaller machines (L50–L120), use a garage jack under the differential carrier assembly. Do not forget to lock the axle to prevent oscillation. Place the axle stands under the frame's rear edge. Figure 5 Support points Do not use a jack with a small lifting surface under the differential carrier assembly. Use a wheel trolley for safe handling of the wheels.
Page 23 Date: Safety when working with Service Information 2014/4/24 batteries Profile: WLO, L150E [GB] Safety when working with batteries Figure 1 Battery charging WARNING Risk of serious corrosive injuries! Batteries contain sulphuric acid which is very corrosive to the human body and parts of the machine. In addition, batteries give off hydrogen gas when they are loaded (supplying electricity) or being charged.
Page 24  Always cover the top of the battery with a rag or other non-conducting material when you work close to the batteries.  Always refit the terminal caps on the batteries.  Batteries contain substances hazardous to health and the environment. Therefore, discarded batteries be handled 191 Environmentally safe handling according to governing local/national regulations.
Page 25: Starting With Booster Batteries
Service Information 2014/4/24 batteries Profile: WLO, L150E [GB] Starting with booster batteries When starting with booster batteries, the following must be observed: Check that the booster batteries or other power source have the same voltageas the standard batteries. WARNING The batteries could explode due to the current surge if a fully charged battery is connected to a completely discharged battery.
Page 26 Service Information 2014/4/24 and fuel Profile: WLO, L150E [GB] Safety when handling oils and fuel  When changing oil in engine, hydraulic system or transmission: Keep in mind that the oil may be hot and can cause scalding or burn injuries.
Page 27 Safety when working with Service Information 2014/4/24 air conditioning refrigerant Profile: WLO, L150E [GB] Safety when working with air conditioning refrigerant General Special competence is required for service work and more involved work which requires opening of the air conditioning system.
Page 28 remove the filler plug on the compressor. If you suspect a leak, certified and trained personnel at a licensed workshop should be contacted for troubleshooting and repair.  The refrigerant gas is heavier than air and will sink to the floor. Therefore, make sure that any escaped gas is ventilated before work is started in any low-lying areas.
Page 29 2014/4/24 accumulators Profile: WLO, L60E, L120E, L90E, L180E HL, L330E, L50E, L220E, L110E, L180E, L70E, L150E [GB] Safety when handling accumulators WARNING If the pressure is not released before opening the system, oil under high pressure will jet out, resulting in serious personal injuries.
Page 30: Safety When Working On Hydraulic Systems
2014/4/24 hydraulic systems Profile: WLO, L150E [GB] Safety when working on hydraulic systems The hydraulic systems in our loaders operate at very high pressures, up to approx. 42 MPa (6090 psi). To avoid serious personal injuries it is very important that the systems are maintained in the right way, and that all persons who come into contact with the machines are very careful in their work and are very attentive to any defects.
Page 31 Start the engine and engage float mode with the switch SW903 on the instrument panel Activate the boom suspension system in gear-dependent position. Move the control lever (lift/lower) forward to float position and wait for 30 seconds. NOTE! The engine shall run at idle since there is a risk that the machine lifts in case float mode is not activated.
Page 32 Safety when using lifting Service Information 2014/4/24 equipment Profile: WLO, L150E [GB] Safety when using lifting equipment Figure 1 Do not overload lifting or support equipment.  All lifting devices, e.g., slings, straps, ratchet blocks, etc., must meet governing national regulations for lifting devices.
Page 33 Service Information 2014/4/24 exposure Profile: WLO, L150E [GB] Checklist after a fire or heat exposure  As a precaution, seal rings (O-rings or axle/shaft seals) should always be handled as if they were made of fluor rubber, see also section “Fluor rubber”.
Page 34 2014/4/24 plastics and rubber Profile: WLO, L150E [GB] Health hazards with paint, plastics and rubber Work on painted surfaces Never weld or cut with a torch on painted surfaces. All paint decomposes when heated and generates a vast number of...
Page 35 If the machine has been exposed to a fire or other intense heat, the safety actions in the following checklist shall be followed 191 Checklist after a fire or heat exposure unconditionally at all times: Asbestos information The components in Volvo CE's machines are free from asbestos, that is why it is important to use genuine Volvo spare parts.
Page 36 The world stands before gigantic challenges on environmental matters where clean water, climate change, and use of chemicals are some of the most important issues. Volvo has an important function in meeting these challenges and contributing to a more ecologically sustainable development. Quality, safety and environment are Volvo core values and have for a long time been integral parts of our company and our products.
Page 37: Waste Handling
Waste handling Service Information 2014/4/24 Profile: WLO, L150E [GB] Waste handling Contribute to careful use of natural resources by following the steps below when handling waste. If possible, deposit the waste for recycling. REUSE of products is the best from an environmental aspect.
Page 38 Service Information 2014/4/24 handling Profile: WLO, L150E [GB] Environmentally safe handling Always choose an environmentally friendly alternative where one is available, e.g., biodegradable oils. Always follow national and local environmental regulations. All waste shall be brought to a waste handling company, approved by the authorities.
Page 39 2014/4/24 fluids Profile: WLO, L150E [GB] Environmentally hazardous fluids Pay attention to leakage of fuel, oils and other fluids from the machine that may contaminate the environment. Take appropriate actions to seal the leak immediately and decontaminate contaminated ground as soon as possible.
Page 40 2014/4/24 environmentally contaminated areas Profile: WLO, L150E [GB] Working in environmentally contaminated areas Machines that are used in environmentally contaminated and/or health-hazardous areas shall be specially equipped for operation in such an environment. Used cab and engine air filters from machines working in environments with asbestos or other hazardous dust shall be put...
Page 41 Date: Decontamination Service Information 2014/4/24 Profile: WLO, L150E [GB] Decontamination Start decontamination as soon as possible. Certain substances spread quickly in the environment. Decontamination after leaks/spills Use suitable absorbing materials to collect leaking oil or fuel, e.g., absorbent mats. Prevent leaking oil/fuel from draining into rain water/storm water drains.
Page 43 Service Information Document Title: Function Group: Information Type: Date: Recommended lubricants, Service Information 2014/4/24 oils Profile: WLO, L150E [GB] Recommended lubricants, oils Oil grade Recommended viscosity at various outdoor temperatures °C °F +104 +122 Engine Volvo Ultra Diesel Engine Oil...
Page 44 2014/4/24 hydraulic systems Profile: WLO, L150E, L150D [GB] Cleanliness, brake and hydraulic systems Maintain the best possible cleanliness when working on these systems. Wipe off all pipe and hose connections before disconnecting and remove paint flakes, etc. Plug all pipes, hoses, cylinders, etc. immediately after disconnecting. Never...
Page 45: Electric Welding
Information Type: Date: Electric welding Service Information 2014/4/24 Profile: WLO, L150E [GB] Electric welding For electric welding on the machine or on attachments on machine:  ground connection turned off with battery disconnect switch.  fuse FH4 must be removed, located next to the battery disconnect switch.
Page 47 Warranty inspection 100 Service Information 2014/4/24 hours Profile: WLO, L150E [GB] Go back to Index Page Warranty inspection 100 hours The service points where "optional equipment" is stated are not included in the accounted time for the interval Op nbr 172-002...
Page 48 Parking brake Climate control system, fan and controls including air conditioning Loader unit's functions including automatic tilt (bucket positioner) and automatic lift (boom kick-out). Optional equipment. Steering pressure, check 2. Proceed as follows: Secure the frame joint with the steering joint lock and place blocks in front of and behind the wheels. Connect pressure gauge 11666020 and hose 11666037 to the pressure check connection on the steering valve.
Page 49 Figure 2 Inflation pressure in tires, check Wheel nuts and tightening torques, check 030 Wheels, tightening torques 4. Tightening torques, see: Cab mounts, tightening torques, check 5. Service program 1:4 Checking of tightening torques is not needed for machines with viscous cab mounts. 030 Cab, tightening torques Tightening torques, see: Figure 3...
Page 50 Bolts for support bearing 7. Bolted flange 030 Propeller shaft, tightening torque Tightening torques, see: Figure 5 Propeller shaft Screw Axles, attaching bolts, tightening torques, check 8. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. 030 Front axle, tightening torque Tightening torques, see: Figure 6...
Page 51: Pipes And Hoses
Cooling system, check level and freezing point 12. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant. The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 52 Figure 8 Coolant level 13. Freezing point, check Check the freezing point with a glycol tester at the expansion tank. The glycol tester's value should show approx. -38 °C (-36 °F). The machine is delivered with a coolant mixture of 50% glycol and 50% water for optimal cooling and corrosion characteristics.
Page 53 NOTE! Keep track of the sheet metal strip that is located at the top of the plastic casing. Remove the primary filter. Shake the filter carefully, without damaging it. Avoid compressed air, vacuum cleaners and water. Reinstall the plastic casing with the sheet metal strip at the top. Install the pre-filter and close the side cover.
Page 54 Figure 11 Fuel filter, primary Hand pump Water trap Draining nipple Drain hose Drive belts, check 16. At the correct belt tension, it should be possible to press down the belt between the belt pulleys approx. 8 mm (0.32 in) with a force of 25-30 Nm (18-22 lbf ft). Adjusting Loosen the alternator's attaching bolt.
Page 55 Figure 13 Oil-bath air cleaner Hydraulic oil, check the level 18. The hydraulic oil level shall be between max. and min. Filling takes place from the top of the hydraulic tank. Figure 14 Hydraulic oil, checking level Cap, filling up Sight-glass...
Page 56: Transmission, Oil Filter, Change
WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately. Wash the affected area with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention. Battery, electrolyte level, cables and connections, check 19.
Page 57: Transmission Oil Level, Check
Figure 16 Transmission oil filter Transmission oil level, check 21. The machine shall be parked on level ground when checking. The gear selector shall be in neutral position and the parking brake shall be applied. When checking the oil level with the engine running and oil at operating temperature, the level shall be between the markings High and Low on the lower part of the glass.
Page 58 Figure 17 Sight-glass Framework, grease 22. Boom Figure 18 Boom Grease nipples Greasing bearings Service life of bushings and pins can be extended if the machine is greased regularly and in the right way. Before greasing. Wipe off the grease nipples and grease gun so that sand and dirt particles are not introduced when greasing.
Page 59 Warranty inspection 100 Service Information 2014/4/24 hours Profile: WLO, L150E [GB] Go back to Index Page Warranty inspection 100 hours The service points where "optional equipment" is stated are not included in the accounted time for the interval Op nbr 172-002...
Page 60 Parking brake Climate control system, fan and controls including air conditioning Loader unit's functions including automatic tilt (bucket positioner) and automatic lift (boom kick-out). Optional equipment. Steering pressure, check 2. Proceed as follows: Secure the frame joint with the steering joint lock and place blocks in front of and behind the wheels. Connect pressure gauge 11666020 and hose 11666037 to the pressure check connection on the steering valve.
Page 61 Figure 2 Inflation pressure in tires, check Tires as well as inflation pressure in tires, check 191 Some simple rules regarding tyre handling 4. See: For inflation pressure in tires, see operator's manual. Cab mounts, tightening torques, check 5. Checking of tightening torques is not needed for machines with viscous cab mounts. 030 Cab, tightening torques Tightening torques, see: Figure 3...
Page 62 Bolts for support bearing 7. Bolted flange 030 Propeller shaft, tightening torque Tightening torques, see: Figure 5 Propeller shaft Bolt Axles, attaching bolts, tightening torques, check 8. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom 030 Front axle, tightening torque Tightening torques, see: Figure 6...
Page 63 Cooling system, checking level and freezing point 12. Level check. Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant. The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 64 Figure 8 Coolant level 13. Freezing point, check Check the freezing point with a glycol tester at the expansion tank. The glycol tester's value should show approx. -38 °C (-36 °F). The machine is delivered with a coolant mixture of 50% glycol and 50% water for optimal cooling and corrosion characteristics.
Page 65 NOTE! Keep track of the sheet metal strip that is located at the top of the plastic casing. Remove the primary filter. Shake the filter carefully, without damaging it. Avoid compressed air, vacuum cleaners and water. Reinstall the plastic casing with the sheet metal strip at the top. Install the pre-filter and close the side cover.
Page 66 Figure 11 Fuel filter, primary Hand pump Water trap Draining nipple Drain hose Drive belts, check 16. Proceed as follows: NOTE! The unit belt is self-adjusting and does not have to be adjusted. Remove the plastic casing that covers the alternator. Check the unit belt for damage and cracks.
Page 67 Drive belt Oil-bath air cleaner (optional equipment) 17. Change oil as needed. Volume: 9.1 litres (2.4 US gal). Figure 13 Oil-bath air cleaner Hydraulic oil, check the level 18. The hydraulic oil level shall be between max. and min. Filling takes place from the top of the hydraulic tank.
Page 68 Figure 14 Hydraulic oil, checking level Cap, filling up Sight-glass WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately. Wash the affected area with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention.
Page 69 Figure 15 Battery box, left side WARNING Risk of burns! Use protective work gloves. Transmission, oil filter, change 20. Use oil filter pliers when removing the oil filter. Installing filter: Brush new oil on the rubber seal. Spin on the filter until the gasket just touches the sealing surface. Tighten another 1/2 to 3/4 turn by hand. Warm up the machine and check that the oil filter gasket seals tight.
Page 70: Transmission Oil Level, Check
Transmission oil level, check 21. The machine shall be parked on level ground when checking. The gear selector shall be in neutral position and the parking brake shall be applied. When checking the oil level with the engine running and oil at operating temperature, the level shall be between the markings High and Low on the lower part of the glass.
Page 71 Greasing bearings Service life of bushings and pins can be extended if the machine is greased regularly and in the right way. Before greasing. Wipe off the grease nipples and grease gun so that sand and dirt particles are not introduced when greasing.
Page 73 Warranty inspection 1000 Service Information 2014/4/24 hours Profile: WLO, L150E [GB] Go back to Index Page Warranty inspection 1000 hours The service points where "optional equipment" is stated are not included in the accounted time for the interval Op nbr 172-004...
Page 74 Test-run and check Start and stop function. Instruments, lighting, direction indicators, reflectors, flashing hazard lights, wipers, washers, horn, and back- up alarm (if installed). Steering system. Gear positions / automatic shifting. Differential lock. Brake system. Control light for low brake pressure. Parking brake Climate control system, fan and controls including air conditioning...
Page 75 NOTE! In neutral position the pressure gauge normally shows approx. 2.5 MPa (363 psi), which is the priority valve's opening pressure in the central block. Stop the engine. Figure 2 Steering pressure, checking Pressure gauge 11666020 + Hose 11666037 Hydraulic pressure check 913 Hydraulic pump, checking and adjusting standby pressure 4.
Page 76 For inflation pressure in tires, see operator's manual. Figure 3 Inflation pressure in tires, check Wheel nuts and tightening torques, check 030 Wheels, tightening torques 9. Tightening torques, see: Cab mounts, tightening torques, check 030 Cab, tightening torques 10. Tightening torques, see: Checking of tightening torques is not needed for machines with viscous cab mounts.
Page 77 Bolts for support bearing 12. Bolted flange 030 Propeller shaft, tightening torque Tightening torques, see: Figure 6 Propeller shaft Bolt Axles, attaching bolts, tightening torques, check 13. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. 030 Front axle, tightening torque Tightening torques, see: Figure 7...
Page 78 Torque wrench Extension, min. 200 mm (8 in) Socket 41 mm 14. Rear axle 030 Rear axle, tightening torques Tightening torques, see: Figure 8 Rear axle Attaching bolts WARNING Risk of burns. The fluid may be hot. Transmission, oil and filter, changing 15.
Page 79 Figure 9 Transmission, principle illustration Cap for filler pipe Oil level check Drain plug Cover, suction strainer 16. Transmission oil filter, changing Use oil filter pliers when removing the filter. Installing filter Brush new oil on the gasket. Spin on the filter until the gasket just touches the sealing surface. Tighten another 1/2 to 3/4 turn by hand. Warm up the machine and check that the oil filter gasket seals tight.
Page 80 Figure 10 Transmission oil filter Oil-bath air cleaner (optional equipment) 17. Change oil as needed. Volume: 9.1 litres (2.4 US gal) Figure 11 Oil-bath air cleaner Air cleaner, changing 18. Primary filter...
Page 81 When the alarm text "Clogged air filter" is shown, or every 1000 hours, the filter shall be changed or cleaned. Operating time between filter changes can vary depending on the machine's operating environment. Certain environments may require frequent filter changes. The filter can be cleaned after instruction from an authorized brand name workshop.
Page 82 Figure 13 Front axle Level check and filling Draining 20. Rear axle If the machine is equipped with axle oil cooling, change the axle oil every 4000 hours. NOTE! Handle the waste oil in an environmentally safe way. 030 Rear axle, capacity Oil volume, rear axle, see: NOTE! When filling, operate the machine for a few minutes and check the level again.
Page 83 Figure 15 Draining Hydraulic oil, draining sediment and level check 22. Draining sediment Drain sludge and condensation water from the hydraulic oil tank through the drain on the machine's right side. Figure 16 Hydraulic oil, drain point for sludge 23. Level check The hydraulic oil level shall be between max.
Page 84 Cooling system, checking level and freezing point 24. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant. The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 85 Figure 18 Coolant level 25. Freezing point, check Check the freezing point with a glycol tester at the expansion tank. The glycol tester's value should show approx. -38 °C (-36 °F). The machine is delivered with a coolant mixture of 50% glycol and 50% water for optimal cooling and corrosion characteristics.
Page 86 Figure 20 Steering cylinder Pin lock, front bolt Pin lock, rear bolt Lock WARNING Risk of burns! Use protective work gloves. Engine oil and engine oil filter, change 27. Draining engine oil. Drain the oil when the engine is warm. Connect drain hose and drain the oil in a collection container.
Page 87 Fill the filters with engine oil and brush oil on the gaskets. NOTE! New oil shall be used. Spin on the filters until the gaskets just touch the sealing surfaces. Then tighten another full turn. Figure 22 Part-flow filter Full-flow filter 29.
Page 88 Fuel filter, primary and secondary filter, change 30. When installing, only tighten the filters by hand. For removing and installing cup on the primary filter, use dismantling tool 11666167. 233 Fuel system, bleeding Bleed the fuel system, see Figure 24 Primary fuel filter Secondary fuel filters Bowl...
Page 89: Pipes And Hoses
Figure 26 Drive belt Attaching bolt Adjusting screw WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately. Wash the affected area with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention.
Page 90 35. Check that all pipes and hoses are intact and not deformed. Cab, ventilation unit 36. Cab (ventilation filter), change The cab's filters consist of pre-filter and a primary filter. The filters should be checked once a week. NOTE! The change interval may be longer or shorter, depending on how dusty the environment is. NOTE! Use breathing protection when changing filters.
Page 91 Remove the primary filter. Shake the filter carefully, without damaging it. Avoid compressed air, vacuum cleaners and water. Reinstall the plastic casing with the sheet metal strip at the top. Install the pre-filter and close the side cover. Figure 29 Primary filter, principle illustration Side cover Primary filter.
Page 92 Figure 31 Grease points Steering cylinders' pivot points Frame joint's upper bearing Propeller shafts and support bearings Side window's hinges (right side) Cab's door Grease nipples for rear axle bearing Frame joint's lower bearing Greasing bearings Service life of bushings and pins can be extended if the machine is greased regularly and in the right way. Before greasing.
Page 93 Function Group: Information Type: Date: Warranty inspection 1000 Service Information 2014/4/24 hours Profile: WLO, L150E [GB] Go back to Index Page Warranty inspection 1000 hours Op nbr 172-004 11666051 Pressure gauge 11666020 Pressure gauge 11666019 Pressure gauge 11666003 Pressure gauge...
Page 94 Test-run and check Start and stop function. Instruments, lighting, direction indicators, reflectors, flashing hazard lights, wipers, washers, horn, and back- up alarm (if installed). Steering system. Gear positions / automatic shifting. Differential lock. Brake system. Control light for low brake pressure. Parking brake Climate control system, fan and controls including air conditioning...
Page 95 In neutral position the pressure gauge normally shows approx. 2.5 MPa (363 psi), which is the priority valve's opening pressure in the central block. Stop the engine. Figure 2 Steering pressure, checking Pressure gauge 11666020 + hose 11666037 Hydraulic pressure check 913 Hydraulic pump, checking and adjusting standby pressure 4.
Page 96 Figure 3 Inflation pressure in tires, check Wheel nuts and tightening torques, check 030 Wheels, tightening torques 9. Tightening torques, see: Cab mounts, tightening torques, check 030 Cab, tightening torques 10. Tightening torques, see: Checking of tightening torques is not needed for machines with viscous cab mounts. Figure 4 Cab mounts Propeller shafts, tightening torques, check...
Page 97 Bolts for support bearing 12. Bolted flange 030 Propeller shaft, tightening torque Tightening torques, see: Figure 6 Propeller shaft Screw Axles, attaching bolts, tightening torques, check 13. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. 030 Front axle, tightening torque Tightening torques, see: Figure 7...
Page 98 Torque wrench Extension, min. 200 mm (8 in) Socket 41 mm 14. Rear axle 030 Rear axle, tightening torques Tightening torques, see: Figure 8 Rear axle Attaching bolts WARNING Risk of burns. The fluid may be hot. Transmission, oil and filter, changing 15.
Page 99 Figure 9 Transmission, principle illustration Cap for filler pipe Oil level check Drain plug Cover, suction strainer 16. Transmission oil filter, changing Use oil filter pliers when removing the filter. Installing filter Brush new oil on the gasket. Spin on the filter until the gasket just touches the sealing surface. Tighten another 1/2 to 3/4 turn by hand. Warm up the machine and check that the oil filter gasket seals tight.
Page 100 Figure 10 Transmission oil filter Oil-bath air cleaner (optional equipment) 17. Change oil as needed. Volume: 9.1 litres (2.4 US gal) Figure 11 Oil-bath air cleaner Air cleaner, changing 18. Primary filter...
Page 101 When the alarm text "Clogged air filter" is shown, or every 1000 hours, the filter shall be changed or cleaned. Operating time between filter changes can vary depending on the machine's operating environment. Certain environments may require frequent filter changes. The filter can be cleaned after instruction from an authorized brand name workshop.
Page 102 Figure 13 Front axle Level check and filling Draining 20. Rear axle If the machine is equipped with axle oil cooling, change the axle oil every 4000 hours. NOTE! Handle the waste oil in an environmentally safe way. 030 Rear axle, capacity Oil volume, rear axle, see: When filling, operate the machine for a few minutes and check the level again.
Page 103 Figure 15 Draining Hydraulic oil, draining sediment and level check 22. Draining sediment Drain sludge and condensation water from the hydraulic oil tank through the drain on the machine's right side. Figure 16 Hydraulic oil, drain point for sludge 23. Level check The hydraulic oil level shall be between max.
Page 104 Cooling system, checking level and freezing point 24. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant. The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 105 Figure 18 Coolant level 25. Freezing point, check Check the freezing point with a glycol tester at the expansion tank. The glycol tester's value should show approx. -38 °C (-36 °F). The machine is delivered with a coolant mixture of 50% glycol and 50% water for optimal cooling and corrosion characteristics.
Page 106 Figure 20 Steering cylinder Pin lock, front bolt Pin lock, rear bolt Lock WARNING Risk of burns! Use protective work gloves. Engine oil and engine oil filter, change 27. Draining engine oil Drain the oil when the engine is warm. Connect drain hose and drain the oil in a collection container.
Page 107 Fill the filters with engine oil and brush oil on the gaskets. NOTE! New oil shall be used Spin on the filters until the gaskets just touch the sealing surfaces. Then tighten another full turn. Figure 22 Part-flow filter Full-flow filter 29.
Page 108 Figure 23 Oil dipstick Filler pipe engine oil Fuel filter, primary and secondary filter, change 30. When installing, only tighten the filters by hand. For removing and installing cup on the primary filter, use dismantling tool 11666167. 233 Fuel system, bleeding Bleed the fuel system, see Figure 24 Primary fuel filter...
Page 109 Figure 25 Coolant filter Drive belts, check 32. Proceed as follows: NOTE! The unit belt is self-adjusting and does not have to be adjusted Remove the plastic casing that covers the alternator. Check the unit belt for damage and cracks. Figure 26 Drive belt WARNING...
Page 110: Pipes And Hoses
other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention. Battery, electrolyte level, cables and connections, check 33. The battery electrolyte shall be 10 mm (0.4 in) over the plates in the battery. Top up with distilled water as needed. Check Cable terminals and terminal studs must be well cleaned, tightened and greased externally with, e.g., vaseline as corrosion protection.
Page 111 Figure 28 Pre-filter, principle illustration Side cover Pre-filter Clasps for pre-filter 37. Main filter, changing NOTE! Use breathing protection when handling filters. Open the side cover. Remove the pre-filter. Remove the nuts that hold the plastic casing for the primary filter. NOTE! Keep track of the sheet metal strip that is located at the top of the plastic casing.
Page 112 Figure 29 Primary filter, principle illustration Side cover Primary filter. Inside plastic casing Nuts, 8 pcs. Pre-filter Framework, grease 38. Boom Figure 30 Boom Grease nipples 39. Frame and cab...
Page 113 Figure 31 Grease points Steering cylinders' pivot points Frame joint's upper bearing Propeller shafts and support bearings Side window's hinges (right side) Cab's door Grease nipples for rear axle bearing Frame joint's lower bearing Greasing bearings Service life of bushings and pins can be extended if the machine is greased regularly and in the right way. Before greasing.
Page 114 (if installed). Oil-bath air cleaner (optional equipment) 2. On L150E with engine D9A the oil-bath air cleaner is located behind the cab's right side. On other models the oil- bath air cleaner is located behind the cab's left side.
Page 115 Framework, grease 3. Boom Figure 2 Boom Grease nipples The boom's lower bucket pin's shall be greased daily in tough operating conditions.
Page 116 Service Information 2014/4/24 50 hours Profile: WLO, L150E [GB] Maintenance service, every 50 hours The 50 hr interval includes daily service The service points where "optional equipment" is stated are not included in the accounted time for the interval Op nbr 173-004...
Page 117 2. On L150E with engine D9A the oil-bath air cleaner is located behind the cab's right side. On other models the oil- bath air cleaner is located behind the cab's left side. Change oil as needed. Volume: 9.1 litres (2.4 US gal)
Page 118 Cooling system, checking level 5. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant. The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 119 Figure 4 Coolant level Framework, grease 6. Boom Figure 5 Boom Grease nipples 7. Frame and cab Grease points 1 - 4 if machines operate in an aggressive or corrosive environment. Figure 6 Grease points Steering cylinders' pivot points Frame joint's upper bearing Grease nipples for rear axle bearing Propeller shafts and support bearings Greasing bearings...
Page 120  Add grease to the bearing to reduce friction between pin and bushing.  Replace old grease that may be dirty. The grease space under the outer seal collects and prevents dirt particles and fluid from penetrating into the bearing. Grease the bearing until new grease comes out through the outer seal.
Page 121 Loader unit's functions including automatic tilt (bucket positioner) and automatic lift (boom kick-out). Optional equipment. Oil-bath air cleaner (optional equipment) 2. On L150E with engine D9A the oil-bath air cleaner is located behind the cab's right side. On other models the oil-...
Page 122 bath air cleaner is located behind the cab's left side. Change oil as needed. Volume: 9.1 litres (2.4 US gal). Figure 1 Oil-bath air cleaner Tires as well as inflation pressure in tires, check 191 Some simple rules regarding tyre handling 3.
Page 123 Figure 3 Checking engine oil level Oil dipstick Filler pipe Hydraulic oil, check the level 5. The hydraulic oil level shall be between max. and min. Filling takes place from the top of the hydraulic tank. Figure 4 Hydraulic oil, checking level Cap, filling up Sight-glass...
Page 124 Cooling system, checking level 7. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 125 Figure 6 Coolant level Cab, ventilation unit 8. Primary filter, check and clean NOTE! Use breathing protection when handling filters Open the side cover. Remove the pre-filter. Remove the nuts that hold the plastic casing for the primary filter. NOTE! Keep track of the sheet metal strip that is located at the top of the plastic casing.
Page 126 Primary filter, principle illustration Side cover Primary filter. Inside plastic casing Nuts, 8 pcs. Pre-filter Water trap, check 9. Drain as needed NOTE! Collect fuel by using a collection container or a plastic hose NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Draining of water from the fuel must be done manually.
Page 127: Pipes And Hoses
Pipes and hoses 11. Check that all pipes and hoses are intact and not deformed. Framework, grease. 12. Boom Figure 9 Boom . Grease nipples 13. Frame and cab Figure 10 Grease points Steering cylinders' pivot points Frame joint's upper bearing Grease nipples for rear axle bearing WARNING Beware of rotating parts.
Page 128 Unlock and raise the radiator casing. Swing out the fan completely to open position. Blow clean the radiator with compressed air from the inside. NOTE! The radiator's fins may be damaged if handled carelessly. Figure 11 Radiator (principle illustration) Greasing bearings Service life of bushings and pins can be extended if the machine is greased regularly and in the right way.
Page 130 Service Information 2014/4/24 500 hours Profile: WLO, L150E [GB] Go back to Index Page Maintenance service, every 500 hours The 500 hr service interval includes daily, 50 hr, as well as the 250 hr service intervals The service points where "optional equipment" is stated are not included in the accounted time for the interval...
Page 131: Transmission Oil Level, Check
Brake system. Control light for low brake pressure. Parking brake Climate control system, fan and controls including air conditioning. Loader unit's functions including automatic tilt (bucket positioner) and automatic lift (boom kick-out). Oil-bath air cleaner (optional equipment) 2. Change oil as needed. Volume: 9.1 litres (2.4 US gal) Figure 1 Oil-bath air cleaner...
Page 132 Figure 2 Sight-glass Wheel nuts and tightening torques, check 030 Wheels, tightening torques 4. Tightening torques, see: Tires as well as inflation pressure in tires, check 191 Some simple rules regarding tyre handling 5. See: For inflation pressure in tires, see operator's manual. Figure 3 Inflation pressure in tires, check WARNING...
Page 133 NOTE! Handle the oil in an environmentally safe way. Figure 4 Draining point Drain for engine oil 7. Removing oil filters Open left engine cover. Use oil filter pliers when removing the oil filters. Installing oil filters Fill the filters with engine oil and brush oil on the gaskets. NOTE! New oil shall be used.
Page 134 Oil volume, see: 030 Engine, volume Fill the indicated oil volume. Run the engine warm and check that the oil filters' gaskets seal tight. If not, remove the filter and check the sealing surface. Normally, it does not help to tighten more. NOTE! After replacing the oil filter, the engine must be run at low idle for at least one minute to guarantee satisfactory lubrication of the engine before the machine is put to work.
Page 135 10. The hydraulic oil level shall be between max. and min. Filling takes place from the top of the hydraulic tank. Figure 8 Hydraulic oil, checking level Cap, filling up Sight-glass Battery, electrolyte level, cables and connections, check WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately.
Page 136 Cooling system, checking level 12. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant. The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 137 13. Primary filter, clean and check NOTE! Use breathing protection when handling filters. Open the side cover. Remove the pre-filter. Remove the nuts that hold the plastic casing for the primary filter. NOTE! Keep track of the sheet metal strip that is located at the top of the plastic casing. Remove the primary filter.
Page 138 Figure 12 Attaching bolt Adjusting screw Condenser, check 15. Clean as needed. NOTE! High-pressure washer may not be used. Cleaning Open the radiator casing. Blow clean with compressed air. Close the radiator casing. Figure 13 Condenser Brakes, checking 16. Checking precharging pressure 520 Brake system, checking hydraulic function See: Leakage...
Page 139 17. Check that all visible gaskets are intact and that they are not exposed to leakage. Pipes and hoses 18. Check that all pipes and hoses are intact and not deformed. Boom, grease 19. Framework Figure 14 Boom Grease nipples 20.
Page 140 Radiator, engine, check 21. Clean as needed NOTE! The radiator should be cleaned at regular intervals to ensure cooling of the engine. If the machine's operating site is dusty, the radiator should be checked daily. Unlock and raise the radiator casing. Swing out the fan completely to open position.
Page 141 Service Information 2014/4/24 500 hours Profile: WLO, L150E [GB] Go back to Index Page Maintenance service, every 500 hours The 500 hr service interval includes daily, 50 hr, as well as the 250 hr service intervals The service points where "optional equipment" is stated are not included in the accounted time for the interval...
Page 142 Brake system. Control light for low brake pressure. Parking brake Climate control system, fan and controls including air conditioning. Loader unit's functions including automatic tilt (bucket positioner) and automatic lift (boom kick-out). Oil-bath air cleaner (optional equipment) 2. Change oil as needed. Volume: 9.1 litres (2.4 US gal) Figure 1 Oil-bath air cleaner...
Page 143 Figure 2 Sight-glass Wheel nuts and tightening torques, check 030 Wheels, tightening torques 4. Tightening torques, see: Tires as well as inflation pressure in tires, check 191 Some simple rules regarding tyre handling 5. See: For inflation pressure in tires, see operator's manual. Figure 3 Inflation pressure in tires, check WARNING...
Page 144 Handle the oil in an environmentally safe way. Figure 4 Draining point Drain for engine oil 7. Removing oil filters Open right and left engine cover. Remove the cover on the intermediate wall to access the oil filters. Use oil filter pliers when removing the oil filters. Installing oil filters Fill the filters with engine oil and brush oil on the gaskets.
Page 145 Part-flow filter Full-flow filter 8. Filling engine oil Oil volume, see: 030 Engine, volume Fill the indicated oil volume. Run the engine warm and check that the oil filters' gaskets seal tight. If not, remove the filter and check the sealing surface.
Page 146 Bowl Hydraulic oil, check the level 10. The hydraulic oil level shall be between max. and min. Filling takes place from the top of the hydraulic tank. Figure 8 Hydraulic oil, checking level Cap, filling up Sight-glass WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately.
Page 147 Cooling system, checking level 12. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant. The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 148: Drive Belts
13. primary filter, check and clean NOTE! Use breathing protection when handling filters. Open the side cover. Remove the pre-filter. Remove the nuts that hold the plastic casing for the primary filter. NOTE! Keep track of the sheet metal strip that is located at the top of the plastic casing. Remove the primary filter.
Page 149 Figure 12 Drive belt Condenser, check 15. Clean as needed NOTE! High-pressure washer may not be used. Cleaning Open the radiator casing. Blow clean with compressed air. Close the radiator casing.
Page 150 Figure 13 Condenser Brakes, checking 16. Checking precharging pressure 520 Brake system, checking hydraulic function See: Leakage, general, check 17. Check that all visible gaskets are intact and that they are not exposed to leakage. Pipes and hoses, check 18. Check that all pipes and hoses are intact and not deformed. Framework, grease 19.
Page 151 Figure 15 Grease points Steering cylinders' pivot points Frame joint's upper bearing Grease nipples for rear axle bearing Propeller shafts and support bearings The propeller shafts' splined joints shall only be greased as needed. WARNING Beware of rotating parts. Keep a safe distance. Radiator, engine, check 21.
Page 152 Figure 16 Radiator (principle illustration) Greasing bearings Service life of bushings and pins can be extended if the machine is greased regularly and in the right way. Before greasing. Wipe off the grease nipples and grease gun so that sand and dirt particles are not introduced when greasing.
Page 153 2014/4/24 1000 hours Profile: WLO, L150E [GB] Maintenance service, every 1000 hours The 1000 hr service interval includes daily as well as the 50 hr, 250 hr, and 500 service intervals. The service points where "optional equipment" is stated are not included in the accounted time for the interval...
Page 154 Steering system. Gear positions / automatic shifting. Differential lock. Brake system. Control light for low brake pressure. Parking brake Climate control system, fan and controls including air conditioning Loader unit's functions including automatic tilt (bucket positioner) and automatic lift (boom kick-out). Optional equipment.
Page 155 Figure 2 Steering pressure, checking Pressure gauge 11666020 + hose 11666037 Brakes, checking 4. Brakes, pressure and function check. 520 Brake system, check and adjusting pressure in circuit See: 5. Brake accumulators, checking precharge pressure 520 Brake system, checking hydraulic function See: 6.
Page 156 Wheel nuts and tightening torques, check 030 Wheels, tightening torques 8. Tightening torques, see: Oil-bath air cleaner (optional equipment) 9. Change oil as needed. Volume: 9.1 litres (2.4 US gal) Figure 4 Oil-bath air cleaner Transmission oil level, check 10. The machine shall be parked on level ground when checking. The gear selector shall be in neutral position and the parking brake shall be applied.
Page 157 Figure 5 Sight-glass Air cleaner, changing 11. Primary filter When the alarm text "Clogged air filter" is shown, or every 1000 hours, the filter shall be changed or cleaned. Operating time between filter changes can vary depending on the machine's operating environment. Certain environments may require frequent filter changes.
Page 158 Figure 6 Air cleaner, primary filter WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Axles and hub, change oil 12. Front axle If the machine is equipped with axle oil cooler, change axle oil every 4000 hours. NOTE! Handle the waste oil in an environmentally safe way.
Page 159 NOTE! Handle the waste oil in an environmentally safe way. 030 Rear axle, capacity Oil volume, rear axle, see: NOTE! When filling, operate the machine for a few minutes and check the level again. Topping up may be needed. Figure 8 Rear axle Level check and filling Draining...
Page 160 15. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. The filter cannot be cleaned; it must be replaced. Figure 10 Axle oil cooling, front axle Support 9993831 Filters 16. Rear axle The filter cannot be cleaned; it must be replaced.
Page 161 Figure 11 Axle oil cooling, rear axle Filters Hydraulic oil, draining sediment and level check 17. Draining sediment Drain sludge and condensation water from the hydraulic oil tank through the drain on the machine's right side. Figure 12 Hydraulic oil, draining sludge Plug 18.
Page 162 Cooling system, checking level and freezing point 19. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant. The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 163 Figure 14 Coolant level 20. Freezing point, check Check the freezing point with a glycol tester at the expansion tank. The glycol tester's value should show approx. -38 °C (-36 °F). The machine is delivered with a coolant mixture of 50% glycol and 50% water for optimal cooling and corrosion characteristics.
Page 164 NOTE! Handle the oil in an environmentally safe way. Figure 16 Draining point Drain for engine oil 22. Removing oil filters Open right and left engine cover. Remove the cover on the intermediate wall to access the oil filters. Use oil filter pliers when removing the oil filters. Installing oil filters Fill the filters with engine oil and brush oil on the gaskets.
Page 165 Part-flow filter Full-flow filter 23. Filling engine oil Oil volume, see: 030 Engine, volume Fill the indicated oil volume. Start the engine and check that the oil filter gaskets seal tight. If not, remove the filter and check the sealing surface.
Page 166 Bowl Coolant filter, change 25. Coolant filter, change The filter cannot be cleaned, it must be changed as a complete unit. Close the valve on the filter head before removing the filter. NOTE! Time interval 1000 hours or max. 6 months Figure 20 Coolant filter Drive belts, check...
Page 167 Figure 21 Drive belt WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately. Wash the affected area with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention. Battery, electrolyte level, cables and connections, check 27.
Page 168 28. Screw out the drain plug and drain any condensation water or oil. NOTE! Handle the fluids in an environmentally safe way. Figure 23 Intercooler Drain plug Leakage, general, check 29. Check that all visible gaskets are intact and that they are not exposed to leakage. Pipes and hoses, check 30.
Page 169 Figure 24 Pre-filter principle illustration Side cover Pre-filter Clasps for pre-filter 32. Primary filter, clean and check NOTE! Use breathing protection when handling filters Open the side cover. Remove the pre-filter. Remove the nuts that hold the plastic casing for the primary filter. NOTE! Keep track of the sheet metal strip that is located at the top of the plastic casing Remove the primary filter.
Page 170 Figure 25 Primary filter principle illustration Side cover Primary filter. Inside of plastic casing. Nuts, 8 pcs. Pre-filter NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Framework, grease 33. Boom, grease Figure 26 Boom Grease nipples 34.
Page 171 Figure 27 Grease points Steering cylinders' pivot points Frame joint's upper bearing Propeller shafts and support bearings Side window's hinges (right side) Cab's door Grease nipples for rear axle bearing Frame joint's lower bearing Condenser, check 35. Clean as needed NOTE! High-pressure washer may not be used Open the radiator casing.
Page 172 Condenser WARNING Beware of rotating parts. Keep a safe distance. Radiator, engine, check 36. Clean as needed NOTE! The radiator should be cleaned at regular intervals to ensure cooling of the engine. If the machine's operating site is dusty, the radiator should be checked daily. Unlock and raise the radiator casing.
Page 173 2014/4/24 1000 hours Profile: WLO, L150E [GB] Maintenance service, every 1000 hours The 1000 hr service interval includes daily as well as the 50 hr, 250 hr, and 500 service intervals. The service points where "optional equipment" is stated are not included in the accounted time for the interval...
Page 174 Steering system. Gear positions / automatic shifting. Differential lock. Brake system. Control light for low brake pressure. Parking brake Climate control system, fan and controls including air conditioning Loader unit's functions including automatic tilt (bucket positioner) and automatic lift (boom kick-out). Optional equipment.
Page 175 Figure 2 Steering pressure, checking 11666020 pressure gauge + 11666037 hose Brakes, checking 4. Brakes, pressure and function check 520 Brake system, check and adjusting pressure in circuit See: 5. Brake accumulators, checking precharge pressure 520 Brake system, checking hydraulic function See: 6.
Page 176 Wheel nuts and tightening torques, check 030 Wheels, tightening torques 8. Tightening torques, see: Oil-bath air cleaner (optional equipment) 9. Change oil as needed. Volume: 9.1 litres (2.4 US gal) Figure 4 Oil-bath air cleaner Transmission oil level, check 10. The machine shall be parked on level ground when checking. The gear selector shall be in neutral position and the parking brake shall be applied.
Page 177 Figure 5 Sight-glass Air cleaner, changing 11. Primary filter When the alarm text "Clogged air filter" is shown, or every 1000 hours, the filter shall be changed or cleaned. Operating time between filter changes can vary depending on the machine's operating environment. Certain environments may require frequent filter changes.
Page 178 Figure 6 Air cleaner, primary filter WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Axles and hub, change oil 12. Front axle If the machine is equipped with axle oil cooling, change the axle oil every 4000 hours. NOTE! Handle the waste oil in an environmentally safe way.
Page 179 NOTE! Handle the waste oil in an environmentally safe way. 030 Rear axle, capacity Oil volume, rear axle, see: NOTE! When filling, operate the machine for a few minutes and check the level again. Topping up may be needed. Figure 8 Rear axle Level check and filling Draining...
Page 180 Axles, oil cooling (optional equipment), filter, change 15. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. The filter cannot be cleaned; it must be replaced. Figure 10 Axle oil cooling, front axle Support 9993831 Filters 16.
Page 181 Figure 11 Axle oil cooling, rear axle Filters Hydraulic oil, draining sediment and level check 17. Draining sediment Drain sludge and condensation water from the hydraulic oil tank through the drain on the machine's right side. Figure 12 Hydraulic oil, draining sludge Plug 18.
Page 182 Cooling system, checking level and freezing point 19. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant. The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 183 Figure 14 Coolant level 20. Coolant, freezing point, check Check the freezing point with a glycol tester at the expansion tank. The glycol tester's value should show approx. -38° C (-36° F). The machine is delivered with a coolant mixture of 50% glycol and 50% water for optimal cooling and corrosion characteristics.
Page 184 NOTE! Handle the oil in an environmentally safe way. Figure 16 Draining point Drain for engine oil 22. Removing oil filters Open left engine cover. Use oil filter pliers when removing the oil filters. Installing oil filters Fill the filters with engine oil and brush oil on the gaskets. NOTE! New oil shall be used Spin on the filters until the gaskets just touch the sealing surfaces.
Page 185 Run the engine warm and check that the oil filters' gaskets seal tight. If not, remove the filter and check the sealing surface. Normally, it does not help to tighten more. NOTE! After replacing the oil filter, the engine must be run at low idle for at least one minute to guarantee satisfactory lubrication of the engine before the machine is put to work.
Page 186 25. Coolant filter, changing The filter cannot be cleaned, it must be changed as a complete unit. Close the valve on the filter head before removing the filter. NOTE! Time interval 1000 hours or max. 6 months. Figure 20 Coolant filter Drive belts, check 26.
Page 187 Figure 22 Intercooler Drain plug WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately. Wash the affected area with soap and plenty of water. If electrolyte gets into your eyes or any other sensitive body part, rinse immediately with plenty of water and seek immediate medical attention.
Page 188 30. Check that all pipes and hoses are intact and not deformed. Cab, ventilation unit 31. Cab (ventilation filter), change The cab's filters consist of pre-filter and a primary filter. The filters should be checked once a week. NOTE! The change interval may be longer or shorter, depending on how dusty the environment is NOTE! Use breathing protection when changing filters Open the side cover...
Page 189 NOTE! Keep track of the sheet metal strip that is located at the top of the plastic casing Remove the primary filter. Shake the filter carefully, without damaging it. Avoid compressed air, vacuum cleaners and water. Reinstall the plastic casing with the sheet metal strip at the top. Install the pre-filter and close the side cover.
Page 190 Boom Grease nipples 34. Frame and cab Figure 27 Grease points Steering cylinders' pivot points Frame joint's upper bearing Propeller shafts and support bearings Side window's hinges (right side) Cab's door Grease nipples for rear axle bearing Frame joint's lower bearing Condenser, check 35.
Page 191 Condenser WARNING Beware of rotating parts. Keep a safe distance. Radiator, engine, check 36. Clean as needed NOTE! The radiator should be cleaned at regular intervals to ensure cooling of the engine. If the machine's operating site is dusty, the radiator should be checked daily. Unlock and raise the radiator casing.
Page 193 Service Information 2014/4/24 2000 hours Profile: WLO, L150E [GB] Go back to Index Page Maintenance service, every 2000 hours The 2000 hr service interval includes daily as well as the 50 hr, 250 hr, 500 hr, and 1000 hr service intervals The service points where "optional equipment"...
Page 194 Cab, pre-filter Coolant filter Fuel filter: Secondary filter Fuel filter: Primary filter Air cleaner: Safety filter Air cleaner: Main filter Glycol 25 litres (6.6 US gal) Test-run and check Start and stop function. Instruments, lighting, direction indicators, reflectors, flashing hazard lights, wipers, washers, horn, and back- up alarm (if installed).
Page 195 Steering pressure, check 3. Proceed as follows: Secure the frame joint with the steering joint lock and place blocks in front of and behind the wheels. Connect the pressure gauge 111666020 and the hose 11666037 to the pressure check connection on the steering valve.
Page 196 Hydraulic oil, draining 7. If the hydraulic tank is filled with engine oil or bio-oil, the oil shall be changed at 2000 hours. Machines filled with hydraulic oil, change at 4000 hours. NOTE! When changing hydraulic oil, use the hose that is used for draining engine oil. The hose is located in the battery box.
Page 197 Figure 4 Inflation pressure in tires, check Wheel nuts and tightening torques, check 030 Wheels, tightening torques 9. Tightening torques, see: Oil-bath air cleaner (optional equipment) 10. Clean the insert and change the oil Volume: 9.1 litres (2.4 US gal) Figure 5 Oil-bath air cleaner WARNING...
Page 198 Figure 6 Front axle Level check and draining Draining 12. Rear axle If the machine is equipped with axle oil cooling, then change the axle oil every 4000 hours. NOTE! Handle the waste oil in an environmentally safe way. 030 Rear axle, capacity Oil volume front axle.
Page 199 Figure 8 Draining Axles, oil cooling (optional equipment), filter, change 14. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. The filter cannot be cleaned; it must be replaced.
Page 200 Figure 9 Axle oil cooling, front axle Support 9993831 Filters 15. Rear axle The filter cannot be cleaned; it must be replaced. Figure 10 Axle oil cooling, rear axle Filters WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Transmission, oil and filter, changing 16.
Page 201 Figure 11 Transmission, principle illustration Cap for filler pipe Oil level check Drain plug Cover, suction strainer 17. Transmission oil filter, changing Use oil filter pliers when removing the oil filter. Installing filter Brush new oil on the rubber seal. Spin on the filter until the gasket just touches the sealing surface.
Page 202 Figure 12 Transmission oil filter Hydraulic oil, draining sediment and level check (applies when using hydraulic oil) 18. Draining sediment Drain sludge and condensation water from the hydraulic oil tank through the drain on the machine's right side. Figure 13 Hydraulic oil, draining sludge Plug 19.
Page 203 Figure 14 Hydraulic oil, checking level Cap, filling up Sight-glass Hydraulic system's return oil filter, change 20. Proceed as follows: Remove the cap. Lift out and dismantle the filter insert. Remove the filter and install a new filter. NOTE! The filter is for 'one-time' use only and must be changed. Check the seal rings when installing.
Page 204 Figure 15 Hydraulic system's return oil filter, principle illustration Cap, return oil filter Hydraulic oil, filling point (when using bio-oil) 030 Hydraulic system, volume 21. Hydraulic oil volume, see: The hydraulic oil level shall be between max. and min. Filling takes place from the top of the hydraulic tank.
Page 205 Figure 16 Hydraulic oil, checking level Cap, filling up Sight-glass Coolant filter, changing 22. Coolant filter, change The filter cannot be cleaned, it must be changed as a complete unit. Close the valve on the filter head before removing the filter. NOTE! Time interval 1000 hours or max.
Page 206 Draining point Drain for engine oil 24. Removing oil filters Open left engine cover. Use oil filter pliers when removing the oil filters. Installing oil filters Fill the filters with engine oil and brush oil on the gaskets. NOTE! New oil shall be used. Spin on the filters until the gaskets just touch the sealing surfaces.
Page 207 Figure 20 Oil dipstick Filler pipe engine oil Fuel filter, primary and secondary filter, change 26. When installing, only tighten the filter by hand. For removing and installing bowl, use dismantling tool 11666167 233 Fuel system, air bleeding, D10B Bleed the system, see Figure 21 Primary fuel filter Secondary fuel filters...
Page 208 Figure 22 Attaching bolt Adjusting screw Intercooler, drain 28. Screw out the drain plug and drain any condensation water or oil. NOTE! Handle the fluids in an environmentally safe way. Figure 23 Intercooler Drain plug WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately.
Page 209 Cooling system, checking level and freezing point 30. Level check Fill coolant in the expansion system. NOTE! Use genuine Volvo coolant The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 210 -38° C (-36° F). The machine is delivered with a coolant mixture of 50% glycol and 50% water for optimal cooling and corrosion characteristics. That is why the same coolant mixture shall be filled, regardless of ambient temperature conditions. Figure 26 Coolant check Glycol tester Leakage, general, check...
Page 211 Figure 27 Secondary filter 35. Primary filter When the alarm text "Clogged air filter" is shown, or every 1000 hours, the filter shall be changed or cleaned. Operating time between filter changes can vary depending on the machine's operating environment. Certain environments may require frequent filter changes.
Page 212 Figure 29 Pre-filter, principle illustration Side cover Pre-filter Clasps for pre-filter 37. Main filter, changing NOTE! Use breathing protection when changing filters Open the side cover. Remove the pre-filter. Remove the nuts that hold the plastic casing for the primary filter. NOTE! Keep track of the sheet metal strip that is located at the top of the plastic casing.
Page 213 Figure 30 Primary filter, principle illustration Side cover Primary filter. Inside plastic casing Nuts, 8 pcs. Pre-filter Valve clearance, checking and adjusting 214 Valves, adjusting, D10B 38. See: Breather filter, changes 39. Transmission The filter cannot be cleaned; it must be replaced. Figure 31 Breather filter, transmission Breather filter...
Page 214 40. Hydraulic system The filter cannot be cleaned; it must be replaced. Figure 32 Breather filter, hydraulic system Breather filter 41. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. The filter cannot be cleaned; it must be replaced.
Page 215 Figure 33 Breather filter, front axle Support 9993831 Breather filter 42. Rear axle The filter cannot be cleaned; it must be replaced. Figure 34 Rear axle Breather filter 43. Fuel tank The filter cannot be cleaned; it must be replaced.
Page 216 Figure 35 Breather filter, fuel tank Breather filter Framework, grease 44. Boom Figure 36 Boom Grease nipples 45. Frame and cab...
Page 217 Figure 37 Grease points Steering cylinders' pivot points Frame joint's upper bearing Propeller shafts and support bearings Side window's hinges (right side) Cab's door Grease nipples for rear axle bearing Frame joint's lower bearing Condenser, check 46. Clean as needed NOTE! High-pressure washer may not be used Cleaning...
Page 218 Beware of rotating parts. Keep a safe distance. Radiator, engine, check 47. Clean as needed NOTE! The radiator should be cleaned at regular intervals to ensure cooling of the engine. If the machine's operating site is dusty, the radiator should be checked daily. Unlock and raise the radiator casing.
Page 219 Service Information 2014/4/24 2000 hours Profile: WLO, L150E [GB] Go back to Index Page Maintenance service, every 2000 hours The 2000 hr service interval includes daily as well as the 50 hr, 250 hr, 500 hr, and 1000 hr service intervals The service points where "optional equipment"...
Page 220 Cab, pre-filter Coolant filter Fuel filter: Secondary filter Fuel filter, primary filter Air cleaner, safety filter Air cleaner, primary filter Glycol 25 litres (6.6 US gal) Test-run and check Start and stop function. Instruments, lighting, direction indicators, reflectors, flashing hazard lights, wipers, washers, horn, and back- up alarm (if installed).
Page 221 Steering pressure, check 3. Proceed as follows: Secure the frame joint with the steering joint lock and place blocks in front of and behind the wheels. Connect the pressure gauge 11666020 and the hose 11666037 to the pressure check connection on the steering valve.
Page 222 Hydraulic oil, draining 7. If the hydraulic tank is filled with engine oil or bio-oil, the oil shall be changed at 2000 hours. Machines filled with hydraulic oil, change at 4000 hours. NOTE! When changing hydraulic oil, use the hose that is used for draining engine oil. The hose is located in the battery box.
Page 223 Figure 4 Inflation pressure in tires, check Wheel nuts and tightening torques, check 030 Wheels, tightening torques 9. Tightening torques, see: Oil-bath air cleaner (optional equipment) 10. Clean the insert and change the oil Volume: 9.1 litres (2.4 US gal) The oil-bath air cleaner is located behind the cab's right side.
Page 224 Figure 6 Front axle Level check and filling Draining 12. Rear axle If the machine is equipped with axle oil cooling, then change the axle oil every 4000 hours. NOTE! Handle the waste oil in an environmentally safe way. 030 Rear axle, capacity Oil volume, rear axle, see: NOTE! When filling, operate the machine for a few minutes and check the level again.
Page 225 Figure 8 Draining Axles, oil cooling (optional equipment), filter, change 14. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. The filter cannot be cleaned; it must be replaced.
Page 226 Figure 9 Axle oil cooling, front axle Support 9993831 Filters 15. Rear axle The filter cannot be cleaned; it must be replaced. Figure 10 Axle oil cooling, rear axle Filters WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Transmission, oil and filter, changing 16.
Page 227 Figure 11 Transmission, principle illustration Cap for filler pipe Oil level check Drain plug Cover, suction strainer WARNING Risk of burns! Use protective work gloves. 17. Transmission oil filter, changing Use oil filter pliers when removing the oil filter. Installing filter Brush new oil on the rubber seal.
Page 228 Figure 12 Transmission oil filter Hydraulic oil, draining sediment and level check 18. Draining sediment Drain sludge and condensation water from the hydraulic oil tank through the drain on the machine's right side. Figure 13 Hydraulic oil, draining sludge Plug 19.
Page 229 Figure 14 Hydraulic oil, checking level Cap, filling up Sight-glass Hydraulic system's return oil filter, change 20. Proceed as follows: Remove the cap. Lift out and dismantle the filter insert. Remove the filter and install a new filter. NOTE! The filter is for 'one-time' use only and must be changed. Check the seal rings when installing.
Page 230 Figure 15 Hydraulic system's return oil filter, principle illustration Cap, return oil filter Hydraulic oil, filling point (applies when using bio-oil) 21. Filling takes place from the top of the hydraulic tank. The hydraulic oil level shall be between max. and min. 030 Hydraulic system, volume Hydraulic oil volume, see:...
Page 231 Figure 16 Hydraulic oil, checking level Cap, filling up Sight-glass Coolant filter, changing 22. Coolant filter, change The filter cannot be cleaned, it must be changed as a complete unit. Close the valve on the filter head before removing the filter. NOTE! Time interval 1000 hours or max.
Page 232 Draining point Drain for engine oil 24. Removing oil filters Open right and left engine cover. Remove the cover on the intermediate wall to access the oil filters. Use oil filter pliers when removing the oil filters. Installing oil filters Fill the filters with engine oil and brush oil on the gaskets.
Page 233 Figure 20 Oil dipstick Filler pipe engine oil Fuel filter, primary and secondary filter, change 26. When installing, only tighten the filter by hand. For removing and installing cup on the primary filter, use dismantling tool 11666167 233 Fuel system, bleeding Bleed the system, see Figure 21 Primary fuel filter...
Page 234 Figure 22 Drive belt Intercooler, drain 28. Screw out the drain plug and drain any condensation water or oil. NOTE! Handle the fluids in an environmentally safe way. Figure 23 Intercooler Drain plug WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately.
Page 235 Coolant, checking level and freezing point 30. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 236 Figure 25 Coolant level 31. Coolant, freezing point, check Check the freezing point with a glycol tester at the expansion tank. The glycol tester's value should show approx. -38° C (-36° F). The machine is delivered with a coolant mixture of 50% glycol and 50% water for optimal cooling and corrosion characteristics.
Page 237 Figure 27 Secondary filter 35. Primary filter When the alarm text "Clogged air filter" is shown, or every 1000 hours, the filter shall be changed or cleaned. Operating time between filter changes can vary depending on the machine's operating environment. Certain environments may require frequent filter changes.
Page 238 NOTE! The change interval may be longer or shorter, depending on how dusty the environment is NOTE! Use breathing protection when changing filters. Open the side cover. Loosen the clasps for the pre-filter and remove it. Install the new filter carefully. Close the side cover.
Page 239 Figure 30 Primary filter, principle illustration Side cover Primary filter. Inside plastic casing Nuts, 8 pcs. Pre-filter Breather filter, changes 38. Transmission The filter cannot be cleaned; it must be replaced. Figure 31 Breather filter, transmission Breather filter 39. Hydraulic system The filter cannot be cleaned;...
Page 240 Figure 32 Breather filter, hydraulic system Breather filter 40. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. The front axle's breather filter is located to the right inside the front cover under the boom. The filter cannot be cleaned;...
Page 241 Breather filter, front axle 9993831 Breather filter 41. Rear axle The filter cannot be cleaned; it must be replaced. Figure 34 Rear axle Breather filter 42. Fuel tank The breather filter is located inside the machine's right engine cover. The filter cannot be cleaned; it must be replaced.
Page 242 Figure 35 Breather filter, fuel tank Breather filter Boom, grease 43. Boom Figure 36 Boom Grease nipples 44. Frame and cab...
Page 243 Figure 37 Grease points Steering cylinders' pivot points Frame joint's upper bearing Propeller shafts and support bearings Side window's hinges (right side) Cab's door Grease nipples for rear axle bearing Frame joint's lower bearing Condenser, check 45. Clean as needed NOTE! High-pressure washer may not be used Cleaning...
Page 244 Condenser WARNING Beware of rotating parts. Keep a safe distance. Radiator, engine, check 46. Clean as needed NOTE! The radiator should be cleaned at regular intervals to ensure cooling of the engine. If the machine's operating site is dusty, the radiator should be checked daily. Unlock and raise the radiator casing.
Page 246 2014/4/24 4000 hours Profile: WLO, L150E [GB] Go back to Index Page Maintenance service, every 4000 hours The 4000 hr service interval includes daily, 50 hr, 250 hr, 500 hr, 1000 hr as well as the 2000 hr service intervals The service points where "optional equipment"...
Page 247 Cab, pre-filter Coolant filter Fuel filter: Secondary filter Fuel filter: Primary filter Air cleaner: Safety filter Air cleaner: Main filter Glycol 25 litres (6.6 US gal) Test-run and check Start and stop function. Instruments, lighting, direction indicators, reflectors, flashing hazard lights, wipers, washers, horn, and back- up alarm (if installed).
Page 248 Steering pressure, check 3. Proceed as follows: Secure the frame joint with the steering joint lock and place blocks in front of and behind the wheels. Connect the pressure gauge 11666020 and the hose 11666037 to the pressure check connection on the steering valve.
Page 249 Hydraulic oil, draining 7. If the hydraulic tank is filled with engine oil or bio-oil, the oil shall be changed at 2000 hours. Machines that are filled with hydraulic oil, change at 4000 hours. NOTE! When changing hydraulic oil, use the hose that is used for draining engine oil. The hose is located in the battery box.
Page 250 Inflation pressure in tires, check Wheel nuts and tightening torques, check 030 Wheels, tightening torques 9. Tightening torques, see: Oil-bath air cleaner (optional equipment) 10. Clean the insert and change the oil Volume: 9.1 litres (2.4 US gal) Figure 5 Oil-bath air cleaner WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin.
Page 251 Figure 6 Front axle Level check and filling Draining 12. Rear axle If the machine is equipped with axle oil cooling, change the axle oil every 4000 hours. NOTE! Handle the waste oil in an environmentally safe way. 030 Rear axle, capacity Oil volume, rear axle, see: NOTE! When filling, operate the machine for a few minutes and check the level again.
Page 252 Figure 8 Draining Axles, oil cooling (optional equipment), filter, change 14. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. The filter cannot be cleaned; it must be replaced.
Page 253 Figure 9 Axle oil cooling, front axle 9993831 Filters 15. Rear axle The filter cannot be cleaned; it must be replaced. Figure 10 Axle oil cooling, rear axle Filters WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Transmission, oil and filter, changing 16.
Page 254 Figure 11 Transmission, principle illustration Cap for filler pipe Oil level check Drain plug Cover, suction strainer 17. Transmission oil filter Use oil filter pliers when removing the oil filter. Installing filter Brush new oil on the rubber seal. Spin on the filter until the gasket just touches the sealing surface. Tighten another 1/2 to 3/4 turn by hand. Warm up the machine and check that the oil filter gasket seals tight.
Page 255 Figure 12 Transmission oil filter Hydraulic system's return oil filter, change 18. Proceed as follows: Remove the cap. Lift out and dismantle the filter insert. Remove the filter and install a new filter. NOTE! The filter is for 'one-time' use only and must be changed. Check the seal rings when installing.
Page 256 Figure 13 Hydraulic system's return oil filter, principle illustration Cap, return oil filter Hydraulic oil, filling 030 Hydraulic system, volume 19. Hydraulic oil volume, see: The hydraulic oil level shall be between max. and min. Filling takes place from the top of the hydraulic tank.
Page 257 Figure 14 Hydraulic oil, checking level Cap, filling up Sight-glass Coolant filter, changing 20. Coolant filter, change The filter cannot be cleaned, it must be changed as a complete unit. Close the valve on the filter head before removing the filter. NOTE! Time interval 1000 hours max.
Page 258 Figure 16 Draining point Drain for engine oil 22. Removing oil filters Open left engine cover. Use oil filter pliers when removing the oil filters. Installing oil filters Fill the filters with engine oil and brush oil on the gaskets. NOTE! New oil shall be used.
Page 259 Figure 18 Oil dipstick Filler pipe engine oil Fuel filter, primary and secondary filter, change 24. When installing, only tighten the filters by hand. For removing and installing cup on the primary filter, use dismantling tool 11666167 233 Fuel system, air bleeding, D10B Bleed the system, see Figure 19 Primary fuel filter...
Page 260 Figure 20 Drive belt Attaching bolt Adjusting screw Intercooler, drain 26. Screw out the drain plug and drain any condensation water or oil. NOTE! Handle the fluids in an environmentally safe way. Figure 21 Intercooler Drain plug WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately.
Page 261 Cooling system, checking level and freezing point 28. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 262 Check the freezing point with a glycol tester at the expansion tank. The glycol tester's value should show approx. -38° C (-36° F). The machine is delivered with a coolant mixture of 50% glycol and 50% water for optimal cooling and corrosion characteristics.
Page 263 Figure 25 Secondary filter 33. Primary filter When the alarm text "Clogged air filter" is shown, or every 1000 hours, the filter shall be changed or cleaned. Operating time between filter changes can vary depending on the machine's operating environment. Certain environments may require frequent filter changes.
Page 264 NOTE! The change interval may be longer or shorter, depending on how dusty the environment is. NOTE! Use breathing protection when changing filters. Open the side cover. Loosen the clasps for the pre-filter and remove it. Install the new filter carefully. Close the side cover.
Page 265 Figure 28 Primary filter, principle illustration Side cover Primary filter. Inside plastic casing Nuts, 8 pcs. Pre-filter Valve clearance, checking and adjusting 214 Valves, adjusting, D10B 36. See: Breather filter, changes 37. Transmission The filter cannot be cleaned; it must be replaced. Figure 29 Breather filter, transmission...
Page 266 Breather filter 38. Hydraulic system The filter cannot be cleaned; it must be replaced. Figure 30 Breather filter, hydraulic system Breather filter 39. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. The front axle's breather filter is located to the right inside the front cover under the boom. The filter cannot be cleaned;...
Page 267 Figure 31 Breather filter, front axle Support 9993831 Breather filter 40. Rear axle The filter cannot be cleaned; it must be replaced. Figure 32 Rear axle Breather filter 41. Fuel tank...
Page 268 The filter cannot be cleaned; it must be replaced. Figure 33 Breather filter, fuel tank Breather filter Framework, grease 42. Boom Figure 34 Boom Grease nipples 43. Frame and cab...
Page 269 Figure 35 Grease points Steering cylinders' pivot points Frame joint's upper bearing Propeller shafts and support bearings Side window's hinges (right side) Cab's door Grease nipples for rear axle bearing Frame joint's lower bearing Condenser, check 44. Clean as needed NOTE! High-pressure washer may not be used.
Page 270 Beware of rotating parts. Keep a safe distance. Radiator, engine, check 45. Clean as needed NOTE! The radiator should be cleaned at regular intervals to ensure cooling of the engine. If the machine's operating site is dusty, the radiator should be checked daily. Unlock and raise the radiator casing.
Page 271 2014/4/24 4000 hours Profile: WLO, L150E [GB] Go back to Index Page Maintenance service, every 4000 hours The 4000 hr service interval includes daily, 50 hr, 250 hr, 500 hr, 1000 hr as well as the 2000 hr service intervals The service points where "optional equipment"...
Page 272 Cab, main filter Cab, pre-filter Coolant filter Fuel filter: Secondary filter Fuel filter: Primary filter Air cleaner: Safety filter Air cleaner: Main filter Glycol 25 litres (6.6 US gal) Test-run and check Start and stop function. Instruments, lighting, direction indicators, reflectors, flashing hazard lights, wipers, washers, horn, and back- up alarm (if installed).
Page 273 Matris read-off, connection point Steering pressure, check 3. Proceed as follows: Secure the frame joint with the steering joint lock and place blocks in front of and behind the wheels. Connect the pressure gauge 11666020 and the hose 11666037 to the pressure check connection on the steering valve.
Page 274 Hydraulic oil, draining 7. If the hydraulic tank is filled with engine oil or bio-oil, the oil shall be changed at 2000 hours. Machines that are filled with hydraulic oil, change at 4000 hours. NOTE! When changing hydraulic oil, use the hose that is used for draining engine oil. The hose is located in the battery box.
Page 275 Figure 4 Inflation pressure in tires, check Wheel nuts and tightening torques, check 030 Wheels, tightening torques 9. Tightening torques, see: Oil-bath air cleaner (optional equipment) 10. Clean the insert and change the oil Volume: 9.1 litres (2.4 US gal) The oil-bath air cleaner is located behind the cab's right side.
Page 276 Figure 6 Front axle Level check and filling Draining 12. Rear axle If the machine is equipped with axle oil cooling, then change the axle oil every 4000 hours. NOTE! Handle the waste oil in an environmentally safe way. 030 Front axle, capacity Oil volume rear axle, see: NOTE! When filling, operate the machine for a few minutes and check the level again.
Page 277 Figure 8 Draining Axles, oil cooling (optional equipment), filter, change 14. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. The filter cannot be cleaned; it must be replaced.
Page 278 Figure 9 Axle oil cooling, front axle Support 9993831 Filters 15. Rear axle The filter cannot be cleaned; it must be replaced. Figure 10 Axle oil cooling, rear axle Filters WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. Transmission, oil and filter, changing 16.
Page 279 Figure 11 Transmission, principle illustration Cap for filler pipe Oil level check Drain plug Cover, suction strainer 17. Transmission oil filter Use oil filter pliers when removing the oil filter. Installing filter Brush new oil on the rubber seal. Spin on the filter until the gasket just touches the sealing surface. Tighten another 1/2 to 3/4 turn by hand. Warm up the machine and check that the oil filter gasket seals tight.
Page 280 Figure 12 Transmission oil filter Hydraulic system's return oil filter, change 18. Proceed as follows: Remove the cap. Lift out and dismantle the filter insert. Remove the filter and install a new filter. NOTE! The filter is for 'one-time' use only and must be changed. Check the seal rings when installing.
Page 281 Figure 13 Hydraulic system's return oil filter, principle illustration Cap, return oil filter Hydraulic oil, filling 030 Hydraulic system, volume 19. Hydraulic oil volume, see: The hydraulic oil level shall be between max. and min. Filling takes place from the top of the hydraulic tank.
Page 282 Figure 14 Hydraulic oil, checking level Cap, filling up Sight-glass Coolant filter, changing 20. Coolant filter, change The filter cannot be cleaned, it must be changed as a complete unit. Close the valve on the filter head before removing the filter. NOTE! Time interval 1000 hours max.
Page 283 Figure 16 Draining point Drain for engine oil 22. Removing oil filters: Open right and left engine cover. Remove the cover on the intermediate wall to access the oil filters. Use oil filter pliers when removing the oil filters. Installing oil filters: Fill the filters with engine oil and brush oil on the gaskets.
Page 284 Figure 18 Oil dipstick Filler pipe engine oil Fuel filter, primary and secondary filter, change 24. When installing, only tighten the filter by hand. For removing and installing cup on the primary filter, use dismantling tool 11666167 233 Fuel system, bleeding Bleed the system, see Figure 19 Primary fuel filter...
Page 285 Figure 20 Drive belt Intercooler, drain 26. Screw out the drain plug and drain any condensation water or oil. NOTE! Handle the fluids in an environmentally safe way. Figure 21 Intercooler Drain plug WARNING The battery electrolyte contains corrosive sulphuric acid. Electrolyte spilled on bare skin should be removed immediately.
Page 286 Cooling system, checking level and freezing point 28. Level check Fill coolant in the expansion tank. NOTE! Use genuine Volvo coolant The coolant level shall be between max. and min. Filling The engine shall be run warm and the temperature control shall be set to "warm".
Page 287 Figure 23 Coolant level 29. Freezing point, check Service program 2:14 Check the freezing point with a glycol tester at the expansion tank. The glycol tester's value should show approx. -38° C (-36° F). The machine is delivered with a coolant mixture of 50% glycol and 50% water for optimal cooling and corrosion characteristics.
Page 288 Figure 25 Secondary filter 33. Primary filter When the alarm text "Clogged air filter" is shown, or every 1000 hours, the filter shall be changed or cleaned. Operating time between filter changes can vary depending on the machine's operating environment. Certain environments may require frequent filter changes.
Page 289 NOTE! The change interval may be longer or shorter, depending on how dusty the environment is. NOTE! Use breathing protection when changing filters. Open the side cover. Loosen the clasps for the pre-filter and remove it. Install the new filter carefully. Close the side cover.
Page 290 Figure 28 Primary filter, principle illustration Side cover Primary filter. Inside plastic casing Nuts, 8 pcs. Pre-filter Valve clearance, checking and adjusting 214 Valves, adjusting 36. See: Breather filter, changes 37. Transmission The filter cannot be cleaned; it must be replaced. Figure 29 Breather filter, transmission Breather filter...
Page 291 38. Hydraulic system The filter cannot be cleaned; it must be replaced. Figure 30 Breather filter, hydraulic system Breather filter 39. Front axle Start the engine and raise the boom. Use support 9993831 to secure the boom. The front axle's breather filter is located to the right inside the front cover under the boom. The filter cannot be cleaned;...
Page 292 Figure 31 Breather filter, front axle Support 9993831 Breather filter 40. Rear axle The filter cannot be cleaned; it must be replaced. Figure 32 Rear axle...
Page 293 Breather filter 41. Fuel tank The breather filter is located inside the machine's right engine cover. The filter cannot be cleaned; it must be replaced. Figure 33 Breather filter, fuel tank Breather filter Framework, grease 42. Boom Figure 34...
Page 294 Boom Grease nipples 43. Frame and cab Figure 35 Grease points Steering cylinders' pivot points Frame joint's upper bearing Propeller shafts and support bearings Side window's hinges (right side) Cab's door Grease nipples for rear axle bearing Frame joint's lower bearing Condenser, check 44.
Page 295 Figure 36 Condenser WARNING Beware of rotating parts. Keep a safe distance. Radiator, engine, check 45. Clean as needed NOTE! The radiator should be cleaned at regular intervals to ensure cooling of the engine. If the machine's operating site is dusty, the radiator should be checked daily. Unlock and raise the radiator casing.
Page 296 Figure 37 Radiator (principle illustration) Greasing bearings Service life of bushings and pins can be extended if the machine is greased regularly and in the right way. Before greasing. Wipe off the grease nipples and grease gun so that sand and dirt particles are not introduced when greasing.
Page 297 Information Type: Date: Maintenance service, every Service Information 2014/4/24 6000 hours Profile: WLO, L150E [GB] Maintenance service, every 6000 hours Op nbr 173-022 NOTE! Time interval 6000 hours or max. 4 years Coolant, changing WARNING Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant may rush out and cause severe burns.
Page 298 Fill the cooling system to max. level in the expansion tank. Fit the cap on the expansion tank. Run the engine warm and set the control to "warm". Stop the engine and let it cool down. Run the engine warm and top up so that the cooling system is completely filled and bled free from air. Figure 2 Coolant level...
Page 299 Date: Mechanical release Service Information 2014/4/24 parking brake Profile: WLO, L150E [GB] Mechanical release of parking brake Op nbr 176-001 WARNING Risk of burns! Use protective work gloves. Figure 1 Plugs for releasing parking brake If the parking brake cannot be released with the parking brake control, release it manually as follows: ...
Page 300 Date: Towing Service Information 2014/4/24 Profile: WLO, L150E [GB] Towing NOTE! Towing of machine may not take place other than in exceptional cases, then a tow bar must be used and towing speed may be max. 10 km/h (6.2 mph).
Page 301 Service Information 2014/4/24 platform Profile: WLO, L150E [GB] On another vehicle's platform The frame joint must be locked if the machine is lifted up onto another vehicle. Figure 1 Transport the machine with the bucket facing the transport vehicle's direction of travel.
Page 302 Service Information Document Title: Function Group: Information Type: Date: Lift Service Information 2014/4/24 Profile: WLO, L150E [GB] Lift Figure 1 Lifting eyes Only use lifting eyes intended for this purpose and lock the frame joint.
Page 303 Service Information Document Title: Function Group: Information Type: Date: Over ramp Service Information 2014/4/24 Profile: WLO, L150E [GB] Over ramp First check that the ramp has the adequate width and durability required and that it cannot shift.
Page 304 In a lift or other confined Service Information 2014/4/24 space Profile: WLO, L150E [GB] In a lift or other confined space Back the machine in. Apply the parking brake and switch off the engine before starting the lift. WARNING If the machine is to be driven from a loading dock onto the platform of a truck trailer or railway car, make sure that the vehicle is securely braked, for example, wheels blocked.
Page 305 Service Information 2014/4/24 Profile: WLO, L150E, L50G, L250G, L180F, L150G, L180F HL, L220F, L110F, L150F, L350F, L120F, L110G, L70F, L60F, L90G, L70G, L60G, L350G, L120G, L220G, L90F, L180G, L180G - Do Not Use! [GB] Electric welding The battery disconnect switch must be turned off or the battery ground lead must be disconnected before any electric welding on the machine or connected attachments is carried out.
Page 306: Charging Batteries
Charging batteries Service Information 2014/4/24 Profile: WLO, L150E [GB] Charging batteries Explosion hazard When a battery is being charged, an explosive mixture of oxygen and hydrogen gas is formed. A short circuit, open flame or spark near the battery can cause a powerful explosion. Always switch off the charging current before removing the charging clamps.
Page 307 2014/4/24 hydraulic systems Profile: WLO, L150E [GB] Cleanliness, brake and hydraulic systems Maintain the best possible cleanliness when working on these systems. Wipe off all pipe and hose connections before disconnecting and remove paint flakes, etc. Plug all pipes, hoses, cylinders, etc. immediately after disconnecting. Never...
Page 308 Service Information 2014/4/24 system of the machine Profile: WLO, L150E [GB] Working on the electrical system of the machine  Only use test instruments with a light-emitting diode, never a test light with a light bulb, for example, during trouble-shooting of the electrical system! The high firing voltage of the bulb can destroy expensive electronic components.
Page 310: General Description
Date: General description Service Information 2014/4/24 Profile: WLO, L150E [GB] General description The engine is a straight six-cylinder, turbocharged, four-stroke and direct-injected diesel engine with an air-cooled intercooler. It has an overhead camshaft, four valves per cylinder and unit injectors.
Page 311 The cooling system is based on a concept where cooling for engine, transmission, hydraulics and axle oil cooling (optional equipment) are integrated. These systems' cooling depends on the cooling fan speed. Engine identification Identification plate 1 Engine designation, serial number, part number and assembly plant are stamped in one field on the engine block's left rear edge Identification plate 2 A decal with the software's ID-number, the engine's serial number and assembly plant is located on the valve cover to...
Page 312: Engine Description
Date: Engine, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Engine, description The engine type is D10B. Engine type, product and serial number are stamped on the cylinder block above the starter motor (right-hand side of machine). Figure 1 The engine is a straight six-cylinder, direct-injected diesel with 9.6 litre cylinder volume, turbocharger, intercooler and electronically controlled fuel injection EMS (Engine Management System).
Page 313 Profile: WLO, L150E [GB] Engine, description D9 L150E with engine D9A is introduced at serial number 8000. D9A is a straight six cylinder, direct-injected diesel engine with a 9.4 litre cylinder capacity, with turbo, intercooler, and electronically controlled fuel injection.
Page 314 Date: Engine identification, D9 Service Information 2014/4/24 Profile: WLO, L150E [GB] Engine identification, D9 Identification plate 1 Engine designation, serial number, part number and assembly plant are stamped in two fields on the engine block's left front edge Stamping, field 1...
Page 315 Figure 1 Engine identification, D9A...
Page 316 Date: Engine identification, D10 Service Information 2014/4/24 Profile: WLO, L150E [GB] Engine identification, D10 Identification plate Engine designation, serial number and part number are stamped in three fields on the engine block's left trailing edge Stamping, field 1 Engine designation...
Page 318 Document Title: Function Group: Information Type: Date: Engine, removing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine, removing Op nbr 210-070 9998547 Lifting tool 821 Engine hood, removing 1. Remove the engine hood. See: WARNING Risk of burns when removing the header tank cap because of excess pressure in the cooling system.
Page 319 Figure 2 Clamp 4. Remove the side panels. 5. Loosen the following from the right side of the machine:  Disconnect the cab heater hose from the engine block (1).  Remove the charge-air pipe (2).  Disconnect the return fuel line from the injection pump (3). ...
Page 320 Figure 3 Machine's right side 6. Loosen the following from the left side of the machine: WARNING Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage.  Loosen the fuel line from the primary fuel filter (1). ...
Page 321 Figure 4 Suspension of secondary steering pump  Disconnect the connector for the engine connection (6).  Loosen the clamps and cables to the preheating coil (7).  Remove the primary fuel filter from the partition wall (8).  Disconnect the connector for the cabling to the air filter indicator (9). Figure 5 Machine's left side...
Page 322 7. Remove the bolts for the coolant pipe's brackets. Remove the plate between the partition wall and bottom plate. WARNING Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage. Loosen the receiver dryer from the partition wall and place it to the side. Figure 6 Receiver drier Plate...
Page 323 Figure 8 Transmission bolt Oil pipe Rear axle 12. Remove the lower transmission bolts, 4 pcs. 13. Secure the hydraulic transmission in place with a sling and a ratchet blocks as illustrated. Figure 9 Hydraulic transmission secured (engine removed) 14. Fit lifting device 9998547 to the engine's front and rear lifting eyes.
Page 324 Figure 10 Lifting device position 9998547 15. Remove the remaining attaching bolts, 8 pcs., for the hydraulic transmission. 16. Remove the bolts securing the engine mounting. Remove the engine. Engine's weight, including oil: approx. 1130 kg (approx. 2500 lbs) Figure 11 Engine mount 17.
Page 325 Function Group: Information Type: Date: Engine, removing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine, removing Op nbr 210-070 11668016 Lifting tool 9998547 Lifting tool Ratchet block, 750 kg (1653 lbs) 191 Safety rules when servicing 1.
Page 326 Figure 2 Clamp 821 Engine hood, removing 4. Remove the engine hood, see 5. Remove the side plates on both sides. Figure 3 6. Remove the engine compartment's rear partition wall and bottom plate. Figure 4 Partition walls 7. Disconnect the oil pipe between the flywheel housings and the hydraulic transmissions from the flywheel housing. Figure 5...
Page 327 Oil pipe between flywheel housing and hydraulic transmission 8. Disconnect the hose to the cab heater from the engine block.  Remove the expansion tank.  Remove the charge-air pipe.  Remove the upper radiator hose.  Remove the electric connections from the starter motor. Figure 6 Charge air pipe Header tank...
Page 328 WARNING Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage. 10. Remove the condenser and place it on the radiator.  Loosen the air conditioning's receiver dryer from the partition wall. Mark up and remove the cable connections on the pressure monitor.
Page 329 Figure 9 Partition wall's upper attachment Partition wall's lower attachment 12. Remove the partition wall. Partition wall, weight: approx. 45 kg (99 lbs) Figure 10 13. Secure the hydraulic transmission in place with a sling and a ratchet blocks as illustrated.
Page 330 Figure 11 Hydraulic transmission secured (engine removed) 14. Fit tool 11 668 016 and connect 999 8547 and a lifting device to the engine. Figure 12 Lifting tool 999 8547 Figure 13 Lifting tool 11 668 016 15. Remove the bolts in the flywheel housing for the hydraulic transmission. 16.
Page 331 Figure 14 17. If changing the engine, transfer the components required to the new engine. NOTE! Never transfer a component that could cause a malfunction.
Page 332 Function Group: Information Type: Date: Engine, removing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine, removing Op nbr 210-070 9998547 Lifting tool Sling, 3 m, 2 pcs. Sling, 4 m, 1 pcs. Lifting eye M12, 2 pcs.
Page 333 Drain point for coolant Drain for engine oil 821 Engine hood, removing 4. Remove the engine hood, see 5. Drain the engine oil. Use the drain hose located in the machine's toolbox. 210 Engine, volume Volume, see 6. Remove the side panels by the engine and remove the clamp that holds the oil drain. Figure 2 Clamp 030 Hydraulic transmission, volume...
Page 334 Figure 4 1. Charge-air pipe 6. Cable, engine heater 2. Radiator hose 7. Radiator hose, lower 3. Hose 8. Filter housing 4. Connector (SE2603) 9.Plate 5. Radiator hose, upper 9. Remove the charge-air pipe. 10. Disconnect the upper and lower radiator hose from the engine. 11.
Page 335 Figure 5 1. Upper radiator hose 5. Charge-air pipe 2. Radiator hose 6. Air hose 3. Bottom plate 7. Bracket 4. Breather hose 8. Guard 15. Remove the protection for the AC compressor. 16. Disconnect the hose from the radiator. 17.
Page 336 Figure 6 Lifting eye M12, 2 pcs. Shackle M16, 2 pcs. Sling, 4 m (13 ft) Figure 7 Tensioning strap Bracket with oil filter Tighten up the oil filters against the engine with a tensioning strap. 24. Disconnect the connectors for the AC compressor and alternator.
Page 337 Figure 8 Connector, MA802 Connector, RD 25. Loosen the belt tensioner and remove the belt. Disconnect the AC compressor and lay it on the frame. 26. Mark the hose connections on the fuel filter bracket. Disconnect the fuel hoses from the fuel filters and collect the fuel that drains.
Page 338 Figure 10 Connector EL Connector EMS Starter motor connections 28. Remove the clamps. Disconnect the hose and connector RT. Figure 11 Hose Connector, RT 29. Remove the cover for the box with the main fuses and disconnect the cables and their clamps. See fig.
Page 339 Figure 12 Cables 30. Disconnect the bracket and move it aside. 31. Disconnect the bridge for the contacts to the shift solenoids from the transmission. Figure 13 32. Remove the air filters for the transmission and rear axle. Secure the hydraulic transmission with lifting eyes, shackle, sling and ratchet block.
Page 340 Figure 14 (Engine removed.) Lifting eye M12, 2 pcs. Shackle M16, 1 pc. Sling, 4 m (13 ft) Ratchet block, 750 kg NOTE! Do not tighten up the transmission. 33. Install tool 9998547 on the engine. Figure 15 Lifting tool 34.
Page 341 Figure 16 35. Remove the bolts on the hydraulic transmission, except the two upper bolts. Tighten up the transmission using the lifting device. Remove the two upper bolts. Remove the engine. Engine's weight: 1250 kg (2756 lbs) 36. If changing the engine, transfer the components required to the new engine. NOTE! Never transfer a component that could cause a malfunction.
Page 343 Information Type: Date: Engine, installing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine, installing Op nbr 210-072 9998547 Lifting tool 1. Fit lifting device 9998547 and a lifting device to the engine. Fit the engine.
Page 344 Figure 2 Engine mount 4. Fit the oil pipe to the flywheel housing. Use a new O-ring. Figure 3 Transmission bolt Oil pipe Rear axle 5. Fit the partition wall. Partition wall, weight: approx. 65 kg (143 lbs)
Page 345 Figure 4 6. Fit the partition wall's support members. 7. Fit the condenser. 8. Fit the plates in the bottom and on the partition wall, and fit the receiver dryer. Figure 5 Receiver drier Plate Bottom plate 9. Connect the following on the left side of the machine: ...
Page 346  Fit the radiator's upper hose (3).  Fit the coolant hoses (2 pcs.) and expansion tank with bracket (4).  Fit the charge-air pipe's clamp and the sheet metal lead-through in the partition wall (5).  Refit the secondary steering pump. ...
Page 347  Fit the drive belt (5), and tension according to the following: Turn the adjusting screw until the belt is so tight that it can only be pushed in approx.: 8 mm (0.3 in). Figure 7 Attaching bolt Adjusting screw ...
Page 348 Figure 8 11. Fit the clamp securing the oil drain. Fill oil. 030 Engine, volume Volume: Fill coolant. 030 Cooling system volume Volume: Figure 9...
Page 349 Clamp 821 Engine hood, installing 12. Fit the engine hood. See: 233 Fuel system, air bleeding, D10B 13. Bleed the fuel system. See...
Page 350 Function Group: Information Type: Date: Engine, installing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine, installing Op nbr 210-072 11668016 Lifting tool 9998547 Lifting tool Ratchet block, 750 kg (1653 lbs) 1. Fit tool 11 668 016 and connect 999 8547 and a lifting device to the engine.
Page 351 Figure 3 5. Fit:  The connector for the oil level sensor at the front edge of the oil sump.  The AC compressor.  The alternator.  The connector for the E-ECU and the cables for the starter motor. ...
Page 352 Figure 4 Water trap, fuel Charge-air pipe, preheating coil Receiver drier Connector, oil level sensor Alternator, AC compressor Connector, E-ECU 6. Fit the fuel lines.
Page 353 Figure 5 Fuel lines 7. Fit: The expansion tank. The charge-air pipe. The upper radiator hose. Electric connections for the starter motor. The hose to the heating coil in the cab. Figure 6 Charge-air pipe...
Page 354 Expansion tank Upper radiator hose 8. Fit the engine compartment's rear partition wall and bottom plate. Figure 7 Engine compartment's rear partition wall and bottom plate 9. Fit the oil pipe between the flywheel housing and the hydraulic transmission. Figure 8 Oil pipe between flywheel housing and hydraulic transmission 10.
Page 355 Figure 10 Clamp 13. Fill engine oil 14. Fill coolant. 15. Start and warm up the engine, check that there are no leaks. 16. Restore the machine to operating condition.
Page 356 Document Title: Function Group: Information Type: Date: Engine, installing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine, installing Op nbr 210-072 9998547 Lifting tool Washer M12, 2 pcs. Nut M12, 2 pcs. Ratchet block, 750 kg Sling, 3 m, 2 pcs.
Page 357 3. Lower the engine and install the bolts for the engine mount. Then remove the lifting device. 210 Engine mounting, tightening torque Tightening torque: See Figure 2 4. Remove the tensioning straps that hold up the engine oil filters. Figure 3 Tensioning strap Bracket with oil filter 5.
Page 358 Figure 4 Cables 6. Install the hose for the heater. Plug in connector RT. Install the clamp. Figure 5 Hose Connector RT 7. Install the bridge for the contacts to the shift solenoids on the transmission's right side. Figure 6...
Page 359 8. Install the clamps for the cable harness and plug in connectors EMS and EL. Connect the cables to the starter motor. Figure 7 Connector EL Connector EMS Starter motor connections 9. Install the bracket with fuel filters and connect the hoses acc. to marking. Plug in connectors SE2301 and SE2302. Install the clamps.
Page 360 Figure 9 MA802 Connector RD 11. Lift the intermediate wall into place and install the bolts. Remove the lifting tool. Weight approx.: 65 kg (143 lbs) Figure 10 Lifting eye M12, 2 pcs. Shackle M16, 2 pcs. Sling, 4 m (13 ft) 12.
Page 361 Figure 11 Right side Figure 12 1. Upper radiator hose 5. Charge-air pipe 2. Radiator hose 6. Air hose 3. Bottom plate 7. Guard 4. Breather hose 8. Bracket 13. Install the bottom plate and the radiator hoses. 14. Install the bracket for the AC hoses. 15.
Page 362 16. Clamp the air hose and the drain hose. 17. Install the air hose on the alternator and secure it with cable ties. 18. Install the protection over the AC compressor. Left side Figure 13 1. Charge-air pipe 5. Radiator hose, upper 2.
Page 363 25. Fit the oil pipe between the flywheel housing and the hydraulic transmission. Figure 14 Oil pipe 821 Engine hood, installing 26. Install the hood, see 260 Cooling system volume 27. Fill coolant. Volume, see 210 Engine, volume 28. Fill engine oil. Approx. 35 l. Volume, see 421 Hydraulic transmission, capacity 29.
Page 364: Compression Test
Service Information Document Title: Function Group: Information Type: Date: Compression test Service Information 2014/4/24 Profile: WLO, L150E [GB] Compression test Op nbr 210-002 9990185 Lifting tool 9998248 Adapter 9998248 Adapter 9998248 Adapter 9998248 Adapter 9998248 Adapter 9998248 Adapter 9988539 Pressure gauge...
Page 365 remove the valve cover. NOTE! Do not use a nut runner since the studs bolts may come loose from the cylinder head and damage electrical cables and valve cover. 6. Remove the unit injector's electrical connections. Remove the electrical connections for the control valve. 7.
Page 366 9990185 88880003 9. Remove the bolt for the unit injectors' attaching yoke. Remove the unit injectors. Fit 9998249 on the unit injectors and place them in separate, well sealed plastic bags. NOTE! Clean very thoroughly around the injectors before removing them. Figure 4 Removing unit injectors, Delphi E3 9996400...
Page 367 Figure 5 10. Clean the unit injectors' copper sleeves. Fit the brush on the extension and clean the copper sleeve. Clean all copper sleeves. Figure 6 9998599 Cleaning tool Extension Brush Protective sleeve 11. Fit the six adapters 999 8248 in the cylinder head and tighten down these with the unit injectors' attaching yokes. Figure 7...
Page 368 Adapter 999 8248 12. Install the rocker arm bridge with lifting tool 9998255 and 88880003. 214 Rocker arm shaft, tightening torques Tightening of rocker arm bridge shall take place according to 214 Valves, adjusting 13. Check that the valve clearances are correct, see 14.
Page 369 Figure 9 9990185 88880003 16. Remove the adapters 9998248 from all cylinders. 17. Install the unit injectors with new O-rings and centre the unit injectors between the valve springs. Install the attaching yokes. 237 Tightening torques, unit injector Tightening torque: see NOTE! Clean thoroughly before assembling, dust and dirt particles can cause malfunctions.
Page 370 25. Restore the machine to operating condition.
Page 371 Document Title: Function Group: Information Type: Date: Compression test, D10B Service Information 2014/4/24 Profile: WLO, L150E [GB] Compression test, D10B Op nbr 21002 9998532 Extractor 9998009 Adapter 9988539 Compression gauge 214 Valves, adjusting, D10B Conditions: Valves correctly adjusted, see .
Page 372 Figure 2 6. Remove the rubber seal around the injector. 7. Remove the injector by twisting the injector and pulling up at the same time. If needed, use extractor 9998532 to remove the injector. Figure 3 9998532 8. Install the adapter 9998009 and tighten it down with the injector's attaching yoke and nut. Tightening torque: 50 Nm(37 lbf ft).
Page 373 9998009, Adapter 9998539, Compression gauge 9. Connect the compression gauge 9988539. 10. Remove fuse FU18. This is to prevent fuel from coming out of the pressure valves on the injection pump when the engine is cranked with the starter motor. NOTE! Red central warning will be shown on the instrument panel and a buzzer is activated when the starter motor is run without FU18.
Page 374 Figure 6 17. Install fuse FU18. 233 Fuel system, air bleeding, D10B 18. Bleed the fuel system, see 19. Start the engine, and check that there are no leaks. 20. Run the engine at increased engine speed for approx. 5 minutes to purge any remaining air.
Page 375 2014/4/24 VCADS Pro Profile: WLO, L150E [GB] Cylinder compression, VCADS Pro Connect VCADS Pro computer and perform 21006-3 Cylinder compression, test. (21006-3) This test indicates if there is any deviation in compression in any cylinder in relation to the other cylinders.
Page 376 Function Group: Information Type: Date: Stall speed, VCADS Pro Service Information 2014/4/24 Profile: WLO, L150E [GB] Stall speed, VCADS Pro Connect VCADS Pro computer and perform 28407-8, Sensor values check. (28407-8) This test shows the instantaneous values of the sensors.
Page 377 Function Group: Information Type: Date: Idle, VCADS Pro Service Information 2014/4/24 Profile: WLO, L150E [GB] Idle, VCADS Pro Connect VCADS Pro computer and perform 17030-2, parameter, programming. (17030-2) This test shows, among others, the parameter value for the set speed interval.
Page 379 Engine rotation speed Service Information 2014/4/24 sensor, replacing Profile: WLO, L150E [GB] Go back to Index Page Engine rotation speed sensor, replacing Op nbr 386-008 9998517 Setting tool 191 Service position 1. Place the machine in service position 1, see 2.
Page 380 4. Remove the cable clamp under the starter motor. Figure 3 5. Remove the cable box's outer casing (1). Figure 4 6. Remove the intermediate wall in the cable box. 7. Loosen the cable clamp (2). Remove and unplug the connector (1). Figure 5 8.
Page 381 Figure 6 9. Insert the tool in the hole for the sensor and press it to stop against the flywheel. Figure 7 10. Remove the tool and measure the distance between the lock ring and the end of the tool. Note the value A. Figure 8 11.
Page 382 Figure 9 12. Calculate the speed sensor distance as follows. Distance, lock ring – end of tool (A) Distance, sensor – end of tool (B) Tool depth 20 mm (0.787 in) Distance, speed sensor = A - B - 20 13.
Page 383 19. Install the side panel.
Page 384 Service Information 2014/4/24 sensor, replacing Profile: WLO, L150E, TOC Release B [GB] Go back to Index Page Engine rotation speed sensor, replacing Op nbr 386-008 9998517 Setting tool 191 Service position 1. Place the machine in service position 1, see 2.
Page 385 4. Remove the cable clamp under the starter motor. Figure 3 5. Remove the cable box's outer casing (1). Figure 4 6. Remove the intermediate wall in the cable box. 7. Loosen the cable clamp (2). Remove and unplug the connector (1). Figure 5 8.
Page 386 Figure 6 9. Insert the tool in the hole for the sensor and press it to stop against the flywheel. Figure 7 10. Remove the tool and measure the distance between the lock ring and the end of the tool. Note the value A. Figure 8 11.
Page 387 Figure 9 12. Calculate the speed sensor distance as follows. Distance, lock ring – end of tool (A) Distance, sensor – end of tool (B) Tool depth 20 mm (0.787 in) Distance, speed sensor = A - B - 20 13.
Page 388 19. Install the side panel.
Page 389 Service Information 2014/4/24 sensor (camshaft), replacing Profile: WLO, L150E [GB] Engine rotation speed sensor (camshaft), replacing Op nbr 386-088 9998517 Setting tool 191 Service position 1. Place the machine in service position 1, see 2. Remove the cable clamps on the front of the engine.
Page 390 Figure 2 6. Remove the intermediate wall in the cable box. 7. Remove and unplug the connector (1). Figure 3 8. Move the lock ring to the middle on the setting tool 9998517 Setting tool. Figure 4 9. Insert the tool in the sensor hole and press it to stop against the camshaft gear. 10.
Page 391 Figure 6 12. Calculate the speed sensor distance as follows. Distance, lock ring – end of tool (A) Distance, sensor – end of tool (B) Tool depth 20 mm (0.787 in) Distance, speed sensor = A - B - 20 13.
Page 393: Cylinder Head, Description
Cylinder head, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cylinder head, description The engine has six cylinder heads, one for each cylinder. Each cylinder head is held by four bolts placed at equal distances around the cylinders.
Page 394 Figure 3 Gasket, cylinder block cylinder head Cylinder head flame protection edge Gasket (cylinder head) The cylinder head, which is positioned furthest back on the engine nearest the flywheel housing, is equipped with a bleeder nipple. The nipple ensures that the cooling system bleeding which occurs during operation is then sent to the expansion tank.
Page 395 Cylinder head, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cylinder head, description The cylinder head is made of cast iron and made in one piece, which is a condition for a stable support for the overhead camshaft in its bearings.
Page 396 Cylinder head, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cylinder head, description D9 The cylinder head, which covers all cylinders, is equipped with an overhead camshaft and has four valves per cylinder. The cylinder head is made of cast iron, and is cast in one piece. This is a prerequisite for stable bearing positions for the overhead camshaft.
Page 397 Each cylinder has separate inlet and exhaust channels with so-called cross-flow. The valve guides, which are made of alloyed cast iron, and the valve seats made of steel, are replaceable. All valve guides are equipped with oil seals. The lower part of the unit injector is positioned in a copper sleeve, which is flared at the bottom and sealed with a rubber ring at the top end.
Page 398 2014/4/24 description D9 Profile: WLO, L150E [GB] Cylinder head gasket, description D9 The cylinder head gasket is made of steel sheet metal with vulcanized rubber seals for oil and coolant passages. There is also a number of convex stampings that, due to a higher position than the rubber seals, facilitate installation of the cylinder head.
Page 399 Date: Valve cover, changing Service Information 2014/4/24 gasket Profile: WLO, L150E [GB] Valve cover, changing gasket Op nbr 999 3590 Rotation tool Exhaust valves 821 Engine hood, removing 1. Remove the engine hood, see 2. Remove the valve cover. 3. Remove the old gasket from the valve cover.
Page 401 Cylinder block, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cylinder block, description The cylinder block is cast in one piece and has wet, replaceable cylinder linings. Combustion pressure tensile breaking strength in cylinder head screws is led through stiffened sections of the cylinder block wall directly to the main bearings.
Page 402 Cylinder block, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cylinder block, description The cylinder block is cast in one piece and has wet, replaceable cylinder linings. Combustion pressure tensile breaking strength in cylinder head screws is led through stiffened sections of the cylinder block wall directly to the main bearings.
Page 403 Cylinder block, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cylinder block, description The cylinder block is made of cast iron and provided with so called wet cylinder liners. For the cylinder block to obtain high rigidity and good sound dampening its sides are curved round each cylinder.
Page 404 Cylinder block, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Cylinder block, description D9 Cylinder block, D9 The cylinder block is made of cast iron is equipped with wet cylinder liners. The cylinder block's sides are shaped around each cylinder to obtain high stiffness and good sound insulation.
Page 405 Figure 2 Main bearings, D9A Ladder frame Cast nipples Sleeves...
Page 406 Service Information 2014/4/24 Profile: WLO, L150E [GB] Crankcase ventilation, D9 The crankcase ventilation consists of three oil traps located in the upper timing gear casing and in the valve cover as well as an external oil trap located on the engine.
Page 407 Oil trap...
Page 409 Cylinder liner, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cylinder liner, description The wet cylinder linings are replaceable and equipped with a flame protection edge (A). The flame protection edge, which fits into a groove in the cylinder head, reduces the stress on the cylinder head gasket.
Page 410 Cylinder liner, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cylinder liner, description The cylinder liner seals against the coolant casing with rubber rings. At the top with a seal (1) of EPDM-rubber, installed in a groove in the liner. The lower seal consists of three rings installed in grooves in the block.
Page 411 Service Information 2014/4/24 description D9 Profile: WLO, L150E [GB] Cylinder liners and pistons, description D9 Cylinder liner, D9A D9A has a cylinder block with wet cylinder liners. The bottom part of the liner is sealed against the coolant casing with two rubber rings.
Page 412 the connecting rod results in optimal transfer of the piston forces to the connecting rod. The piston has three piston rings; one compression ring of the "Keystone" type, one compression ring with a rectangular cross-section and a spring-loaded oil scraper ring. Figure 2 Piston, D9A Nozzle...
Page 413 Figure 3 Connecting rods, D9A...
Page 414: Pistons, Description
Pistons, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Pistons, description The oil-cooled pistons are manufactured using a light alloy. Cooling is conducted through piston cooling nozzles located in the cylinder block. Gudgeon pins are displaced by 0.80 mm (0.031 in), which reduces piston stress during combustion.
Page 415 Service Information 2014/4/24 Profile: WLO, L150E [GB] Piston rings, description Each piston is equipped with two compression rings and one oil ring. The uppermost compression ring is of the "Keystone" type (dual trapezoid-formed cross section). Compressions rings should be placed with the text facing upwards.
Page 416 Service Information 2014/4/24 description Profile: WLO, L150E [GB] Valve mechanism, description The D12D has a four-valve system and overhead camshaft. The camshaft is journaled in 7 bearing brackets with replaceable bearing shells. The foremost bearing is a thrust bearing. The camshaft is induction hardened and has three cams per cylinder. In addition to the inlet and exhaust cams there are cams for the unit injectors.
Page 417 Toothed wheel Cam gear Bushing Roller Valve yoke Ball socket Machined groove...
Page 418 2014/4/24 description Profile: WLO, L150E [GB] Valves and valve seats, description Valve stems are equipped with oil seals and the valve seats are replaceable. Standard sized and oversized seats are available as spare parts. An oversized seats has a larger outer diameter and is used if the cylinder head requires milling of the valve seat position.
Page 419 Service Information 2014/4/24 description D10 Profile: WLO, L150E [GB] Valve mechanism, description D10 Valve mechanism, D10 The valve mechanism receives its movement from the camshaft via valve rods and rocker arms. The valve spindles are equipped with oil seals. The valves seats are replaceable. The oversize seat has a bigger outside diameter and is used if the cylinder head requires machining of the valve seat positions.
Page 420 2014/4/24 description D9 Profile: WLO, L150E [GB] Valve mechanism, description D9 D9 has rocker arm-controlled valves, with four valves per cylinder and overhead camshaft. The camshaft is carried in seven bearings brackets with replaceable bearing cups. The rear bearing is also the thrust (axial) bearing. The camshaft is induction-hardened and has three cams per cylinder.
Page 421 Figure 2 Valve springs, D9A Camshaft's marking The camshaft's marking for basic setting as well as for adjusting valves and unit injectors is marked on the camshaft's flange in front of the rear bearing bracket. There are two dash markings on the bearing bracket. When setting the valves and unit injectors, the marking on the camshaft's flange shall be in the middle between the dash markings.
Page 422 Internal Exhaust Gas Recirculation (IEGR), description As a part of V-ACT (Volvo Advanced Combustion Technology), a system is used for IEGR ( Internal Exhaust Gas Recirculation). On D12D this takes place using a double rocker arm, consisting of an exhaust rocker arm and a follower arm, which enables a second opening of the exhaust valves.
Page 423 Figure 2 Oil system for double rocker arm, engaging and disengaging IEGR Rocker arm shaft IEGR valve Non-return valve Drain valve Drain valve Control slide Piston Oil pump Oil sump The oil comes from the oil sump and passes via the oil pump, the IEGR valve and rocker arm shaft to the double rocker arm. The rocker arm shaft is provided with lubrication oil through a hole in the rocker arm bushing (oil is only allowed through the non-return valve in one direction).
Page 424 Figure 3 IEGR disengaged Non-return valve Drain valve Control slide Piston If the oil pressure in the rocker arm is 150 kPa (1.5 bar, 21.8 PSI) or lower, the spring force in the control slide will not be overcome. The control slide will remain in the original position. Figure 4 IEGR engaged Non-return valve...
Page 425 IEGR activated The oil pressure forces the piston to its upper position. The follower arm follows along. When the camshaft rotates, it will first strike ”the roller” on the exhaust rocker and the normal valve lift will take place. The next step is that the camshaft will strike the contact face on the follower arm. The camshaft forces the follower arm and piston downward.
Page 426 Figure 8 Valves with double rocker arm...
Page 427 Document Title: Function Group: Information Type: Date: Valves, adjusting Service Information 2014/4/24 Profile: WLO, L150E [GB] Valves, adjusting Op nbr 214-012 9993590 Gear wheel 88830035 Guide Bolt, M14x35, 2 pcs. Lifting eye M16, 4 pcs 191 Safety rules when servicing 1.
Page 428 Figure 2 88830035 Guide 9993590 Gear wheel 5. Remove the bolts that hold the valve cover. Remove the valve cover. 6. Fit a ratchet handle in 9993590 Gear wheel and turn the crankshaft in the engine's rotational direction to the closest camshaft marking for one of the cylinders.
Page 429 214 Valve system specifications Specifications, see Adjust each unit injector's rocker arm to zero clearance. Then tighten down the adjusting screw another 180° - 240°. Angle tighten the lock nut 45°. Figure 4 8. Adjust the remaining valves and unit injectors as before. 9.
Page 430 Date: Valves, adjusting, D10B Service Information 2014/4/24 Profile: WLO, L150E [GB] Valves, adjusting, D10B Op nbr 21412 9993590 Gear WARNING In order to eliminate the risk of engine start when the crankshaft is rotated, the emergency stop should be pressed in, the ignition key should be turned off and the engine should be cold.
Page 431 Inspection hole for reading off flywheel position Hole for 9993590 5. Rotate the crankshaft in the engine's rotational direction (clockwise) until the flywheel is at 0° and the valves on cylinder 6 break over. Then the piston for cylinder 1 is at top dead center after compression. Adjust valves 1, 2, 4, 5, 8 and 9.
Page 432 Function Group: Information Type: Date: Valves, adjusting Service Information 2014/4/24 Profile: WLO, L150E [GB] Valves, adjusting Op nbr 214-012 88820003 Setting tool 9993590 Gear wheel Feeler gauge 191 Safety rules when servicing 1. Place the machine in service position, see 821 Engine hood, removing 2.
Page 433 Figure 2 Camshaft marking 6. Loosen the lock rocker arm and adjust to correct valve clearance according 214 Valve mechanism, double rocker arm tighten lock nut. Tightening torque: 030 Valve mechanism, tightening torques Figure 3 Adjusting screw Lock nut Feeler gauge Adjusting exhaust valve 7.
Page 434 Figure 4 Adjusting screw Lock nut Feeler gauge 214 Valve mechanism, double rocker arm 8. Check-measure the valve clearance according to NOTE! Before checking the double rocker arm's clearance, check that the exhaust valve clearance is correct according to 214 Valve mechanism, double rocker arm Checking, double rocker arm (IEGR) 9.
Page 435 Draining nipple 10. Insert the go-side of 88820003 between the double rocker arm's contact surface and the camshaft's basic circle. The checking tool must be able to pass between the contact surface and the camshaft, if the IEGR-"lift" is not too great.
Page 436 Figure 7 Double rocker arm Follower arm (IEGR-rocker arm) Exhaust rocker arm Stop nut Sleeve Nipple Lock nut Piston Adjusting, double rocker arm (IEGR) 15. Keep the camshaft in the same position as when adjusting valve clearance. Loosen the lock nut and counterhold the piston with an Allen head wrench.
Page 437 18. Check-measure according to step 6-10. 211 Valve cover, tightening torque 19. Install the valve cover, see 821 Engine hood, installing 20. Fit the engine hood, see 21. Restore the machine to operating condition.
Page 438 Service Information 2014/4/24 description Profile: WLO, L150E [GB] Engine timing gears, description The engine timing gears are positioned at the front end of the engine on a 10 mm (0.39 in) thick steel plate, which is bolted to the cylinder block.
Page 439 Transmission Crankshaft gear Intermediate gear Coolant pump Air compressor (engine D12CAABE2 and D12CABE2) Intermediate gear (adjustable) Camshaft gear Oscillation damper, camshaft Fuel pump and belt pulley Toothed wheel, position sensor Intermediate gear Intermediate gear Lubricating oil pump Spray nozzle Sealing strip Lower timing casing cover Sound insulation Upper timing casing cover...
Page 440 Service Information 2014/4/24 Profile: WLO, L150E [GB] Camshaft, description The camshaft is carried in seven bearings. Axial clearance is determined by the camshaft drive gear, the collar on the camshaft's forward-most pivot pin and the pressure plate which is bolted to the front surface of the cylinder block.
Page 441 Camshaft, description D9 Service Information 2014/4/24 Profile: WLO, L150E [GB] Camshaft, description D9 The camshaft is induction-hardened and its bearing pins can be machined, with oversize bearing cups. Each cylinder has three cams, seen from the front: inlet, unit injector and exhaust.
Page 442 Engine timing gear, description D9 Engine timing gear, D9 Engine D9A's timing gear is located at the rear end of the engine as opposed to other Volvo engines which have it at the front. The advantages with the timing gear at the rear are, among others, lower noise level and fewer parts, for example, the flywheel housing is also used as timing gear casing.
Page 443  The drive belt drives the alternator (and AC compressor if installed), while the belt tensioner keeps the belt tight. Figure 2 Belt transmission, D9A Transfer gear Drive belt, coolant pump, etc. Coolant pump Idler gear Belt tensioner Belt tensioner Drive belt, alternator and AC compressor...
Page 444 Service Information 2014/4/24 Profile: WLO, L150E [GB] Timing gear, description The transmission is made up of cylindrical gear drives with helical teeth. The injection pump and camshaft are driven by the crankshaft gear and an idler gear. The oil pump is driven by the crankshaft and an idler gear.
Page 445 2014/4/24 description Profile: WLO, L150E [GB] Timing gear casing, description The timing gear casing is cast in aluminium. Sound-damping plates, comprised of double metal plates with a layer of plastic in between, are installed on the outside of the casing.
Page 447: Crankshaft, Description
Crankshaft, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Crankshaft, description The crankshaft (2) is carried in seven main bearings. The axial bearing comprises pressure plates located near the centre main bearing. The crankshaft is balanced statically and dynamically.
Page 448 Crankshaft, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Crankshaft, description The crankshaft is drop forged and has induction hardened bearing surfaces and recesses. It is journaled by seven main bearings, of which the centre bearing is a thrust bearing. The gear wheel at the front of the shaft is pressed onto the shaft and also has a wedge-shaped cross.
Page 449 Service Information 2014/4/24 damper, description D9 Profile: WLO, L150E [GB] Crankshaft and vibration damper, description D9 Crankshaft and vibration damper, D9 The crankshaft is drop-forged and also has induction-hardened bearing surfaces and recess hollows. It is carried in seven main bearings, where the middle bearing also is the thrust bearing. The thrust bearing consists of thrust washers, placed at the middle main bearing.
Page 450 2014/4/24 description Profile: WLO, L150E [GB] Connecting rods, description The I-sectioned connecting rods are drilled for pressure lubrication by the gudgeon pin. Because of the oblique bearing positions, the connecting rods can be drawn up through the cylinder lining during removal.
Page 451 2014/4/24 description Profile: WLO, L150E [GB] Vibration damper, description The vibration damper comprises a hermetically-sealed housing in which a steel flywheel mass (1) with a rectangular cross- section is placed. The flywheel mass (damper ring) is centre-carried on a bushing (2) and all sides are surrounded by a viscous liquid (silicone) (3).
Page 452 2014/4/24 description Profile: WLO, L150E [GB] Main and big-end bearing, description The bearings are precision-manufactured and ready for installation. Five over-dimensioned sizes can be retained as spare parts. Pressure plates for the connecting rod's axial bearing are available in three over-dimensioned sizes.
Page 453 Function Group: Information Type: Date: Crankshaft, replacing front Service Information 2014/4/24 oil seal Profile: WLO, L150E [GB] Crankshaft, replacing front oil seal Op nbr 216-014 9990112 Installation tool 9990118 Cone 9990192 Puller 9992000 Handle 9996400 Impact puller 191 Safety rules when servicing 1.
Page 454 Figure 2 Idler gear Coolant pump Transfer gear Belt tensioner, belt for alternator and compressor Alternator AC Compressor Belt pulley/Vibration damper Belt pulley Belt tensioner, belt for coolant pump 5. Remove the bolts that hold the transfer gear. Clean the hub. Move the transfer gear up and tie it with a strap or similar.
Page 455 Make sure that the guide pin on the crankshaft ends up in one of the "slots" in the tool, otherwise the tool bottoms out on the guide pin. Figure 5 9990112 9992000 11. Fit the vibration damper/belt pulley. Tightening torque, attaching bolts: 105 Nm (77 lbf ft). 12.
Page 456 Crankshaft front seal, Service Information 2014/4/24 replacement Profile: WLO, L150E [GB] Crankshaft front seal, replacement Op nbr 21614 999 3590 Gear 999 3625 Guide 999 3712 Socket 999 3714 Pull rod (shorten to 350 mm 13.8 in) 999 3746 Intermediate piece...
Page 457 Figure 2 Retaining bolt Adjusting screw 5. Remove the crankshaft pulley bolts. Remove the pulley and vibration damper. 6. Remove the E-ECU. 7. Remove the cover on the right-hand side of the flywheel housing. Fit tool 999 3625 and 999 3590 to lock the crankshaft with help from the handle.
Page 458 Figure 4 999 3771 999 3746 11 666 014 10. Loosen the seal by striking it on one side with a drift. Break off the seal using a chisel. Installing 11. Place the sealing ring on tool 999 6795 and tap the ring into the timing gear cover. Figure 5 999 6795 12.
Page 459 Figure 6 999 3746 999 3712 11 666 014 999 3714 (shorten to 350 mm 13.8 in) 14. Remove the tools and lock the crankshaft. Make sure that the ratchet handle provides an adequate counter-hold without damaging other components. 15. Fit the centre bolt. Use a torque amplifier if possible. Tightening torque:550 Nm (405.7 lbf ft).
Page 460 Side panel Radiator protection Base plate 22. Remove the radiator protection. 23. Fold the fan shroud back. Close the side panels. 24. Restore the machine to operating condition.
Page 461 Oil sump, description D9 Service Information 2014/4/24 Profile: WLO, L150E [GB] Oil sump, description D9 The oil sump is made of die-cast reinforced plastic. The seal against the cylinder block consists of a moulded rubber strip located in a groove in the sump.
Page 462 2014/4/24 description Profile: WLO, L150E [GB] Engine mounting, description The engine is mounted in a frame located in the leading edge of the engine (rear of machine). The front central mounting comprises a curved, cast-iron frame secured in the engine and a rubber element secured in the front cross-stay. The rear edge of the engine (flywheel housing) is fitted to the transmission.
Page 464 Information Type: Date: Rubber cushion, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Rubber cushion, replacing Op nbr 218-001 Sling 2 m (6.6 ft), 2 pcs. Ratchet block 750 kg (1650 lb) Shackle, 2 pcs.
Page 465 Figure 2 Shackle Sling Sling Ratchet block 6. Lift the engine so that the rubber cushion is clear of the cross member. 7. Loosen the part of the engine mount that the rubber cushion is bolted in from the engine block. Remove the bolts in the engine mount's partition.
Page 466 Information Type: Date: Rubber cushion, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Rubber cushion, replacing Op nbr 218-001 Sling 2 m (6.6 ft), 2 pcs. Ratchet block 750 kg (1650 lb) Shackle, 2 pcs.
Page 467 Figure 2 4. Loosen obstructing hoses in the collecting clamps on both sides in the frame member. Figure 3 5. Remove the bolts (4 pcs.) that hold the cross member against the frame. Remove the bolts that hold the rubber cushion against the cross member. 6.
Page 468 Figure 4 Shackle Sling Sling Ratchet block 7. Lift the engine approx. 40 mm. Check that the pipes to the intercooler and preheating do not touch the intermediate plate. 8. Move the cross member forward. Place spacers between the cross member and engine mount as safety supports. 9.
Page 469 2014/4/24 description D9 Profile: WLO, L150E [GB] Piston cooling system, description D9 The opening valve has direct connection with the channel for filtered oil. At a pressure of approx. 2.5 bar (250 kPa) (36 psi), the valve opens and lets oil through to the reduction valve.
Page 470 Service Information 2014/4/24 description Profile: WLO, L150E [GB] Lubrication system, description The engine is force-feed lubricated through a pump driven from the crankshaft via an intermediate gear. The lubrication system has two full-flow filters and one by-pass filter. The oil flow is controlled through six valves.
Page 471 Service Information 2014/4/24 description D9 Profile: WLO, L150E [GB] Lubrication system, description D9 Lubrication system, D9A The lubrication system in the D9A is a force-feed lubrication system, with force-feed from a gear pump. The pump is located at the trailing edge and is driven by the engine's crankshaft gear.
Page 472 2014/4/24 description D10 Profile: WLO, L150E [GB] Lubrication system, description D10 The engine is equipped with a pressure lubrication system with two full-flow filters, partial-flow filters and an oil cooler. The engine is lubricated by an oil pump driven by the crankshaft via an idler gear.
Page 473 Figure 1 Pressure limiting valve Overflow valve, full-flow oil filter Overflow valve, oil cooler Piston cooling valve Piston cooling nozzle...
Page 474 2014/4/24 oil cooler, description Profile: WLO, L150E [GB] Lubrication oil pump and oil cooler, description Lubrication oil pump, D10 The oil pump is located at the front of the oil sump and is driven by the crankshaft via a transfer gear. It is of the double- pump type with two pairs of gears.
Page 475 Lubrication oil pump Oil distributor housing Suction strainer Safety valve Suction pipe Delivery pipe Oil cooler, D9 The oil cooler (2) is bolted on the inside of the cooling casing's side cover (3) and is connected to the filter housing with surface-routed pipes.
Page 476 (12) forces the lubricating oil to the original oil filter housing and from there on to an additional Volvo CE filter housing, where all the oil filters are located for better serviceability. Then the oil is led to the engine block's distribution pipe and is distributed via channels to all lubrication points in the engine.
Page 477 Figure 1 Principle illustration of lubrication system Pressure limiting valve Overflow valve for full-flow filters Piston cooling valve Overflow valve for full-flow filters (not in use) Safety valve By-pass valve Full-flow filter By-pass filter Turbocharger Oil cooler Nozzle Oil pump...
Page 479 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Description, oil pump The oil pump is located on the front edge of the oil sump and is run by the crankshaft via an idler gear. The gear-type pump sucks in oil through the strainer and the suction pipe on the pump's suction side.
Page 480: Oil Pump, Description
Oil pump, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Oil pump, description The gear type oil pump is entirely made of aluminium and bolted to the front main bearing cap. The pump housing and the rear end plate are machined together and cannot be replaced separately.
Page 481: Oil Pressure Check
Function Group: Information Type: Date: Oil pressure, check Service Information 2014/4/24 Profile: WLO, L150E [GB] Oil pressure, check Op nbr 22121 999 3721 Service display unit VCADS-Pro The following applies when checking: Oil pressure, operating: (2275 rpm) 300-500 kPa (43.5-72.5 psi) Oil pressure, low idle speed, min: (650 rpm) 60 kPa (8.7 psi)
Page 482 Information Type: Date: Lubrication pressure, Service Information 2014/4/24 check Profile: WLO, L150E [GB] Lubrication oil pressure, check Op nbr 221-021 11666018 Pressure gauge 11666027 Adapter 11666037 Hose 14211660 Measuring nipple, M16 x1.5 NOTE! The check should be performed with the engine at operating temperature.
Page 484 Lubrication pressure, Service Information 2014/4/24 checking with pressure gauge Profile: WLO, L150E [GB] Go back to Index Page Lubrication oil pressure, checking with pressure gauge Op nbr 221-022 11666017 Pressure gauge 11666027 Adapter 11666037 Hose 14211660 Measuring nipple NOTE! The check should be performed with the engine at operating temperature.
Page 485 11666037, 11666017 3. Start the engine. 220 Lubrication system, specification Read off the oil pressure. Oil pressure, see 4. Remove the tools and fit the plug. Wipe off any oil spill.
Page 486 Service Information 2014/4/24 checking with pressure gauge Profile: WLO, L150E [GB] Go back to Index Page Lubrication oil pressure, checking with pressure gauge Op nbr 221-022 11666052 Pressure gauge 14290266 Hose 14211660 Measuring nipple 1. Remove the plug and connect 14211660, 14290266 Hose and 11666052 Pressure gauge.
Page 487 Service Information 2014/4/24 checking with pressure gauge Profile: WLO, L150E [GB] Lubrication oil pressure, checking with pressure gauge Op nbr 221-022 11666017 Pressure gauge 11666027 Adapter 11666037 Hose 14211660 Measuring nipple NOTE! The check should be performed with the engine at operating temperature.
Page 488 3. Start the engine. 220 Lubrication system, specification Read off the oil pressure. Oil pressure, see 4. Remove the tools and fit the plug. Wipe off any oil spill.
Page 489: Oil Pump, Replacement
Date: Oil pump, replacement Service Information 2014/4/24 Profile: WLO, L150E [GB] Oil pump, replacement Op nbr 22114 Removing 1. Remove the oil sump. 2. Remove the bolts of the oil pressure pipe support and then remove the pipe from the cylinder block.
Page 490 Figure 2 7. Fit the oil pressure pipe with new O-ring to the oil pump end plate. Fit the end plate to the oil pump. 8. Mark the oil pressure pipe union with a touch-up pen (do not make permanent marks!) Tighten the oil pressure pipe union towards the engine block.
Page 491 Oil cooler, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Oil cooler, description The oil cooler is bolted directly against the cylinder block inside the cover for the cylinder block coolant duct and is thus entirely surrounded by the coolant.
Page 493 Information Type: Date: Oil cooler, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Oil cooler, replacing Op nbr 223-006 191 Safety rules when servicing 1. Place the machine in service position, see 2. Drain the coolant from the engine.
Page 494  the transfer gear  the coolant pump and the coolant pump's backpiece from the engine block. NOTE! Use a ratchet handle with 1/2" drive to relieve the belt tensioners. Figure 2 Idler gear Coolant pump Transfer gear Belt tensioner, belt for alternator and compressor Alternator AC Compressor Belt pulley/Vibration damper...
Page 495 13. Install the oil cooler in the oil cooler casing, use new seal rings. Tightening torque: 27 Nm (20 lbf ft) Figure 4 Oil cooler with seal rings 14. Install a new gasket on the oil cooler casing. Fit the oil cooler casing on the engine block. Figure 5 15.
Page 496 255 Turbocharger, replacing 25. Install the turbo, see 26. Fill coolant in the cooling system. 27. Install the protective covers and the hatch in the intermediate wall. 28. Start, run the engine until warm, check for leaks. Adjust the coolant level and engine oil level, as needed.
Page 497 Information Type: Date: Oil cooler, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Oil cooler, replacing Op nbr 223-006 191 Safety rules when servicing 1. Place the machine in service position, see 2. Drain the coolant from the engine.
Page 498 Information Type: Date: Oil cooler, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Oil cooler, replacing Op nbr 223-006 191 Safety rules when servicing 1. Place the machine in service position, see 2. Drain the coolant from the engine.
Page 499 Figure 2 6. Loosen the coolant hose for the cab heating coil from the oil cooler casing's rear edge. 7. Remove all bolts for the oil cooler casing. Remove the casing. Figure 3 8. Remove the oil cooler and its seal rings from the engine block. Figure 4 9.
Page 500 Figure 5 Oil cooler with seal rings 11. Check the oil cooler casing's seal, change if needed. Figure 6 12. Fit the oil cooler casing on the engine block. Tightening torque: 24 Nm. Figure 7 Tightening diagram for oil cooler casing. 13.
Page 501 Figure 8 Clamp for intercooler pipe Flex hose Oil cooler casing's water line 17. Fill coolant in the cooling system. 18. Start, run the engine until warm, check for leaks. If needed, adjust the coolant level in the cooling system.
Page 502: Fuel System, Description
Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel system, description The following are the main parts of the fuel system: fuel tank, feed pump, injection pump, fuel filter, leak fuel line, injectors, delivery pipe, compensating overflow valve, and fuel filter with water trap.
Page 503 Date: Fuel system, description D9 230 Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel system, description D9 Fuel system, D9 D9A has vertical, centrally located unit injectors and four valves. This results in identical geometry in the combustion chamber. There are always individual differences between the cylinders in a combustion engine. On the D9A, there is a cylinder balancing system, the function of which is to even out the power between the cylinders.
Page 504 Figure 1 Fuel system, D9A Primary filter Fuel tank Main filter Overflow valve Unit injectors Fuel pump Control unit cooling coil...
Page 505 Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel flow, description D9 The fuel pump draws (sucks) the fuel from the tank via the prefilter and water trap through the filter housing. The fuel is then drawn through the cooling circuit for the control unit to the connection, where the fuel is mixed with return fuel from the fuel channel in the cylinder head, and then to the fuel pump's suction side.
Page 506 Fuel pump Tank fixture Prefilter Water trap Main filter Control unit cooling coil Connection Fuel channel for unit injectors Unit injector Air bleeder screw Overflow valve Return line Safety valve Non-return valve Drain valve Level sensor Main filter's hand pump Non-return valve Prefilter's hand pump...
Page 507 Date: Fuel system, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel system, description Schematic description of the low pressure fuel system at continuous operation Figure 1 Schematic description of the low pressure fuel system at continuous operation Fuel feed pump...
Page 508 Injector Outlet prefilter Safety valve Non-return valve Non-return valve Breather valve Hand pump Fuel is pumped by the fuel feed pump (1) via the tank (2), the prefilter (4), water trap (5) in to the filter head (3). Then it is pumped on through the engine control unit's cooling circuit (6) to the overflow valve (7).
Page 509 Profile: WLO, L60E, L180F, L220F, L150E, L220E, L180E, L110E, L90E, L70E, L150F, L330E, L120F, L110F, L70F, L60F, L350F, L90F, L120E, L180F HL [GB] Instructions for working with electronic fuel injection  Never disconnect any cables from the control unit or from the sensors, when the engine is running. The ignition key must be in position 0 and the engine stopped.
Page 510: Fuel System, Bleeding
Date: Fuel system, bleeding Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel system, bleeding Op nbr 233-001 191 Safety rules when servicing 1. Place the machine in service position, see 2. Turn off the main electric power with the battery disconnect switch.
Page 511 Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel filter, description The fuel system is equipped with two fuel filters, a primary filter with water trap, and a secondary filter. The filters have a common filter head that is mounted on the machine frame.
Page 512 2014/4/24 description D9 Profile: WLO, L150E [GB] Fuel feed pump, description D9 Fuel feed pump, D9 The feed pump on D9 is of the gear type and is driven by the timing gear. The pump's housing and end are made of cast iron.
Page 513 Service Information 2014/4/24 description D10B Profile: WLO, L150E [GB] Fuel feed pump, description D10B Fuel feed pump, D10 In order for the injection pump to function, it must be supplied with fuel at a certain pressure. Thus function is handled by the feed pump, which is of the piston type.
Page 514 Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel filter, description The fuel system is equipped with two fuel filters, a primary filter with water trap, and a secondary filter. The filters have a common filter head that is mounted on the machine frame.
Page 515 Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel filters, description D9 The fuel system has two fuel filters; one pre-filter and one main filter. They are mounted on two separate filter housings. The prefilter is equipped with a hand pump for bleeding air from the fuel system and draining water. In the water trap, there is a drain valve and a level sensor.
Page 516 Date: Feed pump, checking feed Service Information 2014/4/24 pressure Profile: WLO, L150E [GB] Feed pump, checking feed pressure Op nbr 233-004 11666017 Pressure gauge 11666037 Hose 13933485 Testing nipple 1. Clean thoroughly and remove the drain nipple (Drain) on the fuel filter housing.
Page 517 Drain plug 3. Connect the hose and pressure gauge to the measuring nipple. 4. Make sure that the gearshift selector is in neutral and that the parking brake is applied. Start the engine and check that the feed pressure is at least 300 kPa (3 bar) at 1200 rpm. NOTE! When low feed pressure is suspected, check the feed pressure with loaded engine, for example, at stall speed or full load.
Page 518 Function Group: Information Type: Date: Feed pump, checking feed Service Information 2014/4/24 pressure Profile: WLO, L150E [GB] Feed pump, checking feed pressure Op nbr 233-004 11666052 Pressure gauge 14290266 Hose 9993720 Nipple 14341364 Adapter 936442 Measuring nipple 1. Remove the plug and connect 936442, 14290266 Hose and 11666052 Pressure gauge to the fuel filter housing.
Page 519 In case pressure is too low: If the feed pressure is low, the cause may be clogged suction line, defective feed pump, clogged fuel filter, defective overflow valve, or the pump sucks air on the suction side. The filters can be checked by measuring the feed pressure before the filter. Use 9993720 Nipple and14341364 Adapter to measure the pressure before the filters.
Page 520: Fuel Pump Inspection
Information Type: Date: Fuel pump, inspection Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel pump, inspection Op nbr 233-010 Figure 1 A Overflow hole's placement B M8 screw Check if engine oil or fuel leaks through the overflow hole (A), located between the seals in the feed pump's housing (easiest done using a mirror).
Page 521 Date: Fuel pump (valves), Service Information 2014/4/24 inspection Profile: WLO, L150E [GB] Fuel pump (valves), inspection Op nbr 233-009 Figure 1  A Safety valve  B Non-return valve for bleeding of fuel system Screw out the safety valve's plug (A) on the feed pump and remove the valve peg and the spring. Check the valve peg's sealing surface for damage and dirt.
Page 522 Fuel filter, checking Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel filter, checking Op nbr 233-020 1. Check that the fuel is not contaminated in the bowl under the primary filter. The check is performed to make sure that the primary filter is not clogged.
Page 523 Fuel system, air bleeding, Service Information 2014/4/24 D10B Profile: WLO, L150E [GB] Fuel system, air bleeding, D10B Op nbr 23301 NOTE! The fuel shut-off valve must receive current (ignition key in position ON) during system bleeding. 1. Open the bleeder screw on the primary filter housing (B) 2.
Page 524 Figure 2 Hand pump Bleeder screw 7. Loosen the bleeder screw on the injection pump fuel shut-off valve and operate the hand pump (A) until the fuel flowing out is free from air bubbles. 8. Tighten the screw. Figure 3 Bleeder screw 9.
Page 525: Fuel System, Bleeding
Date: Fuel system, bleeding Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel system, bleeding Op nbr 233-001 NOTE! Take care of fuel spills by using a hose and collection container. 1. Clean around the bleeder screws and the connection on the cylinder head.
Page 526 Hand pump, secondary filter head Bleeder screw Connection, cylinder head 3. Start the engine and let it run at high idle for approx. 10 minutes to purge any remaining air from the system.
Page 527 Date: Fuel system, bleeding Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel system, bleeding Op nbr 233-001 191 Safety rules when servicing 1. Place the machine in service position, see 2. Turn off the main electric power with the battery disconnect switch.
Page 529 Function Group: Information Type: Date: Feed pump, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Feed pump, replacing Op nbr 233-002 9993590 Gear wheel Feed pump, removing NOTE! Take care of any fuel spills using containers.
Page 530 4. Remove the feed pump. Feed pump, installing 5. Install the feed pump with a new gasket. 6. Connect the fuel hoses to the feed pump. 233 Fuel system, air bleeding, D10B 7. Bleed the fuel system, see 8. Start the engine and check for leaks.
Page 531 Information Type: Date: Feed pump, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Feed pump, replacing Op nbr 233-002 Feed pump, removing NOTE! Take care of fuel spills by using collection containers. 191 Safety rules when servicing 1.
Page 532 Figure 2 5. Mark the fuel hoses and remove them. Place a suitable container to collect fuel. 6. Cover the ends of the hoses to prevent impurities from entering the fuel system. 7. Remove the feed pump. Feed pump, installing 8.
Page 533: Fuel Tank Removal
Information Type: Date: Fuel tank, removal Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel tank, removal Op nbr 23410 Ratchet block 750 kg (1654 lbs.), 2 pcs. Sling, 1 m (3.3 ft) Sling, 2 m (6.6 ft) Sling, 4 m (13 ft) Sling 6 m (19.7 ft), 2 pcs.
Page 534 6. Remove the bolts of the engine oil and coolant draining hoses. 7. Lift the radiator out and remove the fan protector. 8. Remove the fuel lines and combined tank unit from the tank. Figure 2 Combined tank unit Rear retaining bolts, fuel tank 9.
Page 535 Figure 4 Lifting device, fuel tank, right rear Ratchet block, 750 kg (1654 lbs.) Sling, 2 m (6.6 ft) 11. Remove the tank's front and rear retaining bolts (4 pcs). 12. Lower the tank with the ratchet block. Tank weight 110 kg (242.5 lbs.).
Page 536 2014/4/24 description Profile: WLO, L150E [GB] Injection advance curve, description A slower injection timing is desirable at low engine speeds. This allows lower cylinder pressure and reduces nitric oxide emissions (NO ). At higher speeds, faster injection timing must increases nitric oxide (NO ) emissions but also contributes to better combustion and reduced hydrocarbon (HC) emissions.
Page 537 Advance curve shaft Control rod Relief groove Figure 2 Injection sequence, principle diagram Relief gap Delivery gap Pump element Spool Relief groove A setting solenoid (1) is used to control injection conversion. The vertical motion of the solenoid is transformed by a control arm (2) into the turning motion of the advance curve shaft (3).
Page 538 Figure 3 Injection advance curve unit Setting solenoid Control arm Advance curve shaft Adjustable spool Injection advance curve is regulated by the engine control unit (E-ECU). In order to regulate injection timing, the system requires:  Flywheel position sensor that reads BTDC. ...
Page 539 Injection pump, description 236 Service Information 2014/4/24 Profile: WLO, L150E [GB] Injection pump, description The D10B injection pump is a so-called H-pump which operated according to the EMS system principle, se 236 Regulator, description , with the addition of a built-in injection advance curve unit for variable injection timing.
Page 540 Service Information 2014/4/24 Profile: WLO, L150E [GB] Regulator, description The injection pump regulator is electronically controlled and contains an electromagnetic actuator with position sensor. The actuator is guided by the engine control unit (E-ECU) which receives information from the different engine sensors. The control unit calculates the optimum injection volume and injection time for every load type with this information.
Page 541 Function Group: Information Type: Date: Checking stalling speed Service Information 2014/4/24 Profile: WLO, L150E [GB] Checking stalling speed Op nbr 23602 Figure 1 Checking idle speed Display panel Connection point for service display unit Before checking the stalling speeds, make sure that the engine, hydraulic transmission and hydraulic system have reached normal operating temperature.
Page 542 A divergent stalling speed is not in itself a fault that calls for repair but should be used as an aid in connection with fault tracing.
Page 543 Information Type: Date: Injection pump, installing, Service Information 2014/4/24 and setting injection angle Profile: WLO, L150E [GB] Injection pump, installing, and setting injection angle Op nbr 23672 999 3590 Gear 999 3625 Guide 999 3824 Screw Installing 1. Fit the injection pump shelf.
Page 544 Figure 2 999 3824 6. Remove the E-ECU. 7. Remove the cap on the right-hand side of the flywheel housing. Fit tool 999 3625 and 999 3590 in order to rotate the crankshaft. Figure 3 999 3590 999 3625 8. Remove the protective plugs from the flywheel timing marks on the left-hand side of the flywheel. 9.
Page 545 rotating again in the engine rotation directionuntil the correct timing number for injection angle is visible in the centre of the indicator on the flywheel housing. Timing numbers for injection angle: D10B LAE2: 5° ±0.5 BTDC Figure 5 Flywheel timing marks 11.
Page 546 Information Type: Date: Injectors, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Injectors, description The injectors have two main functions:  disperse the fuel, to ensure ignition and combustion  together with the air's turbulence, finely disperse the fuel jets in the combustion chamber so that a mixture of air and fuel is obtained.
Page 547 Figure 1 L55388A Injector Nozzle holder Nozzle Injector needle Spring Adjusting washers Thrust pin Guide pins Guide Guide pins Injector sleeve Union screw Seals...
Page 548 Delphi, Service Information 2014/4/24 description Profile: WLO, L150E [GB] Unit injector, Delphi, description Unit injectors, tolerance classification The unit injectors are manufactured with tolerance classification. Each unit injector is marked with a code (1) on top of the electric connection.
Page 549 Figure 2 Unit injector Pump part Valve part Injector part The time of injection and the amount of fuel to be injected is determined by the control unit, which sends signals to the electro-magnetically controlled fuel valve in the unit injector's valve housing. The duration of the injection determines the amount of fuel that is injected into the cylinder.
Page 550 Service Information 2014/4/24 Profile: WLO, L150E [GB] Unit injectors, description D9 The engine has six unit injectors, one for each cylinder. The unit injector is located vertically and in the centre between the four valves. The pressure force to the unit injector is transferred via a rocker arm from a cam on the overhead camshaft.
Page 551 Figure 2 Unit injectors, D9A Pump part Valve part Injector part The time of injection and the amount of fuel to be injected is determined by the control unit, which sends signals to the electro-magnetically controlled fuel valve in the unit injector's valve housing. The time duration of injection decides the amount of fuel that is injected into the cylinder.
Page 552 Delphi, Service Information 2014/4/24 description Profile: WLO, L150E [GB] Unit injector, Delphi, description Unit injectors, tolerance classification The unit injectors are manufactured with tolerance classification. Each unit injector is marked with a code (1) on top of the electric connection.
Page 553 Figure 2 Unit injector Pump part Valve part Injector part The time of injection and the amount of fuel to be injected is determined by the control unit, which sends signals to the electro-magnetically controlled fuel valve in the unit injector's valve housing. The duration of the injection determines the amount of fuel that is injected into the cylinder.
Page 554 Service Information Document Title: Function Group: Information Type: Date: Unit injector, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Unit injector, replacing Op nbr 237-012 9990006 Puller 9990185 Lifting tool 9990262 Adapter 9993590 Gear wheel 9993625 Guide 9996400 Impact puller 9998599 Cleaning tool Bolt, M14x35, 2 pcs.
Page 555 Figure 1 4. Remove the valve cover. 5. Remove the VEB adapter. Figure 2 6. Loosen the bolts for the rocker arm shaft, evenly distributed across the rocker arm shaft to avoid shear stresses. Remove the bolts. Lift away the rocker arm shaft with tool 9990185. Rocker arm shaft's weight: ca 30 kg (66 lb) Figure 3 9990185...
Page 556 Figure 4 8. Clean very thoroughly around the unit injector. Remove the electric connection. Remove the bolt for the attachment caliper. Remove the injector together with the attachment caliper. Figure 5 9996400 9990262 9990006...
Page 557 9. Fit the protective sleeve that is included in the kit 9998599. Clean the copper sleeve with the brush/brushes. Figure 6 Extension Brush Protective sleeve Installing 10. Fit new o-rings on the unit injector. Fit the unit injector together with the attachment caliper. Tightening torque, bolts for attachment caliper: 20 Nm (15 lbf ft), angle torquing 60°.
Page 558 Angle torque the bolts 8—14: 120° Check that the bolts' tightening torque is: min. 190 Nm (140 lbf ft), max. 260 Nm (192 lbf ft) Figure 8 Tighten diagram 13. Check that the seal rings on the VEB adapter are placed correctly. Fit the VEB adapter. Figure 9 214 Valves, adjusting 14.
Page 559 Figure 10 Tighten diagram 821 Engine hood, installing 16. Fit the engine hood, see 233 Fuel system, bleeding 17. Bleed the fuel system, see 18. Perform parameter programming according to VCADS Pro operation number 17030-2.
Page 560 Document Title: Function Group: Information Type: Date: Unit injector, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Unit injector, replacing Op nbr 237-012 9990185 Lifting tool 9998251 Sealing plug 9998599 Cleaning tool 9998249 Protecting sleeve 9996400 Impact puller 9990262 Adapter...
Page 561 6. Remove the unit injector's electrical connections. 7. Remove the electrical connections for the control valve. 8. Remove the valve cover's stud bolt located in front of the control valve. Figure 2 Control valve 9. Remove the control valve and the pipe between the valve and rocker arm shaft. NOTE! Catch the O-rings on both sides of the pipe.
Page 562 9990185 88880003 11. Remove the bolt for the unit injector's attaching yoke. NOTE! Clean very thoroughly around the unit injector that is to be removed. 12. Remove the unit injector. Fit 9998249 on the unit injector. NOTE! To protect the unit injectors from dirt particles, etc., place them in separate, well sealed plastic bags. Figure 4 Removing unit injectors, Delphi E3 9996400...
Page 563 Figure 5 13. Clean the unit injectors' copper sleeves. Fit the brush on the extension and clean the copper sleeve. Clean all copper sleeves. Check that the unit injector's copper sleeve is free from damage. Figure 6 Cleaning kit 9998599 9998616 9998570 9998580...
Page 564 Installing 15. Fit new O-rings on the unit injector. 16. Install the unit injector and centre it between the valve springs. Install the attaching yoke. 237 Tightening torques, unit injector Tightening torque: see Figure 8 17. Connect the unit injectors' electrical cables. 18.
Page 565 22. Install new O-rings on the pipe between the rocker arm shaft and the control valve. Lubricate the O-rings with oil and install the pipe in the rocker arm shaft. 23. Check that the seal ring on the pipe is installed correctly before the bolts for the control valve are tightened. 030 Tightening torques, control valve Tightening torque: see 24.
Page 566: Control Unit, Description
Service Information 2014/4/24 Profile: WLO, L150E [GB] Control unit, description The control unit (E-ECU) is the central part of the injection system. Control unit (A) is positioned on the left side on the engine and suspended in damping rubber mountings. All cable connections for the engine sensors have connectors of the DIN standard type and they are placed together in a so called cable box (B).
Page 567 1. Crankcase pressure sensor Coolant level sensor Camshaft speed sensor Oil pressure sensor Charge air pressure and temperature sensor Air pressure and temperature sensor Coolant temperature sensor Crank shaft speed sensor Fuel pressure sensor Water in fuel sensor Oil level and temperature sensor In the control system there is also a sensor for atmospheric pressure.
Page 568 Service Information Document Title: Function Group: Information Type: Date: Intake and exhaust system, Service Information 2014/4/24 description Profile: WLO, L150E [GB] Intake and exhaust system, description Figure 1 Inlet and exhaust system Air cleaner Turbocharger Muffler Preheating coil Intercooler Inlet system The air is sucked in via the air cleaner and passes to the turbo.
Page 569: Turbocharger, Description
Document Title: Function Group: Information Type: Date: Turbocharger, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Turbocharger, description Figure 1 Turbocharger (principle diagram) Lubricating oil supply Exhaust, from engine to turbocharger Exhaust, out from engine Air via air filter Air to inlet pipe The turbocharger consists of a turbine section and a compressor section between which there is a bearing housing.
Page 570 Service Information 2014/4/24 Profile: WLO, L150E [GB] Turbocharger, description The turbocharger is driven by the exhaust gasses as they pass through the turbine housing. The exhaust gas flow causes the turbine rotor in the turbine housing to rotate. The compressor rotor is positioned on the same shaft as the turbine rotor.
Page 571 Service Information 2014/4/24 Profile: WLO, L150E [GB] Turbocharger, description The turbocharger is driven by the exhaust gasses as they pass through the turbine housing. The exhaust gas flow causes the turbine rotor in the turbine housing to rotate. The compressor rotor is positioned on the same shaft as the turbine rotor.
Page 573 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Turbocharger, description D9 The turbocharger is driven by the exhausts that pass the turbine housing on the way out to the exhaust system. The exhaust flow turns the turbine in the turbine housing. On the same shaft as the turbine, there is a compressor rotor. The compressor rotor is located in a housing that is connected between the air cleaner and the engine's induction manifold.
Page 574 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Turbocharger, description D9 The turbocharger is driven by the exhausts that pass the turbine housing on the way out to the exhaust system. The exhaust flow turns the turbine in the turbine housing. On the same shaft as the turbine, there is a compressor rotor. The compressor rotor is located in a housing that is connected between the air cleaner and the engine's induction manifold.
Page 575: Turbocharger, Inspection
Turbocharger, inspection Service Information 2014/4/24 Profile: WLO, L150E [GB] Turbocharger, inspection Op nbr 255-002 If the engine looses a lot of charge pressure, it becomes weak. The best way of checking the engine performance is to check the stall speed of the machine. If the engine looses a little charge pressure, this will not noticeably affect the performance.
Page 577 Function Group: Information Type: Date: Turbocharger, changing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Turbocharger, changing Op nbr 25571 Removing 191 Safety rules when servicing 1. Place the machine in service position, see 2. Loosen hose, exhaust pipe and connection pipe on the turbocharger.
Page 578 NOTE! In case of turbocharger failure, all inlet pipes and hoses shall be checked and cleaned. Remains of broken fan blades in the inlet pipes can result in engine failure. Installing NOTE! Always use new seals when installing. 6. Fit the turbocharger. Figure 3 7.
Page 579 Function Group: Information Type: Date: Turbocharger, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Turbocharger, replacing Op nbr 255-071 Removing 191 Safety rules when servicing 1. Place the machine in service position, see 2. Remove the right side panel.
Page 580 Figure 2 6. Clean all sealing surfaces. NOTE! In case of turbocharger failure, all inlet pipes and hoses shall be checked and cleaned. Remains of broken fan blades in the inlet pipes can result in engine failure. Installing NOTE! Always use new seals when installing. 7.
Page 581 12. Start the engine and check for leaks. 13. Restore the machine to operating condition.
Page 582 Information Type: Date: Turbocharger, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Turbocharger, replacing Op nbr 255-071 Removing 191 Safety rules when servicing 1. Place the machine in service position, see 2. Loosen the inlet hose. Remove the exhaust pipe, flex hose and connection pipe from the turbo.
Page 583 blades in the inlet pipes can result in engine failure. Installing NOTE! Always use new seals when installing. 6. Fit the turbocharger. Tightening torque, stud bolt: 24 Nm (17.7 lbf ft) Tightening torque, nut: 48 Nm (35.4 lbf ft) Figure 3 7.
Page 584 Service Information 2014/4/24 Profile: WLO, L150E [GB] Air cleaner, description The air cleaner prevents dust and other impurities from entering the engine. The air passes through the main filter and the safety filter, after having circulated in the precleaner. At the inlet between the filter housing and the turbo, there is a combined pressure-drop and air temperature sensor.
Page 585 Service Information 2014/4/24 Profile: WLO, L150E [GB] Air cleaner, description The air cleaner prevents dust and other impurities from entering the engine. The air passes through the main filter and the safety filter, after having circulated in the precleaner. At the inlet between the filter housing and the turbo, there is a combined pressure-drop and air temperature sensor.
Page 586 Service Information 2014/4/24 Profile: WLO, L150E [GB] Preheating coil, description There is an electrical preheating element on the inlet side of the engine. Provided the engine coolant temperature is below +20 °C (+68 °F), the element will be connected when the operator turns the ignition key to the running position and presses the preheating switch.
Page 587 Service Information 2014/4/24 Profile: WLO, L150E [GB] Preheating coil, description An electric preheating coil is located on the inlet side. An indicator light on the instrument panel flashes when preheating is required. The coil is switched on when the operator turns the ignition key to position 1 and the engine temperature is lower than 20 °C (68 °F).
Page 588 Intercooler, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Intercooler, description The engine is equipped with an intercooler which lowers the temperature of the air before it is forced into the engine cylinders. Engine overcharging, or air forced into the cylinders by the turbocharger, raises air temperature. When the air is cooled after the turbocharger, air volume is reduced and more air (oxygen) can be forced into the cylinders.
Page 589 Service Information 2014/4/24 inspection Profile: WLO, L150E [GB] Charge air system, inspection Op nbr 258-030 1. Check if the intercooler is damaged in the cells and connections. If there are damages, change the intercooler. See 261 Radiator, replacing 2. Check if the intercooler is clogged externally. If the intercooler is clogged, clean the intercooler externally.
Page 590 Function Group: Information Type: Date: Intercooler, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Intercooler, replacing Op nbr 258-002 Sling 2 m (6.6 ft) 191 Safety rules when servicing 1. Place the machine in service position, see Removing 2. Remove the bottom plate in front of the radiator 3.
Page 591 Figure 2 Striker plate Grating door 7. Remove the side panels from the radiator framework. 8. Remove the grille from the condenser. Figure 3 Bolts for expansion tank Bolts for grating 9. Loosen the condenser's four mounting points. Loosen the clamps for the condenser's pipes. NOTE! The expansion tank must be disconnected from the intermediate wall to access the nut for the condenser.
Page 592 Figure 4 Member Radiator bracket Condenser brackets Clamps AC-pipes 11. Loosen and plug the air hoses from the intercooler. 12. Lift the radiator on the right side so that the bolts for the radiator frame can be accessed. NOTE! Secure the lift under the radiator frame against the frame, see figure. Figure 5 Radiator frame Blocking...
Page 593 Weight: 30 kg (53 lb) NOTE! Make sure that the condenser is not damaged. Figure 6 Installing 15. Install rubber strips on the intercooler. Check the rubber spacers in the radiator frame. Figure 7 Intercooler Rubber strips 16. Fit the rubber spacers when the intercooler is lifted into place. NOTE! Make sure that the condenser is not damaged.
Page 594 27. Install the plastic casing over the radiator. 28. Install the bottom plate in front of the radiator. 29. Restore the machine to operating condition.
Page 595 Function Group: Information Type: Date: Intercooler, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Intercooler, replacing Op nbr 258-002 Sling 2 m (6.6 ft) 191 Safety rules when servicing 1. Place the machine in service position, see Removing 2. Remove the bottom plate in front of the radiator 3.
Page 596 Figure 2 Striker plate Grating door 7. Remove the side panels from the radiator framework. 8. Remove the grille from the condenser. Figure 3 Bolts for expansion tank Bolts for grating 9. Loosen the condenser's four mounting points. Loosen the clamps for the condenser's pipes. NOTE! The expansion tank must be disconnected from the intermediate wall to access the nut for the condenser.
Page 597 Figure 4 Member Radiator bracket Condenser brackets Clamps AC-pipes 11. Loosen and plug the air hoses from the intercooler. 12. Lift the radiator on the right side so that the bolts for the radiator frame can be accessed. NOTE! Secure the lift under the radiator frame against the frame, see figure. Figure 5 Radiator frame Blocking...
Page 598 Weight: 30 kg (53 lb) NOTE! Make sure that the condenser is not damaged. Figure 6 Installing 15. Install rubber strips on the intercooler. Check the rubber spacers in the radiator frame. Figure 7 Intercooler Rubber strips 16. Fit the rubber spacers when the intercooler is lifted into place. NOTE! Make sure that the condenser is not damaged.
Page 599 27. Install the plastic casing over the radiator. 28. Install the bottom plate in front of the radiator. 29. Restore the machine to operating condition.
Page 601: Cooling System, Description
Cooling system, description 260 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cooling system, description The engine cooling system is regulated with a thermostat. Coolant is circulated with a centrifugal pump driven by the timing gear.
Page 602 Function Group: Information Type: Date: Cooling system, description 260 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cooling system, description Figure 1 Cooling system The advantages with an integrated cooling system  Higher engine output and lower sound level as the cooling fan rarely works at maximum speed.
Page 604 Cooling system, description 260 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cooling system, description The engine cooling system is regulated with a thermostat. Coolant is circulated with a centrifugal pump driven by the timing gear.
Page 605 Function Group: Information Type: Date: Cooling system, description 260 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Cooling system, description Figure 1 Cooling system The advantages with an integrated cooling system  Higher engine output and lower sound level as the cooling fan rarely works at maximum speed.
Page 606 2014/4/24 engine, description Profile: WLO, L150E [GB] Coolant circulation in engine, description The coolant is pumped via a pipe into the distribution jacket in the side of the engine cylinder block. The main part of the coolant is forced upward between the oil cooler flanges, whereas a small part of the coolant is circulated into the lower cooling jackets around the cylinder liners.
Page 607 Cooling system, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Cooling system, description D9 Coolant circulation The coolant is pumped by the coolant pump directly into the cylinder block's distribution casing in the block's right side. Some of the coolant is pressed into the cylinder liners' lower cooling casings via the holes.
Page 608 Oil cooler Thermostat...
Page 610 Document Title: Function Group: Information Type: Date: Radiator, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Radiator, replacing Op nbr 261-008 Tools: Lifting eye M10 lifting sling Removing Tools: Lifting eye M 10, 2 pcs.
Page 611 Risk of burns when removing the header tank cap because of excess pressure in the cooling system. 3. Remove the cap from the expansion tank. Drain the coolant. Use existing located in the right battery box or the tool box on the machine. 030 Engine, volume Volume: See NOTE!
Page 612 Figure 5 Striker plate Grating door 6. Loosen the hose clamps for the coolant hoses and disconnect them. Loosen the pipe clamps and remove the air hose. Figure 6 Hose clamp Pipe clamp Air hose...
Page 613 Figure 7 Hose clamp Hose clamp Pipe clamp Air pipe 7. Remove the bolts for the grating above the condenser. Remove the bolts for the expansion tank. Figure 8 Bolts for expansion tank, 3 pcs. Bolts for grating 8. Remove the bolts for the bracket for the AC condenser's gas pipe. Remove the bolts for the AC condenser's brackets and lift it to the side.
Page 614 Figure 9 Condenser Bolt 9. Remove the member on both sides. Figure 10 Bolt Member 10. Connect a lifting device and sling to the cooler unit. Remove the radiator's upper and lower attachments. Weight: 160 kg (353 lbs)
Page 615 11. Lift away the cooler unit. NOTE! Make sure that the AC condenser and its components are not damaged. Figure 11 Lower radiator attachment Upper radiator bracket Lifting eye M10, 2 pcs. 12. Place the cooler unit on a clean and level surface. Remove the bolts and disconnect the radiator or intercooler from the radiator frame.
Page 616 Bolt Installing 13. Install the rubber spacers in the radiator frame. Place the radiator and intercooler in the frame and bolt together with the bolts. Use tensioning straps or similar to press the end parts of the frame into place. Figure 13 Bolt 14.
Page 617 Figure 14 Lower radiator attachment Upper radiator bracket Lifting eye M10 15. Fit the members and tighten the bolts. Figure 15 Bolt Member 16. Lift back the condenser and bolt it down. Figure 16...
Page 618 Condenser Bolt 17. Fit the grating above the condenser and bolt it down. Refit the bracket for the expansion tank. Figure 17 Bolts for expansion tank Bolts for grating 18. Fit the coolant hoses and the air hose, and tighten them down with the clamps. Figure 18 Hose clamp Hose clamp...
Page 619 Figure 19 Hose clamp Pipe clamp Air hose 20. Install the side panel and the grating door, and secure the gas damper with the striker plate. Figure 20 Striker plate Grating door 21. Install the plastic casing and bolt it down. Secure the angle iron. Install the filler pipe.
Page 620 Figure 21 Bolt, 4 pcs. Angle iron Fan shroud Filler pipe Lower radiator attachment 030 Engine, volume 22. Fill coolant. Volume, see 23. Start the engine and check that there are not any leaks.
Page 621 Function Group: Information Type: Date: Radiator, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Radiator, replacing Op nbr 261-008 Lifting eye M10, 2 pcs. Shackle M16, 2 pcs. Lifting sling, 2 m (6.6 ft), 2 pcs Bolt, M9x35, 2 pcs.
Page 622 Figure 2 Intercooler hose Pipe clamp 5. Remove the plate on the intermediate wall's lower edge (under fan shroud). Remove the plate in the bottom of the fan shroud. 6. Loosen the hydraulic connections under the fan shroud. Mark the hoses. Figure 3 7.
Page 623 Remove the bolts for the AC condenser's brackets and loosen required clamps. Lift aside the AC condenser. NOTE! Avoid folding the hoses. NOTICE Hoses must not be disconnected as they contain refrigerant. See the Service Manual regarding the handling of air conditioning systems. Figure 4 8.
Page 624 Figure 6 Shackle M16, 2 pcs. Lifting sling, 2 m (6.6 ft), 2 pcs 11. Connect a lifting device and lifting sling to the fan shroud. Remove the fan shroud, complete with fan motor and fan. 12. Loose the retaining bolts at the lower edge on the back so that the radiator hangs freely. Connect lifting eyes and sling.
Page 625 Figure 8 Bolt Installing 14. Install the rubber spacers in the radiator frame. Place the radiator and intercooler in the frame and bolt together with the bolts. Use tensioning straps or similar to press the end parts of the frame into place. 15.
Page 626 17. Fixate the radiator against the frame with two M8x35 bolts. 18. Install the fan shroud, complete with fan motor and fan. Weight: 45 kg (99 lbs) 19. Connect a sling to the cooler unit, lift up and reinstall. Weight: 355 kg (783 lbs) 20.
Page 627 Figure 11 24. Install the plate on the intermediate wall's lower edge (under fan shroud). Install the plate in the bottom of the fan shroud. 821 Engine hood, installing 25. Fit the engine hood, see 030 Cooling system, volume 26. Fill coolant. Volume, see 27.
Page 628 Date: Coolant pump, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Coolant pump, description The coolant pump is installed on the timing gear casing back plate and is driven from the engine timing gears. Figure 1 Coolant pump, cross section The seal for the coolant is made in one piece and made of hard coals ceramics.
Page 629 Service Information 2014/4/24 description Profile: WLO, L150E [GB] Thermostat housing, description The engine is provided with a piston-type thermostat. The thermostat housing is integrated in the cylinder head. The sensor for the coolant temperature is found on the thermostat housing.
Page 630 Service Information 2014/4/24 Profile: WLO, L150E [GB] Thermostat, description The engine is equipped with a piston-type thermostat with a wax-filled sensor. When the engine is cold, the thermostat keeps the entrance to the radiator closed. The coolant is led through a bypass line directly back to the coolant pump. As the engine heats, the volume of wax increases and the thermostat gradually opens the passage to the radiator while the bypass line closes.
Page 631 Information Type: Date: Thermostat, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Thermostat, replacing Op nbr 262-098 191 Safety rules when servicing 1. Place the machine in service position, see WARNING Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant may rush out and cause severe burns.
Page 632 unnecessary coolant spill. Remove the thermostat. Figure 3 4. Clean the cover, thermostat housing and the groove for the seal ring. Fit a new seal ring and fit the new thermostat in the housing. Fit the cover. 5. Use pump and fill coolant through the drain nipple located behind the right rear wheel, or fill in the expansion tank. Fill coolant to the max.
Page 633 Information Type: Date: Thermostat, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Thermostat, replacing Op nbr 262-098 191 Safety rules when servicing 1. Place the machine in service position, see WARNING Open the expansion tank cap slowly and carefully. The cooling system operates at high pressure and hot coolant may rush out and cause severe burns.
Page 634 unnecessary coolant spill. Remove the thermostat. Figure 3 4. Clean the cover, thermostat housing and the groove for the seal ring. Fit a new seal ring and fit the new thermostat in the housing. Fit the cover. 5. Use pump and fill coolant through the drain nipple located behind the right rear wheel, or fill in the expansion tank. Fill coolant to the max.
Page 636 Function Group: Information Type: Date: Coolant pump, replacing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Coolant pump, replacing Op nbr 262-002 191 Safety rules when servicing 1. Place the machine in service position, see WARNING Open the expansion tank cap slowly and carefully.
Page 637 Draining coolant, engine block 3. Remove the bottom plate between the radiator and engine. Remove the side panel. Figure 3 4. Remove the belt guard over the coolant pump. 5. Use a ratchet handle with 1/2" drive to unload the belt tensioner (9), see figure. Remove the belt. Remove the belt tensioner.
Page 638 Figure 5 Figure 6 8. Clean the sealing surfaces. Fit a new seal ring. Fit the coolant pump, belt tensioner, transfer gear, belt guard, and the holder for the oil filler pipe. Fit the screw that holds the clamp for the drain hose for the expansion tank. 9.
Page 639 Function Group: Information Type: Date: Coolant pump, changing Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Coolant pump, changing Op nbr 26202 1. Open the engine hood. Figure 1 WARNING Risk of burns when removing the header tank cap because of excess pressure in the cooling system.
Page 640 Figure 3 Coolant drain 5. Take out the hose for draining coolant from the battery box on the machine's right side. Figure 4 6. Connect the hose to the coolant drain on the machine's right side. Drain the coolant. Figure 5 Coolant drain 7.
Page 641 Figure 6 Protective plate Bolts Protective plate 8. Cut the cable tie. Figure 7 Hose clamps Cable tie Clamp 9. Loosen the hose clamps and disconnect the hoses from the pump. 10. Remove the screw for the stop wire's clamp. 11.
Page 642 Figure 8 Bolts 12. Remove the bolts from the suction pipe and disconnect the pipe from the pump. Figure 9 Suction pipe 13. Remove the bolts for the rear end plate, and remove the pump end plate. Figure 10 Pump end plate Bolts Bracket 14.
Page 643 Figure 11 Collecting plate Filter bracket Bolt 15. Remove the bracket. 16. Loosen the pump's upper bolted joint. Figure 12 Spacer Bolts 17. Loosen the lower bolted joint. Figure 13 Bracket...
Page 644 Bolts 18. Lift away the pump. Figure 14 Coolant pump 19. Cover the open connections with protective plugs. Installing 20. Clean the pump's contact surfaces. 21. Fit new O-rings and fit the pump. 22. Bolt down the pump and bracket. Figure 15 Bracket Bolts...
Page 645 Figure 16 Spacer Bolts 24. Fit the collecting plate and the filter bracket on the engine. Figure 17 Filter with bracket Bracket Collecting plate Bolts 25. Fit the lower bolt in the pump end plate. Figure 18 Pump end plate Bolt 26.
Page 646 Figure 19 Suction pipe 28. Fit the hoses and the screw for the stop wire's clamp. Figure 20 Hose clamps Cable tie Clamp 29. Clamp the small hose with cable ties (2). 30. Fit the protective plate and tighten the four bolts for the pump end plate. Figure 21 Bolts Bracket...
Page 647 31. Fit the bolts for the clamps. Figure 22 Pipe clamps Bolts 32. Remove the drain hose and put it back in the right battery box. Close the drain nipple. 33. Fill coolant to the max. marking on the expansion tank. Run the engine until its warm and top up until the cooling system is completely full and bled of air.
Page 648 2014/4/24 description Profile: WLO, L150E [GB] Hydraulic cooling fan, description The fan control shall adjust the cooling fan speed (rpm) in an optimal way so that energy consumption and sound level are minimized, with sufficient cooling capacity. Cooling is achieved by continuous sensing of the temperature in the components to give optimal cooling fan speed.
Page 649 Figure 1 Outlet temperature, radiator, 70–80 °C Radiator constant Temperature Selected temperature: 70 °C gives A1 =0.0 Figure 2 Hydraulic oil temperature, 70–95 °C Hydraulic oil temperature, constant Temperature Selected temperature: 80 °C gives A2 =0.3 Figure 3 Axle oil temperature, 90–133 °C Front and rear axle temperature (respectively), constant Temperature Selected temperature: 100 °C gives A3 =0.3...
Page 650 Figure 4 Transmission oil temperature 90–105 °C Transmission oil temperature, constant Temperature Selected temperature: 105 °C gives A4 = 1.0 Figure 5 Coolant temperature, engine 85–95 °C Coolant temperature, constant Temperature Selected temperature: 90 °C gives A5 =0.5 Figure 6 Charge-air temperature (T)+20 °C–(T)+35 °C Charge-air temperature, constant Temperature= Induction temperature (T) +20 °C...
Page 651 Sound test When measuring sound, service personnel can use the service display unit to request that the fan is run at a constant speed. The request applies until the computer system is shut off. The constant speed is the same as 70% of the max. allowed speed in the current setting (see cooling fan's max.
Page 652 Cooling motor, Service Information 2014/4/24 description Profile: WLO, L150E [GB] Cooling fan motor, description The cooling fan is driven by a vane motor with fixed displacement. Figure 1 Cooling fan motor, principle diagram Non-return valve A non-return valve, located in the vane motor, prevents cavitation in the motor when the motor stops and the cooling fan continues to rotate.
Page 653 2014/4/24 hydraulic diagram description Profile: WLO, L150E [GB] Reversible cooling fan, hydraulic diagram description The valve block for controlling the reversible fan consists of four pressure-controlled directional valves and two solenoid valves.  MA205 controls the flow direction to the fan.
Page 654 Figure 1 Retardation phase  The V-ECU reduces the output voltage to MA202, the LS-pressure drops and the flow decreases.  MA204 is activated and the rear sides on all directional valves are drained to tank. Thus, the flow will be directed to tank via the directional valves.
Page 655 Figure 2 Reversing phase  MA205 is activated and the control pressure is now directed to the rear of directional valve 1 and 4, which then are closed.  Directional valve 2 and 3 are drained to tank.  MA202 receives PWM signal corresponding to maximum speed from V-ECU. Oil from inlet P opens valve 2 and flows on through valve 1 to the fan.
Page 656 Figure 3...
Page 657 Service Information Document Title: Function Group: Information Type: Date: Reversible cooling fan, Service Information 2014/4/24 electric description Profile: WLO, L150E [GB] Reversible cooling fan, electric description 301 Reversible cooling fan For electric description of reversible cooling fan, see...
Page 658 2014/4/24 pump / Brake pumpFlow pressure control, description Profile: WLO, L150E [GB] Pump 3 (P3) Cooling fan pump / Brake pumpFlow and pressure control, description Figure 1 Pump 3 (P3) Fan pump/Brake pump, Flow and pressure control Pressure reducing valve, max.
Page 659 Pilot valve, max. steering pressure Priority slide Shuttle valve, selects highest LS pressure Shuttle valve, selects highest pressure to SE201 Sensor, engine speed ensure brake charging Restriction SE2606 Sensor, coolant temperature engine Restriction SE210 Sensor, coolant temperature, radiator outlet Pressure check connection, P3 SE211 Sensor, fan speed Brake accumulator block...
Page 660 (P3) standby Service Information 2014/4/24 pressure, checking adjusting (LS-line removed) Profile: WLO, L150E [GB] Pump 3 (P3) standby pressure, checking and adjusting (LS-line removed) (LS disconnected) Op nbr 263-011 14290266 Hose 11666052 Pressure gauge 14341364 Adapter Part no. 935100 Plug NOTE! Measuring connections are available in earlier and later versions.
Page 661 Pressure check connection 2. Run the machine until the engine, hydraulic transmission and hydraulic system are at operating temperature. 3. Read off the stand-by pressure for the cooling fan at high idle. 263 Pump 3 (P3) Cooling fan pump/Brake pump, specifications Stand-by pressure, see Adjusting 4.
Page 662 (P3) standby Service Information 2014/4/24 pressure, checking adjusting (LS-line removed) Profile: WLO, L150E [GB] Pump 3 (P3) standby pressure, checking and adjusting (LS-line removed) (LS disconnected) Op nbr 263-011 14290266 Hose 11666052 Pressure gauge 14341364 Adapter Part no. 935100 Plug NOTE! Measuring connections are available in earlier and later versions.
Page 663 Pressure check connection 2. Run the machine until the engine, hydraulic transmission and hydraulic system are at operating temperature. 3. Read off the stand-by pressure for the cooling fan at high idle. 263 Pump 3 (P3) Cooling fan pump/Brake pump, specifications Stand-by pressure, see Adjusting 4.
Page 664 Function Group: Information Type: Date: motor, checking Service Information 2014/4/24 working pressure Profile: WLO, L150E [GB] Fan motor, checking working pressure Op nbr 263-004 11666052 Pressure gauge 14290266 Hose 9993721 Service display 11666020 Pressure gauge 11666037 Hose NOTE! In cases where correct cooling fan speed is achieved, there is no need to carry out a pressure check.
Page 665 Figure 2 3. Start the engine and go to the service display for cooling fan speed under the Engine menu. FAN PRESSURE TEST Max Press. Test Fan rev yyyy rpm Engine rev zzzz rpm 4. Press * and then apply full throttle. Read off the cooling fan speed. 263 Cooling fan max.
Page 666 Pressure check connection MA202 6. If the components are fully functional, check the output pressure to the cooling fan, by connecting measuring equipment to the pressure check connection on the central block. 263 Pump 3 (P3) Cooling fan pump/Brake pump, specifications Max.
Page 667 (P3) standby Service Information 2014/4/24 pressure, checking adjusting (LS-line removed) Profile: WLO, L150E [GB] Pump 3 (P3) standby pressure, checking and adjusting (LS-line removed) Op nbr 263-011 11666052 Pressure gauge 14290266 Hose 11666019 Pressure gauge 11666037 Hose 9993721 Service display NOTICE Check and when necessary clean the radiator.
Page 668 Figure 2 11 666 019, 11 666 037 or 11666052, 14290266 MA502 MA202 3. Connect 9993721 to the socket in the rear wall. Figure 3 4. Start the engine and go to the service display for radiator fan speed under the Engine menu. FAN PRESSURE TEST Max Press.
Page 669 Recheck the stand-by pressure. Turn off the engine. Pug in connectors MA502 and MA202. Remove the pressure gauge and 9993721. Figure 4 Flow compensator, P3...
Page 670 Information Type: Date: Cooling hydraulics, Service Information 2014/4/24 funktion check Profile: WLO, L150E [GB] Cooling fan hydraulics, funktion check Op nbr 263-051 9993721 Service display 11666051 Pressure gauge 14290266 Hose 14290262 Adapter NOTE! Earlier and later type checking points occur. For checking points of earlier type, use adapter.
Page 671 Reversible cooling fan, Service Information 2014/4/24 funktion check Profile: WLO, L150E [GB] Reversible cooling fan, funktion check Op nbr 263-017 9993721 Service display NOTE! 263 Brake/fan hydraulics, checking function Before the check, carry out 1. Connect the service display unit to the socket under the fuse box cover.
Page 672 7. Browse on to sub menu "Reversible fan". ENGINE Reversible Fan Mode xxxxxx Activate Sel. 8. Increase the engine speed to ≥1900 rpm. Monitor the cooling fan speed on the service display unit and press "SELECT" on the operator's information panel. The text "Manual reversing activated"...
Page 673 2014/4/24 Brake pump Max. speed, checking the setting Profile: WLO, L150E [GB] Pump 3 (P3) Radiator fan/Brake pump Max. fan speed, checking the setting Op nbr 999 3721 Service display unit NOTICE Check and when necessary clean the radiator. A clogged radiator with a reduced air flow will result in inaccurate values.
Page 674 Figure 2 SE210 Max. radiator fan speed The following maximum speeds can be selected from the service display unit. On service display unit Meaning Equivalent to max. speed Noise reduction kit 1280 rpm EU execution 1400 rpm High cooling performance 1550 rpm (machine without axle oil cooling) 1400 rpm (machine with axle oil cooling)
Page 675 Engine rev zzzz rpm 7. Plug in SE210. Remove the service display unit.
Page 676 Information Type: Date: Cooling motor, Service Information 2014/4/24 changing non-return valve Profile: WLO, L150E [GB] Cooling fan motor, changing non-return valve Op nbr 263-065 9993721 Service display 9993770 Press tool 11666020 Pressure gauge 11666037 Hose 14360000 Vacuum pump / 24V 191 Safety rules when servicing 1.
Page 677 Figure 2 Non-return valve Early version Later version O-ring Ball Spring Bottom plate 5. Fit the new non-return valve and tighten the plug. Tightening torque: 70 Nm (51.6 lbf ft) 263 Cooling fan motor, changing 6. Fit the cooling fan motor, see 7.
Page 678 Function Group: Information Type: Date: Cooling motor, Service Information 2014/4/24 changing Profile: WLO, L150E [GB] Cooling fan motor, changing Op nbr 263-062 9993721 Service display 9993770 Press tool 11666020 Pressure gauge 11666037 Hose 14360000 Vacuum pump / 24V Removing 191 Safety rules when servicing 1.
Page 679 Figure 2 Fan motor's attaching bolts Speed sensor, SE211 5. Open the fan gate and remove the protective grating over the cooling fan. Figure 3 Protective grating 6. Remove the split pin on the cooling fan's hub nut. Loosen the lock nut approx. 2–3 turns. Leave the nut in place as protection for the shaft threads. 7.
Page 680 Figure 4 999 3770 10. Loosen and plug the hoses. Transfer the hose connections to the new fan motor. Installing 11. Connect the hoses to the fan motor. Place the cable harness to the speed sensor (SE211) behind the hoses to the fan motor. 12.
Page 681 Date: Cooling motor, Service Information 2014/4/24 changing Profile: WLO, L150E [GB] Cooling fan motor, changing Op nbr 263-062 Lifting eye M10, 2 pcs. Lifting sling, 2 m (6.6 ft), 2 pcs. Lifting sling, 1 m Shackle M16, 2 pcs. Shackle M10, 2 pcs.
Page 682 6. Remove the bracket for the expansion tank from the intermediate wall. Remove the guards for drive belts and alternator. Disconnect the cable harness and the hoses from the intermediate wall. 7. Remove the intermediate wall. Weight, intermediate wall:approx. 45 kg (99 lbs). Figure 2 Sling, 2 m Shackle M16...
Page 683 Figure 4 10. Mark and disconnect the hoses for the fan motor. NOTE! Collect any oil spills. Figure 5 11. Remove the two upper bolts from the fan motor bracket and install the lifting eyes in the holes. Secure the fan motor with a sling.
Page 684 12. Remove the two bolts and tap away the attaching plate with a rubber mallet. Figure 7 Installing 13. Install the attaching plate on the engine. Figure 8 14. Install the fan motor. Weight, fan motor: 20 kg (44 lbs) Figure 9 15.
Page 685 Figure 10 16. Connect the hoses. (Start with the one closest to the fan housing.) Figure 11 17. Install the fan rotor and the hub. Install the nut and the lock pin. 030 Tightening torques, cooling fan Tightening torque, see...
Page 686 Figure 12 18. Install the intermediate wall. Weight:45 kg (99 lbs) Figure 13 Sling, 2 m Shackle M16 Lifting eye M10 19. Install the filter bracket on the intermediate wall. Install the panel behind the filter bracket on the intermediate wall.
Page 687 Figure 14 V1038100 20. Install the bracket for the expansion tank on the intermediate wall. 21. Clamp the cable harness and hoses against the intermediate wall. Install the guards for the drive belts and alternator. 821 Engine hood, installing 22. Fit the engine hood, see 23.
Page 688 2014/4/24 ECU), description Profile: WLO, L150E [GB] Engine control unit (E-ECU), description The engine control unit monitors engine system function by retrieving and processing information from engine sensors. The engine control unit is a central part of the injection system in that it regulates injection volume from the injection pump.
Page 690 2014/4/24 instructions Profile: WLO, L150E [GB] Electrical system, work instructions Fully charged and otherwise satisfactory batteries must always be used when testing the electrical system. Test the batteries with an acid tester. The battery disconnect switch should be turned off.
Page 691: Electrical System, Description
Service Information 2014/4/24 description Profile: WLO, L150E [GB] Electrical system, description The machine has a 24 V electrical system with two 12 volt batteries located on each side of the rear frame behind the rear wheels. The battery disconnect switch is located under the radiator casing.
Page 692 Figure 2 Principle illustration of electrical system...
Page 693: Electronic Control System, Description
Function Group: Information Type: Date: Electronic control system, Service Information 2014/4/24 description Profile: WLO, L150E [GB] Electronic control system, description Figure 1 Position of control units Engine control unit E-ECU Vehicle control unit V-ECU Instrument control unit I-ECU General The machine electronics include three control units that communicate with each other via two data busses. Each control unit processes values from sensors and controls and helps to control components so that desired function is maintained.
Page 694 If a malfunction occurs in any system, information sent via the data bus can be read by the operator in the operator's information display unit or with the service display unit and VCADS Pro. Figure 2 Principle diagram with ECUs...
Page 695: Software Description
Updating of the machine's software is handled through release of a new edition. The releases are designated with Year:edition, for example, R2001:5 and gets a new part number. Updating of software for control units takes place through downloading of new software from VOLVO with VCADS Pro.
Page 696 2014/4/24 ECU, description Profile: WLO, L150E [GB] Instrument control unit I-ECU, description The instrument control unit is integrated with the main instrument and receives information from the data bus. The information is processed and shown on gauges, control lights, warning lights and information display.
Page 697 Service Information Document Title: Function Group: Information Type: Date: Communication with data Service Information 2014/4/24 buses Profile: WLO, L150E [GB] Communication with data buses Figure 1 Communication E-ECU Engine control unit I-ECU Instrument control unit V-ECU Vehicle control unit Service socket for service display unit...
Page 698 The bus also functions as a "back-up" for the control bus, if it should fail for some reason. The system status is continuously updated and available for reading via the information bus. By connecting the service display unit or VCADS Pro to service sockets, it's possible to read error codes, perform tests, empty logged information, download parameters and download software.
Page 699 Service Information 2014/4/24 description Profile: WLO, L150E [GB] Vehicle control unit V-ECU, description The vehicle control unit is the controlling unit in the system for the functions below and contains overall functionality that is machine-related. The vehicle control unit is located near the electrical distribution box behind the operator seat.
Page 700  Warming of hydraulic oil  Boom Suspension System  Automatic lift arm lowering (Return to dig)  Secondary steering  Cooling fan adjustment  Reversal of cooling fan  Attachment lock  Brake pressure charging  Soft start and safety for AC ...
Page 701 Service Information 2014/4/24 description Profile: WLO, L150E [GB] Engine control unit E-ECU, description D10B The engine control unit is the central part in the injection system. It is located on the engine's left side and is mounted in rubber-dampened mounts.
Page 702 Figure 2 Engine control unit, D12D The control unit stores information if a fault should occur or if any part of the system reacts abnormally. Sporadic faults are stored in the control unit and can then be traced at a later time. Functions ...
Page 703 Information Type: Date: Software functions Service Information 2014/4/24 function group Profile: WLO, L150E [GB] Software functions per function group 2 Engine 22 Lubrication and oil system 301 Engine oil pressure  301 Engine Oil Level  301 Engine oil temperature ...
Page 704 301 Engine Shutdown  301 Time-controlled high idle  301 Automatic engine shut-off  301 Engine Protection  3 Electrical system 31 Battery 301 System voltage  301 Voltage feed for sensors  301 Voltage feed E-ECU, I-ECU, V-ECU  301 Key feed ...
Page 705 301 Axle oil temperature  301 Differential lock  5 Brakes 52 Hydraulic brake system 301 Brake pressure  301 Output brake pressure  301 Brake pressure charging  301 Brake test  52 Parking brake 301 Parking brake  6 Steering 64 Steering 301 Secondary steering...
Page 706 Document Title: Function Group: Information Type: Date: Description of table for Service Information 2014/4/24 software functions Profile: WLO, L150E [GB] Description of table for software functions Input signals Conditions for output functions Output functions    Charge-air High temperature > 90 °C (194 °F) Amber central warning ...
Page 708: Engine Oil Pressure
Engine oil pressure Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine oil pressure This function monitors engine oil pressure and informs the operator if the pressure is too low or if system error occurs. The Engine Shutdown function, which limits engine speed to 900 rpm, is activated if the engine oil pressure is too low, see...
Page 709 Engine oil pressure Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine oil pressure This function monitors engine oil pressure and informs the operator if the pressure is too low or if system error occurs. 301 Engine Protection...
Page 710: Engine Oil Level
Date: Engine Oil Level Service Information 2014/4/24 Profile: WLO, L150E [GB] Engine Oil Level This function monitors engine oil level and informs the operator if the level is below permissible levels or if system fault occurs. NOTE! The engine oil level is not monitored continuously but only in connection with start (before engine is started) and according to the conditions below, depending on to ECU which the sensor is connected.
Page 711    Monitoring, System fault, signal outside limits Amber central warning SE213 lamp  302 ERROR Monitoring Engine Oil Level (MID 187 ERROR Monitoring PID 098) Engine Oil Level Level sensor connected to E-ECU    VCADS VCADS Pro parameter BJD "Connected to E-ECU" Amber central warning parameter BJD ...
Page 713: Engine Oil Temperature
Engine oil temperature Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine oil temperature This function monitors engine oil temperature and informs the operator if the engine oil temperature is too high or if system malfunction occurs.
Page 714 Engine oil temperature Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine oil temperature This function monitors engine oil temperature and informs the operator if the engine oil temperature is too high or if there is a malfunction in the system.
Page 716: Fuel Level
Fuel Level Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Fuel Level This function monitors fuel level in the fuel tank and informs the operator if the level is too low or if system fault occurs.
Page 717 Fuel Level Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Fuel Level This function monitors fuel level in the fuel tank and informs the operator if the level is too low or if there is a system malfunction.
Page 718 Date: Fuel temperature (D10) Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel temperature (D10) This function monitors fuel temperature and informs the operator if system fault occurs. Fuel temperature is used internally in E-ECU engine control. Input signals Conditions for output functions Output functions ...
Page 719 Fuel shut-off (D10) Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel shut-off (D10) This function monitors fuel shut-off and informs the operator if there is a system malfunction. Fuel shut-off is used internally in E-ECU for engine control. Input signals...
Page 720 Date: Fuel feed pressure Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel feed pressure This function monitors feed pressure and informs the operator if system malfunction occurs. Feed pressure is used internally in E-ECU engine control. Input signals Conditions for output functions Output functions ...
Page 721: Water In Fuel
Information Type: Date: Water in fuel Service Information 2014/4/24 Profile: WLO, L150E [GB] Water in fuel The function monitors fuel in the water trap and informs the operator when water is detected. Input signals Conditions for output functions Output functions ...
Page 722 Function Group: Information Type: Date: Injectors Service Information 2014/4/24 Profile: WLO, L150E [GB] Injectors The function monitors the fuel injectors and informs the operator if there is a system malfunction. Input signals Conditions for output functions Output functions  Monitoring, ...
Page 723 Air filter pressure Service Information 2014/4/24 Profile: WLO, L150E [GB] Air filter pressure The function monitors the extent to which the air filter is blocked and informs the operator when changing is required or if system malfunction occurs. Input signals...
Page 724 Temperature induction air Service Information 2014/4/24 Profile: WLO, L150E [GB] Temperature induction air The function monitors intake air temperature and informs the operator if there's a system malfunction. Temperature is used internally in E-ECU engine control. 301 Cooling fan adjustment...
Page 726 Date: Charge-air temperature Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Charge-air temperature This function monitors charge-air temperature and informs the operator if the temperature is too high or if there is a system malfunction. 301 Cooling fan adjustment...
Page 727 Date: Charge-air temperature Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Charge-air temperature This function monitors charge-air temperature and informs the operator if the temperature is too high or if there is a system malfunction. Charge-air temperature is also used as an input signal for: 301 Cooling fan adjustment ...
Page 728 Boost pressure Service Information 2014/4/24 Profile: WLO, L150E [GB] Boost pressure This function monitors boost pressure and informs the operator if there is a system malfunction. The boost pressure is used internally in the E-ECU for engine control. Input signals...
Page 729: Barometric Pressure
Service Information 2014/4/24 Profile: WLO, L150E [GB] Barometric pressure This function monitors barometric pressure and informs the operator if system fault occurs. Barometric pressure is used internally in E-ECU to calculate charge air pressure and to compensate the amount of fuel when operating at high altitudes.
Page 730 Service Information 2014/4/24 Profile: WLO, L150E [GB] Preheating of inlet air The function activates preheating and informs the operator if there is a system error/malfunction. The operator activates the preheating with switch SW201 and E-ECU connects the preheating if the coolant temperature is lower than +20 °C (68 °F).
Page 731: Exhaust Gas Recirculation (Egr)
Service Information 2014/4/24 (EGR) Profile: WLO, L150E [GB] Exhaust Gas Recirculation (EGR) The function monitors the EGR valve for return of combustion gases and informs the operator if the function is not ensured or if there is a system malfunction.
Page 732 Date: Engine crankcase pressure Service Information 2014/4/24 Profile: WLO, L150E [GB] Engine crankcase pressure The function monitors the crankcase pressure and informs the operator when the pressure is too high or if there is a system malfunction. 301 Engine Protection...
Page 733: Coolant Level
Coolant Level Service Information 2014/4/24 Profile: WLO, L150E [GB] Coolant Level The function monitors the coolant level and informs the operator if the level is too low or if there is a system malfunction Input signals Conditions for output functions Output functions ...
Page 735 Service Information 2014/4/24 engine Profile: WLO, L150E [GB] Go back to Index Page Coolant temperature, engine This function monitors the engine coolant temperature and informs the operator if the temperature is too high or if there is a system malfunction.
Page 736 Service Information 2014/4/24 engine Profile: WLO, L150E [GB] Go back to Index Page Coolant temperature, engine This function monitors the engine coolant temperature and informs the operator if the temperature is too high or if there is a system malfunction.
Page 737 Service Information 2014/4/24 outlet radiator Profile: WLO, L150E [GB] Coolant temperature, outlet radiator This function monitors the coolant temperature after the radiator and warns the operator if system fault occurs. 301 Cooling fan adjustment Coolant temperature is used as input signal for cooling fan adjustment, see...
Page 738 Cooling fan adjustment Service Information 2014/4/24 Profile: WLO, L150E [GB] Cooling fan adjustment This function optimally controls cooling fan speed to achieve minimal energy consumption and sound level, provides adequate cooling and informs the operator if system fault occurs. With the service display unit or VCADS Pro max. cooling fan speed is set by selecting rpm range (A, B or C) depending on the cooling demands for the engine.
Page 739  Charge-air Pressure test temperature,  Output signal = 1000 SE2507  Request for pressure test from service panel mA to MA202  Induction (maximum flow and hydraulic pressure to cooling Cooling fan speed > temperature, fan) 1800 rpm SE2501 ...
Page 740  Coolant temperature, outlet radiator  Charge air temperature  Intake temperature In case of incorrect input signal from any of these sensors, full consideration is given to other sensors that adjust the cooling fan rpm for the selected setting (A, B or C): ...
Page 742 Reversible cooling fan Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Reversible cooling fan The function controls reversal of the cooling fan to prevent clogging of the air passages in the radiator and informs if the operator if there is a system malfunction.
Page 743  Charge-air allowed, a new reversal attempt is performed every 10th temperature, second until reversal is allowed: SE2507   Hydraulic Charge-air temperature High  temperature, Request for auxiliary brake  SE906 Request for brake pressure charging  Engine On/Off ...
Page 744  VCADS Pro parameter BGK (Reversible fan installed)  VCADS Pro parameters BGN and BGO (Setting of interval times)  SELECT key In case of incorrect input signals for the following, reversal will take place according to pre-selected interval mode: ...
Page 745 Reversible cooling fan Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Reversible cooling fan The function controls reversal of the cooling fan to prevent clogging of the air passages in the radiator and informs if the operator if there is a system malfunction.
Page 746  Charge-air allowed, a new reversal attempt is performed every 10th temperature, second until reversal is allowed: SE2507   Hydraulic Charge-air temperature High  temperature, Request for auxiliary brake  SE906 Request for brake pressure charging  Engine On/Off ...
Page 747 In case of incorrect input signals for the following, reversal will not be activated:  VCADS Pro parameter BGK (Reversible fan installed)  VCADS Pro parameters BGN and BGO (Setting of interval times)  SELECT key In case of incorrect input signals for the following, reversal will take place according to pre-selected interval mode: ...
Page 748 Service Information 2014/4/24 Profile: WLO, L150E [GB] Increased fan speed for AC Increased fan speed for cooling fan is engaged in case of increased pressure in the AC system to increase air flow through the condenser when cooling fan control doesn't call for cooling.
Page 749: Accelerator Pedal
Accelerator Pedal Service Information 2014/4/24 Profile: WLO, L150E [GB] Accelerator Pedal The function transfers the accelerator pedal's position to a throttle application on the engine and engages the secondary function (Limp Home) in case of a system error/malfunction. Accelerator pedal SW214 consists of APS (pedal position sensor) for accelerator pedal function and IVS (idle sensor) that are used to engage the Limp Home function.
Page 750: Hand Throttle
Service Information 2014/4/24 Profile: WLO, L150E [GB] Hand Throttle The function makes it possible to set a working rpm for the engine and informs the operator if there is a system malfunction. When starting the machine, the hand throttle is disengaged regardless of the hand throttle's position. For re-engaging hand throttle, the control is turned counter-clockwise to position 0 and then to the desired rpm.
Page 751 Service Information 2014/4/24 Profile: WLO, L150E [GB] Increased engine rpm The function prevents reduction of engine rpm in case of high power usage. When operating forward or reverse, engine speed > 1050 rpm, the function is activated if the throttle pedal is released quickly or if the engine rpm drops quickly.
Page 752 Function diagram Throttle pedal movement Normal engine speed reduction Engine speed conditions Start of controlled engine speed reduction Time delay before controlled engine speed reduction is activated Controlled engine speed reduction Increased engine speed Controlled engine speed reduction Idle speed...
Page 753 Engine speed for V-ECU Service Information 2014/4/24 Profile: WLO, L150E [GB] Engine speed for V-ECU This functions reads engine speed on the input shaft of the transmission and informs the operator if there is a system malfunction. The engine speed is presented in the operating display on the information display unit. The engine speed is also used as input signal for different software functions.
Page 754: Engine On/Off
Date: Engine On/Off Service Information 2014/4/24 Profile: WLO, L150E [GB] Engine On/Off Engine On/Off is used as a condition in software functions to define when the engine is considered to be On and Off, respectively. Input signals Conditions for output functions Output functions ...
Page 755 Function Group: Information Type: Date: Limitation of engine speed Service Information 2014/4/24 on first gear Profile: WLO, L150E [GB] Limitation of engine speed on first gear Funktionen begränsar motorvavtalet på första växeln vid manuell vald växling för att uppfylla ljudkraven.
Page 757 Engine speed for E-ECU Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine speed for E-ECU This function monitors boost pressure and informs the operator if there is a system malfunction. Engine speed is used internally in E-ECU engine control.
Page 758 Date: Engine speed for E-ECU Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Engine speed for E-ECU This function monitors boost pressure and informs the operator if there is a system malfunction. 301 Engine Protection The engine rpm is used internally in the E-ECU for engine control and as input signal for In case of engine speed sensor malfunction, the E-ECU uses sensor SE2703 for camshaft speed instead.
Page 759 Date: Camshaft speed Service Information 2014/4/24 Profile: WLO, L150E [GB] Camshaft speed This function monitors camshaft speed and informs the operator if there is a system malfunction. The E-ECU uses camshaft speed for engine control. Input signals Conditions for output functions Output functions ...
Page 760 Service Information 2014/4/24 pump Profile: WLO, L150E [GB] Speed (rpm) injection pump This function monitors the speed (rpm) on the injection pump and informs the operator if there is a system malfunction. Speed is used internally in E-ECU for engine control.
Page 761: Engine Shutdown
Engine Shutdown Service Information 2014/4/24 Profile: WLO, L150E [GB] Engine Shutdown The function makes limited movement of the machine possible even if alarm levels for coolant temperature, engine oil pressure, transmission oil temperature or clutch slipping have been reached. Input signals...
Page 762 Information Type: Date: Time-controlled high idle Service Information 2014/4/24 Profile: WLO, L150E [GB] Time-controlled high idle The function limits the engine speed to reduce the sound level during the set time. Input signals Conditions for output functions Output functions Overall conditions for the function ...
Page 763 Service Information 2014/4/24 Profile: WLO, L150E [GB] Automatic engine shut-off The function control engine shut-off when the conditions according to the table have been fulfilled, and informs the operator that the engine will be shut off within 1 minute. When the engine is shut off the parking brake will also be applied.
Page 764: Engine Protection
Service Information 2014/4/24 Profile: WLO, L150E [GB] Engine Protection The function informs the operator and limits the engine's rpm and torque as well as machine speed to prevent any engine damage. Engine shut-off takes place first when speed is below 2 km/h (1.2 mph). This makes it possible to move the machine away from hazardous situations before engine shut-off takes place.
Page 765  Engine shut-off after seconds if speed is < 2 km/h (1.2 mph) NOTE! The parking brake is applied automatically at engine shut-    Engine coolant level, SE2603 Low coolant level Red central warning lamp  WARNING Low Engine Coolant Level ...
Page 766: System Voltage
Information Type: Date: System voltage Service Information 2014/4/24 Profile: WLO, L150E [GB] System voltage The function monitors system voltage and informs the operator if the system voltage is too high or too low. Input signals Conditions for output functions Output functions ...
Page 767 Voltage feed for sensors Service Information 2014/4/24 Profile: WLO, L150E [GB] Voltage feed for sensors This function monitors 5 V voltage feed for sensors and informs the operator if the voltage is too high or too low. Input signals Conditions for output functions Output functions ...
Page 768 2014/4/24 V-ECU Profile: WLO, L150E [GB] Voltage feed E-ECU, I-ECU, V-ECU System voltage for start of I-ECU and V-ECU takes place via RE12. When voltage is supplied to I-ECU and V-ECU, an I-ECU frame ground connection for relay RE11 is activated. RE11 uses and connects voltage feed for E-ECU, I-ECU and V-ECU.
Page 769 Date: Key feed Service Information 2014/4/24 Profile: WLO, L150E [GB] Key feed Key feed is used as a condition in software functions to define when voltage feed considered to be On and Off, respectively. Input signals Conditions for output functions Output functions ...
Page 770: Theft Protection
Date: Theft protection Service Information 2014/4/24 Profile: WLO, L150E [GB] Theft protection The function has the task of preventing machine theft. The function is activated with VCADS Pro. Figure 1 Keypad When the theft protection is activated, a correct four-digit code has to be entered via the keypad and then the "SELECT"–...
Page 771 Activation of theft protection  Directional gear N  Ignition (position 0) > 60 seconds (delay period)  Engine stop  Parking brake applied, MA501 without voltage  [T1] [T1]Prevents operation of the parking brake via switch SW501.
Page 772 Service Information 2014/4/24 Profile: WLO, L150E [GB] Starter motor engagement The function monitors the time that the starter motor is engaged to prevent overheating of the starter motor and informs the operator to wait 5 minutes before the next start attempt.
Page 773 Service Information 2014/4/24 engine fault Profile: WLO, L150E [GB] Indication of serious engine fault This function informs that the engine should be stopped immediately due to a serious engine system malfunction. Possible system malfunctions:  SID 023, Error control rod actuator (PWM2301) ...
Page 774 Service Information 2014/4/24 Profile: WLO, L150E [GB] Interval Wiper This function controls the front and rear intermittent wipers and informs the operator if there is a system malfunction. The wiper is activated for 0.5 seconds with a 5 second pause. The sequence is repeated until the control is set to position 0.
Page 775 2014/4/24 washing Profile: WLO, L150E [GB] Wiping during and after washing This function controls the front and rear wipers during washing. Wiper control starts when each washer control is held in position On and stops when the control is released. Wiping continues for 5 seconds following washing.
Page 776: Fuel Consumption
Date: Fuel consumption Service Information 2014/4/24 Profile: WLO, L150E [GB] Fuel consumption This function calculates machine fuel consumption which is shown on the display panel. Fuel consumption calculations according to the following:  Current consumption in litres per hour, dissolution 0.1 litre.
Page 777 Reduced computer Service Information 2014/4/24 communication Profile: WLO, L150E [GB] Reduced computer communication This function informs the operator in the event of ECU system communication malfunction and continued operation with reduced performance. Input signals Conditions for output functions Output functions ...
Page 778 Interruption in computer Service Information 2014/4/24 communication Profile: WLO, L150E [GB] Interruption in computer communication This function informs the operator in the event of ECU system communication malfunction, continued operation may result in damage. Input signals Conditions for output functions Output functions ...
Page 779: Service Interval
Service interval Service Information 2014/4/24 Profile: WLO, L150E [GB] Service interval This function informs the operator about the time remaining to next service and which service interval should be performed and to inform when 8 operating hours remain to next service.
Page 780 Function Group: Information Type: Date: Washer fluid level Service Information 2014/4/24 Profile: WLO, L150E [GB] Washer fluid level This function monitors washer fluid level and provides appropriate warning for low fluid level. Input signals Conditions for output functions Output functions ...
Page 781: Outdoor Temperature
Outdoor temperature Service Information 2014/4/24 Profile: WLO, L150E [GB] Outdoor temperature This function monitors the outdoor temperature and provides the operator with temperature information or if system fault occurs. Unit settings °C or °F are made with the display panel keyboard.
Page 782 2014/4/24 Profile: WLO, L150E [GB] The function controls shifting based on current operating mode, which gear is to be used, and when shifting shall take place to protect the transmission. The mode selector enables the operator to select different shifting programs depending on operation conditions.
Page 783   Travelling speed, Travelling speed  SE403 Vehicle distance (only in AUTO mode)  Turbine speed, SE402 Automatic with manual kick-down function  Brake pressure,  Directional gear F–N–R SE501   Mode selector in mode L–M–H or AUTO Speed gear 2–4⁽ᵃ⁾...
Page 784 Directional gear When shifting from N (neutral) to F or R, the travelling speed gear is changed from selected gear to engaged gear as follows: Selected Gear Engaged gear Travelling speed < 9 km/h (5.6 mph) 9–16 km/h (5.6–9.9 mph) 16–34 km/h (9.9–21.1 mph) >...
Page 785 Automatic shifting with fully automatic activated Shifting is handled automatically. The conditions for shifting are a combination the mode selector's setting, engine rpm, and machine speed. In AUTO mode, consideration is also given to operating cycle. Automatic shifting takes place between gears 1–4. NOTE! Downshifting to 1st can also be manual with any of the kick-down controls if speed is below 8 km/h (5 mph) within 8 seconds to get earlier downshifting.
Page 786 APS II Service Information 2014/4/24 Profile: WLO, L150E [GB] APS II The function controls gear shifting based on current operating mode and determines which gear should be used and when shifting should take place in order to protect the transmission.
Page 787 SE402   Kick-down activated Kick-down   Incorrect input signal from APS II Amber central warning  302 ERROR APS switch/ERROR APS II-switch ERROR APS II-switch  Gear mode LIGHT position 1 Acknowledge by turning off machine Mode selector in position MAN ...
Page 788 Changing travelling direction Travelling direction change at lower travelling speed occurs in 2nd gear. If travelling speed is too fast, 3rd gear is engaged first and when the machine is stationary, 2nd gear engages according to the table below. Gear Travelling speed conditions <= 15 km/h (9.3 mph) >...
Page 789: Fully Automatic
Information Type: Date: Fully automatic Service Information 2014/4/24 Profile: WLO, L150E [GB] Fully automatic By activating the function with switch SW417, automatic downshifting to first gear via APS takes place when downshifting 301 APS conditions are fulfilled. See Input signals...
Page 790: Travelling Speed
Travelling speed Service Information 2014/4/24 Profile: WLO, L150E [GB] Travelling speed The function calculates travelling speed, provides the operator with travelling speed information and informs the operator if system fault occurs. Travelling speed is used as an input signal to several functions.
Page 791 Information Type: Date: Tire radius Service Information 2014/4/24 Profile: WLO, L150E [GB] Tire radius This function provides input data for calculation of travel speed. Setting of tire dimension is performed with the service display unit. Tires Tire radius Axle ratio 26.5"...
Page 792: Speed Limitation
Date: Speed limitation Service Information 2014/4/24 Profile: WLO, L150E [GB] Speed limitation The function limits the vehicle speed to the governing legal max. travel speeds. Setting of travel speed for speed limitation is performed with VCADS Pro. Input signals Conditions for output functions...
Page 793 Service Information 2014/4/24 steering (CDC) Profile: WLO, L150E [GB] Speed limitation for lever steering (CDC) The function limits the vehicle speed when lever steering (comfort drive control) is activated. Setting of travel speed for speed limitation is performed with VCADS Pro.
Page 794: Back-Up Alarm
Document Title: Function Group: Information Type: Date: Back-up alarm Service Information 2014/4/24 Profile: WLO, L150E [GB] Back-up alarm The function informs bystanders and surroundings that the machine is reversing. Input signals Conditions for output functions Output functions  Directional gear ...
Page 795 Date: Transmission oil pressure Service Information 2014/4/24 Profile: WLO, L150E [GB] Transmission oil pressure The function monitors the HT-transmission main oil pressure and informs the operator if transmission oil pressure is low or if there's a system malfunction. Input signals...
Page 796: Transmission Oil Level
Service Information 2014/4/24 Profile: WLO, L150E [GB] Transmission oil level This function monitors transmission oil level and informs the operator if level is low or if system fault occurs. Level check occurs only when all conditions are met after machine start.
Page 798: Transmission Oil Temperature
Transmission Service Information 2014/4/24 temperature Profile: WLO, L150E [GB] Go back to Index Page Transmission oil temperature This function monitors the transmission oil temperature and warns the operator if the temperature is too high or if there's a system malfunction.
Page 799 Transmission Service Information 2014/4/24 temperature Profile: WLO, L150E [GB] Go back to Index Page Transmission oil temperature This function monitors the transmission oil temperature and warns the operator if the temperature is too high or if there's a system malfunction.
Page 800: Transmission Oil Filter
Transmission oil filter Service Information 2014/4/24 Profile: WLO, L150E [GB] Transmission oil filter The function monitors the condition of the transmission oil filter and informs the operator if filter change is required or if there is a system malfunction. The transmission oil filter must be changed to avoid opening of the filter by-pass valve, which can result in reduced transmission performance or loss of function.
Page 801 Date: Turbine speed Service Information 2014/4/24 Profile: WLO, L150E [GB] Turbine speed This function monitors turbine speed and informs the operator if system fault occurs. Turbine speed is used to calculate transmission clutch slipping. Input signals Conditions for output functions Output functions ...
Page 803 Transmission slipping Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Transmission slipping The function monitors and informs the operator about slipping in transmission clutches. If slipping continues for more than 0.5 seconds, the Engine Shut Down function is activated, which limits engine speed to 900 rpm to protect the transmission,...
Page 804 Transmission slipping Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page Transmission slipping The function monitors and informs the operator about slipping in transmission clutches. If slipping continues for more than 0.5 seconds, the function Transmission protection is activated, limiting the engine rpm to 1500 rpm via the engine control...
Page 805 Information Type: Date: Transmission Service Information 2014/4/24 disengagement Profile: WLO, L150E [GB] Transmission disengagement This function engages transmission disengagement (Neutral gear) during braking and informs the operator if there is a system malfunction. Input signals Conditions for output functions Output functions ...
Page 806 Service Information 2014/4/24 Profile: WLO, L150E [GB] Overspeed, transmission This function monitors transmission speed and warns the operator if transmission speeds are too high. Shifting will take place to the nearest higher gear at exceptionally high transmission speeds. The same speed limit applies both to forward and reverse.
Page 807: Gear Selector
Date: Gear Selector Service Information 2014/4/24 Profile: WLO, L150E [GB] Gear Selector This function coordinates the three gear selectors for travel direction and informs the operator as to which control is active and if there is a system malfunction. ...
Page 808  Armrest, SW407 Activation of lever steering (CDC)  Engine On/Off  Activation gear selector  Travel speed  Gear selector steering column in position N lever steering (CDC)   Gear selector lever steering in position N Control light lever ...
Page 809    Monitoring, System malfunction, open circuit or short circuit Amber central warning RE602 302 ERROR Lever Steering CDC  ERROR Lever Steering...
Page 810 Date: Gearshifting solenoids Service Information 2014/4/24 Profile: WLO, L150E [GB] Gearshifting solenoids The gearshifting solenoids are controlled according to the gear engagement shifting mode. In the event of system malfunction, the operator is informed. Input signals Conditions for output functions Output functions ...
Page 811 Defective SE, SF Defective SB, SC, SE Defective SB, SC, SF...
Page 812 Information Type: Date: Downshifting signal Service Information 2014/4/24 Profile: WLO, L150E [GB] Downshifting signal This function notifies the operator that a downshift to 1st gear has been performed with a brief buzzer signal. Input signals Conditions for output functions Output functions ...
Page 813 Service Information 2014/4/24 Profile: WLO, L150E [GB] Transmission protection The function limits the engine speed to 1500 rpm via the engine control unit E-ECU to protect the transmission at high transmission oil temperature or in case of slipping in the transmission.
Page 814 Axle oil temperature Service Information 2014/4/24 Profile: WLO, L150E [GB] Axle oil temperature This function monitors the front and rear axle oil temperatures and informs the operator if the temperature is too high or if system malfunction occurs. If axle oil temperature is too high, an alarm is triggered at two levels for each axle.
Page 815: Differential Lock
Differential lock Service Information 2014/4/24 Profile: WLO, L150E [GB] Differential lock This function controls differential lock engagement and informs the operator if the differential lock is engaged or if there is a system malfunction. The differential lock is engaged with the foot switch that via I-ECU and V-ECU activates solenoid valve MA407. When the diff lock is engaged, the mechanical monitor SE408 gives a signal to the V-ECU for acknowledging that the diff lock is engaged and the control light is activated on the instrument panel.
Page 816 Function Group: Information Type: Date: Brake pressure Service Information 2014/4/24 Profile: WLO, L150E [GB] Brake pressure This function monitors brake pressure and informs the operator if brake pressure is too low. Input signals Conditions for output functions Output functions ...
Page 817 Date: Output brake pressure Service Information 2014/4/24 Profile: WLO, L150E [GB] Output brake pressure This function monitors output brake pressure and warns the operator if system fault occurs. The function is used as an input signal for: 301 Transmission disengagement ...
Page 818 Function Group: Information Type: Date: Brake pressure charging Service Information 2014/4/24 Profile: WLO, L150E [GB] Brake pressure charging The function controls brake pressure charging and warns the operator in the event of malfunctions in the brake charging system. During brake charging,...
Page 819  MA502) ERROR Sol.valve Brake pres. charging [T1]Machines manufactured before 2003 can be equipped with sensor with limit value < 12 MPa (120 bar) (1740 psi).
Page 820: Brake Test
Brake test Service Information 2014/4/24 Profile: WLO, L150E [GB] Brake test This function calculates the ability of the machine to retard in order to obtain information concerning the condition of the brakes. The brake test can be performed at a travel speed of >...
Page 821: Parking Brake
Parking brake Service Information 2014/4/24 Profile: WLO, L150E [GB] Parking brake This function controls the parking brake and notifies the operator if an attempt to drive with the parking brake applied is made or if there is a system malfunction.
Page 822 Parking brake release when machine is running and  parking brake is applied with parking brake switch: Parking brake released,  Parking brake switch in Released position MA501 supplied with  Directional gear in position Neutral voltage SE503  Engine On pressurized ...
Page 823 Service Information 2014/4/24 Profile: WLO, L150E [GB] Secondary steering The function makes it possible for the operator to steer the machine in case the primary steering pump fails. The function notifies the operator if there is a malfunction in the primary steering system or if there is a system malfunction.
Page 824  RE601 302 ERROR Secondary Steering Relay ERROR Secondary Steering Relay Incorrect input signals  Speed malfunction (SE403) speed considered to be > 3 km/h (2 mph).  In case of malfunction of Engine On/Off (engine rpm), the engine is considered to be Off. ...
Page 825 Service Information 2014/4/24 Profile: WLO, L150E [GB] Secondary steering The function makes it possible for the operator to steer the machine in case the primary steering pump fails. The function notifies the operator if there is a malfunction in the primary steering system or if there is a system malfunction.
Page 826 Steering No Function  Monitoring,  Engine Off  Amber central warning   SE601 and SE602 System malfunction, open circuit ERROR Monitoring 302 ERROR Monitoring Steering System Oil Steering System Pressure (SE601) (MID 187 PPID 1046) Pressure 302 ERROR Monitoring Steering System Oil Pressure (SE602) (MID 187 PSID 1303) ...
Page 827 Soft start and safety for AC 301 Service Information 2014/4/24 Profile: WLO, L150E [GB] Soft start and safety for AC This function controls engagement and disengagement of the cooling compressor and informs the operator if there's a system malfunction. Selection of which AC system is installed on the machine is performed with VCADS Pro.
Page 828 After the malfunction has been corrected, the AC must be deactivated and then activated again with SW806. Return to normal operation at manoeuvring of  attachment locking with SW904 10 seconds after the pressure monitor is ON,  Pressure monitor Off (1-2nd function⁽ᵃ⁾) at < the cooling compressor is engaged via RE806 0.1-0.2 Mpa (1-2 bar) (14.5-29 psi) or >...
Page 829 0.1-0.2 Mpa (1-2 bar) (14.5-29 psi) or > 2.1-2.5 Mpa (21-25 bar) (305-363 psi)  Pressure monitor (3rd functionᵇ) On > 1.8 MPa (18 bar) (261 psi)  > 120 seconds since SW904 attachment locking was operated Incorrect input signals In case of malfunction of any VCADS-Pro parameter, it is considered to be Off.
Page 830: Hydraulic Oil Level
Service Information 2014/4/24 Profile: WLO, L150E [GB] Hydraulic Oil Level This function monitors the hydraulic oil level and informs the operator that it is time to fill hydraulic oil and to warn if the level drops below the allowed level or if there is a system malfunction.
Page 831 Figure 2 Level monitor with analogue temperature sensor NOTE! that the level monitor is connected in series with the temperature sensor, and that is why no sensing of the hydraulic oil temperature can take place if the hydraulic oil level is under the warning level. Input signals Conditions for output functions Output functions...
Page 832: Hydraulic Oil Temperature
Hydraulic oil temperature Service Information 2014/4/24 Profile: WLO, L150E [GB] Hydraulic oil temperature This function monitors the hydraulic oil temperature and informs the operator when the temperature is too high or if a system fault occurs. 301 Cooling fan adjustment...
Page 833 Service Information 2014/4/24 Profile: WLO, L150E [GB] Warming of hydraulic oil The function makes sure that the temperature in the hydraulic oil quickly reaches operating temperature in case of low outdoor temperature. Warming takes place through pressure-drop across the brake pressure valve, which has a small restriction.
Page 834 Service Information 2014/4/24 Profile: WLO, L150E [GB] Hydraulic power limitation The function limits use of hydraulic power when there is not enough torque from the engine. Limitation takes place using a proportional valve, solenoid valve MA958, to reduce the LS-pressure to the P1-pump and thus reduce flow to the working hydraulics.
Page 836 Boom Suspension System Service Information 2014/4/24 (BSS) Profile: WLO, L150E [GB] Go back to Index Page Boom Suspension System (BSS) This function activates and deactivates the boom suspension system and informs the operator regarding activating or if a system fault occurs.
Page 837  SW 925 in gear-dependent boom suspension suspension system via position (boom suspension system control lamp relay RE7 switched on)⁽ᵃ⁾  Engine On  Directional gear in position Forward, Reverse or Neutral  Gear not in position F1 or R1 ...
Page 838 Gear-dependent:  Engagement of boom  SW 925 in gear-dependent boom suspension suspension system via position (boom suspension system control lamp relay RE7 switched on)⁽ᵃ⁾  Engine On  Directional gear in position Forward, Reverse or Neutral  Gear not in position F1 or R1 ...
Page 839 Boom Suspension System Service Information 2014/4/24 (BSS) Profile: WLO, L150E [GB] Go back to Index Page Boom Suspension System (BSS) This function activates and deactivates the boom suspension system and informs the operator regarding activating or if a system error occurs.
Page 840 Disengagement of boom suspension system takes  place if any of the following conditions are fulfilled: Disengagement boom suspension  Directional gear in position Forward and speed system via relay RE7 gear in position F1  Directional gear in position Reverse and speed Under the menu “Hydraulics”...
Page 841 [T1]Control light is lit continuously as long as function is activated. Speed-dependent boom suspension with activated Fully automatic Input signals Conditions for output functions Output functions Overall conditions  Boom suspension  Engagement of boom  system, SW925 SW 925 in speed dependent boom suspension suspension system via ...
Page 842 Service Information 2014/4/24 Profile: WLO, L150E [GB] Attachment locking The function informs the operator that attachment locking is open and that the operator must confirm locking when changing attachments by acknowledging the warning with the SELECT– button on the keypad.
Page 843  ERROR Sol. valve Attachment lock [T1]On keypad...
Page 844 2014/4/24 lowering (Return to dig) Profile: WLO, L150E [GB] Automatic lift arm lowering (Return to dig) The function automatic lift arm lowering (Return to dig) is engaged when the lever for operating the lift arms is moved to hold position for lift arm lowering. The lift arms will then be lowered, the lever releases from hold position and the lift arms stop at a pre-set position via position sensors on the boom.
Page 845: Central Lubrication
Central lubrication Service Information 2014/4/24 Profile: WLO, L150E [GB] Central lubrication The function engages central lubrication (CU802) and prevents the machine from being greased unnecessarily, for example, when the machine runs at idle and has the gear selector in Neutral position.
Page 846 Central lubrication, status Service Information 2014/4/24 indication Profile: WLO, L150E [GB] Central lubrication, status indication The function monitors the lubrication oil level and informs the operator in case of low lubrication oil level or if there's a system malfunction. Input signals...
Page 847 2014/4/24 parameters Profile: WLO, L150E [GB] Setting software parameters The machine is equipped to set certain software parameters in order to affect functionality and display format. The parameters can be read and set using the information display unit, service display unit and VCADS Pro.
Page 848 Designation Description Possible values Language and units Language selection Svenska / English / Deutsch / Francais / Espanol Selection of units Metrics / US Engine, fan Maximum rpm setting for cooling fan engine A / B / C Axleoilcooler Indicates if the machine is equipped with axle Y / N oil cooler or not Tire...
Page 849 Engine oil level gauge 11144494 installed Should cranck times be considered to avoid overheating of starter motors To govern the hydraulic function of the attachment bracket.To inform the driver that he has chosen to open the attachment locking and when locking he has to verify and confirm that the pins are in lock position. Active charging of Brake pressure system To rapidly reach a acceptable working temperature in the hydraulic system Selection of installed sensor 0 = Connection on sensor 1 = Connection on sensor cable 2 = Connection on...
Page 850 2014/4/24 information Profile: WLO, L150E [GB] General fault diagnosis information The section entitled "Fault diagnosis" provides descriptions of symptom and function disturbance fault diagnosis with regards to the electrical system. Information regarding the different functions of the electrical components, measurement values and possible fault detection is also available.
Page 851: Troubleshooting Strategy
Date: Troubleshooting strategy Service Information 2014/4/24 Profile: WLO, L150E [GB] Troubleshooting strategy The basis for all troubleshooting is that a malfunction, symptom or defect is noticed. Troubleshooting strategy and procedures are illustrated in the following flow chart. Start 302 Collection of basic data Basic data collection, see Check for error messages.
Page 852 Error messages are examined to verify that the symptom/malfunction has been repaired and to ensure that no additional defects have occurred as a result of the repair procedure. 301 Setting software parameters Parameters are checked to ensure that reasonable values are set. See [ 1]Additional information includes wiring diagrams, function descriptions and component troubleshooting.
Page 853: Troubleshooting Tools
Information Type: Date: Troubleshooting tools Service Information 2014/4/24 Profile: WLO, L150E [GB] Troubleshooting tools Service manual Service information for troubleshooting is available in the service manual. The different types of information are listed below:  Instructions for lead and connector checks...
Page 854 Information Type: Date: VCADS Pro service tool Service Information 2014/4/24 Profile: WLO, L150E [GB] VCADS Pro service tool General Figure 1 VCADS Pro computer The following is a short description of the VCADS Pro service tool: The name VCADS Pro is short for Vehicle Computer Aided Diagnostic System Professional.
Page 855 Figure 3 Example, tests and programming possibilities Under Operations, there are several tests and programming possibilities divided according to function group. The tests show, for example, sensor values, as well as graphic display of how a signal varies in time. Programming is used to reprogram control units.
Page 856 Figure 5 Example, read-out parameters Read-out and programming of parameters take place from operation, function group 1 - Service and maintenance. For more 301 Setting software parameters information about parameters, see Job Card Figure 6 Example, job card The job card function is used to store work operations that have been performed with VCADS Pro, for example, test results and results of error code read-outs and programming of parameters.
Page 857 Service Information 2014/4/24 troubleshooting Profile: WLO, L150E [GB] Special tools for troubleshooting The recommended measuring tools for checking electrical leads and components, for example, are listed below. 302 Multi-pin breaker box 999 8699 302 Extension cable 999 0062 302 Template 999 0130...
Page 858 Function Group: Information Type: Date: Multi-pin breaker box 999 Service Information 2014/4/24 8699 Profile: WLO, L150E [GB] Multi-pin breaker box 999 8699 Description: Multi-pin breaker box Part no. 999 8699 Specification: Multi-pin breaker box 62-pin with D-SUB connector. The multi-pin breaker box is universal and can be used...
Page 859: Extension Cable
Document Title: Function Group: Information Type: Date: Extension cable 999 0062 Service Information 2014/4/24 Profile: WLO, L150E [GB] Extension cable 999 0062 Description: Extension cable Part no. 999 0062 Specification: Extension cable 2.5 m for multi-pin breaker box 999 8699.
Page 860 Document Title: Function Group: Information Type: Date: Template 999 0130 Service Information 2014/4/24 Profile: WLO, L150E [GB] Template 999 0130 Description: Template Part no. 999 0130 Specification: Template for Multi-pin breaker box 999 8699. Front and back adapted for adapter cables 981 3194 for measuring to I-ECU, connection P1 and 999 8533 for connection to I-ECU P2.
Page 861 Document Title: Function Group: Information Type: Date: Template 999 0133 Service Information 2014/4/24 Profile: WLO, L150E [GB] Template 999 0133 Description: Template Part no. 999 0133 Specification: Template for Multi-pin breaker box 999 8699. Adapted for adapter cable 999 0020 for measuring to I-ECU connection P3 and for connection to 16-pin connector in the electrical distribution box.
Page 862: Adapter Cable
Service Information Document Title: Function Group: Information Type: Date: Adapter cable 951 1355 Service Information 2014/4/24 Profile: WLO, L150E [GB] Adapter cable 951 1355 Description: Adapter cable Part no. 951 1355 Specification: Adapter cable 42-pin for Multi-pin breaker box 999 8699.
Page 863 Document Title: Function Group: Information Type: Date: Adapter cable 981 3194 Service Information 2014/4/24 Profile: WLO, L150E [GB] Adapter cable 981 3194 Description: Adapter cable Part no. 981 3194 Specification: 30-pin adapter cable for testing instrument control unit (I-ECU) connector P1.
Page 864 Document Title: Function Group: Information Type: Date: Adapter cable 999 0014 Service Information 2014/4/24 Profile: WLO, L150E [GB] Adapter cable 999 0014 Description: Adapter cable Part no. 999 0014 Specification: The adapter cable is used for measuring engine control unit (E-ECU) connector EA and EB.
Page 865 Document Title: Function Group: Information Type: Date: Adapter cable 999 0020 Service Information 2014/4/24 Profile: WLO, L150E [GB] Adapter cable 999 0020 Description: Adapter cable Part no. 999 0020 Specification: Adapter cable 22-pin for measuring to I-ECU connector P3 and for connection to 16-pin connector...
Page 866 Document Title: Function Group: Information Type: Date: Adapter cable 999 0191 Service Information 2014/4/24 Profile: WLO, L150E [GB] Adapter cable 999 0191 Description: Adapter cable Part no. 999 0191 Specification: Adapter cable for measuring against component with 2-pin and 3-pin connectors.
Page 867 Document Title: Function Group: Information Type: Date: Adapter cable 999 0216 Service Information 2014/4/24 Profile: WLO, L150E [GB] Adapter cable 999 0216 Description: Adapter cable Part no. 999 0216 Specification: Adapter cable for measuring against component with 2-pin, 3-pin, and 4-pin connectors.
Page 868 Document Title: Function Group: Information Type: Date: Adapter cable 999 8505 Service Information 2014/4/24 Profile: WLO, L150E [GB] Adapter cable 999 8505 Description: Adapter cable Part no. 999 8505 Specification: The adapter cable is used for measuring engine control unit (E-ECU) connector EA and EB.
Page 869 Document Title: Function Group: Information Type: Date: Adapter cable 999 8533 Service Information 2014/4/24 Profile: WLO, L150E [GB] Adapter cable 999 8533 Description: Adapter cable Part no. 999 8533 Specification: 22-pin adapter cable for testing instrument control unit (I-ECU) connector P2.
Page 870 Document Title: Function Group: Information Type: Date: Adapter cable 999 8534 Service Information 2014/4/24 Profile: WLO, L150E [GB] Adapter cable 999 8534 Description: Adapter cable Part no. 999 8534 Specification: Adapter cable for testing components with a 4-pin DIN connector.
Page 871 Service Information Document Title: Function Group: Information Type: Date: Adapter cable 999 8563 Service Information 2014/4/24 Profile: WLO, L150E [GB] Adapter cable 999 8563 Description: Adapter cable Part no. 999 8563 Specification: Adapter cable for measuring in 12–pin engine cable harness.
Page 872 Service Information Document Title: Function Group: Information Type: Date: Multimeter 981 2519 Service Information 2014/4/24 Profile: WLO, L150E [GB] Multimeter 981 2519 Description: Multimeter Part no. 981 2519 Specification: Multimeter used fault diagnosis. (Similar multimeters can also be used)
Page 873 Service Information Document Title: Function Group: Information Type: Date: Test pins 999 0008 Service Information 2014/4/24 Profile: WLO, L150E [GB] Test pins 999 0008 Description: Test pins Part no. 999 0008 Specification: Test pins used together with multimeter...
Page 874 Collection of basic data Service Information 2014/4/24 Profile: WLO, L150E [GB] Collection of basic data General Collection of basic data is the first step in all troubleshooting. This is done to get a quick and improved overall picture of how the malfunction shows up.
Page 875  External circumstances that affect the problem?  Is the engine difficult to start?  Is there abnormal smoke?  Is there any abnormal engine noise?  Have you detected/confirmed any changes in fuel consumption, oil consumption or engine power? ...
Page 876 Function Group: Information Type: Date: Service display unit 999 Service Information 2014/4/24 3721 Profile: WLO, L150E [GB] Service display unit 999 3721 Description: Service display unit Part no. 999 3721 Specification: The service display unit can be used for fault diagnosis when additional information is required from the display panel.
Page 877 Document Title: Function Group: Information Type: Date: Extension cable 11 668 006 302 Service Information 2014/4/24 Profile: WLO, L150E [GB] Extension cable 11 668 006 Description: Extension cable Part no. 11 668 006 Specification: Extension cable for Service display unit.
Page 878 Lead and connector checks 302 Service Information 2014/4/24 Profile: WLO, L150E [GB] Lead and connector checks General An important part of electrical system fault diagnosis is lead and connector checks, which can provide the cause of malfunctions in the form of loose connections or damaged electrical leads.
Page 879 Figure 1 Connector, mechanical contact check Figure 2 Engine control unit connector, check of mechanical contact Open circuit, check Open circuits in electrical cables and cable harnesses can be caused by chafing due to friction, pressure due to squeezing and tension load. Checks for open circuits are conducted as follows: Dismantle the appropriate connector in both ends of the cable harness.
Page 880 Ignition in position 1. Close all breakers, activate circuit functions and check if any fuses are tripped. Dismantle the appropriate connector to the circuit components so they do not to affect the test. Resistance test between lead and ground. The resistance should be ∞ Ω for a lead without short circuit to ground. Figure 5 Check for short circuit to ground (frame ground connection) with resistance testing Figure 6...
Page 881 Figure 8 Basis for test of short circuit to voltage Contact resistance and oxidation, check Loose contacts or temporary recurring malfunctions can be difficult to diagnose and are often caused by corrosion, vibrations of poorly connected leads. Dampness in the connectors can also cause contact problems as well as damaged pins or sleeves. Resistance in the connectors and leads should be ≈...
Page 882 Figure 10 Connectors, spraying with contact spray...
Page 883 Component fault diagnosis, Service Information 2014/4/24 general Profile: WLO, L150E [GB] Component fault diagnosis, general The following is a description of component and circuit fault diagnosis. The section contains the following information: 302 Component fault diagnosis, description  302 Test methods, description ...
Page 884 2014/4/24 description Profile: WLO, L150E [GB] Component fault diagnosis, description Check-measurement of components and electrical cabling should be performed when an error message has been detected. Measurements are performed to check component, cabling, output signals from control units and frame ground connections.
Page 885 Symptoms caused by error/malfunction source. Possible causes of error/malfunction. 302 SAE error codes, translation to error messages, general Type of error/malfunction acc. to FMI, see Reference value (set point) for check-measurement. The column indicates which test points are referred to. 302 Test methods, description Recommended measuring method, see Check-measurement of separate component...
Page 886 Information Type: Date: Test methods, description Service Information 2014/4/24 Profile: WLO, L150E [GB] Test methods, description Test methods and their symbols are described below. 3020 Connecting special tools See also Testing of control unit and cable harness. 302 Adapter cable 999 0191 302 Adapter cable 999 8534 302 Multimeter 981 2519...
Page 887 Figure 3 Cable harness and component, test If access to component to be diagnosed is difficult, test the cable harness and component. The test instrument is connected to the test box and is set for resistance testing (ohm). Test of component only 302 Adapter cable 999 0191 302 Adapter cable 999 8534 302 Multimeter 981 2519 Tools: Figure 4...
Page 888 Date: Conditions when checking Service Information 2014/4/24 Profile: WLO, L150E [GB] Conditions when checking The following checks (measurements) are mostly described using symbols, in order to clarify the conditions and to reduce reading time. The symbols are described below. NOTICE When checking components, i.e.
Page 889 Measuring of cable harness, short- circuiting to ground. Checking component/cable harness, symbols Measuring component with or without connected cable harness. Symbol Description Symbol Description Measuring with Measuring short- adapter. circuiting to ground with adapter. Measuring against Measuring short- component with test circuiting to ground in pins.
Page 890 Profile: WLO, L150E [GB] Error texts and troubleshooting information, general The machine control units include integrated diagnostic programs which monitor input and output signals for components and functions. Any error signals generate error texts in the information display panel.
Page 891 Error messages by function Service Information 2014/4/24 group Profile: WLO, L150E [GB] Error messages by function group 22 Lubrication system 302 ERROR Monitoring Engine Oil Level (MID 128 PID 098) 302 ERROR Monitoring Engine Oil Level (MID 187 PID 098) 302 ERROR Monitoring Engine Oil Temp.
Page 892 302 ERROR E-ECU PID 102 302 ERROR E-ECU PID 108 302 ERROR E-ECU PID 172 302 ERROR E-ECU PID 174 302 ERROR E-ECU SID 001 - E-ECU SID 006 302 ERROR E-ECU SID 017 302 ERROR E-ECU SID 021 (D10) 302 ERROR E-ECU SID 021 (D10) 302 ERROR E-ECU SID 022 302 ERROR E-ECU SID 064...
Page 893 87 Air conditioning 302 ERROR AC-system See operators manual 9 Hydraulic system 302 ERROR Monitoring Hydraulic Oil Temp. (MID 187 PPID 1041) 302 ERROR Solenoid valve Hydraulic power limitation 302 ERROR Pressure regulator RTD 302 ERROR Relay Hold position 302 ERROR Relay BSS 302 ERROR Sol.
Page 894 Parameter Identification Description (identification of parameter/value). A unique number for every parameter. PPID Proprietary Parameter Identification Description (Volvo-unique identification of parameter/value). A Volvo-unique number for each parameter. Subsystem Identification Description (identification of component). SID–number depends on which control unit (MID) they're sent from. Every control unit has a number series of its own for SID. Exceptions are SID–number 151–255, these are general for all systems.
Page 895 The troubleshooting information in this service manual is based on Volvo error texts. During reading of error codes from VCADS Pro, SAE error codes must be translated to Volvo error texts for further troubleshooting. The following references are for tables used when translating from SAE error codes to Volvo error texts.
Page 896 SAE error codes MID 128 Service Information 2014/4/24 Engine control unit (E-ECU) Profile: WLO, L150E [GB] SAE error codes MID 128 Engine control unit (E-ECU) SAE code Reference to troubleshooting information PID 045 302 ERROR Preheating Relay (MID 128 PID 45)
Page 897 SAE error codes MID 187 Service Information 2014/4/24 Vehicle control unit (V- ECU) Profile: WLO, L150E [GB] SAE error codes MID 187 Vehicle control unit (V-ECU) SAE code Reference to troubleshooting information PID 084 302 ERROR Monitoring Travel Speed (MID 187 PID 84)
Page 899 ERROR Monitoring Engine Service Information 2014/4/24 Oil Level (MID 128 PID 098) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Engine Oil Level (MID 128 PID 098) Component: SE2205 Sensor engine oil level Function Measures the engine oil level after the engine has been off for a time that is calculated depending on the oil's temperature.
Page 900 Sub-system 1 – 2 ≈ 3 V, pulse every 30 second (normal level) Control unit/ Signal cable cable ≈ 0 Ω 1 – harness Ground cable ≈ 0 Ω 2 –...
Page 901 ERROR Monitoring Engine Service Information 2014/4/24 Oil Level (MID 128 PID 098) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Engine Oil Level (MID 128 PID 098) Component: SE2205 Sensor engine oil level Function Measures the engine oil level after the engine has been off for a time that is calculated depending on the oil's temperature.
Page 902 Component 1 – 2 ≈ 12 Ω Sub-system 1 – 2 ≈ 3 V, pulse every 30 second (normal level) Control unit/ Signal cable ≈ 0 Ω cable 1 – EB4 harness Signal cable ≈ ∞ Ω 1 – Ground cable ≈...
Page 903 Service Information 2014/4/24 Oil Level (MID 187 PID 098) Profile: WLO, L150E [GB] ERROR Monitoring Engine Oil Level (MID 187 PID 098) Component: SE213 Sensor engine oil level Function Measures engine oil level when engine is shut off for more than 10 minutes and system voltage is on.
Page 904 Control unit/ Ground cable cable ≈ 0 Ω 2 – harness Feed cable ≈ 5 V 1 – Signalling circuit 3 – EB31 ≈ 0 Ω...
Page 906 ERROR Monitoring Engine Service Information 2014/4/24 Oil Pressure (MID 128 PID 100) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Engine Oil Pressure (MID 128 PID 100) Component: SE2203 Sensor engine oil pressure Function Engine oil pressure meter.
Page 907 Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Feed cable ≈ 5 V 1 – Feed cable – ≈ ∞ Ω Signal cable 2 – EA14 ≈ 0 Ω Signal cable ≈ ∞ Ω 2 –...
Page 908 ERROR Monitoring Engine Service Information 2014/4/24 Oil Pressure (MID 128 PID 100) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Engine Oil Pressure (MID 128 PID 100) Component: SE2203 Sensor engine oil pressure Function Engine oil pressure meter.
Page 909 Sub-system 2 – 4 ≈ 0.5 V (engine off) Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Feed cable ≈ 5 V 1 – Feed cable ≈ ∞ Ω 1 – Signal cable 2 – EB11 ≈ 0 Ω Signal cable ≈...
Page 911 Service Information 2014/4/24 Oil Temp. (MID 128 PID 175) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Engine Oil Temp. (MID 128 PID 175) Component: SE2202 Sensor engine oil temperature Function Measures engine oil temperature. The sensor is combined with SE2203 engine oil pressure.
Page 912 Component 3 – 4 Resistance values according to table Sub-system 3 – 4 ≈ 3 V (20 °C/68 °F) ≈ 0.4 V (100 °C/212 °F) Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Signal cable 3 – EA1 ≈...
Page 913 Service Information 2014/4/24 Oil Temp. (MID 128 PID 175) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Engine Oil Temp. (MID 128 PID 175) Component: SE2202 Sensor engine oil temperature Function Measures engine oil temperature. The sensor is combined with SE2205 engine oil level.
Page 914 Sub-system 3 – 4 ≈ 3 V (20 °C/68 °F) ≈ 0.4 V (100 °C/212 °F) Control unit/ Ground cable ≈ 0 Ω cable 4 – harness Signal cable ≈ ∞ Ω 3 – Signal cable ≈ 0 Ω 3 – EA31 Resistance values Oil temp.
Page 915 Service Information 2014/4/24 Level (MID 187 PID 096) Profile: WLO, L150E [GB] ERROR Monitoring Fuel Level (MID 187 PID 096) Component: SE207 Sensor fuel level Function Senses the level in the fuel tank for display in the gauge on the information display unit.
Page 916 Component 1 – 2 According table below. Control unit/ Ground cable cable ≈ 0 Ω 1 – harness Signal line ≈ 5 V 2 – Resistance values SE207 part no. 11039720 Display in instrument Usable fuel volume (litres) Float position[ 1] (mm) Resistance (Ω) Full tank...
Page 917  Empty tank 35[T1] [T1]At indication of empty tank, there's fuel for approx. 1 hour of operation. [ 1]Distance from sensor's lower edge to top edge of float. [ 2]Distance from lower edge of sensor to current fuel level.
Page 919 Information Type: Date: ERROR Preheating Relay Service Information 2014/4/24 (MID 128 PID 45) Profile: WLO, L150E [GB] Go back to Index Page ERROR Preheating Relay (MID 128 PID 45) Component: RE2501 Preheating relay induction air Function Activates preheating coil. References 301 Preheating of inlet air ...
Page 920 FMI 3   Error message Short-circuiting to voltage on cable between preheating relay  Amber central warning and control unit or short-circuiting in preheating relay.   Engine start difficult in Activation of preheating not allowed. cold weather.  White smoke at cold start.
Page 921 Information Type: Date: ERROR Preheating Relay Service Information 2014/4/24 (MID 128 PID 45) Profile: WLO, L150E [GB] Go back to Index Page ERROR Preheating Relay (MID 128 PID 45) Component: RE2501 Preheating relay induction air Function Activates preheating coil. References 301 Preheating of inlet air ...
Page 922 FMI 3   Error message Short-circuiting to voltage on cable between preheating relay  Amber central warning and control unit or short-circuiting in preheating relay.  lamp Activation of preheating not allowed.  Engine start difficult in cold weather. ...
Page 924 Service Information 2014/4/24 Air Temp. (MID 128 PID 105) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Charge Air Temp. (MID 128 PID 105) Component: SE2507 Sensor charge-air temperature Function Measures charge-air temperature. The sensor is combined with SE2508 Sensor boost pressure.
Page 925 Component 3 – 4 Resistance values according to table Sub-system 3 – 4 ≈ 2.6 V (20 °C/68 °F) ≈ 1.6 V (40 °C/104 °F) Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Signal cable ≈ ∞ Ω 3 –...
Page 926 Service Information 2014/4/24 Air Temp. (MID 128 PID 105) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Charge Air Temp. (MID 128 PID 105) Component: SE2507 Sensor charge-air temperature Function Measures charge-air temperature. The sensor is combined with SE2508 Sensor boost pressure.
Page 927 Sub-system 3 – 4 ≈ 2.6 V (20 °C/68 °F) ≈ 1.6 V (40 °C/104 °F) Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Signal cable ≈ ∞ Ω 3 – Signal cable 3 – EA47 ≈ 0 Ω SE2507 resistance values Air temp.
Page 928 Service Information Document Title: Function Group: Information Type: Date: Communication with data Service Information 2014/4/24 buses Profile: WLO, L150E [GB] Communication with data buses Figure 1 Communication E-ECU Engine control unit I-ECU Instrument control unit V-ECU Vehicle control unit Service socket for service display unit...
Page 929 The bus also functions as a "back-up" for the control bus, if it should fail for some reason. The system status is continuously updated and available for reading via the information bus. By connecting the service display unit or VCADS Pro to service sockets, it's possible to read error codes, perform tests, empty logged information, download parameters and download software.
Page 931 ERROR Monitoring Engine Service Information 2014/4/24 Air Filter (MID 128 PID 107) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Engine Air Filter (MID 128 PID 107) Component: SE2502 Monitor air filter pressure Function Detects clogged air filter. The monitor is combined with SE2501 Sensor, induction air temperature.
Page 932 Sub-system 1 – 2 ≈ 3 V Control unit/ Ground cable cable ≈ 0 Ω 2 – harness Feed cable ≈ 0.8 × system voltage 1 – Feed cable ≈ ∞ Ω 1 –...
Page 933 ERROR Monitoring Engine Service Information 2014/4/24 Air Filter (MID 128 PID 107) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Engine Air Filter (MID 128 PID 107) Component: SE2502 Monitor air filter pressure Function Detects clogged air filter. The monitor is combined with SE2501 Sensor, induction air temperature.
Page 934 Sub-system 1 – 2 ≈ 3 V Control unit/ Ground cable cable ≈ 0 Ω 2 – harness Feed cable ≈ 0.8 × system voltage 1 – Feed cable ≈ ∞ Ω 1 –...
Page 935 Information Type: Date: ERROR Monitoring Service Information 2014/4/24 (MID 128 PPID 19) Profile: WLO, L150E [GB] ERROR Monitoring EGR (MID 128 PPID 19) Component: MA2504 EGR-valve Function Return of exhausts for maximal combustion. References 301 Exhaust Gas Recirculation (EGR) ...
Page 936 Sub-system ≈ U ᵇᵃᵗ (inaktiv) EB30 – ≈ 0 V ᵇᵃᵗ (active) Control unit/ EMS7 – cable ≈ U ᵇᵃᵗ harness EB30 – ≈ ∞ Ω FU63 removed...
Page 937 Date: ERROR Monitoring Service Information 2014/4/24 Crankcase Pr (MID 128 PID 153) Profile: WLO, L150E [GB] ERROR Monitoring Crankcase Pr (MID 128 PID 153) Component: SE2509 Sensor crankcase pressure Function Measures crankcase pressure References 301 Engine crankcase pressure  370 Wiring diagram 29 ...
Page 938 Feed cable ≈ ∞ Ω EB17 – Ground cable ≈ 0 Ω 4 – Signal cable ≈ ∞ Ω EB28 –...
Page 939 Function Group: Information Type: Date: ERROR Radiator Service Information 2014/4/24 Control Profile: WLO, L150E [GB] ERROR Radiator Fan Control Component: MA202 Proportional valve cooling fan Function Controls cooling fan rpm. References 301 Cooling fan adjustment  EC18, feed 370 Wiring diagram 5 ...
Page 940 Feed cable 1 – EC18 ≈ 0 Ω [T1]Resistance increase with temperature increase...
Page 941 Information Type: Date: ERROR Solenoid valve Service Information 2014/4/24 Reversible fan Profile: WLO, L150E [GB] ERROR Solenoid valve Reversible fan Component: MA204 Solenoid valve retardation Function Controls retardation of cooling fan. References 301 Reversible cooling fan  EC1, feed 370 Wiring diagram 5 ...
Page 942 Feed cable 1 – EC1 ≈ 0 Ω [T1]Resistance increase with raised temperature...
Page 943 Monitoring Service Information 2014/4/24 Radiator Fan Revolutions (MID 187 PPID 1161) Profile: WLO, L150E [GB] ERROR Monitoring Radiator Fan Revolutions (MID 187 PPID 1161) Component: SE211 Sensor cooling fan speed Function Measures cooling fan speed. References 301 Cooling fan adjustment ...
Page 944 Signalling circuit 2 – EA28 ≈ 0 Ω...
Page 946 Service Information 2014/4/24 Coolant Temp. (MID 128 PID 110) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Engine Coolant Temp. (MID 128 PID 110) Component: SE2606 Sensor coolant temperature engine block Function Reads coolant temperature in engine.
Page 947 ≈ ∞ Ω 1 – ≈ ∞ Ω 2 – Sub-system 1 – 2 ≈ 3.0 V (20 °C/68 °F) ≈ 0.6 V (85 °C/185 °F) Control unit/ Ground cable cable ≈ 0 Ω 2 – harness Signal cable ≈ 5 V 1 –...
Page 948 Service Information 2014/4/24 Coolant Temp. (MID 128 PID 110) Profile: WLO, L150E [GB] Go back to Index Page ERROR Monitoring Engine Coolant Temp. (MID 128 PID 110) Component: SE2606 Sensor coolant temperature engine block Function Reads coolant temperature in engine.
Page 949 ≈ ∞ Ω 1 – ≈ ∞ Ω 2 – Sub-system 1 – 2 ≈ 3.0 V (20 °C/68 °F) ≈ 0.6 V (85 °C/185 °F) Control unit/ Ground cable cable ≈ 0 Ω 2 – harness Signal cable ≈ 5 V 1 –...
Page 950 Information Type: Date: ERROR Monitoring Coolant Service Information 2014/4/24 Level (MID 128 PID 111) Profile: WLO, L150E [GB] ERROR Monitoring Coolant Level (MID 128 PID 111) Component: SE2603 Sensor coolant level Function Monitors coolant level. References 301 Coolant Level ...
Page 951 Sub-system EB23 – EB11 ≈ 0.8 x U bat (normal level) ≈ 0 V (low level) Control unit/ Signal cable cable 1 – EB10 ≈ 0 Ω harness Signal cable ≈ 0 Ω EB23 –...
Page 952 ERROR Monitoring Coolant Service Information 2014/4/24 Outlet Temp. (MID 187 PPID 1157) Profile: WLO, L150E [GB] ERROR Monitoring Coolant Outlet Temp. (MID 187 PPID 1157) Component: SE210 Sensor coolant temperature outlet radiator Function Reads coolant temperature at radiator outlet. References 301 Coolant temperature, outlet radiator ...
Page 953 Control unit/ Ground cable cable ≈ 0 Ω 1 – harness Signalling circuit ≈ 5 V 2 – SE210 resistance and voltage values Temp. (°C) Temp. (°F) Resistance Voltage (V) Temp. (°C) Temp. (°F) Resistance Voltage (V) 3.8 kΩ 4.64 +140 0.5 kΩ...
Page 954 ERROR Accelerator Pedal Service Information 2014/4/24 Reduced Function Activated Profile: WLO, L150E [GB] ERROR Accelerator Pedal Reduced Function Activated Component: SE214 APS Sensor accelerator pedal position Function To give the desired, calibrated set point for throttle setting. References 301 Accelerator Pedal ...
Page 955 Sub-system 9 – 3 ≈ 0.35 V (accelerator pedal not applied) ≈ 2.2 V (accelerator pedal fully applied) Control unit/ Ground cable cable ≈ 990 Ω B – harness Feed cable ≈ 5 V C – Signalling circuit A – 9 ≈...
Page 956 ERROR Accelerator Pedal Service Information 2014/4/24 No Back-up Function Profile: WLO, L150E [GB] ERROR Accelerator Pedal No Back-up Function Component: SE214 IVS Sensor applied accelerator pedal Function To engage Limp Home function if an accelerator pedal APS (Accelerator Pedal Sensor) malfunction is detected.
Page 957 Control unit/ Feed cable Cable harness ≈ 24 V P3.15 – Signal cable D – 13 ≈ 0 Ω...
Page 958 Function Group: Information Type: Date: ERROR Hand throttle Service Information 2014/4/24 Profile: WLO, L150E [GB] ERROR Hand throttle Component: R205 Potentiometer Function  The hand throttle consists of a rotary potentiometer that gives increased voltage with clockwise rotation. The hand throttle is disengaged when the accelerator pedal or brake pedal is applied.
Page 959 Component 14 - 22 ≈ 80–900 Ω 22 – 0.7–4.6 V 14 -...
Page 960 Service Information 2014/4/24 Revolutions (MID 187 PID 190) Profile: WLO, L150E [GB] ERROR Monitoring Engine Revolutions (MID 187 PID 190) Component: SE201 Sensor engine speed converter Function Measures the input transmission speed for the V-ECU. The measurement is made against the converter gear wheel.
Page 961 ≈ ∞ Ω EA27 – ≈ ∞ Ω EA42 – Cable Ground cable harness 1 – EA42 ≈ 0 Ω Signalling circuit 2 – EA27 ≈ 0 Ω...
Page 962 Function Group: Information Type: Date: ERROR Relay Interval Service Information 2014/4/24 Wiper Profile: WLO, L150E [GB] ERROR Relay Interval Wiper Component: RE5 Relay interval wiper rear RE6 Relay interval wiper front Function Controls interval wiping. References 301 Interval Wiper ...
Page 963 "Er" ambient temperature Service Information 2014/4/24 (MID 187 PID 171) Profile: WLO, L150E [GB] "Er" ambient temperature (MID 187 PID 171) Component: SE807 Sensor ambient temperature Function The sensor measures ambient temperature (outdoor temperature) which is presented in the information display unit.
Page 964 Control unit/ Ground cable cable ≈ 0 Ω 2 – harness Signal line ≈ 5 V 1 – SE807 resistance and voltage values Air temp. (°C) Air temp. (°F) Resistance (kΩ) +104 +122...
Page 965 Service Information 2014/4/24 Computer Function (J1708/ J1587) Profile: WLO, L150E [GB] ATTENTION! Reduced Computer Function (J1708/J1587) Component: SAE J1708/J1587 Information bus Function The information bus is connected to all control units and service sockets. Information and diagnostic signals are sent by the bus.
Page 966   Error message Data bus open circuit.  Red central warning  Data bus short circuit to voltage or ground.   Function Safety mode Internal data bus short circuit in cable harness.  The machine can only be operated in 1st and 2nd gear both...
Page 967 Service Information 2014/4/24 Computer Function (J1939) Profile: WLO, L150E [GB] ATTENTION! Reduced Computer Function (J1939) Component: SAE J1939 Control bus (CAN-bus) Function The control bus is connected to all control units. The system's control signals are sent on the control bus.
Page 968 directions (Safety mode) Check-measuring Testing Test points Set point Condition Test method Sub-system CAN High V-ECU U ≈ 2–5 V DC EC16 – CAN Low U ≈ 0–3 V DC EC17 – CAN High – CAN Low U ≈ 0–1 V DC EC16 –...
Page 969 Function Group: Information Type: Date: STOP! COMPUTER FAILURE Service Information 2014/4/24 STOP THE VEHICLE Profile: WLO, L150E [GB] STOP! COMPUTER FAILURE STOP THE VEHICLE Component: SAE J1708/J1587 Information bus SAE J1939 Check bus (CAN-bus) References 301 Interruption in computer communication ...
Page 970 Function Group: Information Type: Date: ERROR E-ECU PID 094 Service Information 2014/4/24 Profile: WLO, L150E [GB] ERROR E-ECU PID 094 Component: SE2301 Sensor fuel pressure Function Measures the feed pressure after the fuel filter. References 301 Fuel feed pressure ...
Page 971 Component 2 – 4 ≈ 100 kΩ Sub-system 2 – 4 ≈ 0.5 V (engine off) Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Feed cable ≈ 5 V 1 – Feed cable ≈ ∞ Ω 1 – Signal cable 2 –...
Page 973 Function Group: Information Type: Date: ERROR E-ECU PID 094 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU PID 094 Component: SE2301 Sensor fuel pressure Function Measures the feed pressure after the fuel filter. References 301 Fuel feed pressure ...
Page 974 FMI 4  Feed line or signal line open circuit.  Feed line or signal line short-circuited to ground. Check-measuring Measuremen Measuring points Set point Condition Measuring method Component 2 – 4 ≈ 100 kΩ Sub-system 2 – 4 ≈ 0.5 V (engine off) Control unit/ Ground cable cable...
Page 975 Function Group: Information Type: Date: ERROR E-ECU PID 094 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU PID 094 Component: SE2301 Sensor fuel pressure Function Measures the feed pressure after the fuel filter. References 301 Fuel feed pressure ...
Page 976 Component 2 – 4 ≈ 100 kΩ Sub-system 2 – 4 ≈ 0.5 V (engine off) Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Feed cable ≈ 5 V 1 – Feed cable ≈ ∞ Ω 1 – Signal cable 2 –...
Page 978 Information Type: Date: ERROR E-ECU PID 102 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU PID 102 Component: SE2508 Sensor boost pressure Function Measures boost pressure. The sensor is combined with SE2507 Sensor, charge-air temperature.
Page 979 Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Feed cable ≈ 5 V 1 – Feed cable ≈ ∞ Ω 1 – Signal cable 2 – EA3 ≈ 0 Ω Signal cable ≈ ∞ Ω 2 – [T1]At elevation ≈...
Page 980 Information Type: Date: ERROR E-ECU PID 102 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU PID 102 Component: SE2508 Sensor boost pressure Function Measures boost pressure. The sensor is combined with SE2507 Sensor, charge-air temperature.
Page 981 Measuremen Measuring points Set point Condition Measuring method Sub-system 2 – 4 ≈ 1.1 V (engine off [T1]  Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Feed cable ≈ 5 V 1 – Feed cable ≈ ∞ Ω 1 –...
Page 982 Information Type: Date: ERROR E-ECU PID 102 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU PID 102 Component: SE2508 Sensor boost pressure Function Measures boost pressure. The sensor is combined with SE2507 Sensor, charge-air temperature.
Page 983 Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Feed cable ≈ 5 V 1 – Feed cable ≈ ∞ Ω 1 – Signal cable 2 – EA22 ≈ 0 Ω Signal cable ≈ ∞ Ω 2 – [T1]At elevation ≈...
Page 984 Date: ERROR E-ECU PID 108 Service Information 2014/4/24 Profile: WLO, L150E [GB] ERROR E-ECU PID 108 Component: Sensor in E-ECU Function The signal from the air pressure sensor is used to calculate boost pressure and to compensate the amount of fuel when operating at high altitudes.
Page 986 Information Type: Date: ERROR E-ECU PID 172 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU PID 172 Component: SE2501 Sensor induction air temperature Function Measures induction air temperature after air cleaner. The sensor is combined with SE2502 Monitor, air filter pressure.
Page 987 Sub-system 3 – 4 ≈ 2.6 V (20 °C/68 °F) ≈ 1.2 V (50 °C/122 °F) Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Signal cable ≈ 5 V 3 – Signal cable ≈ ∞ Ω 3 – SE2501 resistance values Air temp.
Page 988 Information Type: Date: ERROR E-ECU PID 172 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU PID 172 Component: SE2501 Sensor induction air temperature Function Measures induction air temperature after air cleaner. The sensor is combined with SE2502 Monitor, air filter pressure.
Page 989 Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Signal cable ≈ 5 V 3 – Signal cable ≈ ∞ Ω 3 – SE2501 resistance values Air temp. (°C) Air temp. (°F) Resistance Air temp. (°C) Air temp. (°F) Resistance 88.6±5.5 kΩ...
Page 990 Date: ERROR E-ECU PID 174 Service Information 2014/4/24 Profile: WLO, L150E [GB] ERROR E-ECU PID 174 Component: SE2306 Sensor fuel temperature Function Affects adjustment of fuel volume. Measures the temperature before the fuel filter. The sensor is combined with SE2301 Sensor fuel pressure.
Page 991 Control unit / Ground cable cable – Frame ground ≈ 0 Ω harness connection Feed cable – Frame ground ≈ 5 V connection Signal cable 2 – EA27 ≈ 0 Ω...
Page 993 Date: ERROR E-ECU SID 001 - E- Service Information 2014/4/24 ECU SID 006 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU SID 001 - E-ECU SID 006 Component: MA2301–MA2306 Unit injectors 1–6 Function Unit injectors for fuel.
Page 994 lamp FMI 3  Low power.  Short-circuit between high and low side.  Rough running.  Short-circuit to voltage in cable harness to injector's low side.  Abnormal sound.  cylinder FMI 4 operation.  Short-circuit to voltage in cable harness on respective injector's low or high side.
Page 995 Date: ERROR E-ECU SID 001 - E- Service Information 2014/4/24 ECU SID 006 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU SID 001 - E-ECU SID 006 Component: MA2301–MA2306 Unit injectors 1–6 Function Unit injectors for fuel.
Page 996 EA59, EA60, EA61, EA62 high voltage side EA12, EA16, EA20, EA24, EA28, EA32, EA36, EA40, EA44, EA52, EA56 low voltage side Malfunction detection conditions  Detected if engine control unit (E–ECU) registers that a unit injector is activated and, at the same time, there is an open circuit or short-circuit to the unit injector's high or low side.
Page 997 Check-measuring Measuremen Measuring points Set point Condition Measuring method Component/ EA12 – EA62 ≈ 2.3–2.8 Ω (20 °C) cable EA16 – EA59 harness EA20 – EA62 EA24 – EA59 EA28 – EA62 EA32 – EA59 EA36 – EA61 EA40 – EA60 EA44 –...
Page 998 Document Title: Function Group: Information Type: Date: ERROR E-ECU SID 017 Service Information 2014/4/24 Profile: WLO, L150E [GB] ERROR E-ECU SID 017 Component: MA2307 Valve fuel shut-off Function Controls shut-off of fuel. References 301 Fuel shut-off (D10)  370 Wiring diagram 31 ...
Page 999 Sub-system ≈ U ᵇᵃᵗ V 1 – Control unit/ 2 – EB34 ≈ 0 Ω cable harness...
Page 1000 Date: ERROR E-ECU Service Information 2014/4/24 (D10) Profile: WLO, L150E [GB] ERROR E-ECU SID 021 (D10) Component: SE2308 Needle lift sensor Function Indicates engine position and injection timing. The sensor gives a signal when injection starts on cylinder 1. References ...
Page 1002 Function Group: Information Type: Date: ERROR E-ECU SID 021 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU SID 021 Component: SE2703 Sensor camshaft rpm Function Measures rpm on camshaft and indicates camshaft's position. References 301 Camshaft speed ...
Page 1003 ≈ ∞ Ω 1 – ≈ ∞ Ω 2 – Component/ EA7–EA18 ≈ 775–945 Ω cable harness Cable Signal cable (+) harness 1 – EA7 ≈ 0 Ω Signal cable (+) ≈ ∞ Ω EA7 – Signal cable (-) 2 – EA18 ≈...
Page 1004 Function Group: Information Type: Date: ERROR E-ECU SID 021 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU SID 021 Component: SE2703 Sensor camshaft rpm Function Measures rpm on camshaft and indicates camshaft's position. References 301 Camshaft speed ...
Page 1005 Component 1 – 2 ≈ 775–945 Ω ≈ ∞ Ω 1 – ≈ ∞ Ω 2 – Component/ EA45 – EA46 ≈ 775–945 Ω cable harness Cable Signal cable (+) harness 1 – EA45 ≈ 0 Ω Signal cable (+) ≈...
Page 1007 Function Group: Information Type: Date: ERROR E-ECU SID 022 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU SID 022 Component: SE2701 Sensor engine rpm flywheel Function Measures engine rpm on flywheel and indicates flywheel position.
Page 1008 Check-measuring Measuremen Measuring points Set point Condition Measuring method Component/ EA30–EA31 ≈ 775–945 Ω cable harness Sub-system EA30–EA31 ≈ 10.5 V 1000 rpm Control unit/ Signal cable (-) cable 1 – EA31 ≈ 0 Ω harness Signal cable (-) ≈ ∞ Ω EA31–...
Page 1009 Function Group: Information Type: Date: ERROR E-ECU SID 022 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU SID 022 Component: SE2701 Sensor engine rpm flywheel Function Measures engine rpm on flywheel and indicates flywheel position.
Page 1010 Check-measuring Measuremen Measuring points Set point Condition Measuring method Component/ EA37 – EA38 ≈ 775–945 Ω cable harness ≈ ∞ Ω EA37 – ≈ ∞ Ω EA38– Sub-system EA37 – EA38 ≈ 10.5 V AC 1000 rpm Control unit/ Signal cable (-) cable 1 –...
Page 1011 Document Title: Function Group: Information Type: Date: ERROR E-ECU SID 064 Service Information 2014/4/24 Profile: WLO, L150E [GB] ERROR E-ECU SID 064 Component: SE2703 Sensor rpm injection pump Function Measures injection pump speed. References 301 Speed (rpm) injection pump ...
Page 1012 Signalling circuit (-) 2 – EA18 ≈ 0 Ω...
Page 1014 Function Group: Information Type: Date: ERROR E-ECU SID 232 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU SID 232 Component: E-ECU Function Checking voltage feed 5 V to sensor. References 301 Voltage feed for sensors ...
Page 1015 Function Group: Information Type: Date: ERROR E-ECU SID 232 Service Information 2014/4/24 Profile: WLO, L150E [GB] Go back to Index Page ERROR E-ECU SID 232 Component: E-ECU Function Checking voltage feed 5 V to sensor. References 301 Voltage feed for sensors ...
Page 1016 Information Type: Date: STOP! Turn Off Engine SID Service Information 2014/4/24 Profile: WLO, L150E [GB] STOP! Turn Off Engine SID 023 Component: PWM2301 Control rod actuator Function Controls control rod in injection pump. References 301 Indication of serious engine fault ...
Page 1017  Defective sensor for control rod position. Check-measurement Testing Test points Set point Condition Test method Component 2 – 7 ≈ 0,55–0,9 Ω Sub-system EA8 - EA10 ≈ 3 V f ≈ 200 Hz (engine idling) Control unit/ Return line cable 2 –...
Page 1018 Information Type: Date: STOP! Turn Off Engine SID Service Information 2014/4/24 Profile: WLO, L150E [GB] STOP! Turn Off Engine SID 024 Component: SE2307 Sensor control rod position Function Measures control rod position in injection pump. References 301 Indication of serious engine fault ...
Page 1019 Service Information Document Title: Function Group: Information Type: Date: STOP! Turn Off Engine SID Service Information 2014/4/24 Profile: WLO, L150E [GB] STOP! Turn Off Engine SID 240 Component: E-ECU Function Engine protection References 301 Indication of serious engine fault  Suitable ...
Page 1020 Service Information Document Title: Function Group: Information Type: Date: STOP! Turn Off Engine SID Service Information 2014/4/24 Profile: WLO, L150E [GB] STOP! Turn Off Engine SID 253 Component: E-ECU Function Engine protection References 301 Indication of serious engine fault  Suitable ...
Page 1021 Service Information Document Title: Function Group: Information Type: Date: STOP! Turn Off Engine SID Service Information 2014/4/24 Profile: WLO, L150E [GB] STOP! Turn Off Engine SID 254 Component: E-ECU Function Engine protection References 301 Indication of serious engine fault  Suitable If a malfunction occurs during operation, control unit (E–ECU) should be re-programmed or replaced.
Page 1022 Function Group: Information Type: Date: ERROR APS switch/ERROR Service Information 2014/4/24 APS II-switch Profile: WLO, L150E [GB] ERROR APS switch/ERROR APS II-switch Component: SW412 Mode selector Function Shifting programs are selected with switch SW412. References 301 APS  301 APS II ...
Page 1023 functional. Check-measuring Testing Test points Set point Condition Test method  Sub-system 13 – 2 24 V at AUTO (Heavy)[T1] 13 – 11 24 V at H (Normal)⁽ᵃ⁾ 13 – 24 24 V at M (Light mode 2)⁽ᵃ⁾ 13 – 25 24 V at SERVICE (Man)⁽ᵃ⁾...
Page 1024 ERROR Monitoring Travel Service Information 2014/4/24 Speed (MID 187 PID 84) Profile: WLO, L150E [GB] ERROR Monitoring Travel Speed (MID 187 PID 84) Component: SE403 Sensor travel speed Function Measures transmission output shaft speed. The value is used to calculate machine speed.
Page 1025 ≈ ∞ Ω 1 – ≈ ∞ Ω 2 – cable Ground cable harness 1 – EA42 ≈ 0 Ω Signalling circuit 2 – EA14 ≈ 0 Ω...
Page 1026 2014/4/24 Transmission Filter (MID 187 PPID 1029) Profile: WLO, L150E [GB] ERROR Monitoring Transmission Oil Filter (MID 187 PPID 1029) Component: SE401 Monitor differential pressure Function The monitor senses pressure-drop at the transmission oil filter. The monitor opens at a differential pressure of approx. 276 kPa (2.8 bar) (40 psi) and closes at a differential pressure of approx.
Page 1027 Service Information 2014/4/24 Transmission Level (MID 187 PID 124) Profile: WLO, L150E [GB] ERROR Monitoring Transmission Oil Level (MID 187 PID 124) Component: SE413 Sensor transmission oil level Function Monitors oil level in transmission oil sump. References 301 Transmission oil level ...
Page 1028 Sub-system EB32 – EB24 0.25–4.85 V Control unit/ Ground cable cable ≈ 0 Ω 2 – harness Feed cable ≈ 5 V 1 – Signalling circuit 3 – EB32 ≈ 0 Ω...
Page 1029 Service Information 2014/4/24 Transmission Oil Pressure (MID 187 PID 127) Profile: WLO, L150E [GB] ERROR Monitoring Transmission Oil Pressure (MID 187 PID 127) Component: SE405 Sensor transmission oil pressure Function Monitors oil pressure in the transmission in order to warn the operator in the event of low lubricating oil pressure.
Page 1030 Sub-system EB4 – EB24 ≈ 0.5 V (engine off) ≈ 4 kΩ (engine off) ≈ ∞ Ω EB4 – EB24 – EB40 – Control unit/ Ground cable cable ≈ 0 Ω 4 – harness Feed cable ≈ 5 V 1 – Signalling circuit 2 –...
Page 1031 Service Information 2014/4/24 Transmission Temp. (MID 187 PID 177) Profile: WLO, L150E [GB] ERROR Monitoring Transmission Oil Temp. (MID 187 PID 177) Component: SE406 Sensor transmission oil temperature Function Senses transmission oil temperature after the oil cooler. References 301 Transmission oil temperature ...
Page 1032 Control unit/ Ground cable cable ≈ 0 Ω 1 – harness Signalling circuit ≈ 5 V 2 – SE406 resistance and voltage values Oil temp. (° Oil temp. (° Resistance Voltage (V) Oil temp. (° Oil temp. (° Resistance Voltage (V) 3.8 kΩ...
Page 1033 Information Type: Date: ERROR Monitoring Turbine Service Information 2014/4/24 Revolutions (MID 187 PPID 1160) Profile: WLO, L150E [GB] ERROR Monitoring Turbine Revolutions (MID 187 PPID 1160) Component: SE402 Sensor turbine speed Function Measures turbine speed transmission. Measurement is performed against clutch drum (96 splines).
Page 1034 Cable Ground cable harness 1 – EA42 ≈ 0 Ω Signalling circuit 2 – EA41 ≈ 0 Ω...
Page 1035 Document Title: Function Group: Information Type: Date: ERROR Gear Selector Service Information 2014/4/24 Profile: WLO, L150E [GB] ERROR Gear Selector Component: SW402 Gear selector steering wheel column directional gear Function Selection of forward/reverse. References 301 Gear Selector  370 Wiring diagram 9 ...
Page 1036 ≈ U ᵇᵃᵗ at forward 22 – Checking with service display unit. Gear position Service display unit EL. ON/OFF INPUT 3 (pos.) I1 (P2.22) I2 (P2.9) In case of malfunction of F or R signals for more than 0.5 s, then malfunctions must be acknowledged. Acknowledgement is performed by moving the lever to N for more than 0.2 s.
Page 1037 Date: ERROR Gear Selector CDC Service Information 2014/4/24 Profile: WLO, L150E [GB] ERROR Gear Selector CDC Component: SW409 Gear selector lever steering Function Gear selector lever steering (SW409) is engaged with switch SW408. Gear selector lever steering is disengaged when the engine is shut off, the steering column gear selector (SW401B) is activated or if the CDC armrest is raised.
Page 1038 Sub-system EA5 - EA42 U ᵇᵃᵗ at position reverse EA32 - EA42 U ᵇᵃᵗ at position forward...
Page 1039 Date: ERROR Gear Selector F/R Service Information 2014/4/24 Profile: WLO, L150E [GB] ERROR Gear Selector F/R Component: SW404 Gear selector lever carrier Function The gear selector F/R lever carrier (SW404) is engaged with switch SW403. The gear selector F/R lever carrier is disengaged when the engine is shut off, the steering column gear selector (SW401B) is activated or if the CDC armrest is lowered.
Page 1040 Sub-system EA31 - EA42 U ᵇᵃᵗ at position reverse EA17 - EA42 U ᵇᵃᵗ at position forward...
Page 1041 Function Group: Information Type: Date: ERROR Gear shifting Service Information 2014/4/24 solenoids Profile: WLO, L150E [GB] ERROR Gear shifting solenoids Component: Gearshifting solenoids Function The solenoids regulate transmission gear changing. References 301 Gearshifting solenoids  370 Wiring diagram 11 ...
Page 1042 Testing Test points Set point Condition Test method  Component 1 – 2 ≈ 22 Ω [T1] ≈ ∞ Ω 1 – ≈ ∞ Ω 2 – Cable Feed cable harness EC20 – 1 ≈ 0 Ω EC22 – 1 ≈...
Page 1043 ERROR Monitoring Axle Oil Service Information 2014/4/24 Temp. (Front axle) (MID 187 PPID 1154) Profile: WLO, L150E [GB] ERROR Monitoring Axle Oil Temp. (Front axle) (MID 187 PPID 1154) Component: SE410 Sensor front axle temperature Function Senses front axle oil temperature. References 301 Axle oil temperature ...
Page 1044 Signal cable 2 – ≈ 5 V SE410 resistance and voltage values Oil temp. (° Oil temp. (° Resistance Voltage (V) Oil temp. (° Oil temp. (° Resistance Voltage (V) 3.8 kΩ 4.64 +140 0.5 kΩ 3,04 3.7 kΩ 4.62 +158 0.4 kΩ...
Page 1045 ERROR Monitoring Axle Oil Service Information 2014/4/24 Temp. (Rear axle) (MID 187 PPID 1153) Profile: WLO, L150E [GB] ERROR Monitoring Axle Oil Temp. (Rear axle) (MID 187 PPID 1153) Component: SE411 Sensor rear axle temperature Function Senses rear axle oil temperature. References 301 Axle oil temperature ...
Page 1046 Signal cable ≈ 5 V 2 – SE411 resistance and voltage values Oil temp. (° Oil temp. (° Resistance Voltage (V) Oil temp. (° Oil temp. (° Resistance Voltage (V) 3.8 kΩ 4.64 +140 0.5 kΩ 3,04 3.7 kΩ 4.62 +158 0.4 kΩ...
Page 1047 Information Type: Date: ERROR Differential lock Service Information 2014/4/24 Profile: WLO, L150E [GB] ERROR Differential lock Component: MA407 Solenoid valve Differential lock Function Differential lock engagement takes place with switch SW414, which supplies voltage to the I-ECU when activated. The V-ECU activates solenoid valve MA407.
Page 1048 Signalling circuit ≈ 24 V 1 –...
Page 1049 Date: ERROR Solenoid valve Service Information 2014/4/24 Brake pressure charging Profile: WLO, L150E [GB] ERROR Solenoid valve Brake pressure charging Component: MA502 Solenoid valve brake pressure charging Function Controls brake pressure charging. References 301 Brake pressure charging  370 Wiring diagram 15B ...
Page 1050 [T1]Resistance increases with increasing temperature...
Page 1051 Function Group: Information Type: Date: WARNING! Brake Service Information 2014/4/24 Pressure Profile: WLO, L150E [GB] WARNING! Low Brake Pressure Component: SE502 Monitor low brake pressure Function Reads low brake pressure. References 301 Brake pressure  370 Wiring diagram 15B ...