Volvo L40B Service Manual
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Volvo L40B Service Manual

Volvo L40B Service Manual

Compact wheel loader
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L40B Compact Wheel Loader
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Service Manual

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Summary of Contents for Volvo L40B

  • Page 1 L40B Compact Wheel Loader W E B E D I T I O N Service Manual...
  • Page 2 CWL, L40B [GB] Description The L40B wheel loader has a central articulating oscillating joint and four-wheel drive. The lifting frame is equipped with a hydraulic quick-change attachment bracket. TP-kinematics with double-acting lift cylinders provide high breakout force and exact parallel guidance when lifting.

  • Page 3: Tightening Torques

    Service Information Document Title: Function Group: Information Type: Date: Tightening torques Service Information 2014/3/10 Profile: CWL, L40B, L45B [GB] Tightening torques Wheel nuts Wheel nuts Thread M Wrench size (width across flats) Tightening torque (Nm) M22 x 1.5 560 – 600...
  • Page 4 G 1/2 27 alt. 32 G 3/4 32 alt. 41 41 alt. 46 G 1 1/4 G 1 1/2 Valve connections, ORFS-connections with O-ring seals (ISO 6149) Connection thread (mm) Wrench size, width across flats (mm) Tightening torque (Nm) M8 x 1.0 M10 x 1.0 M12 x 1.5 17 alt.
  • Page 5 M20 x 1.5 M22 x 1.5 M26 x 1.5 M27 x 2.0 M33 x 2.0 M42 x 2.0 M48 x 2.0 Connection thread (inches) Allen key dim. (mm) Tightening torque (Nm) G 1/8 G 1/4 G 3/8 G 1/2 G 3/4 G 1 1/4 G 1 1/2 Blanking plugs with O-ring seal (ISO 6149)
  • Page 6 1 11/16 – 12 UN 2 – 12 UN * Threads and sealing surface must not be oiled in before tightening. Hose clamps Hose clamps with worms Intended for hose outside diameter Wrench size, width across flats (mm) Tightening torque (Nm) (mm) 10 –...
  • Page 7 Hex bolts and Allen head bolts Blind rivet Wrench size (width across Torque (Nm) Torque flats) (Nm) Thread bolt Allen head 8.8 FZB & 8.8 FZB & 10.9 12.9 Untreated (mm/inch) (mm/inch) bolt (mm/ Fe/Zn-Fe Fe/Zn-Fe Phosphated Lubricated inch) Lubricated Lubricated 1 120 –...

  • Page 8: Conversion Tables

    Service Information Document Title: Function Group: Information Type: Date: Conversion tables Service Information 2014/3/10 Profile: CWL, L40B, L45B [GB] Conversion tables Length Unit mile 0.01 0.00001 0.3937 0.03281 0.01094 0.000006 0.001 39.37 3.2808 1.0936 0.00062 100000 1000 39370.7 3280.8 1093.6 0.62137...
  • Page 9 28.3495 0.02835 0.000028 0.0625 453.592 0.45359 0.000454 1 ton (metric) = 1.1023 ton (US) = 0.9842 ton (UK) Pressure Unit kp/cm2 Pa=N/m2 lbf/in2 lbf/ft2 kp/cm2 0.98067 98066.5 98.0665 14.2233 2048.16 1.01972 100000 14.5037 2088.6 Pa=N/m2 0.00001 0.001 0.001 0.00015 0.02086 0.01020 0.01 1000...
  • Page 10 x0.948 =Btu x1.055 x0.239 =calorie x4.19 Speed and acceleration m/s2 x3.28 =ft/s2 x0.305 =m/s2 x3.28 =ft/s x0.305 =m/s km/h x0.62 =mph x1.61 =km/h Horsepower/torque Bhp x5252 rpm= TQ (lb·ft) TQ x rpm 5252=bhp Temperature ºC =(ºF-32)/1.8 ºF =(ºC x1.8) +32 Flow factor l/min (dm3/min) x0.264...
  • Page 11 Document Title: Function Group: Information Type: Date: mounts, tightening Service Information 2014/3/10 torques Profile: CWL, L40B [GB] Cab mounts, tightening torques Figure 1 Cab suspension, fixing element Screw Puffer Pipe Washer Fixing element, tightening torque Fixing nuts on frame 200 Nm (148 lbf ft)
  • Page 12 Date: Machine, transporting Service Information 2014/3/10 Profile: CWL, L40B [GB] Machine, transporting Steering joint lock Figure 1 Steering joint lock When transporting the machine on a trailer or by rail, the articulated steering joint must be locked with the steering lock.
  • Page 13 Fixing eyes on rear frame (towing device) Roof fixing bolts with washers Lifting of machine To lift the machine, use the indicated lashing points and lock the steering joint. The location of the lashing points is shown on the diagram. Marking plate - Load/lift Figure 3 Lift machine...
  • Page 14 Service Information Document Title: Function Group: Information Type: Date: E-tool Cab support Service Information 2014/3/10 Profile: CWL, L40B [GB] E-tool Cab support Figure 1 E-tool Cab support...
  • Page 16 Safety concerns everybody! 191 Service Information 2014/3/10 Profile: CWL, L40B [GB] Safety concerns everybody! Always follow the instructions in the machine's Operator's manual. The Operator's Manual must be kept in the machine and must always be to hand. Many hours have been spent in designing and producing the safest and most efficient machine possible. However, all this...
  • Page 17 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 18 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 19 All changes and repairs have been performed as stipulated by Volvo.  Only Volvo Original Parts/accessories or equivalent parts meeting 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 20 Some important rules are given below:  Before starting the engine, check the control lamps by turning the ignition key to position "1", see Operator's Manual.  Carry out all safety checks specified in the Operator's Manual. WARNING Never operate the machine if you are tired or under the influence of alcohol, medicine or other drugs. ...
  • Page 21 Safety rules when servicing 191 Service Information 2014/3/10 Profile: CWL, L40B [GB] Safety rules when servicing This section covers general safety rules when checking and servicing. Other rules, information and warning texts are given in this manual and also in the Operator's Manual.
  • Page 22 Figure 1 Protective equipment  Always stop the engine to service the machine, unless otherwise instructed on plates or in this manual.  Stop the engine before opening engine hood, radiator casings etc. Make sure that no tools or other objects, which can cause damage, are forgotten and left in the machine.
  • Page 23 Service Information 2014/3/10 jacking up the machine Profile: CWL, L40B [GB] Safety when raising and jacking up the machine  When raising or supporting machine parts, always ensure that the equipment used is designed at least for the load concerned.

  • Page 24: Fire Prevention Measures

    Fire prevention measures Service Information 2014/3/10 Profile: CWL, L40B, L45B [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 25 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 26 Service Information 2014/3/10 regarding tyre handling Profile: CWL, L40B [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 27 Service Information 2014/3/10 regarding tyre handling Profile: CWL, L40B [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 28 2014/3/10 exposure Profile: CWL, L35B, L40B, L45B, L30B [GB] Checklist after a fire or heat exposure If a machine has been damaged by fire or been exposed to intense heat, the following precautionary measures according to the following check list must under all circumstances be followed: ...
  • Page 29 2014/3/10 plastics and rubber Profile: CWL, L35B, L40B, L45B, L30B [GB] Health hazards with paint, plastics and rubber Work on painted surfaces No welding or torch-cutting is allowed on painted surfaces. All paint is broken down when heated and forms a wide variety of substances that may be irritating and very hazardous to health after prolonged or repeated exposure.
  • Page 30 If swelling, redness or burning sensations appear and contact with heated fluor rubber is suspected, contact a physician immediately. If a machine or a component for a machine has been exposed to fire or other intense heat, it shall be handled by specially trained personnel.
  • Page 31 Service Information 2014/3/10 and fuel Profile: CWL, L40B [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 32 Service Information 2014/3/10 air conditioning refrigerant Profile: CWL, L35B, L40B, L45B, L30B [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 33 The gases have no smell and may cause serious damage to the lungs already at low concentrations. Refrigerant R134a may, if incorrectly handled, cause serious personal injuries as well as damage to the environment. Therefore, great care must be taken in all work with air conditioning units! The rules given below may be a great help to avoid injuries to all who come into contact with refrigerants.
  • Page 34 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 35: Waste Handling

    Waste handling Service Information 2014/3/10 Profile: CWL, L40B [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 36 Service Information 2014/3/10 handling Profile: CWL, L40B [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 37 2014/3/10 fluids Profile: CWL, L40B [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 38 2014/3/10 environmentally contaminated areas Profile: CWL, L40B [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 39 Date: Decontamination Service Information 2014/3/10 Profile: CWL, L40B [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 41: Lubricant Recommendation

    Other mineral oils may be used if these meet the recommended viscosity classes and quality standards. If other oil qualities are used (e.g. biodegradable oil), approval of Volvo CE is required. If the hydraulic system is factory-filled with biodegradable hydraulic oil (see sticker on filler tube), only the oil quality specified on the sticker may be used for topping up.
  • Page 42 Genuine VOLVO antifreeze to ASTM D4985...
  • Page 43 Service Information 2014/3/10 electrical system Profile: CWL, L40B [GB] Work on the machine's electrical system  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 44: Electric Welding

    Electric welding Service Information 2014/3/10 Profile: CWL, L40B [GB] Electric welding Before starting any electric welding on the machine or attachments connected to the machine, the battery disconnect switch must be turned off or the battery ground lead must be disconnected.
  • Page 45 2014/3/10 hydraulic system Profile: CWL, L40B [GB] Cleanliness, braking and hydraulic system The greatest possible cleanliness must be observed for all work. Wipe all pipes and hose connections clean before disconnecting them, remove all flakes of paint, etc. Plug all pipes, hoses, cylinders, etc. immediately after disconnecting...
  • Page 46 Service Information 2014/3/10 Profile: CWL, L40B [GB] Environmental concern When performing service and maintenance on the machine, take care of the environment. Oil and other fluids are environmentally harmful and can cause great damage. Oil degrades very slowly in water and sediment, e.g., one litre of oil can contaminate one million litres of drinking water.
  • Page 47 Service Information 2014/3/10 inspection Profile: CWL, L40B [GB] Arrival and delivery inspection Before the machine leaves the factory, it is tested and set up. The dealer must also perform an arrival and delivery inspection. Delivery instructions On delivery of the machine, the dealer must issue the delivery documentation to the purchaser according to the required...

  • Page 48: Service Programme

    Date: Service Programme Service Information 2014/3/10 Profile: CWL, L40B [GB] Service Programme Warranty inspection To guarantee the validity of the warranty, all warranty inspections must be performed. This is a condition for the warranty. Condition test The condition test is performed in the workshops of the dealer and gives information on the general condition of the...

  • Page 49: Service Intervals

    Function Group: Information Type: Date: Service intervals Service Information 2014/3/10 Profile: CWL, L40B [GB] Service intervals Every 10 operating hours Check engine oil level Check hydraulic oil level. Double filter system / oil-bath filter (optional equipment) Check fuel system water separator...
  • Page 50 Information Type: Date: Engine, changing oil and Service Information 2014/3/10 filter Profile: CWL, L40B [GB] Engine, changing oil and filter Op nbr 173-059 Figure 1 Engine oil filter change Drain point, engine oil Filling point, engine oil Filter, engine oil 1.
  • Page 51 Change the oil filter at every engine oil change. Loosen the filter cartridge with a filter wrench. 4. Fill the new oil through the filler tube to the upper dipstick mark (MAX) Oil quantity including filter approx. 14 litres (3.7 US gal)
  • Page 52 Function Group: Information Type: Date: Coolant, changing Service Information 2014/3/10 Profile: CWL, L40B [GB] Coolant, changing Op nbr 173-087 Draining WARNING Risk of scalding and burns. The coolant may be hot. 1. Place a collecting vessel under the draining point.
  • Page 53 Take care of the coolant in an environmentally safe way. Filling IMPORTANT! Never fill cold coolant in a hot engine since this can cause cracks in the engine block and cylinder head. 4. The engine must be switched off and the temperature regulator (heating) stand in the largest "red field" position. 5.
  • Page 54 3. To fill, turn the wheel hub so that the word "Oil level" is horizontal. 4. In both hubs, fill oil to overflow. Then fill via the filler and check opening on the axle cradle to overflow. Oil fill quantity L40B, SN 192 and L45B, SN 195 total: 7.9 Liter (2.1 US gal)
  • Page 55 Oil fill quantity L40B, SN 191 and L45B, SN 194 total: 8.4 Liter (2.2 US gal) The dropbox is mounted via a flange to the rear axle and shares an oil system with it. Oil change rear axle with dropbox 5.
  • Page 56 Date: Hydraulic tank, Service Information 2014/3/10 changing oil and filter Profile: CWL, L40B [GB] Hydraulic oil tank, changing oil and filter Figure 1 Hydraulic system, oil and filter change Drain point, hydraulic oil tank Filler pipe Filter casing Breather valve, filter...
  • Page 57 Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. 1. Run the machine until the oil in the hydraulic system is at normal operating temperature. 2. Place the machine in service position on level ground. 3.

  • Page 58: Service Positions

    Service positions Service Information 2014/3/10 Profile: CWL, L40B [GB] Service positions NOTE! Before all maintenance or repair work, park the vehicle on flat ground, lower the tools flat on the ground and release the pressure in the hydraulic system, i.e. turn off the engine, activate the working hydraulics lever several times.
  • Page 59 Towing Service Information 2014/3/10 Profile: CWL, L40B [GB] Towing WARNING Before taking any action for towing or recovering, the parking brake must be applied and the wheels must be blocked to prevent the machine from starting to roll. Work with extreme care when towing/recovering in order to avoid personal injuries and, at worst, fatalities.

  • Page 61: Engine Description

    Machines of SN 1911001- / -1911499 and 1921001- / -1921499 are equipped with the DEUTZ-BF4M 1013 E engine. Machines of SN 1911500- / -1913000 and 1921500- / -1923000 are equipped with the VOLVO-D5D engine. Both engines are four cylinder, four stroke, in-line direct-injected diesel engines, with exhaust turbo and liquid cooling.
  • Page 62 Figure 2 Components, servicing view Oil filler pipe Coolant pump Fuel pump Vibration damper Oil filter Engine mounting Fuel filter Oil sump Oil dipstick Oil cooler Attachment for power take-off Cylinder head Coolant supply Components, exhaust view...
  • Page 63 Figure 3 Components, exhaust view Starter motor Turbocharger Engine fan Exhaust manifold Inlet manifold Transport device Crankcase ventilation Speed (rpm) sensor. Flywheel...

  • Page 64: Compression Test

    Function Group: Information Type: Date: Compression test Service Information 2014/3/10 Profile: CWL, L40B [GB] Compression test Op nbr 210-002 9998694 Adapter 9988539 Pressure gauge 9998007 Adapter Injection valves are removed and valve clearance checked. 237 Injectors all, testing and adjusting incl removing and fitting...
  • Page 65 Figure 3 If necessary, screw on adapter 9998007 for the connector. 4. Connect compression tester 9988539. Crank engine with the starter. 5. Carry out compression test on each cylinder. Compression: 3 +0.8 MPa (30 +8 bar) (435 +116 psi) NOTE! The compression measured depends on the starter rpm during the measurement and the engine's altitude.

  • Page 66: Cylinder Head, Description

    Service Information 2014/3/10 Profile: CWL, L40B [GB] Cylinder head, description The cylinder head is made of cast iron. The inlet air enters vertically (A) and the exhaust gases exit horizontally (B). Inlet and exhaust are on the same side of the cylinder head.
  • Page 67 Figure 1 Due to a new valve spring guide design, it is no longer possible to use a feeler gauge to adjust the valves of L40B machines from SN 1913001 – / 1923001 – and L45B machines from SN 1943001 – / 1953001 –. For this reason, valve clearance must be adjusted using the rotation angle disc.
  • Page 68 Jam nut Adjustment screw Rocker arm Washer Snap ring Spring disc Valve Push rod...
  • Page 69 Function Group: Information Type: Date: Valves, adjusting Service Information 2014/3/10 Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Valves, adjusting Op nbr 214-012 885530 Rotation tool NOTE! Only adjust the valve clearance with cold engine. 1. Place the machine in service position.
  • Page 70 NOTE! Valve overlap means: exhaust valve not yet closed, inlet valve begins to open. Figure 3 5. Adjust the valves marked black in illustration. Inlet valve: 0.3 mm (0.0118 in) Exhaust valve: 0.5 mm (0.0197 in) NOTE! In case the cylinder head gasket has been replaced, increase valve clearance by 0.1 mm (0.0040 in) ! Figure 4 6.
  • Page 71 Figure 6 8. Install the gasket, replace if necessary. 9. Attach the valve cover and retainer plate. Tightening torque 11 Nm (8.1 lb ft) NOTE! Ensure that the rubber seals for the fuel lines are fitted in the correct position during assembly. Figure 7 Valve cover gasket Rubber seal...
  • Page 72 Function Group: Information Type: Date: Valves, adjusting Service Information 2014/3/10 Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Valves, adjusting Op nbr 214-012 885530 Rotation tool 885812 Timing tool NOTE! Only adjust the valve clearance with cold engine.
  • Page 73 NOTICE Valve adjustment with the engine running is not allowed since the valves may strike the piston, causing severe damage. Figure 3 Exhaust valves: (EX) 1, 3, 5, 7 Inlet valves: (IN) 2, 4, 6, 8 5. Rotate the engine until the valves on cylinder no. 1 stand at "valve overlap". NOTE! Valve overlap means: exhaust valve not yet closed, inlet valve begins to open.
  • Page 74 Figure 6 NOTE! The rocker arm must make contact (no gap) with the thrust washer (arrow) of the spring disc. 7. Position the rotation angle disc on the adjuster screw. Secure the magnet of the rotation angle disc to the cylinder head.
  • Page 75 Figure 9 Adjust exhaust valve clearance 10. Rotate the engine one revolution again until the valves of cylinder no. 4 are at "valve overlap". Adjust valve clearance in accordance with the black mark on the adjustment chart for each cylinder. Exhaust valve: (EX)150°...
  • Page 76 2014/3/10 description Profile: CWL, L40B [GB] Engine timing gear, description On the engines, the timing gears are located at the flywheel end for the camshaft and power take-off. Stamped markings on the crankshaft and camshaft gears are used to facilitate correct setting.
  • Page 77 Each bearing runs in a bearing bush that is pressed into the crankcase. There is one inlet, exhaust and injection pump cam per cylinder. The axial stop for the camshaft is located in the timing case cover. L40B machines from SN 1913001- / 1923001- and L45B machines from SN 1943001- / 1953001- are equipped with unregulated internal exhaust gas recirculation (IEGR).

  • Page 78: Crankshaft, Description

    Crankshaft, description Service Information 2014/3/10 Profile: CWL, L40B [GB] Crankshaft, description The forged crankshaft is provided with integrated balancing weights. The gear that drives the engine's timing gear and the flange for the flywheel are shrink-mounted on the crankshaft. Figure 1...
  • Page 79 2014/3/10 description Profile: CWL, L40B [GB] Connecting rod, description The connecting rod, made of forged steel, is provided with a balancing weight (A) at the crankshaft bearing (big-end) to compensate for manufacturing tolerances with regards to weight and the position of the centre of gravity.
  • Page 80 Figure 1...
  • Page 81 Function Group: Information Type: Date: Lubrication system, Service Information 2014/3/10 description Profile: CWL, L40B [GB] Lubrication system, description Lubrication system Figure 1 Oil pressure switch Oil cooler Oil pump Safety valve, oil cooler pressure-control valve) System pressure valve Oil filter, full-flow filter...
  • Page 82 Oil line to turbocharger Tappet with pulse lubrication Push rod,oil duct for lubrication of rocker mechanism Rocker arm Return oil duct to oil pan Spray noozle for cooling...

  • Page 83: Oil Pump, Description

    Service Information 2014/3/10 Profile: CWL, L40B [GB] Oil pump, description The lubrication oil pump is designed as a rotor pump and is mounted in the front cover. The inner rotor (1) is located on the crankshaft (4), by which it is driven.
  • Page 84 Function Group: Information Type: Date: Oil cooler, replacing Service Information 2014/3/10 Profile: CWL, L40B [GB] Oil cooler, replacing Op nbr 223-006 1. Place the machine in service position. Figure 1 2. Switch off the battery connection switch. 173 Coolant, changing 3.
  • Page 85 Figure 2 9. Remove the oil cooler from its housing. Unscrew the plug (1). Figure 3 10. Unscrew the collar bolts (oil cooler attachment) and remove the oil cooler. Figure 4 11. Clean the oil cooler housing and all sealing surfaces. 12.
  • Page 86 Figure 5 13. Put a new gasket (1) on the collar bolt and coat with assembly paste. Insert a new seal ring (2) in the groove and apply a thin coating of oil. Figure 6 14. Screw on and tighten the flange nuts. Tightening torque: pretension 80 Nm (59 lbf ft), re-tension 160 Nm (118 lbf ft).
  • Page 87 Figure 8 18. Plug in the electric pin plug connections (2) and connectors (3) to the oil pressure switch. Fit cable tie. 19. Attach fuel lines (4) and (5). 20. Screw on the engine oil filter (6) and fuel filter (7). 173 Coolant, changing 21.

  • Page 88: Fuel System, Description

    Service Information 2014/3/10 Profile: CWL, L40B [GB] Fuel system, description The fuel flows from the tank via the primary filter to the fuel feed pump and then travel through the secondary filter to the inlet duct of the injection pump. From the injection pump, the fuel travels via the delivery pipes to the injectors.
  • Page 89 Injector Pressure retention valve Fuel return pipe...
  • Page 90 2014/3/10 description Profile: CWL, L40B [GB] Fuel feed pump, description The fuel feed pump is a rotor pump operated via a V-belt. The fuel feed pump has a dual valve. The pressure relief valve (1) is a piston valve that opens at 6 ± 0.5 bar (87 ± 7 psi). At the same time, the valve limits system pressure to 9.5 ±...
  • Page 91 Fuel filters, replacing Service Information 2014/3/10 Profile: CWL, L40B [GB] Fuel filters, replacing Op nbr 233-014 A reduction in engine power can be caused by a clogged fuel filter. If the filter becomes clogged quickly, check fuel for contamination and clean fuel tank if necessary.
  • Page 92 Figure 2 Fuel pre-filter Filter element Sight glass 6. Clean the sealing surface of filter holder. 7. Unscrew sight glass from the filter insert and clean. 8. Check seals for damage and replace if necessary. 9. Screw sight glass on the new filter insert. 10.
  • Page 93 Function Group: Information Type: Date: Feed pump, replacing Service Information 2014/3/10 Profile: CWL, L40B [GB] Feed pump, replacing Op nbr 233-002 2902691 V-belt tension gauge 1. Place the machine in service position. Figure 1 2. Switch off the battery connection switch.
  • Page 94 Figure 2 5. Slacken the bolts (1), move the fuel feed pump in the direction of the arrow and remove the V-belt (2). Figure 3 6. Unscrew the bolts (1) and remove the fuel feed pump. Figure 4 7. Unscrew the bolts (1), remove the fuel feed pump (2) and fasten the clamping strap (3) to the new fuel feed pump. Tightening torque 20 ±...
  • Page 95 Figure 5 8. Fit the clamping strap with fuel feed pump. Screw on the bolts (1) and position the V-belt (2). Figure 6 9. Use a suitable tool to press the clamping strap in the direction of the arrow and tighten the bolts (1) to 30 Nm (22 lbf ft).
  • Page 96 Run for 15 minutes under load and re-tension. 400 ± 50 N NOTE! If the set value is not achieved, the tensioning procedure must be repeated.
  • Page 97 2014/3/10 adjusting incl removing and fitting Profile: CWL, L40B [GB] Injectors all, testing and adjusting incl removing and fitting Op nbr 237-074 9998007 Adapter 9996400 Impact puller Injection valve, removing 1. Remove pressure control valve and valve cover. Unplug cable plug from stop solenoid, governor and temperature sensor.
  • Page 98 Figure 2 4. Remove injection valves. Figure 3 9996400 9998007 NOTE! If seized, use puller 9996400 with adapter 9998007. NOTICE Optimal cleanliness must be observed when testing injectors. Only use clean testing oil acc. to ISO 4113 or clean diesel oil. NOTE! The injection valves are leak-proof.
  • Page 99 Figure 4 6. Attach injection valve to nozzle tester. Figure 5 WARNING Fuel jets out from the injector at very high pressure. If the jet hits body parts, fuel may penetrate and cause blood poisoning. 7. Slowly press the nozzle tester's lever down and read the pressure gauge. If the pressure gauge indicator stays still or suddenly drops, opening pressure is reached.
  • Page 100 Figure 6 10. Set the opening pressure by selecting the necessary adjustment shim. Thicker shims give a higher opening pressure. Assemble the injection valve. Tighten clamping nut. Tightening torque 30 +10 Nm (22 +7.4 lbf ft) Figure 7 Components, injection valve Clamping nut Nozzle Spacer...
  • Page 101 Figure 9 Drop falls Vibration and jet test 16. Disconnect tester pressure gauge The vibration test allows an audible test of ease of movement of the nozzle needle in the nozzle body. New injection valves have different vibration behaviour from used ones. Wear in the needle area causes deterioration.
  • Page 102 Figure 11 Recess 19. Fit clamping claw and loosely install screw . 20. Attach new injection pipes with rubber seals. Tighten lock nuts finger-tight. NOTE! When fitting injection pipes, the seals must be precisely positioned to each other. Bending the injection pipes is not permitted.

  • Page 103: Turbocharger, Description

    Service Information 2014/3/10 Profile: CWL, L40B [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 104 Function Group: Information Type: Date: Air cleaner, description Service Information 2014/3/10 Profile: CWL, L40B [GB] Air cleaner, description Triple-stage intake air cleaning Ejector - pre-cleaner Main filter with control light in instrument panel Secondary filter Air filter (optional) Oil-bath air cleaner...

  • Page 105: Cooling System, Description

    Service Information 2014/3/10 Profile: CWL, L40B [GB] Cooling system, description The cooling system has a closed cooling circuit, with externally operated fans. The coolant pump (1) is operated via the V- belt, delivering coolant to the cylinder block via the oil cooler (2). In the cylinder block, the coolant flows around the cylinder liner (3) and up to the cylinder head grooving (4).
  • Page 106 Information Type: Date: Coolant pump, replacing Service Information 2014/3/10 Profile: CWL, L40B [GB] Coolant pump, replacing Op nbr 262-002 1. Place the machine in service position. 2. Switch off the battery connection switch. 173 Coolant, changing 3. Drain coolant; see 233 Feed pump, replacing 4.
  • Page 107 Figure 3 10. Tighten the bolts alternately to 30 Nm (22 lbf ft). Figure 4 233 Feed pump, replacing 11. Remove the fuel feed pump and tension the V-belt; see 173 Coolant, changing 12. Top up coolant; see 13. Start the engine and allow it to warm up so that the cooling system is completely filled and bled. Check for leaks. Allow the engine to cool and then check level.
  • Page 108 Function Group: Information Type: Date: Thermostat, replacing Service Information 2014/3/10 Profile: CWL, L40B [GB] Thermostat, replacing Op nbr 262-098 1. Place the machine in service position. 2. Switch off the battery connection switch. 173 Coolant, changing 3. Drain coolant; see NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
  • Page 109 7. Coat the seal ring of the new thermostat with assembly paste. 8. Fit the thermostat in the housing. NOTE! The arrow on the thermostat should point upwards. 9. Fasten the hose studs to the thermostat housing. Tightening torque 30 Nm (22 lbf ft). 173 Coolant, changing 10.
  • Page 110 Maximum speed, Service Information 2014/3/10 checking Profile: CWL, L40B [GB] Maximum fan speed, checking Op nbr 263-016 Figure 1 Check the fan motor speed 1. Run machine until warm, oil temperature approx. 50-60° C (122-140° F) 2. Increase engine speed to high idle (full throttle).
  • Page 111 Figure 2 Checking point Hose L-connector Measurement connection Unscrew the hose from fan motor and install checking point. 6. Fasten hose to L-connector and connect pressure gauge (bis max. 250 bar, 3626 psi). 7. Start engine and increase speed to high idle (full throttle). 8.
  • Page 113 Service Information 2014/3/10 instructions Profile: CWL, L40B [GB] Electrical system, instructions When testing the electrical system, always used fully charged batteries in good condition. Test the batteries with an acid tester. The battery disconnect switch should be turned off. When fitting a battery, make sure that the battery is connected with the correct polarity.
  • Page 114 Electric welding Service Information 2014/3/10 Profile: CWL, L40B [GB] Electric welding Before starting any electric welding on the machine or attachments connected to the machine, the battery disconnect switch must be turned off or the battery ground lead must be disconnected.

  • Page 115: Electrical System, Description

    Service Information 2014/3/10 description Profile: CWL, L40B [GB] Electrical system, description The electrical system voltage is 24 Volt. The batteries (G1 and G2 connected in series) are at the right behind the service hatch on the rear frame. Figure 1...
  • Page 116 L40B 1911643 1921859 L45B 1941759 1952000...
  • Page 117 Function Group: Information Type: Date: Instrument panel, Service Information 2014/3/10 description Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Instrument panel, description Figure 1 Forward travel Backup Direction indicators Preheating High beams Parking brake - brake system accumulator pressure...
  • Page 118 If the control light lights up and the buzzer sounds, clean or replace the air filter immediately.  Engine temperature - coolant monitoring (10) If the control light lights up and the buzzer sounds, check the coolant level, top up if necessary and check for leaks. ...
  • Page 119 Function Group: Information Type: Date: Instrument panel, Service Information 2014/3/10 description Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Instrument panel, description Figure 1 Forward travel Backup Direction indicators Preheating High beams Parking brake - brake system accumulator pressure...
  • Page 120 If the control light lights up and the buzzer sounds, clean or replace the air filter immediately.  Engine temperature - coolant monitoring (10) If the control light lights up and the buzzer sounds, check the coolant level, top up if necessary and check for leaks. ...

  • Page 121: Keypad Description

    Document Title: Function Group: Information Type: Date: Keypad, description Service Information 2014/3/10 Profile: CWL, L40B [GB] Keypad, description Figure 1 Marker light / Driving light Work lights, front Working headlights, rear Wiper, rear Rotating beacon Boom suspension system / BSS (optional)
  • Page 122 Date: Electronic unit (ECU) Service Information 2014/3/10 Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Electronic unit (ECU) Figure 1 The electronic unit ECU is locatede behind the service hatch (arrow). The information plate "Fuse allocation" is on the inside of the service hatch.
  • Page 123 Only use fuses of the specified capacity (Amps). Risk of damage or fire in the circuit board!
  • Page 124 Date: Electronic unit (ECU) Service Information 2014/3/10 Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Electronic unit (ECU) Figure 1 The electronic unit ECU is locatede behind the service hatch (arrow). The information plate "Fuse allocation" is on the inside of the service hatch.

  • Page 125: Battery, Description

    Battery, description Service Information 2014/3/10 Profile: CWL, L40B [GB] Battery, description Figure 1 The batteries (two connected in series) are located on the right behind the service hatch (arrow) on the rear frame. The battery disconnector (Q1) is also on the right in the engine compartment The original battery fitted to the machine is totally impermeable and absolutely maintenance-free.

  • Page 126: Battery Charging

    Battery, charging Service Information 2014/3/10 Profile: CWL, L40B [GB] Battery, charging WARNING Hydrogen gas is formed during battery charging. Hydrogen gas is flammable and may be explosive. A short circuit, open flame or spark near the battery can cause a powerful explosion. Therefore, ventilate well. Never smoke near batteries.
  • Page 127 Information Type: Date: Starter lock, replacing Service Information 2014/3/10 Profile: CWL, L40B [GB] Starter lock, replacing Op nbr 334-001 1. Place the machine in service position. 2. Switch off the battery connection switch. 387 Instrument panel (display unit), replacing 3. Remove upper dashboard, see , steps 3 to 8 4.
  • Page 128 Figure 3 Ignition start switch, fixing nuts 7. Insert new ignition start switch and attach with fixing nuts NOTE! When fitting the ignition start switch, ensure it is correctly positioned in the recess. 8. Fit ignition start switch cover. 9. Connect both plug connections on the back of the ignition start switch. 387 Instrument panel (display unit), replacing 10.

  • Page 129: Lighting, Specifications

    Service Information Document Title: Function Group: Information Type: Date: Lighting, specifications Service Information 2014/3/10 Profile: CWL, L40B [GB] Lighting, specifications Lighting Bulbs Rating Low beam H7 24V High beams H3 24V Parking lights, front T4W 24V Parking light, rear R19/10 24V...
  • Page 130 Combination control (by Service Information 2014/3/10 steering wheel), changing Profile: CWL, L40B [GB] Combination control (by steering wheel), changing Op nbr 360-001 1. Place the machine in service position. 2. Switch off the battery connection switch. 387 Instrument panel (display unit), replacing 3.
  • Page 131 Information Type: Date: Electronic unit (ECU), fuse Service Information 2014/3/10 position Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Electronic unit (ECU), fuse position Function Hold solenoids: float position, special valve Instrument panel Number plate lighting Special hydraulics, hydraulic circuit no. 4...
  • Page 132 Function Group: Information Type: Date: Electronic unit (ECU), fuse Service Information 2014/3/10 position Profile: CWL, L40B [GB] Go back to Index Page Electronic unit (ECU), fuse position Function Description Plug / PIN Comment Work light, rear left X117 / 7...
  • Page 133 X113 / 1 Solenoid valve BSS2, bottom valve X113 / 2 Solenoid valve BSS3, bar compensation valve X113 / 3 Locking, Volvo attachment bracket X109 / 12 C-contact, AC system output X112 / 3 Steering column switch right, supply 2a...
  • Page 134 2014/3/10 electronic unit (ECU) Profile: CWL, L40B [GB]CWL, L40B [GB] Pro FET-components in electronic unit (ECU) Profets are electronic components mounted on the cooling element of the electronic unit (ECU). They are used to switch power to the various consumers. A profet has the property of a relay, i.e. control current switches the power. It also acts as a fuse, i.e.
  • Page 135 Solenoid, drive pump, reverse Y9 Marker light, left E22, E40 Marker light, right E32, E50 Hold solenoid, lift Y4 Solenoid, special hydraulics 1 Y3 Solenoid, lowering brake valve (optional) Y26 Solenoid, lowering brake valve (optional) Y27 Solenoid, Q-max. hydraulic motor (80 cc) Y11 Solenoid, Q-max.
  • Page 136 Service Information Document Title: Function Group: Information Type: Date: Component list, Relays Service Information 2014/3/10 Profile: CWL, L40B [GB] Component list, Relays Relay, ECU-2 Relays Function Description Plug / PIN FU K105 Work light, rear left X117 / 7 from...
  • Page 137 Figure 1 Relay, ECU-2...

  • Page 138: Connectors, Overview

    Document Title: Function Group: Information Type: Date: Connectors, overview Service Information 2014/3/10 Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Connectors, overview The connector diagram applies to: electronic unit (ECU) from software version 3.13 Pin-side Horn Description Switches...
  • Page 139 light, right collector X103 1.05 Brake light right Brake light switch X103 Number plate lighting Relays open Battery+ X103 1.05 Direction indicator, rear Profet open Battery+ Profet right collector X104 X104 <6 Heating switch, internal Relays Ground Battery+ X104 <0,015 C-contact switch Heater Ground...
  • Page 140 X106 <1.2 X106 0.02 CAN_Bus H X106 0.02 CAN_Bus L X106 Coding pin X106 <2 Ground X107 X107 Solenoid valve, extra Relays open Battery+ pump hydraulic hammer X107 Solenoid valve, swivel Profet open Battery+ Profet blocking collector X107 Solenoid valve hydraulic Relays open Battery+...
  • Page 141 Direction indicator, front profet open Battery+ Profet left collector X109 Water pump, sweeper Relays open Battery+ unit X109 Locking, VOLVO Profet open Battery+ Profet attachment bracket collector X109 1.05 Indicator, trailer right Profet open Battery+ Profet collector X109 1.05 Indicator, trailer left...
  • Page 142 profet X111 Coding pin X111 0.01 Wiper motor rear "Park Wiper Battery+ Ground position" motor X111 Rotating beacon Relays open Battery+ X111 1.05 Interior light X111 <5 Ground X112 X112 <0,02 Glow time X112 <0,009 Glow time control light Glow time Variant Variant control unit...
  • Page 143 X114 0.015 Pressure switch, control Pressure Battery+ Ground pressure (8.5 bar) switch X114 Solenoid valve hydraulic Profet open Battery+ Profet pump, forward collector X114 Solenoid valve hydraulic Profet open Battery+ Profet pump, reverse collector X114 Solenoid valve, direction Profet open Battery+ Profet valve...
  • Page 144 X115 <10 Steering column switch right, supply 2a X115 <0,03 Steering column switch Relays open Battery+ right, supply 3a X115 0.015 Steering column switch Steering Ground Battery+ right, direction indicator column right switch right X115 0.015 Steering column switch Steering Ground Battery+ right, direction indicator...
  • Page 145 Service Information Document Title: Function Group: Information Type: Date: Connectors, overview Service Information 2014/3/10 Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Connectors, overview The connector diagram applies to: electronic unit (ECU-2) Connector X101 Connecto Designati Connect Description...
  • Page 146 X102:10 Ignition switch, Batt + Ground <0.09 starting X102:11 Ignition switch, Batt + Ground <3.5 Direct  Supply[T3] X102:12 Ground <5 [T1]Shall power up the CPU [T2]Supply via relay [T3]Supply: KL30 Connector X103 Connecto Designati Connect Description Signal Potentia Potentia Current Type Fused...
  • Page 147 controllable X104:10 1301 Seat Batt + Open <7.5 Relay suspension K106 X104:10 Switch forklift, Batt + Open <7.5 Relay supply K106 X104:10 Switch forklift, Batt + Open <7.5 Relay supply K106 X104:10 Y37(S24) (2401) Solenoid valve, Batt + Open <7.5 Relay emission K106...
  • Page 148 X105:10 B12(X24) (2402) Ground <2 X105:11 Pressure switch, Ground Batt + <0.015 pump accumulator brake X105:12 1001 Combination Ground Batt + <0.015 sensor, hydraulic temperature warning contact switch X105:12 1001 Combination Ground Batt + <0.015 sensor, hydraulic temperature warning contact switch X105:13 1002...
  • Page 149 X107:5 2101 or Solenoid valve, Batt + Open Profet Y21(K12) 2101(86) Optional hydraulics 1 (3rd control circuit X107:6 Y26, Y27 2601, Solenoid valve: Batt + Open Profet 2701 lowering brake valve (hose rupture valve) X107:7 Coding pin X107:8 E43(X36) 3 Reversing light, Batt +...
  • Page 150 Profet indicator front, Left X109:11 M4(X30) (2/54) Water pump road Batt + Open Relay sweeping machine X109:12 Y5(X60) (6001) Locking, Volvo Batt + Open Profet attachment carrier X109:13 E64(X30) (4/R) Direction Batt + Open Profet indicator trailer, Right X109:14 E63(X30)
  • Page 151 button, forward X110:4 Joystick push Batt + Ground 0.015 button, reverse X110:5 Joystick push Batt + Ground 0.015 button, differential lock X110:6 Joystick push Batt + Ground 0.015 button, optional hydraulics 1 X110:7 Joystick push Batt + Ground 0.015 button, optional hydraulics 2 X110:8...
  • Page 152 X111:7 1201 Working head Batt + Open Relay light rear, Left K105 X111:8 1301 Working head Batt + Open Relay light rear, Right K105 X111:9 Wiper motor rear, Batt + Open 4(8) Profet Stage 1, J X111:10 E53(X37) Reversing light, Batt + Open 0.875...
  • Page 153 X113:1 1401 Solenoid BSS 1, Batt + Open Profet charging valve X113:2 1501 Solenoid BSS 2, Batt + Open Profet piston bottom valve X113:3 1601 Solenoid BSS 3, Batt + Open Profet piston rod valve X113:4 Supply, inductive Batt + Open <0.03 Relay...
  • Page 154 X114:3 Solenoid valve, Batt + Open Profet pump reverse X114:4 1001 Solenoid valve, Batt + Open Profet direction valve X114:5 Y11/Y7 1101/70 Solenoid valve, Batt + Open Profet   [T2] 1[T3] hydraulic motor 107/140 X114:6 1201 Solenoid valve, Batt + Open Profet hydraulic...
  • Page 155 X115:6 Steering column Batt + Ground 5(10) switch right, Pos 2 X115:7 15/1 Steering column Batt + Open <15 Direct switch right,  Supply 2[T1] X115:8 Steering column Batt + Ground switch right, Dimmed head light X115:9 Steering column Batt + Ground switch right, Full head light...
  • Page 156 Document Title: Function Group: Information Type: Date: ECU 2, functions Service Information 2014/3/10 Profile: CWL, L40B [GB]CWL, L40B [GB] ECU 2, functions The following functions are included in ECU 2: Function No. Description Fender light Head light Wiper / washer front...
  • Page 157 Idle mode Magnetic clamp, special spool (3:rd function) Magnetic clamp, floating position Vehicle heating Daily operating time, Extra function "E3" key 2 Daily travelled distance, Extra function "E3" key 4 Boom movement counter, Extra function "E3" key 6 Solenoid fork lift operation (hose rupture valve), shut off magnetic clamp float position Magnetic clamp, engine brake Ball blocking valve Cab interior functions...
  • Page 158 Right E31(X32) Full head light, Right X109:4 Batt + Open 3.75 Direct 15/1 Steering column switch X115:7 Batt + Open <15 Direct  right, Supply 2[T1] Steering column switch X115:10 Batt + Open <10 Profet right, Supply 2a Steering column switch X115:9 Batt + Ground...
  • Page 159 Membrane key 2, LED A35:L2 1001 Working head light X111:3 Batt + Open Relay front, Left K103 1101 Working head light X111:5 Batt + Open Relay front, Right K103 1701 Working head light X111:4 Batt + Open K103  front, Left[T1] 1801 Working head...
  • Page 160 Current Type Fuse tion and Pin l at ON l at OFF Membrane key 7 A35:7 Y5(X60) (6001) Locking, Volvo X109:12 Batt + Open Profet attachment carrier Function 10 Travel function 20 km/h / 35 km/h Designati Connec Description Connector...
  • Page 161 neutral S11, S12, Voltage supply, Joystick X110:1 Batt + Open <0.09 Profet S13, S14, S15, S16 Joystick push button, X110:3 Batt + Ground 0.015 forward Joystick push button, X110:4 Batt + Ground 0.015 reverse Steering column switch X116:2 Batt + Ground 0.015 left, travel range 1...
  • Page 162 1901 Solenoid valve, Optional X107:3 Batt + Open Profet hydraulics 2 (4th control circuit) Function 12 Operating time counter, Extra function "E3" key 1 Designati Connec Description Connector Signal Potentia Potentia Current Type Fuse tion and Pin l at ON l at OFF Membrane key 1 A35:1...
  • Page 163 DG1:D3 DB Control LED, Travel A9:DG1:D3 direction indication E23(X31) Direction indicator X109:10 Batt + Open 1.05 Profet front, Left E33(X32) Direction indicator X109:5 Batt + Open 1.05 Profet front, Right E41(X36) Direction indicator rear, X103:5 Batt + Open 1.05 Profet Left E51(X37) Direction indicator rear,...
  • Page 164 3101 Seat contact switch X104:7 Ground Batt + <0.015 Bleeper switch contact X102:6 Ground Batt + <0.15 Transist Bleeper supply X102:7 Batt + Open <0.15 Function 18 Water pump sweeping machine (key F1) Designati Connec Description Connector Signal Potentia Potentia Current Type Fuse...
  • Page 165 Function 22 Bar graph, engine temperature Designati Connec Description Connector Signal Potentia Potentia Current Type Fuse tion and Pin l at ON l at OFF Bargraph LED, A9:BG3 Enginel temperature DG2:D2 DB Control LED, Engine A9:DG2:D2 temperature high engine coolant level low B14(X23) (2307) Transducer,...
  • Page 166 Designati Connec Description Connector Signal Potentia Potentia Current Type Fuse tion and Pin l at ON l at OFF – Ground X113:9 <0.1 Supply, inductive X113:7 Batt + Open <0.03 Relay transducer, lift K106 limitation Inductive transducer, lift X113:8 Batt + Ground 0.015 limitation...
  • Page 167 2201 Hand brake control X104:5 Ground Batt + <0.015 switch Pressure switch, pump X105:11 Ground Batt + <0.015 accumulator brake [T1]B9 < 95 bar: LED flashes B22 ON: LED lights steady Function 29 Auxiliary pump (key F3) Designati Connec Description Connector Signal Potentia...
  • Page 168 NVRAM DISTAN Travelled distance NVRAM: IN/OUT PARAM PARAM DISTANCE NVRAM IMP100 Sensor, transmission NVRAM: PARAM PARAM speed: Nr of impulses IMP1000M per 1000 m travelled distance NVRAM VELUNI Unit of the velocity (km/ NVRAM: PARAM PARAM h or Mph) VELUNIT [T1]Never used in production Function 32 Vehicle speed...
  • Page 169 Preheating time, control X112:2 Ground Batt + <0.015 light signal 12V Preheating time, control X112:2 Batt + Ground <0.015 light signal 24V (X22) Preheating time relay X108:9 Batt Ground Profet Via F23 (glow plug / glow pin) (Ing) (TBD) K2, K5 204, 86 Start relay X112:10...
  • Page 170 Magnetic clamp, special spool (3:rd function) Designati Connec Description Connector Signal Potentia Potentia Current Type Fuse tion and Pin l at ON l at OFF Clamping magnet, X110:12 Batt + Ground 0.28 Profet special spool (3:rd  circuit)[T1] Ground for magnetic X110:13 0.28 clamp...
  • Page 171 Inductive sensor, X105:1 FREQ FREQ <0.001 transmission speed 1 Inductive sensor, X105:2 FREQ FREQ <0.001 transmission speed 2  [T1] NVRAM DAYDIS NVRAM Daily travelled NVRAM: IN/OUT PARAM PARAM distance DAYDIST NVRAM IMP100 Sensor, transmission NVRAM: PARAM PARAM speed: Nr of impulses IMP1000M per 1000 m travelled distance...
  • Page 172 clamp 2301 Solenoid valve, X114:9 Batt + Open Profet hydraulic control off Y26, Y27 2601, Solenoid valve: lowering X107:6 Batt + Open Profet 2701 brake valve (hose rupture valve) Y26, Y27 2602, Ground X107:9 <5 2702 [T1]Fork lift operation => Magnet off Function 46 Magnetic clamp, engine brake Designati...
  • Page 173 [T4]Supply: KL30 Function 49 Hydraulic filter check Designati Connec Description Connector Signal Potentia Potentia Current Type Fuse tion and Pin l at ON l at OFF DG2:D6 DB Control LED, A9:DG2:D6 Hydraulic oil collecting filter 1301 Vacuum switch, X114:8 Ground Batt + 0.015 hydraulic oil collecting...
  • Page 174 Membrane key 11 (F3) A35:11 LD1, DB LED display 1, 2, 3, 4, A35:LD1 – LD2, 5, 6 A35:LD6 LD3, LD4, LD5, NVRAM ECUSN NVRAM serial NVRAM: IN/OUT PARAM PARAM number ECUSNO Function 54 Dash board connections Designati Connec Description Connector Signal Potentia...
  • Page 175 Coding pin X105:5 Coding pin X106:5 Coding pin X107:7 Coding pin X108:8 Coding pin X109:9 Coding pin X110:10 Coding pin X111:11 Coding pin X112:12 Coding pin X113:13 Coding pin X114:14 Coding pin X115:15 Function 58 Not connected contact pins Designati Connec Description Connector...
  • Page 176 ECU 2, error codes and Service Information 2014/3/10 diagnostic functions Profile: CWL, L40B [GB]CWL, L40B [GB] ECU 2, error codes and diagnostic functions Two levels/modes of Error Code can be displayed in the instrument panel.  Level 1: Run time diagnostic for the operator ...
  • Page 177 Ignition switch in position “P” Press joystick button “N” at the same time as turning the ignition key into position “1”. (keep pressing joystick button “N” for at least 3 seconds) Press key “5” and “#” at the same time Enter code “372”...
  • Page 178 Figure 1 Menu structure  Navigate between main chapters (Inputs, Eeprom, Reset, Outputs) by pressing key “1” for horizontal left and key “2” for horizontal right.  Navigate between the sub chapters (Analog, Digital) by pressing key “1” for horizontal left and key “2” for horizontal right ...
  • Page 179 0805 Short to ground Solenoid, pump forward X114:2 0806 Open load 0905 Short to ground Solenoid, pump reverse X114:3 0906 Open load 1005 Short to ground Solenoid, hydro motor 80 Y12 only X114:6 191, 194 1006 Open load only 191, 194 1105 Short to ground Solenoid, hydro motor...
  • Page 180 Short to ground Solenoid X113:3 Option not compensation valve activate 3606 Open load Option not activate 3705 Short to ground Solenoid Locking, Volvo X109:12 Option not attachment carrier activate 3706 Open load Option not activate 3805 Short to ground Clamping magnet load...
  • Page 181 4905 Short to ground Solenoid optional X107:5 Option not hydraulics switchable activate from lift 4906 Open load Option not activate 5005 Short to ground Solenoid optional Option not hydraulics 4th function X107:3 activate 5006 Open load Option not activate 5105 Short to ground Seat heater X104:10...
  • Page 182 switch 104_5 Parking brake, control Parking brake parking switch engauged brake release = + 104_7 Seat contact, switch Connect ground 104_8 Fork operation, switch Connect ground 105_11 Pump accumulator, Connect pressure switch 95 bar ground 105_12 Hydraulic oil temperature, Connect warning contact ground 105_9...
  • Page 183 109_2 Tail fender light, right 109_5 Indicator front, right 109_6 Tail fender light, left 109_10 Indicator front, left 109_12 Solenoid locking Volvo attachment only for Volvo carrier attachment carrier 109_13 Direction indicator trailer, right Option 109_14 Direction indicator trailer, left...
  • Page 184 112_13 Airconditioning; C-Contact Option 112_9 Wiper pump, rear 112_10 Starter relay 113_1 Solenoid BSS 1, charging valve Option 113_2 Solenoid BSS 2, piston bottom Option valve 113_3 Solenoid BSS 3, rod compensation Option valve 114_2 Solenoid pump, forward 114_3 Solenoid pump, reverse 114_4 Solenoid direction valve 114_5...
  • Page 185 2014/3/10 description Profile: CWL, L40B [GB] Marking connector/pin description The various parts of the electrical system are connected via multipin connectors which makes the components easily replaceable. All connectors and components are marked in the circuit diagrams with the complete designation. The cable harnesses also include connectors for components e.g.
  • Page 186 Service Information 2014/3/10 Profile: CWL, L40B [GB] Display of bar graph Bar graph, hydraulic oil temperature B10 The contact makes, the check LEDs light. At too high hydraulic oil temperature, LEDs 7 and 8 flash and at the same time the buzzer sounds - only with engine running.
  • Page 187 1 red , light "Reserve" 250 - 206 Ohm 3.94 - 3.71 V 2 green 200 - 160 Ohm 3.68 - 3.4 V 3 green 150 - 130 Ohm 3.31 - 3.12 V 4 green 120 - 90 Ohm 3.01 - 2.62 V 5 green 80 - 60 Ohm 2.46 - 2.08 V...
  • Page 188 Service Information 2014/3/10 Profile: CWL, L40B [GB]CWL, L40B [GB] IB - fuse F02 The list below shows all consumers protected via fuse F02/3A. Failure of this fuse can have several causes. If a short-circuit occurs at one of these consumers, this can cause failure of the switch. For rapid location of the fault, pull all X-fuses marked in the table and check the corresponding pin for short-circuit (Ohmmeter).
  • Page 189 Date: Electrical components, Service Information 2014/3/10 engine side Profile: CWL, L40B [GB] Electrical components, engine side Figure 1 Check switch air filter B11 Solenoid, start extra quantity Y24 Combination sensor, engine temperature B6 Solenoid, engine shut-off Y6 Central plus point glowplugs...
  • Page 190 Information Type: Date: Central ground connections 370 Service Information 2014/3/10 Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Central ground connections Central grounding point operator's cab Figure 1 Grounding point operator's cab The central grounding point operator's cab (A) is on the left in the service compartment of the electronics unit (ECU).
  • Page 191 Information Type: Date: Central ground connections 370 Service Information 2014/3/10 Profile: CWL, L40B [GB]CWL, L40B [GB] Go back to Index Page Central ground connections Central grounding point operator's cab Figure 1 Grounding point operator's cab The central grounding point operator's cab (A) is on the left in the service compartment of the electronics unit (ECU).
  • Page 192 NOTE! The operator's cab and electronics unit grounding points are directly connected to the grounding point in the rear frame.
  • Page 193 Service Information 2014/3/10 compartment Profile: CWL, L40B [GB] Relays and fuses in engine compartment Fuse F100 (50 A) for the glowplug system is on the right in the engine compartment. Figure 1 The relays for glow time control K2, AC system K4 (optional) and start process K5, are in the battery box.
  • Page 194 Information Type: Date: Wiring diagram, figure text 370 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram, figure text Optional equipment NOTE! The current paths of optional equipment are shown in the wiring diagram as dottedlines (-----). Coding Connectors/Leads The wiring diagram shows leads with colour coding: Colour coding BK = black = ⊥...
  • Page 195 Sensor engine temperature Optional 370 Wiring diagram equipment 370 Wiring diagram Pressure switch control pressure 8.5 bar L40B, SN 192 / 370 Wiring diagram L45B, SN 195 Brake light switch 370 Wiring diagram 3 Parking brake control switch 370 Wiring diagram 7...
  • Page 196 Switch, handbrake, power unit disconnection Optional equipment Pressure switch, AC system 370 Wiring diagram Thermostat, AC system 370 Wiring diagram Radio 370 Wiring diagram 7 Seat heating 370 Wiring diagram 7 Glow plug Glowplug 370 Wiring diagram 1 Mirror heating, left Mirror heating, right Work light, front left 370 Wiring diagram 6...
  • Page 197 Marker light, sweeper unit right 370 Wiring diagram Indicator light, sweeper unit left 370 Wiring diagram Indicator light, sweeper unit right 370 Wiring diagram F100 Fuse, preheating system engine 370 Wiring diagram 1 compartment F101 Fuse oil cooler engine compartment F102 Fuse AC system (condenser) engine...
  • Page 198 Relay central electronics shut-off Optional equipment (in cab) Relay Q-max limit (in cab) Relay power unit shut-off, handbrake (in cab) Relay trailer check light (in cab) Wiper motor, front 370 Wiring diagram 8 Wiper motor, rear 370 Wiring diagram 9 Fan motor heating 370 Wiring diagram Water pump, sweeper unit...
  • Page 199 Connector, pressure switch B9 (3-pin) Under cab 370 Wiring diagram 2 370 Wiring diagram Engine connector, natural (8-pin) For L40B up to SN on engine 370 Wiring diagram 1 1913000; 1923000 and L45B up to SN 1943000; 1953000 370 Wiring diagram 2 370 Wiring diagram 4 Engine connector (16-pin) For L40B from SN 1913001;...
  • Page 200 Connector, AC coupling (1-pin) on engine 370 Wiring diagram Trailer socket on boom 370 Wiring diagram Connector, headlight left 370 Wiring diagram 5 Connector, headlight right 370 Wiring diagram 5 Connector, for trailer socket / sweeper unit preparation close to ECU 370 Wiring diagram Connector, X-contact AC system 370 Wiring diagram...
  • Page 201 Optional equipment Connector, valve engine brake (2-pin) Optional equipment Connector, mirror heating (1-pin) Optional equipment Connector, VOLVO radio (ground) (1-pin) Optional equipment Connector, extra consumer (retrofit equipment) (2-pin) Optional equipment Connector, rear-view mirror (2-pin) Cab roof Connector, joystick extension (6-pin)
  • Page 202 Solenoid valve, direction valve 370 Wiring diagram Solenoid valve hydraulic motor 80 370 Wiring diagram Solenoid valve hydraulic motor 107/140 L40B, SN 191 / 370 Wiring diagram L45B, SN 194 Solenoid valve, differential lock 370 Wiring diagram Solenoid valve 1, boom suspension (BSS)
  • Page 203 Solenoid valve, special hydraulics, switchable from tilt hydraulics Solenoid valve, hydraulic circuit no. 5 on towing device Solenoid valve, hammer hydraulics Solenoid valve, engine brake Solenoid valve, 4th control circuit with HPCO Solenoid valve, minus compensation diesel engine Solenoid valve, drive mode shut down Optional equipment...
  • Page 204 Cable markings Service Information 2014/3/10 Profile: CWL, L40B [GB] Cable markings All leads are marked according to the circuit diagram. The 1st to 3rd digits are the designation of the main component. The last two digits are the pin designation.
  • Page 205 Figure 2 Splice point Horn Connections between leads are indicated by a splice point. The leads listed with position figures at the splice point are connected together. The line before/after a position figure means that it is an incoming/outgoing lead. The designation means: Connection of lead 601 to component H6 (horn), terminal 1.
  • Page 206 Document Title: Function Group: Information Type: Date: Electric cables with Service Information 2014/3/10 component marking Profile: CWL, L40B [GB] Electric cables with component marking Hydraulic motor 107 / 140 (only for L40B, SN 191) Figure 1 Pressure switch 95 bar...
  • Page 207 Figure 2 Head lights...
  • Page 208 Figure 3 Relay group starter, A/C unit and fan control (optional)
  • Page 209 Figure 4 Relay group...
  • Page 210 Figure 5 Main line...
  • Page 211 Figure 6 Main line (part 1)
  • Page 212 Figure 7 Main line (part 2)
  • Page 213 Figure 8 Main line (part 3)
  • Page 214 Figure 9 Main line (part 4)
  • Page 215 Figure 10 Central grounding point rear frame Ground, battery disconnector Main line (part 5)
  • Page 216 Figure 11...

  • Page 217: Wiring Diagram

    Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 1 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 1 Engine start Figure 1 Circuit diagram, engine start Changes on ECU-2 Plug/PIN Feed 108/09 Fuse F23 with upstream Profet...
  • Page 218 102/11 Fuse F23 with upstream Profet 112/10 Profet Wiring diagram, engine start Valid for serial numbers Version From serial number L40B 1913001 1923001 L45B 1943001 1953001 Figure 2...
  • Page 219 Circuit diagram, engine start (from serial number) Component position S1 Ignition start switch S3 Steering column switch (drive switch) NOTE! The engine can only be started if the drive switch S3 is in Neutral. Starting the engine with immobilizer (optional), see Operator's Manual. Figure 3 The fuse for the preheat system F100 is on the right of the engine bay.
  • Page 220 The start excess solenoid Y24 is located in the governor housing. Similarly, on L40B machines from SN 1913001; 19230001 and L45B machines from SN 1943001; 1953001 it is found on the governor housing of the temperature switch (start excess solenoid) B29.
  • Page 221 On L40B machines from SN 1913001; 1923001 and L45B machines from SN 1943001; 1953001 connectors X22, X23, X 27 are located on the cover plate of the cylinder head cover. Figure 9...
  • Page 222 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 2 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 2 Sensors Figure 1 Circuit diagram, sensors Changes on ECU-2 Plug/PIN Feed 105/08 Profet 108/10 Fuse F22 Wiring diagram, Sensors...
  • Page 223 Valid for serial numbers Version From serial number L40B 1913001 1923001 L45B 1943001 1953001 Figure 2 Component position B6 The combisensor, engine temperature is behind the controller housing.
  • Page 224 Figure 4 B8 Inductive sensor, gear rpm Figure 5 B9 Pressure switch for pump accumulator brake is on the creep brake valve for L40B SN 192, L45B SN 195 and on the brake valve for L40B SN 191, L45B SN 194.
  • Page 225 Figure 6 B10 Combination sensor, hydraulic oil temperature is on the hydraulic variable displacement pump. Figure 7 B11 Control switch air filter Figure 8 B12 Sensor - fuel tank X24 Plug for fuel tank sensor (4-pin)
  • Page 226 Figure 9 NOTE! Sensor and plug are on the right below the cab floor. Lift floor mat, opening in floor panel. B13 Control switch hydraulic oil filter Figure 10 B14 Sensor coolant level Figure 11...
  • Page 227 Information Type: Date: Wiring diagram 3 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 3 Lights, direction indicators, hazard flashers, brake light Figure 1 Circuit diagram, lights, direction indicators, hazard flashers, brake light Direction indicator left Direction indicator right Hazard flashers "OFF"...
  • Page 228 106/01 Fuse F22 115/11 Profet 102/05 Fuse F22 104/09 Fuse F19...
  • Page 229 Information Type: Date: Wiring diagram 4 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 4 Battery, battery disconnector, alternator Figure 1 Circuit diagram, battery, battery isolation switch, alternator Component position The batteries G1, G2, connected in series, are located on the right behind the service hatch on the rear frame.
  • Page 230 Figure 3...
  • Page 231 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 5 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 5 Lighting...
  • Page 232 Figure 1 Circuit diagram, lighting Changes on ECU-2 Plug/PIN Feed 109/02 Fuse F26 with subsequent Profet 109/03 Fuse F06 109/04 Fuse F05 109/05 Fuse F26 with subsequent Profet 109/06 Fuse F26 with subsequent Profet 109/07 Fuse F07 109/08 Fuse F05 109/10 Fuse F26 with subsequent Profet 103/01...
  • Page 233 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 6 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 6 Work light, rotating beacon Figure 1 Circuit diagram, work light, rotating beacon Changes on ECU-2 Plug/PIN Feed 106/01...
  • Page 234 111/08 Relay K105 with preceding fuse F01 111/13 Fuse F29 with subsequent Profet...
  • Page 235 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 7 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 7 Interior Figure 1 Circuit diagram, interior Changes on ECU-2 Plug/PIN Feed 111/01 Fuse F11 106/01 Fuse F22...
  • Page 236 104/10 Relay K106 with subsequent fuse F17 102/07 Fuse F22 111/14 Fuse F12 104/11 Fuse F24...
  • Page 237 Document Title: Function Group: Information Type: Date: Wiring diagram 8 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 8 Windshield wiper front, washer system front, horn Figure 1 Circuit diagram, wiper front, washer system front, horn Horn Wash Windscreen wipers...
  • Page 238 101/02 Fuse F27 with subsequent Profet 101/03 Fuse F21 112/08 Fuse F03 109/01 Fuse F04...
  • Page 239 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 9 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 9 Wiper / washer, rear Figure 1 Circuit diagram, wipe rear, washer system rear Changes on ECU-2 Plug/PIN Feed 106/01...
  • Page 240 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 10 Drive mode: L40B, SN 191 / L45B, SN 194 Figure 1 Circuit diagram, drive mode: L40B, SN 191 / L45B, SN 194 Return Neutral Forward Gear 1 Gear 2 Gear 3...
  • Page 241 Fuse F25 with subsequent Profet 114/05 Fuse F25 with subsequent Profet Drive mode: L40B, SN 192 / L45B, SN 195 Figure 2 Circuit diagram, drive mode: L40B, SN 192 / L45B, SN 195 Return Neutral Forward Gear 1 Gear 2...
  • Page 242 Y9 Solenoid valve hydraulic pump reverse (grey) Travel switch S3 in neutral Y8 / Y9 OFF Travel switch S3 in Forward Y8 ON Travel switch S3 in Reverse Y9 ON Y10 Solenoid valve direction slide L40B, SN 192 / L45B, SN 195...
  • Page 243 Control pressure p > 8.5 bar (123 psi) : Y10 ON but only forwards Y10 Solenoid valve direction slide L40B, SN 191 / L45B SN 194. Because of earth at "11401", Y10 in forwards is always at Y11 Solenoid valve hydraulic motor L40B, SN 192 / L45B, SN 195...
  • Page 244 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 11 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 11 Operating mode, switching on multifunction lever Valid to: serial number Version Serial number L40B 1911121 1921340 L45B 1941197...
  • Page 245 Changes on ECU-2 Plug/PIN Feed 106/01 Fuse F22 110/01 Profet 114/07 Fuse F26 with subsequent Profet 114/11 Profet Component position S11 Pushbutton (neutral) S12 Pushbutton (forwards) S13 Pushbutton (reverse) S14 Pushbutton (differential lock) Figure 2 Y13 Solenoid valve differential lock Figure 3 B24 Check switch differential locks, rear axle...
  • Page 246 Figure 4 B23 Check switch differential locks, front axle Figure 5 Operating mode, switching on multifunction lever Valid from: serial number Version Serial number L40B 1911122 1921341 L45B 1941198 1951405...
  • Page 247 Figure 6 Circuit diagram, switching on multifunction lever from SN Changes on ECU-2 Plug/PIN Feed 106/01 Fuse F22 110/01 Profet 114/07 Fuse F26 with subsequent Profet 114/11 Profet Component position S11 Pushbutton (neutral) S12 Pushbutton (forwards) S13 Pushbutton (reverse) S14 Pushbutton (differential lock) S15 Pushbutton (optional hydraulics) S16 Pushbutton (optional hydraulics)
  • Page 248 Figure 7 Y13 Solenoid valve differential lock Figure 8...
  • Page 249 B23 Check switch differential locks, rear axle Figure 9 B24 Check switch differential locks, front axle Figure 10...
  • Page 250 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 12 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 12 Working hydraulics Figure 1 Circuit diagram, working hydraulics Changes on ECU-2 Plug/PIN Feed 106/01 Fuse F22 109/12 Fuse F28 with subsequent Profet...
  • Page 251 Figure 2 Y23 Solenoid valve hydraulic control Y5 Solenoid valve for VOLVO tool attachment (option) is on the crossbar on the lifting frame...
  • Page 252 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 13 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 13 Lifting kinematics, circuit diagram A Figure 1 Lifting kinematics, circuit diagram A Changes on ECU-2 Plug/PIN Feed 110/01...
  • Page 253 Lifting kinematics, circuit diagram B Figure 2 Lifting kinematics, circuit diagram B Changes on ECU-2 Plug/PIN Feed 113/04 Relay K106 with subsequent fuse F16 110/08 Fuse F30 with subsequent Profet 113/07 Relay K106 with subsequent fuse F16 110/09 Fuse F30 with subsequent Profet 110/11 Fuse F25 with subsequent Profet 110/12...
  • Page 254 Figure 3...
  • Page 255 Function Group: Information Type: Date: Wiring diagram 14 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 14 Sweeper unit, lighting and water pump (optional) Figure 1 Circuit diagram, sweeper unit, lighting and water pump (optional) Changes on ECU-2 Plug/PIN...
  • Page 256 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 15 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 15 Reversing alarm / reversing light, switchable (optional) Figure 1 Circuit diagram, reversing alarm / light, switchable (optional)
  • Page 257 Changes on ECU-2 Plug/PIN Feed 103/01 Fuse F26 with subsequent Profet 107/08 Fuse F26 with subsequent Profet 103/05 Fuse F28 with subsequent Profet Back-up alarm, switchable (optional) Figure 2 Circuit diagram, reversing alarm, switchable (optional) Changes on ECU-2 Plug/PIN Feed 103/01 Fuse F26 with subsequent Profet 107/08...
  • Page 258 103/05 Fuse F28 with subsequent Profet Component position S19 Switch, reversing alarm Figure 3 V1039546 NOTE! If the warning tone is not permitted or desired, the reversing alarm can be switched off by activating switch S19.
  • Page 259 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 16 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 16 Heating, AC system (optional) Figure 1 Circuit diagram, heating and air conditioning (optional) Changes on ECU-2 Plug/PIN Feed 104/01...
  • Page 260 Figure 2 M3 Fan motor for heating is below operator's seat Figure 3 The relay for the AC unit K4 with fuse F102 is in the battery box. Figure 4...
  • Page 261 Service Information Document Title: Function Group: Information Type: Date: Wiring diagram 17 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 17 Radiator control (optional) Figure 1 Circuit diagram, cooler control (option) Changes on ECU-2 Plug/PIN Feed 108/09 Fuse F23 with subsequent Profet...
  • Page 262 Figure 2 A20 Control unit, radiator Figure 3...
  • Page 263 Document Title: Function Group: Information Type: Date: Wiring diagram 18 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 18 Radiator control with AC system (optional) Figure 1 Circuit diagram, cooler control with AC system (option) Changes on ECU-2 Plug/PIN Feed...
  • Page 264 NOTE! When switching on the A/C system, connection 11 of the power supply A20 is grounded via relay K7. This shifts the signals of sensor B15 and B16 up by 13 °C. Component position B15 Sensor, radiator Y29 Solenoid valve radiator control Figure 2 A20 Control unit, radiator Figure 3...
  • Page 265 Document Title: Function Group: Information Type: Date: Wiring diagram 19 Service Information 2014/3/10 Profile: CWL, L40B [GB] Wiring diagram 19 Boom suspension system BSS (optional) Figure 1 Circuit diagram, boom suspension system / BSS (optional) Changes on ECU-2 Plug/PIN Feed...
  • Page 266 The boom suspension system (BSS) works only above a factory-set drive speed and lift height of the boom. Below this drive speed and lifting height, the boom suspension shuts off. In principle this function can only be preselected with the engine running.
  • Page 267 Figure 4...
  • Page 268 Display unit and keyboard Service Information 2014/3/10 Profile: CWL, L40B [GB] Display unit and keyboard The information display and keypad (film keypad) are arranged on the instrument panel. The instrument panel is connected to the electronics unit (ECU) via a "CAN-BUS" data line.
  • Page 269 Instrument panel (display Service Information 2014/3/10 unit), replacing Profile: CWL, L40B [GB] Instrument panel (display unit), replacing Op nbr 387-021 1. Place the machine in service position. 2. Switch off the battery connection switch. 3. Remove hub cover from steering wheel.
  • Page 270 5. Attach puller and remove steering wheel. NOTE! Ensure correct seat of puller claw to avoid damage to steering wheel. 6. Detach rubber sleeve on travel switch and on steering column switches Figure 3 7. Unscrew fixing bolts on dashboard Figure 4 8.
  • Page 271 Figure 6 10. Unscrew instrument panel fixing nuts 11. Insert new instrument panel in dashboard and fasten with fixing nuts NOTE! Use self-locking nuts 12. Connect lead to film keypad and secure with lock brace 13. Connect plugs and install dashboard Figure 7 14.
  • Page 272 Note markings 17. Fasten central nut and tighten with a torque of 40 ± 5 Nm (29.5 ± 3.7 lbf ft) 18. Refit steering wheel hub cover.
  • Page 273 Information Type: Date: Key pad, replacing Service Information 2014/3/10 Profile: CWL, L40B [GB] Key pad, replacing Op nbr 387-003 1. Place the machine in service position. 2. Switch off the battery connection switch. 387 Instrument panel (display unit), replacing 3. Remove dashboard, see...
  • Page 274 5. Unscrew fixing bolts for film keypad, replace keypad and fasten in place. 6. Connect lead to instrument panel and secure with lock brace 387 Instrument panel (display unit), replacing 7. Install dashboard, see , steps 13 to 18...
  • Page 276 The 100% differential lock integrated in the front and rear axles can be switched hydraulically. Using the inch brake function, stepless adjustment of the drive speed is guaranteed. Hydrostatic drive L40B, SN 192 / L45B, SN 195 Figure 1 Hydrostatic drive, SN 192, SN 195...
  • Page 277 Hydraulic oil tank Suction-return filter Thermostat Differential lock valve Inch brake valve Heat exchanger Hydrostatic drive L40B, SN 191 / L45B, SN 194 Figure 2 Hydrostatic drive, SN 191, SN 194 Hydraulic pump Hydraulic motor A 107cm3 Dropbox Hydraulic motor B 80cm3...
  • Page 278 Heat exchanger...
  • Page 279 Transmission, component Service Information 2014/3/10 position Profile: CWL, L40B [GB] Transmission, component position Component arrangement L40B, SN192 / L45B, SN 195 Figure 1 Drive component arrangement SN 192, SN 195 Suction-return filter Hydraulic oil tank Heat exchanger Thermostat Hydraulic pump...
  • Page 280 Check high pressure, reverse Check high pressure, forward Control pressure Check control pressure, forward Check control pressure, reverse Component arrangement L40B, SN191 / L45B, SN 194 Figure 2 Drive component arrangement SN 191, SN 194 Suction-return filter Hydraulic oil tank...
  • Page 281 High pressure, forward Feed pressure, differential lock Check high pressure, reverse Check high pressure, forward Control pressure Check control pressure, forward Check control pressure, reverse...
  • Page 282 Service Information 2014/3/10 hydrostatic drive Profile: CWL, L40B [GB] Check and adjust hydrostatic drive Check and adjust speed activation. Op nbr 1. Turn off engine. 2. Press travel pedal down until the engine speed adjustment lever lies at full load stop (arrow).
  • Page 283 Figure 3 Temperature regulator adjusting screw 6. Check inch valve. Figure 4 Inch valve 7. Run the machine until a hydraulic oil temperature of 60 + 5 °C (140 + 41 °F) is reached. 8. Secure the machine so that it is stable during the adjustment work (see diagram). Figure 5 Securing the machine 9.
  • Page 284 1. Connect tachometer to engine. Figure 6 2. Start the engine. 3. Set drive or roll switch (multifunction lever) to position “Neutral”. 4. Check low idle speed. Nominal value: see specifications. 5. Press drive pedal to stop, 6. Read high idle speed on tachometer. Nominal value: see specifications. Test and adjust feed pressure.
  • Page 285 4. Increase engine speed to high idle. 5. Read display on pressure gauge. Nominal value: Feed pressure, see specifications. Adjustment 6. Remove seal cap on feed pressure valve (4) and release lock nut. 7. Run engine at low idle speed (see specifications). 8.
  • Page 286 7. Turn the controller cartridge adjustment screw to left or right until the pressure gauge shows a pressure of 50 bar (0,5 MPa) (725 psi). Turn to left: increase pressure Turn to right: reduce pressure 8. Tighten lock nut with a tightening torque of 22 Nm (16,2 lbf ft). 9.
  • Page 287 9. Tighten flange nut with a tightening torque of 22 Nm (16,2 lbf ft). 10. Fit seal cap on disconnection valve. High pressure valve, adjust Op nbr 1. Remove seal cap on high pressure valve (6). Figure 10 5. Disconnection valve 6.
  • Page 288 16. Read pressure gauge, both connections must show the same pressure (∆p=0). NOTE! If the pressures are different, repeat the adjustment in the same way. Test regulation start of hydraulic adjustment motor, and adjust machines L40B, SN 192 and L45B, SN195 Op nbr NOTE! The test temperature of 60 °C (140 °F) must be maintained throughout the entire test.
  • Page 289 more than 8.5 bar / 123 psi, and hence the direction valve Y10 is powered. 1. Remove floor plate. 2. Connect pressure gauge to hydraulic pump connection (1) “High pressure forward”. Figure 12 3. Connect pressure gauge to hydraulic motor connection (2) M1. 4.
  • Page 290 14. Connect electric connector to shift solenoid. Test regulation start of hydraulic adjustment motors, and adjust machines L40B, SN 191 and L45B, SN194 Op nbr NOTE! First check and adjust hydraulic motor B (A6VM 80HA). 1. Remove floor plate. 2. Connect pressure gauge to hydraulic pump connection (1) “High pressure forward”.
  • Page 291 Figure 15 13. Control pressure is triggered too early. Turn adjusting screw counter-clockwise using Allen key. 14. Control pressure is triggered too late. Turn adjusting screw clockwise using Allen key. 15. Check control pressure again. 16. Tighten adjusting screw lock nut with a torque of 10 Nm (7.4 lbf ft). 17.
  • Page 292 21. Tighten lock nut with a tightening torque of 10 Nm (7.4 lbf ft). 22. Remove tachometer and pressure gauge. 23. Carry out test drive. NOTE! If errors occur in direction “Reverse”, repeat the adjustment process completely in reverse travel.

  • Page 293: Hydraulic Diagram Transmission

    Service Information Document Title: Function Group: Information Type: Date: Hydraulic diagram Service Information 2014/3/10 transmission Profile: CWL, L40B [GB] Hydraulic diagram transmission Drive L40B, SN 192 / L45B, SN 195 Figure 1...
  • Page 294 U hydraulic motor via pressure build-up valve 0.5 bar to tank via 3.0 bar valve Flush connection of hydraulic pump, connection T2 Feed pressure Check high pressure, reverse Check high pressure, forward Operating pressure, forward Operating pressure, reverse Drive L40B, SN 191 / L45B, SN 194...
  • Page 295 Figure 2 Hydraulic diagram, drive SN 191, SN 194 Hydraulic pump Feed pump Controller cartridge...
  • Page 296 Feed pressure valve Secondary limiter valve, forward/reverse Shut-off valve with change-over valve Solenoid valve, forward/reverse Control piston Inch brake valve Combination sensor, hydraulic oil temperature Hydraulic motor A Control piston Restriction valve Solenoid valve, direction valve Solenoid valve, hydraulic motor Hydraulic motor B Control piston Restriction valve...
  • Page 297 Information Type: Date: Hydrostatic motor, removal 441 Service Information 2014/3/10 Profile: CWL, L40B [GB] Go back to Index Page Hydrostatic motor, removal Op nbr 1. Place the machine in service position. NOTE! Before removing the hoses, carefully clean the areas in question so that no dirt enters the system. All openings must be sealed with stoppers.
  • Page 298 Information Type: Date: Hydrostatic motor, removal 441 Service Information 2014/3/10 Profile: CWL, L40B [GB] Go back to Index Page Hydrostatic motor, removal Op nbr 1. Place the machine in service position. NOTE! Before removing the hoses, carefully clean the areas in question so that no dirt enters the system. All openings must be sealed with stoppers.
  • Page 299 Hydrostatic motor, Service Information 2014/3/10 installation Profile: CWL, L40B [GB] Go back to Index Page Hydrostatic motor, installation Op nbr 1. Install hydraulic motor (A) and tighten fixing bolts with a torque of 150 Nm (110.6 lbf ft). Figure 1 2.
  • Page 300 Service Information 2014/3/10 installation Profile: CWL, L40B [GB] Go back to Index Page Hydrostatic motor, installation Op nbr NOTE! As the intermediate housing is filled with oil, the toothing on the drive shaft must not be coated with anti-seize agent when inserted.
  • Page 301 Service Information Document Title: Function Group: Information Type: Date: Assembling the hydraulic Service Information 2014/3/10 motor Profile: CWL, L40B [GB] Assembling the hydraulic motor...
  • Page 302 Figure 1 Tightening torque Adjustment dimension “X” 15 mm (0.59 in) Jam nut for adjusting screw, swivel angle limiter 69 Nm (50.9 lbf ft)
  • Page 303 Sealing plug 20 Nm (14.8 lbf ft) Choke screw 8 Nm (5.9 lbf ft) Choke screw 3 Nm (2.2 lbf ft) Cover screw 49 Nm (36.1 lbf ft) Adjustment screw 86 Nm (63.4 lbf ft) Sealing plug M14x1.5 30 Nm (22.1 lbf ft) Sealing plug 40 Nm (29.5 lbf ft) Jam nut for adjustment screw...
  • Page 304 Information Type: Date: Hydrostatic pump, Service Information 2014/3/10 removing and installing Profile: CWL, L40B [GB] Hydrostatic pump, removing and installing Figure 1 Tightening torque Hex bolt 49 Nm (36.1 lbf ft) Cap head bolt 210 Nm (154.9 lbf ft) Cap head bolt with Loctite 245 85 Nm (62.7 lbf ft)
  • Page 306 The parking brake acts by mechanical activation of the disc brake on the front axle. Machines L40B, SN 191 and L45B, SN 194 have two brake pedals. The inch brake pedal on the left is a pump accumulator brake system with hydraulically activated oil bath multiple disc brake on the rear axle.
  • Page 307 Date: Brake system, component Service Information 2014/3/10 Profile: CWL, L40B [GB] Brake system, component Position of components, machine L40B, SN 192 / L45B, SN 195 Figure 1 Inch brake pedal Parking brake Hydraulic pump Hydraulic oil tank Inch brake valve...
  • Page 308 Figure 2 Inch brake pedal Brake pedal Parking brake Hydraulic pump Hydraulic oil tank Inch brake valve Brake valve Brake disc Parking brake caliper Accumulator charge valve Multiple disc brake, rear axle...
  • Page 309 Service Information Document Title: Function Group: Information Type: Date: Hydraulic diagram, brake Service Information 2014/3/10 system, dry brakes Profile: CWL, L40B [GB] Hydraulic diagram, brake system, dry brakes...
  • Page 310 Figure 1 Inch brake valve Brake light switch (5 bar / 73 psi) Pressure switch control pressure (8.5 bar / 123 psi) Warning switch, low brake pressure (95 bar / 1378 psi) Accumulator charge valve Steering pump with priority valve Hydraulic adjustment pump (control pressure) Parking brake caliper Service brake caliper...
  • Page 311 Service Information Document Title: Function Group: Information Type: Date: Hydraulic diagram, brake Service Information 2014/3/10 system, wet brakes Profile: CWL, L40B [GB] Hydraulic diagram, brake system, wet brakes Figure 1...
  • Page 312 Inch brake valve Brake valve Brake light switch (5 bar / 73 psi) Warning emitter, low brake pressure (95 bar / 1378 psi) Accumulator charge valve Steering pump with priority valve Hydraulic adjustment pump (control pressure) Oil bath multiple disc brake, rear axle Connection for hydraulic fan Excess Flow Priority Flow...
  • Page 313 Service Information 2014/3/10 wear Profile: CWL, L40B [GB] Brake linings, checking wear Op nbr 517-001 A brake lining wear measurement gives information on the overall condition of the brake disc set without disassembling the final drive. This is required above all on modified braking behaviour such as: ...
  • Page 314 4. Measure the dimension 'X'. Figure 2 Measuring, dimension X 5. Remove the brake pressure, and screw in the measuring screw (M16 x 1.5). NOTE! Tightening torque: 10 Nm (7.4 lbf ft) 6. Measure the dimension 'Y'. 7. Calculate the difference between X and Y. Dimension 'X' - Dimension 'Y' = Piston stroke 8.
  • Page 315 Information Type: Date: Brake disc, replacing one Service Information 2014/3/10 Profile: CWL, L40B [GB] Brake disc, replacing one Op nbr 511-002 Remove brake disc Figure 1 1. Remove universal shaft (1) on front axle. 2. Withdraw ES bolt (2) and remove handbrake cable (3) from lever.
  • Page 316 (221 lbf ft). 7. Connect handbrake cable to lever and secure with ES bolt. 8. Fit universal shaft and tighten fixing bolt with a torque of 72 Nm (53 lbf ft). 9. Check brake system for function.
  • Page 317 Function Group: Information Type: Date: Brake calliper removed, Service Information 2014/3/10 reconditioning Profile: CWL, L40B [GB] Brake calliper removed, reconditioning Brake caliper, parking brake Op nbr 511-081 Figure 1 Parking brake caliper Brake caliper Shaft seal Coil spring Operating lever...
  • Page 318 Insert Plastic cover Brake lining 1. Remove brake pad (13) 2. Release twist lock (6) and unscrew fixing bolt (7). 3. Remove twist lock (6), disc (5), control lever (4) and coil spring (3). 4. Unscrew rotor assembly (10) from caliper. NOTE! The ring cage and three balls may fall out with the rotor assembly.
  • Page 319 Information Type: Date: Brake disc, replacing one Service Information 2014/3/10 Profile: CWL, L40B [GB] Brake disc, replacing one Remove brake disc Op nbr 511-002 Figure 1 1. Remove universal shaft (1) on front axle. 2. Withdraw ES bolt (2) and remove handbrake cable (3) from lever.
  • Page 320 7. Push brake disc (7) onto universal shaft flange. 8. Fit brake caliper (5), parking brake and brake caliper (6), service brake on brake carrier. Screw in fixing bolt and tighten with a torque of 300 Nm (221 lbf ft). 9.
  • Page 321 Function Group: Information Type: Date: Brake calliper removed, Service Information 2014/3/10 reconditioning Profile: CWL, L40B [GB] Brake calliper removed, reconditioning Brake caliper, service brake Op nbr 511-081 Figure 1 Service brake caliper Brake caliper Bleed valve Sealing ring Piston Dust caps...
  • Page 322 10 bar (1 MPa) (145 psi) pressure gives a piston force of up to 6000 N. 5. Close the open cylinder bore using a sealing plate you have made. 6. Remove the screw clamp and wooden shim, and press the piston out of the brake caliper using compressed air. 7.
  • Page 323 2. Turn off engine and apply parking brake. 3. Evacuate the brake system by pressing the brake pedal repeatedly. 4. Connect pressure gauge to measurement point “M2”. NOTE! On L40B, SN 191 and L45B, SN 194 connect to measurement point “M3”.
  • Page 324 Figure 2 5. Turn ignition key to position “I”, the warning light (parking brake — accumulated pressure brake system) must now flash. Figure 3 Warning light parking brake accumulated pressure, braking system 6. Start engine. If the pressure (at measuring point “M2”) shows 95 bar (1378 psi), the warning light must come on (with parking brake applied).
  • Page 325 Date: Accumulators, checking in Service Information 2014/3/10 machine Profile: CWL, L40B [GB] Accumulators, checking in machine Op nbr 527-003 11666135 Gas filling kit WARNING Charging the accumulator with nitrogen only. Do not use oxygen or compressed air. Danger of explosion NOTE! Test only at room temperature of 20°C (68°F)
  • Page 326 Function Group: Information Type: Date: Accumulator, checking Service Information 2014/3/10 (removed) Profile: CWL, L40B [GB] Accumulator, checking (removed) Op nbr 52701 11666019 Pressure gauge 0–6 MPa (0–60 bar) (0–870 psi) 11666041 Pump 11666037 Hose E 1234 Nipple E 1281 Nipple NOTE! All work on the brake system must be conducted in the cleanest possible conditions.
  • Page 327 Figure 1 Checking removed accumulator Accumulator 11666041 11666037 E 1234 11666019 Included in 11 666 037 E 1281 5. Pump oil into the accumulator. After a few pump strokes, the pressure will increase rapidly to the precharge pressure and will continue to increase slowly.
  • Page 328 Function Group: Information Type: Date: Discarded accumulators Service Information 2014/3/10 Profile: CWL, L40B [GB] Discarded accumulators Op nbr WARNING A discarded accumulator which is not punctured may still contain high pressure and must always be handled with great care. WARNING Use safety glasses.
  • Page 330 Service Information 2014/3/10 description Profile: CWL, L40B [GB] Steering system, description The machine has hydrostatic Load Sensing (LS) articulated steering with two double-action steering cylinders and damped sideways oscillation. The steering pump is a gear pump with priority valve.
  • Page 331 2014/3/10 troubleshooting elimination Profile: CWL, L40B [GB] Steering system, troubleshooting and elimination General The table below should help operators and maintenance staff determine the possible cause of a malfunction in the steering system before damage occurs. It does not claim to be complete, but serves merely to support troubleshooting and diagnosis.
  • Page 332 turned continuously without The steering cylinders are worn. Replace worn parts. giving any steering movement. Worn gear set. Change steering unit. Pressure limiting valve set higher than Adjust pressure limiting valve to spec. sheet. double safety valves. The steering wheel is too slow The steering unit is not getting enough Replace pump, check engine speed, adjust as or heavy to move for quick...
  • Page 333 Function Group: Information Type: Date: Hydraulic diagram, steering Service Information 2014/3/10 system Profile: CWL, L40B [GB] Hydraulic diagram, steering system Figure 1 Hydraulic diagram, steering system Steering valve (ORBITROL) Steering pump Accumulator charge valve Steering cylinder Pressure connection, steering pump...
  • Page 334 Service Information 2014/3/10 adjusting working pressure Profile: CWL, L40B [GB] Steering system, checking and adjusting working pressure Op nbr 645-028 11666020 Pressure gauge 11666037 Hose Test 1. Run the machine until a hydraulic oil temperature of 55 + 5°C (131 + 41°F) is reached.
  • Page 335 Figure 2 Plug - pressure limiting valve 7. Turn pressure limiter valve adjusting screw to left until the pressure gauge shows the nominal value. Turn to right: increase pressure Turn to left: reduce pressure Figure 3 Pressure limiter valve, adjustment screw 8.
  • Page 336 Date: Steering valve, Service Information 2014/3/10 reconditioning (removed) Profile: CWL, L40B [GB] Steering valve, reconditioning (removed) Op nbr 64581 6999 007 Handle 6999 025 Plate 6999 034 Plate Dismantling 1. Mark the steering valve's parts in relation to each other to facilitate assembling.
  • Page 337 Figure 2 Removing rotor kit 3. Remove the lock pin. Remove the steering valve from the vice and remove the ball. Figure 3 Removing ball 4. Remove the inner and outer slides. NOTE! Do not pull on the outer slide. Risk of separating the parts which means that the return springs will lock the inner slide in the housing.
  • Page 338 Figure 4 Removing inner and outer slide 5. Remove the thrust plate, needle bearing, bearing race and the ring. Figure 5 Removing needle bearing and ring 6. Remove the inner and outer seals. 7. Carefully press the inner slide out from the outer slide. Remove the leaf springs.
  • Page 339 Assembling 8. Fit the outer seal ring. Secure the valve housing in a vice. Use soft jaws. Figure 6 Installing seal ring 6999 007 6999 025 6999 034 9. Place the assembled seal on the drift plate and press the seal into the housing. Figure 7 Installing seal ring 6999 007...
  • Page 340 Figure 8 T-shaped groove (inner slide) Hole (outer slide) Punch marks 11. Fit the leaf springs. Make sure that they're fitted correctly. Figure 9 Fitting leaf springs 12. Fit the thrust plate, needle bearing, bearing race and the ring on the inner and outer slide. NOTE! Fit the bearing race with the bevel facing the inner slide.
  • Page 341 machine will self-steer. Figure 11 Inner and outer slides and drive pin's placement in valve housing 14. Fit the O-ring. Fit the distribution plates so that the channel holes line up with the corresponding holes in the valve housing. Figure 12 Distribution plate on valve housing 15.
  • Page 342 Tighten the bolts crosswise. Tightening torque: 30 - 35 Nm (22 -26 lbf ft) Figure 14 Ball's position in valve housing...
  • Page 344 2014/3/10 description Profile: CWL, L40B [GB] Frame and track unit, description The front frame is built as an open box profile on which is attached the lifting bracket that serves as a carrier for the fast change device with the working tools required. The front frame also fixes the front axle.
  • Page 345 Frame and steering joint, Service Information 2014/3/10 general Profile: CWL, L45B, L40B [GB] Frame and steering joint, general In addition to the work prescribed in the Operator's Manual, the following checks and maintenance must be performed at each customer service: ...
  • Page 346 V-ring Swivel joint Circlip Rubber bumper Screw Bearing bolt Shim Screw Grease nipple...
  • Page 347 Function Group: Information Type: Date: Frame joint, changing Service Information 2014/3/10 bearings Profile: CWL, L40B [GB] Frame joint, changing bearings Replace bearings with machine open Op nbr NOTE! The articulated steering joint is re-assembled in the order described below. Figure 1...
  • Page 348 Articulated steering joint, cross-section view 1. Cool new bushes (2, 3 and 10), e.g. in freezer or dip into liquid nitrogen when suspended on a wire. WARNING Risk of frostbite! Wear protective work gloves. 2. Push bushes (2 and 3) into the rear frame until the bush collar lies on the frame. 3.
  • Page 349 18. The pretension “Y” may be between 0.0 and 0.1 mm; set the pretension by selecting appropriate shims (17). 19. Unscrew old screws from upper bearing bolt and raise bearing bolt with two pressure screws. 20. Place specified shims below bearing bolt tighten...
  • Page 351 Service Information 2014/3/10 Profile: CWL, L40B [GB] Cab description The cab is mounted resiliently and complies with ROPS regulations ISO 3471 and SAE 1040, and the cab is also FOPS – certified to ISO 3449 and SAE J231. This guarantees optimum driver safety in the event of the machine overturning or if objects fall onto the cab roof.
  • Page 352 Document Title: Function Group: Information Type: Date: mounts, tightening Service Information 2014/3/10 torques Profile: CWL, L40B [GB] Cab mounts, tightening torques Figure 1 Cab suspension, fixing element Screw Puffer Pipe Washer Fixing element, tightening torque Fixing nuts on frame 200 Nm (148 lbf ft)
  • Page 353 (scratches, dents, breaks) Profile: CWL, L40B [GB] Repairs of minor damage on internal and external plastic parts (scratches, dents, breaks) The plastic parts repair kit, order no. 2815630, consists of: Pos. Order no. Description 2809720 Universal cleaner, 1 ltr.
  • Page 354 Document Title: Function Group: Information Type: Date: mounts, tightening Service Information 2014/3/10 torques Profile: CWL, L40B [GB] Cab mounts, tightening torques Figure 1 Cab suspension, fixing element Screw Puffer Pipe Washer Fixing element, tightening torque Fixing nuts on frame 200 Nm (148 lbf ft)
  • Page 355 Document Title: Function Group: Information Type: Date: mounts, tightening Service Information 2014/3/10 torques Profile: CWL, L40B [GB] Cab mounts, tightening torques Figure 1 Cab suspension, fixing element Screw Puffer Pipe Washer Fixing element, tightening torque Fixing nuts on frame 200 Nm (148 lbf ft)
  • Page 356 Service Information 2014/3/10 Profile: CWL, L40B [GB] Windows, general All windows in the cab are glued directly to the window cut-out of the cab frame. When replacing the cab windows, wear safety goggles and gloves. Use clean tools because dirt residue and lubricant can reduce adhesion, which is extremely important for the seal and strength of the window adhesion.
  • Page 357 Function Group: Information Type: Date: Windscreen, replacing Service Information 2014/3/10 Profile: CWL, L40B [GB] Windscreen, replacing Op nbr 843-002 88830060 Disassembly tool 88830062 Wire unvinding device 1. Place the machine in service position. WARNING Risk of cuts! Wear safety glasses and use protective gloves.
  • Page 358 Figure 2 8. Apply primer thinly to the contact surface (arrows) of the screen (outer edge and ceramic layer on the inside) and allow to dry to at least 15 minutes. 9. Clean/activate contact surface of the frame flange with activator before inserting the new window. Figure 3 10.
  • Page 359 Figure 5 NOTE! If the adhesive bead is applied too thickly and the adhesive extrudes below the screen, remove the surplus adhesive as soon as possible using a wooden spatula. 12. Fill the gap between the screen and frame with sealant and spread evenly with a suitable tool. NOTE! Allow adhesive to harden for at least 2 hours.
  • Page 360 Function Group: Information Type: Date: Rear window, replacing Service Information 2014/3/10 Profile: CWL, L40B [GB] Rear window, replacing Op nbr 843-012 88830060 Disassembly tool 88830062 Wire unvinding device 1. Place the machine in service position. WARNING Risk of cuts! Wear safety glasses and use protective gloves.
  • Page 361 Figure 2 9. Apply primer thinly to the contact surface (arrows) of the screen (outer edge and ceramic layer on the inside) and allow to dry to at least 15 minutes. 10. Clean/activate contact surface of the frame flange with activator before inserting the new window. Figure 3 11.
  • Page 362 Figure 5 NOTE! If the adhesive bead is applied too thickly and the adhesive extrudes below the screen, remove the surplus adhesive as soon as possible using a wooden spatula. 13. Fill the gap between the screen and frame with sealant and spread evenly with a suitable tool. NOTE! Allow adhesive to harden for at least 2 hours.
  • Page 363 Function Group: Information Type: Date: Door window, replacing Service Information 2014/3/10 Profile: CWL, L40B [GB] Door window, replacing Op nbr 843-048 88830060 Disassembly tool 88830062 Wire unvinding device 1. Place the machine in service position. WARNING Risk of cuts! Wear safety glasses and use protective gloves.
  • Page 364 Figure 2 5. Cut out side window with a cutting wire. Using suction lift, remove side window and place on a suitable support. NOTE! Weight of side window approx. 6 kg (13 lb). 6. Cut out sliding window with a cutting wire. Using suction lift, remove sliding window. 7.
  • Page 365 Figure 4 10. Lay new sliding window on a suitable base. NOTE! Weight of sliding window approx. 8 kg (18 lb). 11. Apply primer thinly to the contact surface (metal flange) of the sliding window and allow to dry for at least 15 minutes.
  • Page 366 Allow adhesive to harden for at least 2 hours. 17. Fit outer door panelling, door handle and inner panelling. NOTE! Dispose of remaining adhesive, primer and activator.
  • Page 368 2014/3/10 note when working on the hydraulic system Profile: CWL, L40B [GB] General information to note when working on the hydraulic system NOTE! Precautionary measures to protect against possible risk of accident, injury or death. Special notes for better implementation of operating, control and adjustment procedures and maintenance work.
  • Page 369 Service Information 2014/3/10 on hydraulic components Profile: CWL, L40B [GB] Cleanliness when working on hydraulic components WARNING Hot hydraulic oil and hydraulic oil under pressure may result in severe personal injuries It is very important to keep the hydraulic system free from impurities as these can cause abnormal wear and can lead to expensive malfunctions.
  • Page 370 Hydraulic oil, storage and Service Information 2014/3/10 handling Profile: CWL, L40B [GB] Hydraulic oil, storage and handling  Hydraulic oil should be stored in tightly sealed tanks or barrels.  Only containers used for transporting hydraulic oil should be used for this purpose.
  • Page 371 Service Information 2014/3/10 hydraulic components in workshop Profile: CWL, L40B [GB] Hydraulic system, repair of hydraulic components in workshop  Always wear clean coveralls and be strict about personal cleanliness.  Work on hydraulic components should be performed separate from other work in a so-called "clean room". The room must have good ventilation and the floor must be coated with a binding material.
  • Page 372 Service Information 2014/3/10 storage and transport Profile: CWL, L40B [GB] Hydraulic components, storage and transport  All hydraulic components must be stored in plastic bags or film and they must be plugged. The packaging must not be opened before the component is to be used.

  • Page 373: Troubleshooting Chart

    Function Group: Information Type: Date: Troubleshooting chart Service Information 2014/3/10 Profile: CWL, L40B [GB] Troubleshooting chart Malfunction/Error Possible malfunction cause Malfunction elimination Hydraulic functions of raise, Oil level in hydraulic oil tank too low. Add hydraulic oil and bleed system if necessary.
  • Page 374 forward on fine control "tilt "tilt back/out" faulty or seat damaged. necessary replace non-return valve back". Control valve leaking Oil level in hydraulic oil tank too low. Add hydraulic oil and bleed system if necessary. outside. Return filter dirty. Check return filter, replace filter element if Lines chafing.
  • Page 375 Service Information 2014/3/10 description Profile: CWL, L40B [GB] Hydraulic system, description The hydraulic system is a need-controlled load-sensing hydraulic system supplied via a pump. Thermostatically regulated oil circuit with integral cooling system. Servo-controlled, double-action three-way control block with primary and secondary protection.
  • Page 376 Service Information Document Title: Function Group: Information Type: Date: Hydraulic system, volume Service Information 2014/3/10 Profile: CWL, L40B [GB] Hydraulic system, volume Hydraulic system Oil volume, total 120 litre (31.4 US gal)
  • Page 377 Function Group: Information Type: Date: Hydraulic system, position Service Information 2014/3/10 of main components Profile: CWL, L40B [GB] Hydraulic system, position of main components Figure 1 Hydraulic system, components Locking cylinder, tool attachment Tilt cylinder Lifting cylinder Control valve Hydraulic oil tank...
  • Page 378 2014/3/10 description Profile: CWL, L40B [GB] Hydraulic oil tank, description The driving/working and steering hydraulics, including brakes, are supplied from the hydraulic oil tank. The oil level is read via the sight glass. With the loading device lowered, the lower sight glass must be full and no oil visible in the upper sight glass.
  • Page 379 Figure 2 Hydraulic oil tank Oil level sight gauge Breather filter Suction and return filter Control switch Drain valve...

  • Page 380: Control Valve

    Service Information Document Title: Function Group: Information Type: Date: Control valve Service Information 2014/3/10 Profile: CWL, L40B [GB] Control valve Control valve, up to series no. L40B – 1911121 L40B – 1921340 L45B – 1941197 L45B – 1951404 Figure 1...
  • Page 381 Return to tank LS-signal Locking cylinder connection "unlock" Locking cylinder connection "lock" Connection tilt cylinder piston rod side “Tilt back” Connection tilt cylinder piston head side “Tilt out” Connection lifting cylinder piston rod side “Lower” Connection lifting cylinder piston head side “Raise” Pre-tensioning valve Figure 2 Pre-tensioning valve...
  • Page 382 Pilot valve valvistor Load-holding valve Quantity meter (meter in valve) Connection servo control Connection servo control Secondary protection Quantity meter (meter out valve) LS valve Control valve, from series no. L40B 1911122 – L40B 1921341 – L45B 1941198 – L45B 1951405 –...
  • Page 383 Figure 4 Control valve, from SN Lock / unlock (optional hydraulics) Tilting function Lift function Unlock / tilt secondary limitations Pilot valves for low leak valves Low leak valves Pretensioning valve, regeneration LS flow control valve Pressure balance Lock / tilt in / raise secondary limitations Load holding valves Rod side Piston head side...
  • Page 384 Measurement connection working hydraulics (standby, max. operating pressure) Return Pretensioned return NOTE! All lifting limitations are set to maximum displacement of the push rods. The non-return valves “Regeneration” are below the precontrol valves Lower and Tilt Out. Control valve, section view Figure 5 Pressure balance Low leak valve...
  • Page 385 Information Type: Date: Secondary limiting valve, Service Information 2014/3/10 test and adjust Profile: CWL, L40B [GB] Secondary limiting valve, test and adjust Op nbr 11666003 Pressure gauge 11666037 Hose 2814216 Support NOTE! On inspection, the motor and hydraulic system must have reached operating temperature.
  • Page 386 6. Raise lifting frame again until the piston rod extends. Read display on pressure gauge. For nominal value see 910 Hydraulic system, specification NOTE! If the specified nominal value is not reached, set the pressure on the secondary limiting valve. Check tilt cylinder, piston head side 7.
  • Page 387 Function Group: Information Type: Date: Hydraulic diagram, Service Information 2014/3/10 working hydraulic system Profile: CWL, L40B [GB] Hydraulic diagram, working hydraulic system Hydraulic diagram working hydraulics, up to series no. L40B – 1911121 L40B – 1921340 L45B – 1941197 L45B –...
  • Page 388 Precontrol block (FM1 and FM2 are not closed on TPS version) Precontrol valve Control valve Lifting cylinder Tilt cylinder Locking cylinder Hydraulic diagram working hydraulics, from series no. L40B 1911122 – L40B 1921341 – L45B 1941198 – L45B 1951405 –...
  • Page 389 Hydraulic oil tank Working hydraulics pump Engine Precontrol block (FM1 and FM2 are not closed on TPS version) Precontrol valve Control valve Lifting cylinder Tilt cylinder Locking cylinder...
  • Page 390 Service Information Document Title: Function Group: Information Type: Date: Hydraulic diagram, control Service Information 2014/3/10 valve Profile: CWL, L40B [GB] Hydraulic diagram, control valve Control valve, up to series no. L40B – 1911121 L40B – 1921340 L45B – 1941197 L45B –...
  • Page 391 LS valve Quantity meter (meter out valve) Rod side Piston head side Working pressure LS Channel Return to tank Oil leakage Control valve, from series no. L40B 1911122 – L40B 1921341 – L45B 1941198 – L45B 1951405 – Figure 2...
  • Page 392 2014/3/10 description Profile: CWL, L40B [GB] Hydraulic pump, description The pump is a nine cylinder axial piston pump with variable flow. The drive shaft (9) rotates, causing the cylinder drum (6), pistons (7) and shoe plate (8) to rotate also. The piston stroke depends on the angle assumed by the swivel washer (10).
  • Page 393 Figure 2 Hydraulic pump Distribution plate Pump unit (with cylinder drum and piston) Drive shaft Swivel washer Control piston Housing Pressure compensator Flow compensator Bearings Bearings Figure 3 Hydraulic pump Hydraulic pump Inlet Pressure compensator (main pressure) Flow compensator Exhaust...
  • Page 394 Service Information 2014/3/10 working pressure, checking and adjusting Profile: CWL, L40B [GB] Stand-by pressure and working pressure, checking and adjusting Op nbr 11666003 Pressure gauge 11666037 Hose NOTE! On inspection, the motor and hydraulic system must have reached operating temperature.
  • Page 395 If the specified nominal value is not reached, set the pressure on the flow compensator. 6. Adjust on the pump flow compensator until correct stand-by pressure is obtained. Operating pressure, check 7. Start engine and run at low idle speed. 8.
  • Page 396 Servo valve, description Service Information 2014/3/10 Profile: CWL, L40B [GB] Servo valve, description The precontrol valve with end position lock works on the basis of direct-controlled pressure reducing valves. It consists of the control lever (1), four pressure reducing valves and locks.
  • Page 397 Figure 1 Servo valve Figure 2 Connection diagram, precontrol valve Lowering Tilt back Lifting Tilt, forward Unlock Lock Pump pressure Tank Function of working hydraulics Figure 3 Multi-function lever Neutral position, not activated (spring-centred) Lowering Float position (lockable) Tilt back (lockable) Tilt, forward Raise (optional, lockable)
  • Page 398 Actuation lever, lock, fast change tool attachment and optional hydraulics Unlock Lock (lockable)
  • Page 399 Service Information 2014/3/10 general description Profile: CWL, L40B [GB] Boom Suspension System, general description To improve driving comfort and reduce mechanical stress on frame, transmission and lifting gear, a boom suspension system (BSS) is available as an accessory (option). The boom suspension system (BSS) works only above a factory-set drive speed and lift height of the boom. Below this drive speed and lifting height, the boom suspension shuts off.
  • Page 400 Function Group: Information Type: Date: Hydraulic diagram, Boom Service Information 2014/3/10 Suspension System Profile: CWL, L40B [GB] Hydraulic diagram, Boom Suspension System Hydraulic diagram boom suspension system, up to series no. L40B – 1911121 L40B – 1921340 L45B – 1941197 L45B –...
  • Page 401 L45B 1941198 – L45B 1951405 – Figure 2 Accumulator charge valve Bottom valve Rod compensation valve Valve to limit accumulator charge pressure Safety valve...
  • Page 402 (quickfit), description Profile: CWL, L40B [GB] Hydraulic attachment bracket (quickfit), description The machine is fitted with a hydraulic tool attachment as standard. The hydraulic components of the tool attachment lie inside the lower cross member, protected from external influences. The locking bolts disappear completely into the tool...

  • Page 403: Lock Cylinder

    Service Information Document Title: Function Group: Information Type: Date: Lock cylinder Service Information 2014/3/10 Profile: CWL, L40B [GB] Lock cylinder Figure 1 Sleeve O-ring Washer Scraper Bolt Piston rod Support ring O-ring Bushing Groove ring Piston guide band Sealing ring...
  • Page 404 O-ring Member Screw...
  • Page 405 2014/3/10 repacking removed hydraulic cylinder Profile: CWL, L40B [GB] Implement attachment, repacking removed hydraulic cylinder Op nbr 945-056 2915096 Protecting sleeve NOTE! The protective sleeve (fitting aid) is required if the tool attachment is still mounted on the lifting frame.
  • Page 406 Figure 2 7. Remove the piston strip guide (11) and sealing ring (12) from the piston (13). 8. Clamp piston rod fully, vertically in the vice and unscrew bolts (5). 9. Remove bush (9) from piston rod (6). 10. Remove grooved ring (10) from bush (9). 11.
  • Page 407 Setting time min 12 hours. 17. Place O-ring (8) and support ring (7) in the grooves of the bush (9). 18. Push O-ring (15) and piston (13) on the piston rod (6). 19. Screw on lock nut (14) and tighten with a torque of 330 Nm (243 lbf ft). 20.
  • Page 408 Service Information 2014/3/10 Profile: CWL, L40B [GB] Lifting frame, description The lifting frame consists of two arms attached to the upper part of the front frame. These are connected by a carrier construction so that they also carry the lever for the tilt movement. The movements are generated by cylinders attached between the tilt lever / lifting frame and front frame.
  • Page 409 Function Group: Information Type: Date: Tilting and lifting cylinders 940 Service Information 2014/3/10 Profile: CWL, L40B [GB] Tilting and lifting cylinders Tilt cylinder: 1 pc. double-acting Piston rod diameter 65 mm (2.56 in) Inside diameter 125 mm (4.92 in) Stroke 400 mm (15.75 in)
  • Page 410 Lift cylinder: 2 pcs. double-acting Piston rod diameter 650 mm (1.97 in) Inside diameter 110 mm (4.33 in) Stroke 575 mm (22.64 in) Lock nut (1), tightening torque 1400 Nm (1033 lbf ft) Figure 2 Lifting cylinder, sectional view...
  • Page 411 Service Information Document Title: Function Group: Information Type: Date: Lock cylinder Service Information 2014/3/10 Profile: CWL, L40B [GB] Lock cylinder Figure 1 Sleeve O-ring Washer Scraper Bolt Piston rod Support ring O-ring Bushing Groove ring Piston guide band Sealing ring...
  • Page 412 O-ring Member Screw...
  • Page 413 Many thanks for your purchase. Happy every day. file:///C|/Users/yeqiwen/Documents/QIWEN-YE-END.txt[2014/3/10 21:32:13]...

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