Volvo L150G Wheel Loader Service & Repair Manual Wiring Diagrams PDF Download - MVLVCONL150G.zip
Full workshop service and repair documentation for the Volvo L150G Wheel Loader, complete with electrical wiring diagrams, delivering every technical detail needed to maintain, troubleshoot, fix, and overhaul the machine to professional-shop standards.
The Volvo Construction Equipment L150G Wheel Loader workshop service and repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 2,721 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo L150G Wheel Loaders Service Repair Manual.pdf
TABLE OF CONTENTS
0 - GENERAL...2
03 - SPECIFICATIONS...3
Tightening torques...4
Tightening torque; cylinder head...15
Lubrication system; specifications ...17
Oil cooler; tightening torques ...19
Tightening torques; unit injector_{20-27}...21
Tightening torques; unit injector_{20-08}...23
Exhaust aftertreatment system; specifications ...25
Compressed-air system; specifications ...28
Turbocharger; specifications_{18-59}...30
Turbocharger; specifications_{18-40}...32
Thermostat; specifications ...34
Rocker arm shaft; tightening torques_...35
Valve cover; tightening torques_...37
Exhaust manifold; tightening torques_{16-45}...38
Exhaust manifold; tightening torques_{16-23}...40
EGR system; tightening torques ...42
Cooling fan rpm; specifications ...43
Conversion tables...46
Fuel system; specifications ...50
Engine; specifications ...51
07 - STANDARD TIME...53
Operation numbers for additional work...54
08 - TOOL...56
E1680; Holder...57
E 1708; Checking point...59
E1711...61
E-2000...63
E-2001...65
E-2005...67
E-2007...69
E-2015...71
E-2017...73
E-2018...74
E-2020...76
E-2028...77
Infrared Thermometer...79
Leak detector 951 1207; description...83
88830557 User Instruction...87
1 - STANDARD PARTS; SERVICE...97
16 - LUBRICANT; FUEL; OTHER FLUID...98
Coolant...99
Recommended lubricants...101
Alternative fuels...104
17 - SERVICE...107
Service...111
Electric welding ...114
Arrival Inspection; according to Inspection Programme...116
Delivery Inspection; according to Inspection Programme...117
Maintenance of Stored Machines; according to Inspection Programme...118
Maintenance service; first 1000 hours...119
Maintenance service; every 50 hours...120
Maintenance service; every 250 hours...121
Maintenance service; every 500 hours...122
Maintenance service; every 1000 hours...124
Maintenance service; every 2000 hours_{58-45}...126
Maintenance service; every 2000 hours_{58-27}...129
Maintenance service; every 4000 hours_{57-58}...132
Maintenance service; every 4000 hours_{57-40}...135
Maintenance service; every 4500 hours...138
Maintenance service; every 6000 hours...140
Maintenance service; every 8000 hours...141
Maintenance service; every 12000 hours...142
Brake discs; measuring wear...144
Wheel brakes function; checking...147
Service position 2_{55-12}...148
Service position 1_{54-44}...150
Wheel brake; specification...152
Drive axles; oil; draining...153
Front axle; breather filter; replacing...156
Axle oil cooler; front axle; filter; replacing...158
Rear axle bearing; oil; draining...160
Hydraulic oil tank; draining...162
Transmission oil; draining...164
Engine oil; changing...166
Engine oil; draining...167
EGR venturi tube; checking ...169
Spark plug cable; replacing ...172
Spark plug; replacing ...174
Valves; adjusting_{48-43}...179
Valves; adjusting_{48-17}...185
Oil plugs; installing...191
Take the hose away from the draining point of engine oil and replace the cap...192
Water separator; draining...193
Fuel filters; primary and secondary filter; replace...195
Engine oil filter; removing...197
Fuel tank breather filter; replacing...198
Axle oil cooler; rear axle; filter; replacing...199
Engine air cleaner; replacing...200
Transmission oil filter; replacing...203
Transmission suction strainer; cleaning...205
Automatic central lubrication; filter; cleaning_replacing...207
Cab; extra prefilter; replacing...209
Air pump; oil level; checking...211
Air drier; drier cartridge; replace...213
Transmission breather filter; replacing...215
Rear axle; breather filter; replace...216
Alternator; filter; replace...217
Engine oil filter; installing...219
Engine oil; filling...220
Drive belts; check_{39-20}...221
Drive belts; check_{38-59}...223
Hydraulic tank breather filter; changing...225
Hydraulic oil tank; return oil filter; replace; and magnetic rod; clean...226
Hydraulic oil; filling...228
Transmission oil; filling...230
Rear axle bearing; oil; filling...232
Drive axles; oil; filling...234
Cab; prefilter; replace when required...236
Cab filter; replacing...238
Restore operating condition after all test and adjustment work...241
Warming up machine...242
Transmission oil; checking level...244
Hydraulic oil level; checking...246
Engine oil level; checking...248
Coolant level; checking...249
Brake system charging; checking...251
Steering system working pressure; checking and adjusting...255
Boom suspension accumulator; checking and adjusting...258
Hydraulic pump; standby pressure and working pressure; checking and adjusting...262
Oil-bath air cleaner's reservoir (optional equipment); oil; check...267
Oil-bath air cleaner's reservoir (optional equipment); clean; and oil; change...270
Oil bath air cleaner oil; changing...273
Battery; cables and connections; check...276
Engine radiator; oil cooler and condensor (if installed); clean...278
Hinge; lubricating...281
Restore the machine to original condition...286
Coolant's freezing point; check...287
Tyres; wear and air pressure; checking...289
Air pump; oil; changing...290
DPF (Diesel particulate filter); checking and cleaning ...292
Lubrication; 50 hours maintenance interval...296
Lubrication; 250 hours maintenance interval...299
Lubrication; 500 hours maintenance interval...302
Lubrication; 1000 hours maintenance interval...306
Lubrication; 2000 hours maintenance interval...310
Lubrication; 4000 hours maintenance interval...314
Maintenance service; fire suppression system...318
Hydraulic oil tank; sediment drain...335
Coolant; changing...337
Rear axle pivot bearing; greasing...340
Parking brake; manually releasing...342
Towing...344
Electric welding...346
19 - GENERAL...347
Working on the electrical system of the machine...348
CE-marking; EMC-directive...350
Safety concerns everybody!...354
Checking function...358
Safety when handling the machine...359
Safety rules when servicing...364
Service position 2_{13-25}...367
Service position 1_{12-59}...369
Working under raised boom...371
Fire prevention measures...373
Some simple rules regarding tyre handling...377
Safety when lifting and supporting complete machine...379
Starting with booster batteries...383
Safety when handling oils and fuel...386
Safety when handling accumulators...388
Safety when working on hydraulic systems...390
Checklist after a fire or heat exposure...392
Health hazards with paint; plastics and rubber...395
Environmental handling for the future...398
Waste handling...401
Environmentally safe handling...405
Environmentally hazardous fluids...408
Safety when working with air conditioning refrigerant...411
Working in environmentally contaminated areas...414
Decontamination...417
2 - ENGINE WITH MOUNTING AND EQUIPMENT...421
20 - GENERAL...422
Engine; description_{02-06}...423
Engine; description_{01-45}...428
Component locations_{01-14}...433
Component locations_{00-53}...436
Tech Tool; operations_{00-23}...439
Tech Tool; operations_{00-04}...442
Engine; capacities...444
E-ECU MID 128 pre-programmed; replacing_{59-14}...445
E-ECU MID 128 pre-programmed; replacing_{58-53}...448
21 - ENGINE...451
Engine; specifications...453
Cylinder block; tightening torques_{56-52}...455
Cylinder block; tightening torques_{56-30}...460
Engine rotation speed sensor (crank shaft); replacing...466
Engine rotation speed sensor (camshaft); replacing...469
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope...472
Engine; removing_{53-03}...478
Engine; removing_{52-31}...489
VCADS Pro; MID 128; programming E-ECU_{51-48}...499
VCADS Pro; MID 128; programming E-ECU_{51-30}...501
Engine; installing_{51-01}...503
Engine; installing_{50-34}...513
Cylinder compression; testing_{49-59}...522
Cylinder compression; testing_{49-13}...538
Valve cover; tightening torques_48-24...551
Valve cover; tightening torques...552
Cylinder head; tightening torques...553
Cylinder block; specifications...555
Crankcase ventilation; description_{46-37}...556
Crankcase ventilation; description_{46-14}...561
Crankcase ventilation separator; replacing...564
Valve mechanism; tightening torques...566
Valve system; specifications...567
Rocker arms; replacing...570
Rocker arm shaft; tightening torques...572
Valves; adjusting_{43-13}...574
Valves; adjusting_{42-49}...580
Valve cover; removing...586
Valve cover; installing...589
Engine transmission; tightening torque...594
Engine transmission; specification...599
Camshaft setting; checking_{39-31}...602
Camshaft setting; checking_{39-10}...610
Camshaft; replacing_{38-22}...618
Camshaft; replacing_{37-47}...644
Crank mechanism; specifications...665
Crankshaft; tightening torques...668
Flywheel; tightening torques...669
Belt pulley_vibration damper; tightening torques...670
Oil sump; tightening torque...671
22 - LUBRICATING SYSTEM...672
Lubrication system; description...673
Lubrication system; specifications...680
Lubrication oil consumption; checking...682
Lubrication system; component locations_{32-46}...686
Lubrication system; component locations_{32-25}...690
Lubrication system; tightening torques...693
Lubrication oil pressure; checking with pressure gauge...695
Oil cooler; tightening torques...697
23 - FUEL SYSTEM...699
Fuel system; description_{29-45}...700
Fuel system; description_{29-21}...706
Fuel system; specifications...712
Fuel system; tightening torques...713
Air in fuel system; checking...721
Carbon dioxide in fuel system; checking...725
Fuel system; component location...731
Fuel system hand pump; replacing...733
Feed pump pressure; checking...737
Feed pump; replacing...739
Fuel system; bleeding_{23-22}...741
Fuel system; bleeding_{23-02}...743
Feed pump removed; reconditioning...745
Stall speed; checking...750
Unit injector pretension; adjusting...752
Injectors; checking...755
Yoke; injector; checking...766
Injectors; replacing_{18-54}...771
Injectors; replacing_{18-19}...786
Overflow valve; replacing...798
Injector sleeves; replacing_{17-05}...801
Injector sleeves; replacing_{16-25}...810
25 - INLET & EXHAUST SYSTEM...817
Inlet and exhaust system; description_{14-49}...819
Inlet and exhaust system; description_{14-24}...824
Inlet and exhaust system; component location_{13-45}...829
Inlet and exhaust system; component location_{13-24}...832
Inlet and exhaust system; tightening torques...835
Exhaust manifold; tightening torques_{11-32}...838
Exhaust manifold; tightening torques_{11-12}...840
Exhaust pipe flexible tube; replacing...842
Auxiliary brake (engine braking); description...846
Exhaust Aftertreatment System; description...848
Exhaust Aftertreatment System; component location...856
Regeneration process; description...859
Exhaust aftertreatment system; specifications...862
Perform a service regeneration...865
DPF (Diesel particulate filter); checking and cleaning...868
Exhaust aftertreatment system; tightening torques...872
ACM (Aftertreatment control module) non-programmed; replacing...877
ACM (Aftertreatment control module) pre-programmed; replacing...879
Atomization unit; replacing...881
Drying filter; replacing...886
Spark plug; inspecting...889
Spark plug; replacing...894
Spark plug cable; replacing...899
Air purge tank; replacing...901
Air pump flow; checking...903
Air pump; replacing...905
Burner; replacing...908
Compressor; replacing...914