VOLVO WHEEL LOADERS
L45G, L50G
8.6-9.9 t (19,026-21,804 lbs) 98-114 hp
A passion for performance.
At Volvo Construction Equipment, we’re not just coming along for the ride. Developing products and services that raise productivity – we are confident we can lower costs and increase profits for industry experts. Part of the Volvo Group, we are passionate about innovative solutions to help you work smarter – not harder.
Helping you to do more
Doing more with less is a trademark of Volvo Construction Equipment. High productivity has long been married to low energy consumption, ease of use and durability. When it comes to lowering life-cycle costs, Volvo is in a class of its own.
Designed to fit your needs
There is a lot riding on creating solutions that are suited to the particular needs of different industry applications. Innovation often involves high technology – but it doesn’t always have to. Some of our best ideas have been simple, based on a clear and deep understanding of our customers’ working lives.
You learn a lot in 175 years
Over the years, Volvo has advanced solutions that have revolutionized the use of construction equipment. No other name speaks Safety louder than Volvo. Protecting operators, those around them and minimizing our environmental impact are traditional values that continue to shape our product design philosophy.
We’re on your side
We back the Volvo brand with the best people. Volvo is truly a global enterprise, one that is on standby to support customers quickly and efficiently – wherever they are.
We have a passion for performance.
A strong, dedicated, capable dealer network. Our dealers are strategically located throughout North America to provide the equipment you need and the parts and service support you demand for a productive and profitable operation.
The strength of our dealer network is enhanced with extensive individualized product and product support training at our stateof-the-art Technical Training Center in Asheville and through hands-on training. At our nearby 80-acre Product Demonstration Center, visitors operate equipment from our entire product line under a variety of simulated working conditions. Both facilities are in year-round use by our dealers and customers – more than 2,000 visit each year. Building the best starts right here. The products designed and manufactured by Volvo Construction Equipment have their beginnings at the most advanced Research & Design centers in the industry. Volvo CE machines are designed in 11 R&D centers and produced in 15 manufacturing facilities across the world.
The major R&D center and manufacturing plant in the Americas is located in Shippensburg, Pennsylvania. This facility has been in operation for over 30 years and – with its recently added 200,000 sq. ft. expansion – now covers 570,000 sq. ft. on an 80 acre campus. Dedicated work teams and highly advanced technologies and techniques using the Volvo Production System ensure continuous quality improvements, labor savings and cost control to reach the high quality that our customers have come to expect from Volvo.
Volvo Trucks
Mack Trucks
Volvo Construction Equipment
Volvo Penta
Introducing the best all-rounder.
Volvo proudly introduces the L45G and L50G wheel loaders, built to perform on every site. The compact design enables easy maneuverability into small spaces, while Volvo’s innovative TP linkage gives you the benefits of two machines in one. Experience the versatility for yourself.
Load-sensing hydraulics
Load-sensing hydraulics deliver power to hydraulic functions only when it’s needed, without unnecessary oil pumping, for lower fuel consumption and more sensitivity in load handling.
High lifting force
A careful balance between lifting and tractive forces provides highly effective bucket penetration for all types of digging conditions.
Pilot-controlled valves
Smooth and precise pilot-operated hydraulics enable the operator to easily control attachments with minimum effort and high precision in all applications.
Latest engine technology.
Volvo machines work hard on your job site, not on the environment. Power and efficiency are at the heart of Volvo’s engine, which uses the latest technology to meet Tier 4 Interim/Stage IIIB regulations and reduce emissions as you operate. Environmentally responsible and powerful; that’s Volvo.
Reduce emissions on the move
Volvo’s regeneration system works to reduce emissions without interrupting operation. Particles collected during filter cleaning are oxidized and transformed into non-toxic CO2 every 6-10 hours.
Efficient eco pedal
Avoid excessive fuel use with Volvo’s new eco pedal, which encourages operators to apply the appropriate amount of pressure (push-back) on the throttle pedal, reducing fuel consumption.
Reduce maintenance with the reversible engine cooling fan. The automatic fan blows air back through the cooling pack to remove debris drawn into the radiator and only operates when needed to save fuel.
Diesel Particulate Filter (DPF)
New to Tier 4, the Diesel Particulate Filter (DPF) traps and temporarily holds exhaust particulates (soot) as the machine operates, which are later incinerated inside the DPF during the regeneration process.
Engine cooling fan
Small size: big talent.
Steering
Efficient eco pedal
The eco pedal encourages operators to apply the appropriate amount of pressure (push-back) on the throttle pedal, reducing fuel consumption.
Patented TP linkage
Volvo’s unique Torque Parallel linkage combines Z-Bar and Parallel linkage in one for high breakout torque and parallel movement through the entire lifting range.
Load-sensing hydrostatic steering system served from variable displacement pump. Excellent steering performance is maintained even at low engine speed. At the same time fuel consumption is reduced.
Hydraulic attachment bracket
The Volvo hydraulic attachment bracket enables quick attachment changes for more flexibility on site.
Load-sensing hydraulics
Load-sensing hydraulics deliver power to hydraulic functions only when it’s needed, lowering fuel consumption.
Volvo attachments
Volvo’s range of high quality attachments are perfectly matched to the machine’s linkage, hydraulics and driveline to work as one unit and increase productivity.
Optimized driveline
Engine, transmission and axles work in perfect harmony with the hydraulics and steering for superb quality, performance and reliability.
Industry-leading cab
Adjustable steering wheel, seat and armrest, easily located controls and excellent all-round visibility for the perfect operator environment.
Analysis software
Maintain machine uptime by using Volvo’s diagnostic computer-based analysis software: MATRIS and VCADS Pro.
Differential lock
CareTrack
Volvo’s telematics system guides machine owners towards optimized productivity and their next service – remotely.
Maintain your uptime
The transverse mounted engine design provides easy access to all service points under the engine hood, for quick completion of maintenance checks.
Tier 4 Interim/Stage IIIB engine
Powerful, fuel efficient Volvo engine with V-ACT technology for high torque at low engine speeds. Engineered to meet Tier 4 Interim/ Stage IIIB emissions requirements.
Select the differential lock to transfer 100% power to all wheels and reduce tire slippage for maximum traction on soft and slippery ground.
Compact your service time.
Daily service and maintenance checks have never been easier thanks to the new compact design. Lift the engine hood to quickly access key components from the radiator to the hydraulic filters and use Volvo diagnostic tools to alert when service is required. Volvo keeps you working for longer.
Engine air filter
The dual element air filter is located in the engine compartment for full protection of the engine.
Analysis software
Maintain machine uptime by using Volvo’s diagnostic computerbased analysis software. MATRIS assesses operational data from the machine’s electronic control unit (ECU), while VCADS Pro can adjust machine function according to results.
Maintenance-free axle cradle
The rear axle cradle with integrated oscillating bearings are lubricated with the axle oil and protected by proven seals, saving you hours of maintenance time.
Strength to Support You and Your Business.
The day you receive your new Volvo Wheel Loader is just the start of your working relationship with Volvo. From service and maintenance products to a wide range of options and attachments – Volvo has a comprehensive aftermarket portfolio to continuously add value to your business.
Customer Support Agreements - Gives you peace of mind by reducing total ownership costs, maximizing uptime, and distributing maintenance and major repair costs.
Attachments - Providing customers with a wide variety of attachments keep your machine working and open up new job opportunities.
CareTrack
Volvo designed and built your machines, so no-one knows how to keep them working in top condition more than us. When it comes to your machine, our Volvo trained technicians are the experts.
Our technicians work with industry leading diagnostic tools and techniques, using only Genuine Volvo Parts to deliver the highest levels of quality and service. Talk to your Volvo dealer about how genuine Volvo services can best provide the service and maintenance plan that is the right fit for you and your business.
State-of-the-art machines require state-of-the-art support and your Volvo dealer can provide a catalogue of services designed to get the most out of your machine, helping you maximise uptime, productivity and residual value. Your Volvo dealer can provide a number of sophisticated support offers, including: Service plans ranging from routine wear inspections, through to comprehensive maintenance and repair agreements.
Analysis and diagnostics to help you understand how your machine is running, highlight potential maintenance issues and identify where performance can be improved.
Eco Operator training courses can help your operators work towards a safer, more productive and fuel efficient performance.
Volvo’s state-of-the-art telematics system works with our exclusive machine tracking info system, MATRIS. CareTrack can give you the machine information needed for better planning and smarter working; such as daily usage reports, location reports and service maintenance reminders using guided diagnostics to track and analyze machines remotely. You can save fuel. You can reduce costs. You can maximize profitability. You can with CareTrack.
Get attached.
Get flexible on site with Volvo attachments. Choose from an extensive range of buckets, pallet forks and grapples, perfectly-matched to the machine’s link-arm geometry and breakout force. Volvo’s attachment brackets let you quickly interchange between options so you can ‘attach and go’.
Standard Volvo Attachment Bracket
Volvo’s standard hydraulic attachment bracket, is internationally ISO standardized and allows a quick and safe interchange of attachments for more flexibility on site. The strong, open bracket design enables the operator to clearly see attachment points from the cab.
VOLVO L45G, L50G IN DETAIL.
Engine
Engine: Volvo’s V-ACT Tier 4i / Stage III B approved, 4 liter, 4-cylinder in-line four stroke diesel engine, turbocharger with waste gate, Common Rail fuel injection, cooled external Exhaust Gas Recirculation (EGR), diesel particulate filter (DPF). The throttle application is transmitted electrically from the throttle pedal or the optional hand throttle.
Air cleaning: Three-stage Cyclone precleaner - primary filter - secondary filter. Cooling system: Air-to-air cooling pack. Powerful hydraulic fan electronically controlled.
L45G
Engine Volvo D4H
Max power at r/s (r/min) 30 (1,800)
SAE J1995 gross kW (hp) 75 (101)
ISO 9249, SAE J1349 net kW (hp) 73 (98)
Max torque at r/s (r/min) 24.2 (1,450)
SAE J1995 gross Nm (lbf) 425 (313)
ISO 9249, SAE J1349 net Nm (lbf) 406 (299)
Economic working range r/min 1,200 - 1,800
Displacement l (in3) 4 (244)
L50G
Engine Volvo D4H
Max power at r/s (r/min) 31.7 (1,900)
SAE J1995 gross kW (hp) 87 (117)
ISO 9249, SAE J1349 net kW (hp) 85 (114)
Max torque at r/s (r/min) 24.2 (1,450)
SAE J1995 gross Nm (lbf) 490 (361)
ISO 9249, SAE J1349 net Nm (lbf) 468 (345)
Economic working range r/min 1,200 - 1,800
Displacement l (in3) 4 (244)
Hydraulic system
System supply: One load-sensing axial piston pump with variable displacement. The steering function always has priority.
Valves: Double-acting 3-spool valve (4-spool valve optional). The main valve is controlled by an appropriate pilot valve.
Lift function: The valve has four positions: Lift, hold (neutral), lower and float position. Optional inductive/magnetic automatic boom kick-out can be switched on and off and is adjustable to any position between maximum reach and full lifting height.
Tilt function: The valve has three positions: Rollback, hold (neutral) and dump. Inductive/magnetic automatic tilt can be adjusted to the desired bucket angle (bucket positioner).
Cylinders: Double-acting cylinders for all functions.
Filter: Full-flow filtration through 10 micron (absolute) filter cartridge in a combined suction-return-filter. Integrated valve for thermostatically controlled oil circuit through the oil-cooler.
Instrumentation: All important information is centrally located in the operator’s field of vision. Display for Contronic monitoring system.
Heater and defroster: Heater coil with filtered fresh air and fan with auto and 11 speeds. Defroster vents for all window areas.
Operator’s seat: Operator’s seat with adjustable suspension and retractable seat belt. The seat is mounted on a bracket on the rear cab wall and floor. The forces from the retractable seat belt are absorbed by the seat rails.
Standard: The cab is tested and approved according to ROPS (ISO 3471, SAE J1040), FOPS (ISO 3449). The cab meets with requirements according to ISO 6055 (Operator overhead protection - Industrial trucks) and SAE J386 (“Operator Restraint System”).
L45G, L50G
Emergency exit: Use emergency hammer to break window
Sound level in cab according to ISO 6396: LpA dB(A) 68
External sound level according to ISO 6395: LwA dB(A) 102
L45G
L50G
Service
Filling capacities:
(US gal)
(US gal)
(5.3)
(25)
Drivetrain
Transmission
The hydrostatic transmission is an infinitely variable transmission. The speed gears limit the max. travel speed within the range - without any tractive power interruption. Maximum rimpull is available in all gears, regardless of the driving direction.
Automatic regulation ensures easy operation. Load limiting control protects the engine when additional power is requested by working hydraulics and auxiliary power take-off. No overheating in overload conditions.
Axles: Volvo fully floating axle shafts with hub planetary reductions and cast steel axle housing. Fixed front axle and oscillating rear axle, self-lubricated. 100% differential lock on both axles.
Drivetrain L45G, L50G
Travel speeds (Forward / Reverse) 1st gear km/h (mph) 0 - 5 (0 - 3.1) 2nd gear km/h (mph) 0 - 17 (0 - 10.5) 3rd
Steering
Steering system: Load sensing hydrostatic articulated steering.
System supply: The steering system has priority feed from the load-sensing axial piston pump with variable displacement.
Steering cylinders: Two double-acting cylinders. Elastical end-stops.
L45G, L50G
Steering cylinders 2 Working pressure Mpa (bar)
Electrical system
Contronic electrical system with central warning light and buzzer, providing clear and easy to read information to the operator. LCD display with main and sub information field, adjustable to various languages.
Display information in three categories: Information on continuous operating data, Check requests (based on vehicle and error messages) and Warning (with alarm texts).
Additional audible warning by a buzzer. Indicator and activation lights for various control and monitoring functions.
Gauges for Fuel tank level, hydraulic oil temperature and engine temperature. Keypad also provides display navigation on the central instrument. Direct access buttons for Engine, Transmission, Hydraulics, Axles & Brakes, Electric, Machine, Vehicle messages, Service and Setup. Antitheft equipment optional.
L45G, L50G
Voltage V 24
Batteries V 2x12
Battery capacity Ah 2x100
Cold cranking capacity, approximate A 830
Alternator rating W/A 3 080/110
Starter motor output kW (hp) 5,5 (7.4)
Brake system
Service brake: Reliable wet disc brakes with nitrogen-charged accumulators. Dual circuit on front and rear axle
Secondary brake: Dual circuit and hydrostatic retardation
Inching-brake pedal:
Hydraulic inching brake pedal provides hydrostatic braking for precise control of travel speed and service brake application.
1st stage: Wearless hydrostatic braking (inching)
2nd stage: Service brake application
Parking brake:
Dry disc brake on input shaft of front axle.
Standard: The brake system complies with the requirements of ISO 3450
L45G
Number of brake discs per wheel front/rear 1/1
Accumulators l (US gal) 3x0,5 (3x0.13)
Accumulators for parking brake l (US gal) 1x0,5 (1x0.13)
L50G
Number of brake discs per wheel front/rear front 1
Accumulators l (US gal) 2x0,5, 1x1,0 (2x0.13, 1x0.26)
Accumulators for parking brake l (US gal) 1x1,0 (1x0.26)
SPECIFICATIONS L45G.
L45G With TP-linkage, TPV attachment bracket and 17.5 R25 tires
B mm (in) 5 280 (17' 4'')
C mm (in) 2 650 (8' 8'')
D mm (in) 435 (1' 5'')
F mm (in) 2 990 (9' 9'')
G mm (in) 1 040 (3' 4'')
J mm (in) 3 470 (11' 4'')
K mm (in) 3 725 (12' 2'')
O ° 55
P ° 45
R ° 45
S ° 75
U mm (in) 255 (10'')
X mm (in) 1 730 (5' 8'')
Y mm (in) 2 190 (7' 2'')
Z mm (in) 3 485 (11' 5'')
a2 mm (in) 4 760 (15' 7'')
a 3 mm (in) 2 540 (8' 4'')
a 4 ° 40
E
With TP-Linkage, TPV attachment bracket (welded version) and 17.5 R25 tires
L45G
SPECIFICATIONS L50G.
L50G With TP-linkage, TPV attachment bracket and 17.5 R25 tires
B mm (in) 5 380 (17' 8'')
C mm (in) 2 650 (8' 8'')
D mm (in) 435 (1' 5'')
F mm (in) 2 980 (9' 9'')
G mm (in) 1 000 (3' 3'')
J mm (in) 3 525 (11' 7'')
K mm (in) 3 780 (12' 5'') O ° 54
S ° 76
U mm (in) 255 (10'')
X mm (in) 1 730 (5' 8'')
Y mm (in) 2 190 (7' 2'')
Z mm (in) 3 535 (18' 2'')
a2 mm (in) 4 760 (15' 7'')
a3 mm (in) 2 540 (8' 4'')
a4 ° 40
equipment.
STANDARD EQUIPMENT
Engine
Diesel engine, direct fuel injection
Extra fuel filter
Cold start aid
Dry-type air filter
Preparation for pre-cleaner
Filtration screens on air inlets
Reversible cooling fan
Electrical system
Alternator 55 A
Lighting
Main head lights (halogen) upper/dipped/asymmetrical
Working lights (2 front/2 rear)
Parking lights
Rear lights
Brake lights
Direction indicators
Hazard warning lights
Reversing lights
Cab lighting
Instrumentation & controls
Multi-function joystick
24 Volt accessories socket
Forward horn
Hazard warning switch
Safety start
Electronic Information System
Analog information for:
Fuel level
Engine temperature
Drive system oil temperature
LED-illuminated symbols (color-coded) for:
Direction (forward/reverse)
Indicators (left/right)
Pre-heater (option)
Main beam head lamp
Differential locks
Boom suspension system (option)
Loading fork operation (option)
LED-illuminated symbols (red) with acoustic signal for:
Parking brake
Air filter restriction
Drive system oil temperature
Engine temperature
Engine oil pressure
Battery charging
Return filter
Touch pad with symbols and integrated LEDs for:
Parking lights
Working lights (front/rear)
Windscreen wiper (rear)
Rotating beacon (option)
Boom suspension system on/off (option)
Locking and activation of Volvo-attachment bracket
Activation of multi-function joystick for directional change
Digital LED display activated by dual function keys for:
Entry and retrieval of operating information
Optional anti-theft function control
Drivetrain
Hydrostatic drive
Operator-selected 100% differential locks in both axles
Tires 17.5 R25
Hydraulic system
Load-Sensing Hydraulics
Axial piston pump
Control valve three-spool system
3rd hydraulic circuit and couplings
Cab, Exterior ROPS/FOPS-cab with flexible mountings
Lockable door
All-round tinted safety glass
Windscreen wiper (front/rear)
Windscreen washer (front/rear)
Door stops
External rear view mirrors (right/left)
Cab filtration system
Cab, Interior
4-way adjustable operator’s seat
Left armrest
Cab, Interior Air conditioner
Heater with air-filter and defroster (front/rear)
Adjustable steering column Left armrest
Cab, Interior
Seat belt
Sun visor
Cab filtration
Hook for coat
Cup holder
Emergency hammer
Storage box in the cab
Rear view mirrors (left/right)
Working Equipment Automatic bucket leveller
Hydraulic quick-change attachment bracket
Carriage Body Fenders (front/rear)
Fender extensions (optional)
Lockable engine hood
Lockable fuel-tank cap
Vertical exhaust
Towing device
Lifting eyes
International Standards for Machines and Production
Quality: DIN/ISO 9001
Safety: CE - Criteron
Machine guide-lines 2006/42/EC
ROPS ISO 3471
FOPS ISO 3449
Operating weight ISO 7131
Tipping load / Payload: ISO 14397-1
EMC (Electromagnetic Compatibility)
89/336/EEC plus supplement
Environment: DIN/ISO 14001
Sound regulation: 2000/14/EC
OPTIONAL EQUIPMENT (Standard on certain markets)
Service
Wheel chock
Tool Kit
Central Lub. unit (Volvo)
Engine Hand inch valve
Hand throttle Turbo II Prefilter
Air pre-cleaner, oil-bath type
Tropical cooling
Fuel pre-heater
Electrical Rotating beacon foldable
Prep. rotating beacon magnetic
Rev. alarm audible switchable
Reverse alarm audible
Rev. alarm audio vis. switchable
Anti theft device
Rear lights protection
Headlights protection
Working lights guards, front/rear
Xenon work lights, front/rear
Care Track GSM
Care Track Satellite
Transport lights
El. headlights 350 mm (1' 2")
Road light equipment width 2.5 m (8' 2")
Power outlet 12 V
Rotating beacon magnet
Cab
Door all glass
Foldable r.h. window
Split door
Seat fab. air/susp. heat
Seat mec./susp.
Radio preparation 12 V
Radio
Heated rearview mirrors
Rearview mirrors inside cab
OPTIONAL EQUIPMENT (Standard on certain markets)
Cab
1 lever ctrl. incl. 3rd hyd. function
3 lever ctrl.
4 lever ctrl. incl. 4th hyd. function
Seat belt 3"
Comfort drive control (CDC)
Hydraulics
Hyd. oil mineral VG46 HV
Hydr. Couplings
Boom suspension system
Tilt speed limiter mechanical
Boom kickout
4th function
Tilt control
Hyd. oil BIOsynth VG46 HLP PA
Hyd. oil mineral VG68 HV
Safety valve for tilt cylind.
Hyd. oil mineral VG32 HV
Extra oil ret. line via filter
Other
Color Level 1 (yellow parts)
Preparation for licence plate
Side marking reflectors
SMV warning triangle
Trailer socket
Belly guards, front/rear
Windshield guard, rear
Windshield guard, front
Protect. wax coating incl. cyl.
Engine hood protection
Color Level 1+2
Auto Engine Shutdown L45/50G
GY TL-3A+ 17.5 R25
Removable rear left fender
Tires
Front Mud flaps
MI 17.5R25 XHA
MI 15.5R25 XHA
GY 15.5-25 SGL
Mudguard extension 75 mm
Extended mud flaps
GY 17.5-25 SGL
GY 17.5R25 RT-3B
NO 540/65R24 TRI2
BR 17.5R25 VSW B2,25
MI 15.5R25 XMINE-D2
Wheels for transport only
MI 500/70 R24 XMCL
NO 440/80R24 TRI 2
MI 17.5R25 XMINE-D2
TR 600/55-26.5 T421
MI 17.5R25 XHA B2,4
BR 15.5R25 VUT
MI 15.5R25 XHA B2,4
GY 17.5R25 RT-3B B2,4
GY 550/65R25 GP-3D
MI 17.5R25 XHA SPW
High flow 125 l/min
Long boom
ATTACHMENTS
Buckets Straight with teeth and bolt on edges
High tipping
Light material
Multi purpose Grading
Clamp
Other attachments
Log grapples
Forks
Material handling arm
SELECTION OF VOLVO OPTIONAL EQUIPMENT
Boom Suspension System
Comfort Drive Control (CDC)
Hydraulic 3rd and 4th function
Tilting condenser
Lubrication System
volvo construction equipment
Volvo Construction Equipment is different. Our machines are designed, built and supported in a different way. That difference comes from an engineering heritage of over 175 years.
A heritage of thinking first about the people who actually use the machines. About how to help them be safer, more comfortable, more productive. About the environment we all share.
The result of that thinking is a growing range of machines and a global support network dedicated to helping you do more. People around the world are proud to use Volvo. And we’re proud of what makes Volvo different.
Not all products are available in all markets. Under our policy of continuous improvement, we reserve the right to change specifications and design without prior notice. The illustrations do not necessarily show the standard version of the machine.
Accumulator removed, checking charging pressure
Op nbr527-001
Total procedure time (hr): 0.20
Tools: 88830175Pump 11666051Pressure gauge 14290266Hose
E-2000
1.Connect E-2000 to pressure accumulator. Connect the other tools as shown.
Figure1 Check removed pressure accumulator
Pump 11666041 Accumulators E-2000 Pressure gauge 11666051 Hose 14290266
2.Pump oil into the pressure accumulator. After a few pump strokes, the pressure rises to precharge pressure. Read display on pressure gauge. For set value, see Brakes, specifications NOTE! If the precharge pressure does not reach the set value, change the pressure accumulator.
3.Discard faulty pressure accumulator, see Accumulator, discarding
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Accumulator, check
Op nbr527-009
Total procedure time (hr): 0.40
1.Place the machine in service position. Removal
2.Switch on the engine and depressurise the brake system by depressing the brake pedal repeatedly.
3.Remove hydraulic hose (1).
4.Loosen clamp (2) and remove pressure accumulator. Checking
5.Carry out pressure test on pressure accumulator, see Accumulator removed, checking charging pressure.
Installing
6.Install pressure accumulator. Tighten clamp (2) and fit hydraulic hose (1).
7.Carry out a function test.
Figure1
Accumulator, discarding
WARNING
A discarded accumulator which is not punctured may still contain high pressure and must always be handled with great care.
1. WARNING
Use safety glasses.
Accumulators that are to be discarded must not constitute a hazard. This is done by carefully puncturing the accumulator with a Ø3 mm (0.118 in) drill.
A.Drill here with a Ø3 mm (0.118 in) drill
Figure1 Accumulator
1. 2. 3. Nitrogen gas space Rubber diaphragm Connection for oil
ACM (After treatment control module),
Op nbr254-022
Total procedure time (hr): 0.90
Tools:
Tech ToolService Tool
88890180Interface
88890027Cable
1.Place the machine in service position.
2.Connect VCADS Pro and perform the operation 25801-3 MID 233 control unit, Programming.
3.Switch off the battery connection switch.
4.Unscrew clamp (1) and remove electric plug connector (2) from control unit.
ACM, control unit exhaust after-treatment
5.Unscrew fixing bolts (4 pcs.) and remove control unit (3).
6.Fit new control unit and tighten bolts.
7.Connect electric plug connector to control unit and tighten clamp.
8.Switch on the battery disconnect switch.
9.Complete VCADS Pro-Operation 25801-3 MID 233 Control unit, Programming.
10.Perform a service regeneration to secure the actual soot level in the DPF, see Perform a service regeneration.
11.Perform a trial run and ensure that there are no error codes.
Figure1
ACM (After treatment control module),
Op nbr254-023
Total procedure time (hr): 0.80
Tools:
Tech ToolService Tool
88890180Interface
88890027Cable
1.Place the machine in service position.
2.Connect VCADS Pro computer to the machine, and perform the operation '17030-3 Parameter, programming'.
Use the function: Save all read parameters to job card.
3.Switch off the battery connection switch.
4.Unscrew clamp (1) and remove electric plug connector (2) from control unit.
Figure1 ACM, control unit exhaust after-treatment
5.Unscrew fixing bolts (4 pcs.) and remove control unit (3).
6.Fit new control unit and tighten bolts.
7.Connect electric plug connector to control unit and tighten clamp.
8.Switch on the battery disconnect switch.
9.Connect VCADS Pro computer to the machine, and perform the operation '17030-3 Parameter, programming'.
Program previously read parameters according to work order.
10.Perform a service regeneration to secure the actual soot level in the DPF, see Perform a service regeneration
11.Perform a trial run and ensure that there are no error codes.
Air cleaner primary filter, change
Op nbr
Total procedure time (hr): NaN
This is part of another procedure
NOTE!
During each servicing, check the air lines (filter and engine) for leaks. Replace defective parts and tighten any loose hoseclamps.
1.Upon request, drain the dust valve (1) by pressing the discharge vent together.
Air cleaner
1. 2. Dust valve Lock tongue, filter cover lock
2.Pull the yellow lock tongue (2) to release the cover lock. Turn the filter cover anti-clockwise andremove.
3.Remove the primary filter (3) from the filter housing.
filter
The primary filter can be cleaned no more than five times. After that, the filter must be replaced. The filter must also bereplaced if it is damaged or if after cleaning the message "Check clogged engine air filter" appears on the information display. Cleaning
4.Insert the cleaned or new primary filter.
5.Clean and close the filter cover.
NOTE!
If the message "Check clogged engine air filter" appears in the information display after primary filter servicing, the secondary filter must also be replaced.
Figure1
Figure2
Primary
Air cleaner secondary filter, change
Total procedure time (hr): NaN
This is part of another procedure NOTE!
The secondary filter should be replaced every third primary filter replacement and at least every other year.
1.First remove the primary filter, see Air cleaner primary filter, change.
2.Remove the secondary filter (4) from the filter housing.
Secondary filter
3.Insert the new secondary filter.
4.Insert the primary filter and close the filter cover; see Air cleaner primary filter, change
Figure1
Air conditioning, capacity
Air conditioning system
Fill quantity for new fill (refrigerant R134a) 1,85 kg (4.1 lb)
Attachment bracket cylinder, reconditioning
Op nbr924-034
1161370 Glue
8714377 Cleaning spray
Applies only to machines with vision-optimised attachment bracket.
Figure1
Vision-optimised attachment bracket
Locking cylinder
Circlip Lock ring Guide Piston rod Piston
1.Remove circlip (1).
2.Push in guide (3), past lock ring (2).
3.Remove the lock ring.
4.Pull out piston rod (4).
5.Remove piston (5) from the piston rod. Clean the threads on the piston and the piston rod. Use cleaning spray 8714377.
6.Clean the cylinder.
7.Check all parts for wear and damage.
8.Apply glue 1161370 to the piston rod threads.
9.Install piston (5) on the piston rod. Tightening torque: 60 N m (6 kgf m) (44 lbf ft) The glue has to harden for four hours.
NOTE!
Figure2
The cylinder must not be filled with oil during the hardening period.
10.Oil the cylinder and piston seal.
11.Push the piston rod into the cylinder.
12.Push in guide (3) past the lock ring groove.
13.Install the lock ring.
14.Pull the guide out against the lock ring.
15.Install the circlip.
Attachment locking hydraulic cylinder (vision-optimised bracket), replacing
Op nbr924-035
Total procedure time (hr): 0.60
Axle stand, 1000 kg (2205 lb)
Applies only to machines with vision-optimised attachment bracket.
Figure1
Vision-optimised attachment bracket
1.Start the engine and secure the lifting arms with the axle stand. Tilt the attachment bracket outwards.
2.Unlock the attachment lock (pull the studs into the attachment bracket) using the locking button. Turn off the engine and take out the ignition key.
3.Remove the cover plate.
4.Disconnect the hydraulic hoses from lead-through connections on the attachment bracket. Plug the lead-through connections.
Figure2
Figure3
1.Hydraulic hoses
5.Remove the bolt retaining the hydraulic cylinder.
6.Press in the pins and push the cylinder over to one side.
7.Remove the lock ring from the pin and tap out the pin. Remove the hydraulic cylinder together with the hoses.
8.Transfer required parts to the new cylinder.
9.Install the new cylinder and install the lock pin and the lock ring. Install the bolt retaining the cylinder.
10.Connect the hoses to the lead-through couplings.
11.Start the engine and test the function of the attachment locking and check that there are no leaks of hydraulic oil.
12.Re-install the cover.
Automatic engine shut-down
This function shuts down the engine automatically to save fuel when the machine is not under working conditions for a longer time. The driver is warned of the pending engine shutdown and has the opportunity to prevent it.
Function description
The engine shut down sequence will be started in real time while the machine is in the automatic engine shutdown conditions.
Automatic engine shutdown conditions
Information message on display unit
Signal tone
The engine is turned off
Automatic engine shutdown conditions (A)
Option parameter (FAU) is activated.
Operating parameter automatic engine shutdown "ON"
Machine stopped and parking brake activated.
Let engine idle at lower idle speed (< 1000 rpm / 16.6 rps)
DPF regeneration is not in progress.
Information message “Automatic engine shutdown” on I-ECU has not disappeared when ESC button pressed on keypad.
Information message, display (B)
Figure2
Information message, display
One minute before engine shutdown, the information message appears on the I-ECU.
To abort the engine shut down sequence:
-Press "ESC" button, or -Release the parking brake.
Signal tone (C)
Three seconds before engine shutdown, a signal tone will be generated 3 times.
The engine is turned off (D)
For more information, see Software parameters, description
Figure1
Axle suspension, replacing bushes and seals
Op nbr755-003
Total procedure time (hr): 4.00
Tools: 11667001Handle 11667110Drift plate
6999068Drift plate 9993722Support 11666054Jack 88830175Pump
1.Remove rear axle, see Axle, removing.
2.Lower the axle onto a suitable surface.
3.Remove gearbox, see Transmission, removing and installing
4.Remove shaft seal ring (1) on both sides of swivel roller bore.
5.Attach tools and withdraw bush from swivel bearing bore.
Figure2
NOTE!
Repeat the procedure on the other side.
6.Clean bush bearing seat.
Figure1
Use thick gloves when shrinking sleeves and bushings with liquid nitrogen. Severe frostbite and cold injuries are sustained on exposed skin. See national regulations for handling liquid nitrogen.
7.Supercool both bearing bushes in liquid nitrogen for approx. 2 to 3 minutes, and insert flush into swivel bearing bore taking into account installation position.
NOTE!
Installation position for bearing bushes. Insert with lubricant groove in 6 o'clock position (arrow).
8.Coat contact face of swivel bearing bore/shaft seal ring with spirit, and coat with grease in the area of the seal and dust lip.
9.Insert both shaft seal rings with drift plate 11667110 taking into account installation position (sealing lip points towardsoil chamber).
10.Install gearbox, Transmission, removing and installing
11.Install rear axle, see Axle, installing
Figure3
Figure4
Axle, installing
Op nbr463-003
Total procedure time (hr): 1.75
WARNING
The work involves handling heavy components -failure to stay alert may result in severe crushing injuries.
1.Suspend machine at the lifting eyes of the rear frame using a suitable lifting tool.
2.Bring rear axle into position below machine using stand jack. NOTE!
Weight of rear axle with dropbox and hydrostatic motor approx. 562 kg (1239 lb)
3.Lower machine onto supports.
4.Raise rear axle using the stand jack and align to the receiver holes on the rear frame.
5.Mount pendulum pin. Pendulum pin weight approx. 13 kg (28.6 lbs)
Figure1
Figure2
NOTE!
To avoid damage to the shaft seal ring when fitting the pendulum pin, pull in pendulum pin evenly with 2 bolts (M16 x 120), see diagram.
6.When the pendulum pin has reached its end position, measure distance from the journal to the machined surface of the crossmember. Select shims.
NOTE!
Allow an axial play of the pendulum pin of 0.2 -0.7 mm (0.08 -0.28 in).
7.Moisten shims with assembly paste and fit. Position bearing cover and tighten with a tightening torque of 220 Nm (162 lbf ft).
NOTE!
The spacers are fitted in the order of their thickness, starting with the thinnest.
8.Lower stand jack and remove mounting jig.
9.Check that the rear axle can move easily in the radial direction. If not, the axial play is too low.
10.Install high pressure hose (1) and leak-oil line (2) to hydrostatic motor
Figure3
Figure4
1. 2. 3. 4. 5. Pendulum pin Shim washer Bearing cap washer screw
11.Remove the vacuum pump; see Vacuum pump, connection
Figure6
Disconnect the vacuum pump
12.Fit hydraulic line (1) for differential lock
13.Fit hydraulic line (2) for service brake on the right and left axle bridges.
14.Connect electric pin plug connections (1) and (2) to solenoid valve hydrostatic motor.
Figure5
Figure7
15.Mount universal shaft (1) on dropbox. Tightening torque 80 Nm (59 lbf ft).
16.Connect the connector for the inductive sensor (2).
17.Suspend machine from the lifting eyes on the rear frame using a suitable lifting tool, raise and remove supports.
18.Fit both rear wheels. Tightening torque 580 ± 20 Nm (428 ± 15 lbf ft)
19.Install the counterweight, see Counterweight, fitting
20.Bleed the brake system, see Brake system, bleeding air
21.Carry out test drive and check brake function.
Figure8
Figure9
Axle, removing
Op nbr463-002
Total procedure time (hr): 1.75
1.Place the machine in service position.
2.Switch on the engine and depressurise the brake system by depressing the brake pedal repeatedly.
3.Block articulation joint using “Joint lock”.
4.Switch off the battery connection switch.
WARNING
The work involves handling heavy components -failure to stay alert may result in severe crushing injuries.
5.Remove the counterweight. Refer to Counterweight, removing.
6.Suspend machine at the lifting eyes of the rear frame using a suitable lifting tool.
7.Remove both rear wheels.
8.Bring suitable supports into position below the rear frame and lower the machine.
9.Remove universal shaft (1) at dropbox
Figure1
Figure2
10.Separate the connector for the inductive sensor (2).
11.Separate electric pin plug connections (1) and (2) from solenoid valve hydrostatic motor.
12.Remove hydraulic line (1) for differential lock
13.Remove hydraulic line (2) for service brake on the right and left axle bridges.
14.Connect vacuum pump, see Vacuum pump, connection
Figure3
Figure4
Figure5
Connect the vacuum pump
15.Remove high pressure hose (1) and leak-oil line (2) on hydrostatic motor
NOTICE
When a hose has been disconnected, plug both the hose and the connection immediately. The hoses should be marked for correct connection.
16.Unscrew fixing bolt (1) for pendulum pin. Remove bearing cover with shims.
17.Bring mounting jig into position below axle using a stand jack. Raise mounting jig to relieve load on pendulum pin.
Figure6
Figure7
Figure8
18.Screw remover bolt (M20) into pendulum pin (1). Drive out pendulum pin with a slip hammer. NOTE!
Pendulum pin, weight approx. 13 kg (28.6 lbs)
19.Lower stand jack. Raise machine until the rear axle can be withdrawn freely below machine. NOTE!
Weight of rear axle with dropbox and hydrostatic motor approx. 562 kg (1239 lb)
Figure9
Figure10
Axles, changing oil
Op nbr
Total procedure time (hr): NaN
This is part of another procedure
Oil change front axle
Planetary carrier and differential share a common oil system.
WARNING
Work carefully when changing oil as hot oil can cause severe burns to unprotected skin.
1.Drain oil from the front axle into a suitable container.
NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
Drain, fill and check screw plug, planetary carrier
Axle drive housing drain plug
Filler/inspection screw plug, axle drive housing
NOTE!
To prevent injury from possible pressure build-up in the planetary carrier's oil system, move drainand inspection screw plug (1) to the highest position, release it carefully and remove. Then set the drain opening to the lowest position and drain oil.
2.Fill both planetary carriers with oil to overflow. For oil grade, see Recommended lubricants
3.Screw in lock screws (1) and (2) and tighten to 30 Nm (22 lbf ft).
4.Fill with oil to overflow via the filler/check bore (3) of the axle drive housing. For volume, see Front axle, capacity Low/highspeed machine.
5.Screw in lock screw (3) and tighten to 30 Nm (22 lbf ft)
Figure1 Front axle
1. 2. 3.
6.Check oil level after a few minutes and top up if necessary.
NOTE!
Rear axle and differential share a separate oil system.
Oil change rear axle with dropbox, low-speed machine
7.Drain oil from the dropbox and rear axle into a suitable container.
NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
Oil change rear axle with dropbox, low-speed machine
Drain, fill and check screw plug, planetary carrier
Axle drive housing drain plug
Filler/inspection screw plug, axle drive housing
Drop box drain plug
Drop box filler/inspection screw plug
8.Fill both planetary carriers with oil to overflow. For oil grade, see Recommended lubricants
9.Screw in lock screws (1) (2) and (4) and tighten to 30 Nm (22 lbf ft)
10.Fill the dropbox with approx. 1 litre (0.3 US gal) via the filler/check bore (5). Then fill the axle drive housing with oil to overflow
Figure2
via the filler/check bore (3). For volume, see Rear axle, capacity Low-speed machine.
11.Screw in lock screws (3) and (5) and tighten to 30 Nm (22 lbf ft).
12.Check oil level after a few minutes and top up if necessary.
NOTE!
Rear axle and differential have separate oil systems.
Oil change rear axle with hydrostatic transmission, high-speed machine
13.Drain oil from the gearbox and rear axle into a suitable container.
NOTICE
Always handle oils and other environmentally hazardous fluids in an environmentally safe manner.
Oil change rear axle with hydrostatic transmission, high-speed machine
Drain, fill and check screw plug, planetary carrier
Axle drive housing drain plug
Filler/inspection screw plug, axle drive housing
Gearbox drain plug
Gearbox fill/check screw plug
Figure3
1. 2. 3. 4.
14.Screw in lock screws (2) and (4) and tighten to 30 Nm (22 lbf ft).
15.Fill both planetary carriers with oil to overflow. Then fill the axle drive housing with oil to overflow via the filler/check bore (3). For oil grade see Recommended lubricants. For volume, see Rear axle, capacity High-speed machine.
16.Screw in lock screws (1) and (3) and tighten to 30 Nm (22 lbf ft)
17.Fill the gearbox with oil to overflow via the filler/check bore (5). For oil grade see Recommended lubricants. For volume, see Rear axle, capacity High-speed machine.
18.Screw in lock screw (5) and tighten to 30 Nm (22 lbf ft)
19.Check oil level after a few minutes and top up if necessary.
Axles, tightening torques
Fixing nuts, front axle to frame
Fixing bolts, rear axle pin
Wheel nuts, front and rear axle
Fixing nuts for propeller shaft on dropbox and front axle
740 Nm (545 lbf ft)
220 Nm (162 lbf ft)
580± 20 Nm (428±15 lbf ft)
80 Nm (59 lbf ft)
Battery disconnect switch, description
The function of the battery isolator switch is to disconnect the the machine's electrical system from the battery voltage when the machine is not used or during maintenance and repair work.
Battery isolator switch
The battery isolator switch is located on the left below the cab door and is connected to the positive side of the batteries. NOTE!
The battery isolator switch does not break the power supply to the radio.
Figure1
Battery, cables and connections, check
Op nbr
Total procedure time (hr): NaN
This is part of another procedure
1.Check that the battery is properly connected and that the cable terminals and poles are clean, properly tightened and protected from corrosion with vaseline or the like.
Figure1 Batteries
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.
Batteries must only be charged using a battery charger.
Check the battery terminal connections and make sure that they are adequately tightened and free from corrosion and dirt. Check the battery voltage when the batteries are at rest (before starting). Each battery must be atleast half-charged.
NOTICE
Always turn off the current to the battery charger before disconnecting the charging clamps.
WARNING
Risk of chemical burns.
The battery electrolyte contains corrosive sulphuric acid which could cause severe chemical burns.
If electrolyte spilled on your bare skin, remove it immediately and wash the affected area with soap and plenty of water. Ifit gets into your eyes or any other sensitive body part, rinse with plenty of water and seek immediate medical attention.
Battery, description
The two 12 Volt batteries connected in series are located in the engine compartment on the left. The original battery fitted to the machine is totally impermeable and absolutely maintenance-free. It may only be replaced with a battery with identical technological features. This excludes danger to operators from acid or acid vapours even if the machine rolls over.
The batteries should be in good condition when troubleshooting the system. If needed, charge the batteries with a battery charger. If the batteries can no longer take the charge, replace the batteries.
Figure1 Batteries
Battery, specifications
Battery Quantity 2 pcs., in series
Battery disconnect switch Connected to positive terminal
Battery voltage 12 V
Battery capacity 2 x 100 Ah Charge
V
V Discharged battery
V and lower
Battery electrolyte density Fully charged battery
The battery must be recharged at
Belts and belt tension, check, replace when needed.
Total procedure time (hr): NaN
This is part of another procedure
1.Remove belt drive cover.
2.Check entire belt drive for damage and replace if necessary.
3.The drive belt, alternator/coolant pump has an automatic spring-loaded tensioning roller. NOTE!
Replace drive belt, alternator/coolant pump and tensioning roller, every 2000 operating hours.
4.The drive belt, compressor AC system can be depressed approx. 15 mm (0.6 inch) when correctly tensioned; adjust if necessary.
5.Install belt drive cover.
Figure1 Drive belt
1. 2. Drive belt, alternator/coolant pump Drive belt, compressor AC system
Bolted joints, check tightening torque
Op nbr
Total procedure time (hr): NaN
This is part of another procedure
Axles and propeller shaft, tightening torque
1.Fastening the front axle to the frame, see Axles, tightening torques
1.Attachment, front axle
2.Fixing bolts of rear axle pin, see Axles, tightening torques
1.Fixing bolts, rear axle pin
3.Fixing nuts for propeller shaft on dropbox and front axle, see Axles, tightening torques
Figure1
Figure2
1.Attachment, propeller shaft on dropbox
Engine mounting, tightening torque
4.Engine mount, frame -rubber items, base stands/engine suspension and bracket, see Engine, tightening torque
1. 2. 3. Attachment, frame rubber items Attachment, base stands/engine suspension Attachment, crankcase and gearcase bracket
Figure4
Boom suspension system, functional check
Op nbr916-001
Total procedure time (hr): 3.00
Tools:
9998699Adapter
9993893Break out harness
88890074Multimeter
936439Testing nipple
88830213Measuring equipment
1.Test switch SW9148 in cab. Select service mode, select I/O list, select V-ECU and test PIN VA63 (turn switch SW9148 on/ off). Wiring diagram WD905
2.Test induction sensor SE9149 on lifting bracket. Select service mode, select I/O list and test PIN VA42. Raise lifting bracket from lower position so that the lifting bracket side piece passes the sensor Wiring diagram WD905
3.Check pressure switch SE9140. This pressure switch is turned on when a precontrol pressure of at least 5 bar (0.5 MPa) is present. For this, the bucket must be tilted in or the lifting bracket raised. Select service mode, select I/O list and test PIN VA65. Wiring diagram WD905
NOTE!
If no I/O list is available, the test can also be performed with an adapter, test cable and multimeter (see Tool).
4.Electric check of solenoid valve MA9173. (Accumulator charge valve) MA9173 is triggered when the BSS system is preselected via SA9148 and SE9140 is under pressure. MA9173 lies at PIN VB68 and can be tested with an adapter, test cable and multimeter. MA9173, description and measuring [VCADS Pro] 91401-3 Solenoid valves, test
5.Hydraulic test of solenoid valve MA9173. (Accumulator charge valve) For this measurement nipples must be fitted at HA and HS (see Tool). Hydraulic diagram, Boom Suspension System Before the measurement points can be mounted, the accumulator must be relieved. Proceed, as follows: —lift up the lifting bracket; engine off —ignition on; lower the lifting bracket and place it on the ground —accumulator should be balanced up to 300kPa If BSS is deactivated, a pressure rise on lifting is measured at HA only as MA9173 is not triggered(see fig. 1). If BSS is activated, a pressure rise on lifting is measured at HA and HS as MA9173 is triggered andthe accumulator is charged (see fig. 2). If this should not be the case, MA9173 or selector valve 1 may be blocked.
Figure1
6.Electric check of solenoid valve MA9174. (Bottom valve)
MA9174 is only triggered when SW9148, SE9149 are active and a speed of 3 km/h has been reached. MA9174 lies at PIN VB69 and can be checked via the I/O list in service mode. At the same time, MA9172 is triggered. Or: MA9174, description and measuring [VCADS Pro] 91401-3 Solenoid valves, test
7.Hydraulic test of solenoid valve MA9174. (Bottom valve)
Measurement connections HA and HS are required. Hydraulic diagram, Boom Suspension System Before the measurement points can be mounted, the accumulator must be relieved. Proceed, as follows: —lift up the lifting bracket; engine off —ignition on; lower the lifting bracket and place it on the ground —accumulator should be balanced up to 300kPa NOTE!
Measurement condition: Lifting bracket raised, BSS not active, speed above 3 km/h.
A constant pressure is measured at HS as MA9174 has not been activated. Pressure peaks are measuredat HA as the oil is connected (see fig. 3). NOTE!
Measurement condition: Lifting bracket raised, BSS active, speed above 3 km/h.
If BSS is active, the lifting bracket is raised (SE9149 active) and the speed is over 3 km/h, MA9174 is triggered. A similar pressure to HA is measured at HS. It can also be seen that the pressure peaks at HA are smaller than in fig. 3. The pressure peaks resulting are damped by the accumulator and drained into the tank (see fig. 4). If the solenoid valve is blocked in the closed position, no damping on the ground side takes place. If a similar pressure to HA is present at HS when SW9148 is not activated, it is possible that MA9174 has seized in the open position and has not closed.
Figure3
8.Electric check of solenoid valve MA9172. (Rod equalizing valve) MA9172 is only triggered when SW9148, SE9149 are active and a speed of 3 km/h has been reached. MA9172 lies at PIN VB67 and can be checked via the I/O list in service mode. At the same time, MA9174 is triggered. Or: MA9172, description and measuring [VCADS Pro] 91401-3 Solenoid valves, test
9.If MA9172 is blocked, this is only evident from symptoms. (Rod equalizing valve) If MA9172 is blocked in the closed position, there is no lifting bracket damping. If MA9172 is blocked in the open position, the machine cannot be raised via the lifting bracket as the oil flows down into the tank.
Figure4
Boom Suspension System, general description
To improve driving comfort and reduce the mechanical stress on the frame, drive train and boom, a boom suspension system (BSS) is available as an optional accessory.
The boom suspension system (BSS) works only above a factory-set drive speed and lift height of theboom. Below this drive speed and lifting height, the boom suspension shuts off. In principle this function can only be preselected with the engine running.
Boom Suspension System, activating
Start engine and lower attachment to the floor.
The Boom Suspension System is activated by operating the switch (1) on the pillar switch panel.
NOTE!
When the switch has been activated, Boom Suspension System activation (from the set driving speed and lifting frame height) can be monitored via the indicator light (2) on the information display.
When the indicator light (2) is on, the Boom Suspension System is active. If the indicator light flashes, the system is inactive. The Boom Suspension System is switched off when the switch (1) is re-activated or after the motor is switched off.
NOTE!
The Boom Suspension System may not be activated during driving. For precise working with attachments, the Boom Suspension System must be disconnected.
Figure1
Booting sequence
Battery disconnector off.
Set the gear selector in neutral position.
Turn the ignition key to position "II" to perform a system test, duration 4 -5 seconds. If the machine is fitted with theft protection, disable this by inputting the code. See Information display, start lockout.
Turn the key to position "IV" and start the engine. If the engine does not start, turn the key backto position "0" and repeat the starting process.
Error messages
When Forward or Reverse gear is engaged, engagement of the starter motor is prevented and the message Information that a gear selector is not in neutral will be shown on the information panel in case of start attempt.
If the starter overheats, the information display shows the message: Check High temp. starter motorWait 5 min. before start. On other faults in the starter circuit, the information display shows the message: Check Engine failure .
Brake calliper removed, reconditioning
Brake caliper, parking brake
Op nbr511-081
Total procedure time (hr): 0.90
Parking brake caliper
Brake caliper
Shaft seal
Coil spring
Operating lever
Washer
Twistlock
Fixing bolt
Ring cage
Balls
Rotor assembly
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!
Figure1
The ring cage and three balls may fall out with the rotor assembly.
5.Remove the three balls (9) and ring cage (8).
6.Using a sharp knife, make several cuts on the outside of the plastic cover (12). Break off the plastic cover and remove insert (11).
7.Press out shaft seal ring (2) from caliper using a pressing mandrel.
8.Clean all parts of the caliper thoroughly with methanol and blow dry with compressed air. NOTE!
Do not use any cleaning agents containing mineral oil.
9.Press in new shaft seal ring (2) into caliper from the outside until it engages in a groove.
10.Coat one side of the new insert (11) with lubricant and insert plastic cover, then coat the other side of the insert with lubricant.
11.Engage brake pad in plastic cover (12).
12.Insert plastic cover (12) on rotor and compress in the vice until the plastic cover engages.
13.Remove brake pad from plastic cover again.
14.Coat ball guide in caliper with lubricant.
15.Insert balls (9) and ring cage (8) in caliper.
16.Insert rotor assembly (10) and position ball guide against balls.
17.Place coil spring (3) on caliper and mount control lever (4) in base position. NOTE!
The coil spring must be guided outside the four pins on the control lever.
18.Fit washer (5) and twist lock (6) so that the tabs engage in the lower bore of the control lever. Screw in control lever (7) and tighten with a torque of 15 Nm (11 lbf ft)
19.Fit brake pad in brake caliper.
Brake disc, replacing one
Op nbr511-002
Total procedure time (hr): 0.80
Remove brake disc
1.Remove universal shaft (1) on front axle.
2.Withdraw ES bolt (2) and remove handbrake cable (3) from lever.
3.Unscrew both fixing bolts on brake caliper (4), unscrew parking brake and remove from brake carrier.
4.Pull brake disc (5) off universal shaft flange.
5. Install brake disc
Push brake disc (5) onto universal shaft flange.
6.Fit brake caliper (4), parking brake onto brake carrier. Screw in fixing bolt and tighten with a torque of 300 Nm (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.
Figure1
Brake linings, checking wear
Op nbr510-001
Total procedure time (hr): 0.40
Brake pad wear measurement on the service brake (disc brake) shows the overall state of the disc pack without dismantling the drive.
The brake pad wear measurement must be performed at least once a year, in particular if the brakingbehaviour changes, e.g. on:
brake noise reduced braking power change in deceleration change in brake fluid level change in brake pressure
NOTE!
The wear measurement must be performed on both output sides.
1.Unscrew the lock screw (1) on the axle bridge
2.Activate the service brake and determine dimension "X" with feeler gauges through the check opening. NOTE!
Dimension "X" is equal to the thickness of the pad/inner disc.
3.Determine dimension 'X'. NOTE!
If dimension "X" is ≤ 4.5 mm (0.17 in), replace the pad/inner disc on both output sides.
Figure1
Figure2
4.Screw in control opening lock screw with new seal ring and tighten to a torque of 30 Nm (22 lbf ft)
Figure3
Brake system, adjusting unloading pressure
Op nbr520-004
Total procedure time (hr): 0.40
Tools: 88830213Measuring equipment
NOTE!
Warm up the machine until the hydraulic system is at operating temperature (60°C/140°F).
1.Place the machine in service position.
2.Release the pressure in the brake system by depressing the brake pedal several times.
3.Block articulation joint using “Joint lock”.
Steering joint lock
Shutdown pressure, check
4.Connect pressure gauge to the measurement connection for accumulator charge pressure.
1. 2. Measurement connection, accumulator charge pressure
Measurement connection, service brake pressure, rear axle
Figure1
Figure2
Brake valve, low-speed machine L45G; SN 12 / L50G; SN 32
Figure3
Brake valve, high-speed machine L45G; SN 22 / L50G; SN 42
1. 2. 3.
Measurement connection, accumulator charge pressure
Measurement connection, service brake pressure, rear axle
Measurement connection, service brake pressure, front axle
5.Start engine and wait for the shutdown pressure to build up in the brake system.
6.Read display on pressure gauge. For set value of shutdown pressure, see Brakes, specifications. If the set value is not reached, adjust the shutdown pressure on the accumulator charge valve.
Shutdown pressure, adjust
7.Unscrew protective cap (arrow) on accumulator charge valve.
Figure4
Adjust shutdown pressure.
8.Release lock nut (1). Adjust shutdown pressure with adjustment screw (2) until the specified set value appears on the pressure gauge.
Turn adjustment screw clockwise: pressure reduction
Turn adjustment screw counterclockwise: pressure increase
9.Retighten lock nut.
Triggering pressure, check
10.Start engine and wait for the shutdown pressure to build up in the brake system.
11.Switch off engine. Reduce the pressure in the brake system by actuating the brake pedal. At the same time, read the pressure on the pressure gauge. The pressure in the pressure accumulator falls to the triggering pressure. For set value of triggering pressure, see Brakes, specifications. If the specified set value is not reached, adjust the triggering pressure at the accumulator charge valve.